DOCUMENT No.

ENGINEERING DESIGN BASIS 6556-00-16-50-DB-01

ELECTRICAL Rev.0
Page 1 of 17

ENGINEERING DESIGN BASIS

DESIGN PHILOSOPHY
5.7 ELECTRICAL

THIS DOCUMENT HAS BEEN APPROVED BY IOCL

IOCL Comments incorporated and issued for

0 10.02.05 SA RCS AAN
implementation
A 02.11.04 Issued for clients comments/Approval SA RCS AAN
Rev. Prepared Checked Approved
Date Purpose
No by by by

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ENGINEERING DESIGN BASIS 6556-00-16-50-DB-01
ELECTRICAL Rev.0
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 %%$

1.0 Site conditions

2.0 Power Source Details
3.0 Power Supply Distribution System
4.0 Protection - Metering Control
5.0 Substation Design
6.0 Equipment Design
7.0 Cabling System
8.0 Earthing System
9.0 Lighting System
10.0 Electric Heat Tracing System
11.0 Electrical Equipment For Hazardous Areas
12.0 Statutory Approval
13.0 Cable Sizes for MV Motors
14.0 Specific requirements
15.0 Attachments
16.0 Deviation to design philosophy

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The electrical design data defines the design requirements agreed by owner/clients in addition to
Design philosophy for electrical facilities no: 6-51-0099 Rev 4 (Any additional deviation must be
recorded as part of this document)
1.0 SITE CONDITIONS
1
A. Equipment design temperature (IS 9676) : 45C
B. Soil Resistivity : Later (after the soil Resistivity test)
C. Minimum temperature. for battery sizing : 10C
D. per IS-1893)
E. Altitude above mean sea level : <1000 m
2.0 POWER SOURCE DETAILS
2.1 General
A. Independent system or existing system : Independent system
2.2 Grid Supply * Refer CPP design basis
A. Name of sub station / MW : *
B. Number of feeders : *
C. Length of feeder :*
D. Type of conductor/ cable size : * mm
E. Voltage : * kV %
F. Frequency : * Hz %
G. Minimum/maximum fault level : * kA / KA
H. Design fault level / Basic Insulation Level : * kA / kV
I. System neutral earthing : *
J. Minimum load power factor stipulated by : *
K. Supply authority :*
L. Parallel operation of incomers : * Yes/No
M. PLCC requirement : * Yes/No
2.3 CPP and its configuration * Refer CPP Design basis
A. Number / type of captive generators : * /Steam, Gas turbine
B. Generator rating/Voltage/Power factor : * MW/ kV/ 0.8
C. Parallel operation with grid : * Yes /No
D. Neutral earthing : High resistance earthed
2.4 Emergency generator * Refer CPP design basis (Emergency
power for lighting from existing PREP power plant)
A. Number / type of emergency generator :*
B. Generator rating/Voltage/Power factor :* kW/ V/ 0.8
C. Starting :* Auto / Manual
D. Short time para :* Yes/No
E. Paralleling with grid system :* Yes /No
2.5 Details of Existing System
Refer CPP design basis

3.0 POWER SUPPLY DISTRIBUTION SYSTEM

1
Based on PREP-IOCL design basis and DFR
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3.1 Voltage and frequency variation

AC System
i. Voltage : +6%
ii. Frequency : +3%
B. DC System (at system output terminals)
i. Electrical Control, Lighting etc. : + 10%
2
ii. Instrumentation Power Supplies : +%
3.2 Utilisation voltage and operating philosophy
A. Primary HV distribution voltage : 33KV
B. Secondary HV distribution voltage : 6.6 KV
C. Primary HV distribution system neutral earthing : Solidly earthed
D. Secondary HV distribution system Neutral : Resistance earthed
3
E. HV motor voltage : 6.6KVabove 160KW & </= 6MW
F. MV motor voltage : 415 VAC upto&including 160KW
G. Auto transfer at 6.6KV bus : Yes
H. Auto transfer at MV (At PCC Level) : Yes
I. Continuous Parallel operation of Incomers :
HV : Yes /No (33KV-Yes, 6.6/11KV-
No, 415V-No)
PCC/PMCC : No
4
J. Load shedding : Yes/ No
K. Motors rated below 0.18 kW : 240V AC, 1ph/ 415V AC 3ph
L. Battery chargers incoming power supply : 415V AC, 3ph
M. UPS System incoming power supply : 415V AC, 3ph
N. AC Lighting/Power Panels and Auxiliary : 415V AC, 3ph
Boards incoming power supply
O. Welding Receptacles : 415V AC, 3ph
P. Bulk loads like Process Heaters etc. : 415V AC, 3ph
Q. Normal Lighting/Emergency Lighting : 240V AC, 1ph
R. Power factor improvement capacitors : As required
S. Convenience outlets : 240V AC, 1ph
T. DC Motor : Not envisaged
U. Motor operated valves : 415V AC, 3ph
5
3.3 Utilization voltage for critical supplies
A. Normal Instrumentation power supply : V AC
B. Critical instrumentation power supply : V AC/ V DC
C. Shut-down system power supply : V AC/ V DC
D. Switchgear protection and Critical lighting : 220V, DC
power supply
E. DC supply for instrumentation : Independent system
F. Plant communication system power supply : 415V, Normal, with battery
backup
G. Fire alarm system power supply : 240V AC Normal
(With battery back up)
2
Refer instrument design basis
3
More than 6MW, the motor shall be connected on 11KV through dedicated transformers
4
Refer DB Document, section 11 of advanced E&I for load shedding
5
Refer instrument design basis for voltage choice for instrument loads
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H. Annunciation panel power supply6 : V AC Normal/AC UPS

V DC (No separate Pnl)
4.0 PROTECTION - METERING CONTROL
7
4.1 Metering for external power supply incomers Not applicable
A. Summation metering : Yes/No
B. Trivector meter : Yes/No
4.2 Control Philosophy
A. Protection relays for HV switchgear : On Switchgear panel
B. HV Switchgear control : Local/ Remote/ ECS
C. Hard wired annunciation panel : No (Part of substation HMI)
D. Numerical Protection/Monitoring system for
i. EHV system : Yes / No (Not applicable)
ii. HV Switchboard : Yes
iii. 415V PMCC/PCC : Yes
iv. 415V MCC : Yes
E. Microprocessor based system for control interlocks : Yes
and monitoring of electrical power system
i. Human machine interface system-HMI : Yes
Operator console : Yes
Engineering console : No, use LAP TOP instead
ii. Data concentrator for each substation (Separate for HV and MV system)
8
: Yes/ No
iii. Interface with higher level control system: Yes
F. Limiting Conditions for Motor start up
(e.g. starting current limitation or method of Starting)
9
i. HV Motors : 550% (No tolerance allowed)
ii. MV Motors : 600% up to 75KW, 550% above
75KW
iii. Method of starting for large HV motors : Direct on line (refer foot note for
F(i)
iv. Method of starting for large MV motors : Direct on line
G. Type of power isolation for remote transformers10
i. Load break switch in switchgear room : No
ii. Push button in transformer bay for tripping: for all transformers
Remote breaker

6
Hard wired annunciation panel is not proposed. Annunciation will be part of substation HMI
7
No grid backup is envisaged as per CPP design basis.
8
Separate data concentrators for HV and MV are not required for same make and type of relays
9
For motors greater than 2.5MW, maximum starting current shall be based on motor startup study
10
As 33KV switchboards are of rating 31.5KA and available in GIS, instead of local isolating panel, it is
suggested to provide push button station with lamp indication for trip of sending end breaker and requires
approval with CEA for implementation.
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11
4.3 Relay protection system
Protection devices for power distribution system shall be as indicated below
Relay Relay description Transformer Motor Outgoing feeder Incomer
number Feeder feeder

(Secondary (Secondary
winding winding HV HV MV HV MV PCC/
voltage voltage PCC/ PMCC
> 3.3 KV) < 0.433 KV) PMCC
51 IDMTL over-current relay Yes Yes - Yes Yes Yes Yes (4)
(4) (13)
51N IDMTL earth-fault relay Yes (7) No - Yes Yes Yes Yes
(4) (13)
51G 51G backup earth-fault relay Yes Yes - No No No No
(secondary neutral)
99 Motor protection relay with locked
rotor feature No No Yes No Yes (8) No No
(50, 50N,46, 49, 50L/R)
64R Instantaneous restricted earth-fault Yes No - No No No No
relay (secondary side)
50 Instantaneous over-current relay Yes Yes - No No No No
50N Instantaneous earth-fault relay Yes (6) Yes - No No No No
87 Differential protection relay Yes (1) No Yes (2) Yes (3) No No No
86 High speed tripping relay Yes Yes Yes Yes Yes Yes Yes
95 Trip circuit supervision relay Yes Yes Yes Yes No Yes No
63 Transformer auxiliary relay Yes Yes - No No No No
27/2 Under-voltage relay with timer - - No - - Yes Yes (5)
(14) (5)

25 Check synchronisation relay - - - - - Yes Yes(9)

(9)
NOTES:
1. For transformers rated 5 MVA and above.
2. For motors rated 1500 kW and above.
3. For critical/long feeders and plant feeders connected to main power generation and
distribution bus.
4. These relay functions can be substituted by inherent releases. At remote substations where
DC supply is not envisaged, 415V switchboard shall have inherent releases instead of
relays.
5. Wherever auto-transfer feature is provided.
6. Instantaneous earth fault 50N shall be provided only for transformer with delta primary.
7. Directional IDMTL earth fault 67N shall be provided for transformer with star primary.
8. For motor feeders rated 55 kW and above.
9. For switchgears having bus transfer scheme, where continuous or momentary paralleling is
envisaged, check synchronising relay shall be integrated with overall paralleling scheme.
10. The bus tie feeders in HV switchboards shall be provided with 51, 51N, 86 and 95 relays.
However MV bus tie shall not have any protective relays.
11. HV capacitor bank feeders shall be provided with 51, 51N, 59 (over voltage), 60 (Neutral
displacement), 86 and 95 relays.
12. In case of HV switchboards with parallel operation of incomers, following additional relays
shall be provided:
a. One set of 87B (Bus differential) and 95 B (Bus wire supervision) for each bus
section.
b. 67 and 67N (Directional IDMTL over current & earth fault) relays for the incomers.
13. The following feeders shall be provided with timers for delayed tripping on bus under
voltage while the under voltage relay shall be common for the bus
a. HV and MV capacitor feeders

11
Generator protection requirement shall be covered separately in respective EPCC document.
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b. HV and MV breaker controlled motor feeders or contactor feeders with DC control

supply.
c. One no. DC supply supervision relay (80) shall be provided for each incoming DC
supply to the switchboard.
14. One set of bus differential relays (87B) and bus wire supervision relay (95 B) for each bus
section shall be provided for HV switchboards connected directly to generation buses and
those used as extension buses at remote substation.
15. In case of numerical relays, all relays shall be comprehensive units including all protection,
metering and control unless other wise specified.
16. Breaker control switch shall be hardwired type in addition to control switch as a part of
numerical relay.
17. Transformer trouble 63TX relay shall be provided for all transformers and relay shall be
located on MV side in case of remotely located transformers. This function shall be realized
part of numerical relays.
4.4 Metering
The metering devices in EHV, HV and MV switchboards shall be as below :
Hour
Feeder Type A V Hz PF MW MWH MVAR MVAH MVA
Run
EHV Incomers
EHV Bus Tie
EHV Transformer
EHV Bus P.T.
HV Incomer X X X X X X - X X X
(2) (2) (2) (1,2)
HV Bus Tie X - - - - - - - - -
HV Transformer X - - - X - - - -
HV Bus P.T. - X - - - - - - - -
HV Plant Feeder X - - - - X - - - -
HV Motor X - - - - X X - - -
kWh
HV Capacitor X X - - - - - - -
PCC/PMCC Incomer X X - X - X - - - -
kWh
PCC/PMCC Bus Tie X - - - - - - - - -
PCC Bus P.T. - X - - - - - - - -
ACB Outgoing X - - - - X - - - -
kWh
MV Motor (>55kW) - - - - - - - - - -
MCC/ASB Incomer X X - - - - - - - -
MCCB/SFU X - - - - X - - - -
O/G(250A) kWh
LDB Incomer X X - - - - - - - -
DG Set X X X X X X X - - -
kW kWh
NOTE :
1. MVA meter in Grid Incomers shall include maximum demand indication also.
2. MW, MVAR, MVA, MVAH meters shall be provided for only Grid Incomer feeders.
3. Field Ammeters are to be provided for all motors rated above 3.7kW.
4. All metering shall be part of numerical relay in case of electrical system having numerical
relays. Energy meter where provided separately shall be digital type.
5. Indicating lamps in switchboards shall be cluster type LED lamps as per EIL specifications.

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5.0 SUBSTATION DESIGN

5.1 EHV Switchyard Not applicable
A. Type : String bus / Tubular bus
B. Structure : Galvanised / Painted / RCC
C. Bus material : Aluminium / Copper
5.2 HV/MV Substation
Description HV * MV
Elevated with trays in cable cellar Yes No
12
Raised with internal trenches Yes Yes
All top cable entry with trays below ceiling No No
Pressurisation against ingress of dust Yes Yes13
Air-conditioned room for operator Yes No
Roof slab for
Power transformer No No
Distribution transformer No No

Note:
1. * Substation with long high voltage switchboards having substantial amount of cabling work
2. Battery room shall be preferably located in corner side at first floor of the substation
building.
5.3 Specific Equipment Locations
A. Batteries
Electrical switchgear batteries : Separate room in sub-station
UPS batteries : Separate room in control room
B. Battery charger for electrical system : In substation air conditioned room
Battery charger for instrumentation : In Control room along with UPS.
C. Variable speed drive panels/Thyristor control panel : Air-conditioned room in substation
D. UPS System : Air conditioned room in control room
E. Lead-Acid and Nickel-Cadmium : In separate rooms
F. Annunciation panel : Not envisaged/ HMI to have
annunciation Operator room in
substation
6.0 EQUIPMENT DESIGN
6.1 EHV Switchyard NOT APPLICABLE
A. Bus bar system : Single/Double
B. Circuit breaker type : Minimum oil/SF6
C. Isolator type : Pantograph/ Semi pantograph/ Centre rotating/ Centre break
6.2 HV Switch-board
A. Execution : Drawout (Fixed for GIS-33KV)
B. Bus bar system : Single/(Double bus for GIS)
C. Circuit breaker typ : SF6/Vacuum
D. Motor Control : Breaker/ Vacuum contactor
6.3 Current Transformer (CT)/potential Transformer (PT)
A. CT Secondary

14
Protection : 1/5A

12
HV cables in cable cellar shall be laid in trenches filled with sand
13
Pressurization not required for remote MCC room located in safe area
14
1A Protection CT for differential, REF protection; Separate CT for differential/ REF protection
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Metering : 1A (No separate metering CT

except Metering CT for motor
PB stn
B. PT Secondary : 110 V AC
15
6.4 Transformers (Power/distribution)
Transformer Vector Tap changer Soak pit Preferred rating
group (kVA)
Main power transformer Yyo/Dy1 OLTC Yes
Generator unit transformer Ynd 11 Off-circuit Yes
Intermediate power transformer Dyn 11 OLTC/Off-circuit Yes / No
Dedicated (e.g. for VFD)16 As Reqd. Off-circuit Yes / No
Distribution transformer Dyn 11 Off-circuit No
(< 2000 KVA)

6.5 MV Switchboard
A. Execution
i. PCC / PMCC
Breaker panels :Draw out/Single front
Contactor feeders :Drawout, single / Double front
ii. MCC :Drawout, single / Double front
iii. ASB :Drawout /Fixed, single/Double Front
iv. LDB :Drawout /Fixed: single/Double Front
v. Motors
PMCC : Above 55KW Upto&Including 160kW
MCC : Upto and including 55 kW
17
vi. Type of switchboard for package : Compartmentalised/Fixed type
B. Motor Starter Type
i. Contactor and switch fuse with overload relay: Up to 22 kW
ii. Contactor, switch fuse and overload relay with: Above 22 up to 55 KW
CBCT for earth fault protection
iii. Contactor and switch fuse with motor protection relay
: Above 55 up to 160KW

iv. Air circuit breaker with motor protection : No

v. Contactor and MCCB with overload relay: No
vi. Contactor, MCCB and overload relay with CBCT:No
for earth fault protection
vii. CT for remote metering : Motor rated above 5.5KW
C. Motor Controls18
i. Auto / Manual switch : Near motor/Switchgear/control room
ii. Local/remote switch : Near motor/Switchgear/control room
iii. Normal / Standby switch : Near motor/Switchgear/control room
iv. Process interlock : PLC /relay panel/switchgear
v. Reacceleration equipment : PLC /relay panel/switchgear
vi. Control voltage for Contactor Starter : 240V AC
vii. Control supply for contactor starter : Control transformer.
viii. Separate transformer for each bus section: Yes/No

15
Rating of Power and intermediate transformers, OLTC requirement including vector grouping of all
transformers shall be decided during basic engineering based on KSLD attached with FEED.
16
To be finalized based on licensors recommendation
17
Package like AC plant MCC, Bagging plant MCC etc
18
6.5C(i to iv): Operating philosophy and location of controls shall be as per process and instrumentation
design basis.
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6.6 Motors
Motors High voltage 415 volts
Enclosure:
Indoor IP55/IP54 IP55/IP54
Outdoor IP55 IP55
Insulation class F (Temp. Rise limited to B) B

Terminal box Phase segregated/ Phase separated / -

Phase insulated
Anti-condensation heater Yes 30 kW and Above
Additional canopy (outdoor motors) Yes Yes
Design voltage / frequency 6 % / 3% 6 % / 3%
variation
Note: Motors for MOV actuator shall have F class of insulation with temperature rise limited to
class-B.
6.7 UPS System
A. Redundancy : 50% /100%
B. Type of redundancy : Parallel redundant/Hot standby
C. Back-up time : 120 minutes
D. Inverter bypass transformer : Static /servo controlled
E. Bypass transfer control : Auto / Manual
F. Separate fault diagnostic unit : Yes/No
G. Battery type : Lead acid/Ni-Cd/VRLA
H. Type of UPS : IGBT/Transistorised
I. Battery execution : Single bank up to 600 Ah/Parallel bank above 600 Ah
6.8 Communication System
A. Plant Communication System : Yes
19
B. Telephone System : Yes
C. Telephone system and plant communication system : Separate/Integrated
D. No. of intercom and external P&T lines : Later By IOCL
E. Battery type for telephone system : Sealed Lead acid (SMF)/ VRLA
F. Battery type for plant communication system : Sealed Lead acid battery/ VRLA
G. Battery backup time : 120 min for both systems
H. Interface of Communication system with fire alarm system: Yes
I. Interface of PA and telephone system : Yes
J. Type of communication system : Digital microprocessor based
6.9 Fire Detection and Alarm System
A. Type : Conventional/Analogue addressable
B. Name of buildings to be provided with detectors : All buildings except watch tower
C. Battery type :Sealed Lead acid (SMF)/Ni-Cd/VRLA
D. Battery backup time :48hrs. (Normal) + 120 minutes. (Alarm)
E. Detection System : Break Glass/ Smoke, Heat, linear beam
F. Type of manual call point : With/Without call back facility
20
G. Number of Sirens and location : 1 Number at Main control room

19
Plant wide Telephone and LAN system shall be common. Refer design basis for LAN system for details.
20
Siren shall be electronic type with 5 tones (as per IOCL comment clause 2.3.10 (9) on fire and safety
document no. 6556-00-16-47-DB-01), Number and range shall be modified as per the availability.

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H. Power supply for Siren : 415 V AC/DC normal supply

I. Any specific requirement of range : 10 Km diametrical
6.10 DC System
A. Battery type
i. Switchgear Protection, control : Lead acid/Ni-Cd/VRLA
Control and critical lighting
ii. Instrumentation System : Lead acid/Ni-Cd/VRLA
iii. Diesel Engine Starting : Lead acid/Ni-Cd/VRLA(automotive type)
21
iv. DC Motors : Lead acid/Ni-Cd/VRLA
B. Battery back up time
i. Switchgear Protection :120 minute when no DG back up and
Control, Lighting 30 minutes where DG set is available
ii. Instrumentation : 30 /60/120minutes
iii. Diesel Engine Starting : 10Starts (FW pumps)& 6 Starts others
iv. DC Motors : refer foot note
6.11 Variable frequency drive
22
i. Type of inverter : See foot note
23
ii. Number of pulse : 6/12
iii. By pass feature required : Yes
iv. VFD rated output voltage : As per licensor/FEED reqt.
6.12 Cables
The power and control cables shall have the following minimum cross sectional areas:
24
A. Medium voltage power cable : 25mm (Al)/2.5 mm (Cu)
B. Control cables : 2.5 mm (Cu)
25
C. Lighting : 2.5 mm (Cu)
26
D. Communication system : 0.9 mm dia (Cu)
E. Fire alarm system : 1.5 mm (Cu)
7.0 CABLING SYSTEM
7.1 Cable details
Design Criteria High voltage27 415 volts
Loads located beyond 1 km 1Core/ 3 Core Cable Cable
Loads located 200-1000 m 1-Core/ 3 Core cable 1-core cable/ 3-core cable
Load located up to 200 m 3 Core Cable Cable / Bus trunking
Loads beyond 1 kA rating Bus duct / cable Bus duct /1 core cable
Recommended limiting size of multi-core 300 300
cable (mm)
Short-circuit withstand time (seconds) 0.2 (Outgoing)/0.60 (Plant)/1.0 N.A.
(Incomer)
Insulation voltage grade Earthed for both 33KV and Earthed
6.6KV system

Type of cable insulation XLPE PVC

21
DC motor application is not envisaged
22
Licensors recommendation/ EIL equipment specification shall apply
23
6 or 12 pulse rectifier as per manufacturers standard and as required for meeting EIL equipment
specification requirement.
24
Cable for motor above 110KW shall be sized considering copper cable.
25
1.5 mm Cu conductor PVC Insulated wire shall be used in conduit with proper colour coding for building
lighting.
26
Cable sizes for PA and FA systems are indicative. These shall be finalised later as per the manufacturers
recommendation
27
1Core or 3 Core HV cable shall be decided during basic engineering based on load and distance
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Design Criteria High voltage27 415 volts

28
Fire survival (Resistant) cable
Fire pump Yes/No Yes/No
Plant communication - Yes/No
Armour for cables inside the substation Yes/No Yes/No

7.2 Cable laying philosophy

A. Process area29 :Overhead cable tray /RCC trench-sand filled
B. Offsite paved area30 :Above Ground cable tray on sleeper/overhead rack/ RCC trench
C. Offsite unpaved area :Above Ground cable tray (on sleeper/ overhead rack) / directly
buried. (see footnote against point 7.2 above)
D. Type of cable trays :Galvanized prefabricated / Site fabricated and painted
E. Special requirements :Cables for fire water system shall be taken on exclusive route
through underground trench starting from main substation in case
applicable
F. Road Crossings for under ground cables31 :PVC Pipes /Cable culvert
G. Road Crossings for above ground cables :Overhead cable bridge/culvert/ERC
8.0 EARTHING SYSTEM
A. Earth electrode : GI pipe
B. Main earth loop material : GI strip
C. Substation earth loop : GI strip
D. EHV switchyard earth grid : Not applicable
E. Lightning system : As per IS2309
9.0 LIGHTING SYSTEM
9.1 Supply System
A. Centralised with separate transformer32 : Yes/No
B. At each substation with separate transformer : Yes /No
C. Separate metering required : Yes/No
9.2 Control Philosophy
A. Outdoor yard : Auto/Manual/centralised (ECS)/Local
33
B. Street lighting : Auto/Manual/centralised(ECS)/Local
34
C. Outdoor process area : Auto/Manual/Centralised (ECS) / Local
D. Process building : Auto/Manual/centralised/Local
E. Auto control : Yes-Synchronous timer/photocell/ No
F. Lamp type for outdoor lighting : HPMV-Process area/HPSV-Street light,
FLM/ (Incandescent type for
DC/emergency Critical lighting)
G. Panel execution : Lighting transformer fed LDB with OG
feeders for lighting panels

28
Where fire proof MOVs are provided cables shall be fire survival type as per IEC331 or mica insulated
29
Cables for FA/PA shall be laid in instrument duct where available and shall be in separate trays where ducts
are not available in ISBL.
30
FA and PA cables in offsite area shall be laid in road berm (opposite to berm used for lighting cable). Where
chemical handled are hazardous for PVC insulation, cables shall be laid above ground.In such cases. Cables
shall be laid overhead on pipe rack or above ground on sleeper level depending on availability of pipe rack/
sleeper. Where there is no rack/ sleeper, cable shall be laid in trenches if cables are large and directly buried if
cables are few.
31
Road crossing through PVC pipe or culvert shall be decided based on number of cables.
32
The secondary voltage for lighting transformer shall be 380V.
33
Lighting shall normally be done using 30m flood light mast as per IOCL philosophy. Street light shall be
considered only where considered absolutely necessary.
34
Local control shall be through FLP lighting panel in process area.
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H. ELCB at Incomer of lighting and Power panels35 : Yes/No

9.3 AC Emergency Lighting
A. Name of process plants : All process Unit except U&O Pump stn
B. Name of buildings : All buildings- Plant and non plant
C. Power supply : As per CPP design basis
9.4 DC Critical Lighting For Escape
A. Name of process units : All process units
36
B. Name of building : All buildings (see footnote)
C. Power supply : 220V DC
D. DC lighting for remote substation : (See foot note)
9.5 Wiring Type
A. Process plant / Building / Shed : Armoured cable
B. Large service building : Concealed/ surface conduit
C. Buildings with false ceiling : cables/Surface conduit above false
Ceiling
D. Substation (Switchgear Room) : METSEC channel
E. Substation (Cable Cellar) : Surface Conduit/armoured cable
F. Other buildings : Concealed/Surface, conduit/
cable(armoured/ unarmoured).

9.6 Specific Lighting Requirements

A. Aviation lighting : Yes /No
B. Navigation lighting : Yes/No
37
C. Security lighting for peripheral road at boundary wall : Yes/No
D. Type of control gear for HPMV/HPSV Lamps : Separate/Integral
E. Control gear box location : Accessible level if separate
F. Type of flood light mast : 30 m Telescopic fitted tubular
10.0 ELECTRIC HEAT TRACING SYSTEM
A. System Design Basis : Product Classification /System approach

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ELCB shall be provided at sub distribution feeder at LDB for lighting panels for AC as well as DC lighting.
36
All buildings except remote buildings not having DC supply shall be provided with DC lighting for escape.
For buildings where DC supply is not available, portable DC light for escape to be provided.
37
To be provided on watch towers through search light
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11.0 ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS

The electrical equipment for hazardous areas shall be selected as per IS-5571 and petroleum rules
The minimum requirement is summarised below:
Equipment Zone-1 Zone-2
Gas Group IIA, IIB Gas Group IIC Gas Group IIA, IIB Gas Group IIC

MV Motors Ex-d Ex-d Ex-e/Ex-n Ex-e/Ex-n

HV Motors Ex-d / Ex-p Ex-d/ Ex-p Ex-p/Ex-e/Ex-n/ Ex-e/Ex-n
Push Button Station Ex-d Ex-d Ex-d Ex-d
Motor Starters Ex-d Ex-d Ex-d Ex-d
Plug & Socket Ex-d Ex-d Ex-d Ex-d
Welding Receptacle Ex-d Ex-d Ex-d Ex-d
Lighting Fixtures Ex-d Ex-d Div.2 Ltg. Div.2 Ltg.
i. Lighting fitting (IS-8224) (IS-8224)
ii. Control Gear Box Ex-d Ex-d Ex-e/Ex-d Ex-e/Ex-d
Junction Boxes Ex-d Ex-d Ex-e/Ex-n Ex-e/Ex-n
Hand Lamps
i. Light fitting Ex-d Ex-d Ex-d Ex-d
ii. Transformer Unit Ex-d Ex-d Ex-d Ex-d
iii. Plug & Socket Ex-d Ex-d Ex-d Ex-d
Break Glass Unit Ex-d Ex-d Ex-d Ex-d
(Fire Alarm System)
Lighting Panel/Power Panel
Ex-d Ex-d Ex-d Ex-d
Transformers Hermetically sealed with surface temperature not exceeding 200C
Notes:
1. The electrical equipment for hazardous areas shall generally be suitable for gas group IIB
and temperature classification T3 as applicable to the selected type of explosion protection.
In case of hydrogen or hydrocarbon mixtures having more than 30% hydrogen, the gas
group to be considered shall be IIC.
2. As additional safety features, the following requirements for electrical equipment shall be
followed
a. All electric motors for vertical oil sump pumps including ETP area shall be
flameproof type.
b. Irrespective of the area classification (whether zone-1 or zone-2), all lighting
fixtures within the storage areas shall be flameproof type.
c. All emergency/critical lighting fixtures and associated junction boxes in hazardous
areas (whether zone-1 & zone-2) shall be flameproof type.
3. Even though fired heaters in process units are not considered for area classification, all
electrical equipments associated with fired heaters in process units shall as a minimum be
suitable for installation in Zone-2 area.
4. Where air conditioning system is designed considering ammonia as refrigerant, the room
housing air conditioning equipment shall be adequately ventilated to classify it as safe
area. For additional safety the following shall be considered:
a. 100% standby system for ventilation
b. Location of MCC/local panels in adjacent separate room.
c. Instrumentation to be flameproofs type or hermetically sealed.
d. AC plant room motors with type`e' protection.
e. Lighting in AC plant room suitable for zone-2 area.
5. Compressor sheds in hazardous area shall be designed to allow adequate ventilation to
allow area classification as Zone-2 Lighting equipment, EOT crane etc. in the shed shall be
flameproof type. All other electrical equipment shall be suitable for Zone-1 or Zone-2 area
depending on extent of hazard.
6. Motors fed from variable frequency drive in hazardous area application shall be type tested
as unit with the VFD panel in case of Ex(e) type of motors and provision for tripping the
motor in case temperature rise exceeds the permissible limits ,shall be considered for
flameproof motors as per relevant standards.

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12.0 STATUTORY APPROVAL

Statutory Authority for Electrical Installation : Central Electrical Inspectorate
Hazardous area equipment : CCE
13.0 CABLE SIZES FOR MV MOTORS
i. Direct on line (D.O.L) start motors (2/4 pole motors)38
Motor Rating Cable Details
Number of runs No. of cores Conductor material Conductor size
per run mm
Below 3.7 KW 1 3 Cu 2.5
3.7 KW 1 3 Cu 4
5.5 KW 1 3 Cu 6
7.5 KW 1 3 Cu 10
9.3 KW 1 3 Cu 16
11 KW 1 3 Cu 16
15 KW 1 3 Cu 16
18.5KW 1 3 Al 35
22 KW 1 3 Al 35
30 KW 1 3 Al 50
37 KW 1 3 Al 70
45 KW 1 3 Al 95
55 KW 1 3 Al 120
75 KW 1 3 Al 185
90 KW 2 3 Al 95
110 KW 2 3 Al 120
125/132 KW 2 3 Cu 120
160 KW 2 3 Cu 120

ii. Cable sizes for motors not confirming to above table e.g. for 2/4 poles motors, extended distance,
reduced voltage starting, low speed motors, shall be worked out on case to case basis.
iii. Cables sizes as indicated above are applicable for a distance up to 350m maximum and for 2/4
poles motors fed from MCCs located near PCCs and PMCCs.
iv. Cables for lighting shall be used to allow the following voltage dips
Street lighting :10%
DC critical lighting :5%
14.0 SPECIFIC REQUIREMENTS
i. Canopy shall be provided for all out door equipment.
ii. Substation shall be sized to ensure 2 nos panel extension on each bus section
for all HV/ MV switchboards except GIS.
iii. Dummy panel shall be provided in switchboards wherever there is expansion
joint in the building.
iv. If signal cables for DCS interface with substations are envisaged, these shall be
laid in separate trays/ trench. However in exceptional cases signal cables may
be laid in electrical trench, properly cleated on trench wall allowing 300mm gap
with other power cables in the trench.
v. For building engineering, each office room, in addition to switch/ socket for
lighting design, shall be provided with minimum 2 nos telephone sockets and 2
number LAN socket at two different location as duly approved during detailed
engineering.
vi. Modular type switches/sockets in main control room and all non plant buildings
shall be modular type.
vii. Lamps shall be standardized for the purpose of inventory in hazardous area
lighting as below.

38
Cable sizes given in the table are indicative and standardized for inventory and are the minimum sizes. The
cable size as required to meet voltage drop criteria shall be provided.
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Well glass normal Lighting : 70W HPMV lamps for well glass fittings
Flood Lighting : 250W HPMV lamps for flood lighting
Critical lighting : 100W GLS lamps

15.0 ATTACHMENTS
Design philosophy for Electrical Facilities 6-51-0099 Rev 4
16.0 DEVIATION TO DESIGN PHILOSOPHY
Document number 6-51-0099 rev 4

The requirement given under engineering design basis document shall be overriding. However
following job specific requirement are highlighted as deviation to Design Philosophy of Electrical
facilities document number 6-51-0099.
16.1 Clause 4.6.1 Voltage drop
i. b(ii) MCC/Aux switchboard situated remote from PCC/PMCC 2%
ii. d - Cable between PCC/PMCC to motor- 5% during normal running
16.2 Clause 4.11 DC Power supply
i. DC power supply system for electrical controls and for critical lighting shall be
separate. For electrical controls and instrumentation, DC system shall be dual
redundant with single set of battery and for critical lighting, DC system shall be
non redundant.
16.3 Clause 4.15.3 Plant communication system-capacity for future expansion
i. Exchange supplied shall be fully wired for hardware, power supply, software etc
for the capacity as required with spare capacity of 20% field call stations with no
future modification in exchange hardware/ software.
ii. Exchange shall have required hardware for communication between two
exchange of the same make
16.4 Clause 4.16 Fire detection and alarm system
i. Cl 4.16.5 : Spare fire alarm loop for future shall be 20% or 1number whichever is
maximum. Each loop shall be engineered to provide the flexibility to add 20%
additional detectors in future, if required.
ii. Cl 4.16.6 : The status for actuation of fire suppression system shall also be wired
to fire alarm panel to annunciate at central fire alarm monitor.
16.5 Clause 5.3 Switchgear
i. Cl 5.3.4 : Each HV Switchboard (above 415V and except 33KV) shall have
minimum 2 numbers spares of each type. (i.e. type like transformer feeder, motor
feeder, plant feeders etc)
ii. Cl 5.3.4 : Each MV Switchboard (Up to 415V) shall have 20% spares of each
type ( Spares in each MCC shall however be 20% subject to 1 number of each
motor feeder module )
16.6 Clause 5.7 Battery charger and Distribution board
i. Cl 5.7.3 : Each DCDB shall have 20% spare feeder for future use.
ii. DCDB outgoing feeders for critical lighting shall be provided with ELCB.
16.7 Clause 5.8 Uninterrupted power supply system
i. Cl 5.8.4: Spare feeders in ACDB shall be 20% for future use with minimum of 1
number of each rating.
ii. Cl 5.8.5 : UPS shall be sized to have 20% spare capacity on calculated load for
future loads.
16.8 Clause 5.13 Cable and Wires
i. Cl 5.13.6 : No unarmored cable shall be used.
ii. Cl 5.13.10 : Control cables shall have 1core spare upto 6core requirement and
20% or 2 core whichever is maximum for cables having requirement above 6
cores.

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iii. For 4-20mA signal interface between switchboards and DCS, screened cable
shall be used.
iv. Cl 5.13.7 : Cables laid for hazardous area shall not have any joints.
16.9 Clause 5.14 Control stations
i. Cl 5.14.1 : Each motor shall be provided with local control station. If specified per
process or equipment control requirement, local control station can be part of
local control panel.
16.10 Clause 5.16 Actuators for motor operated valves
i. MOV shall have separately mounted actuator in area of high vibrations. In
particular the MOVs for Cooling water application shall have separate actuator
located near the valve for local actuation.
16.11 Clause 7.2 Cabling System
i. Clause 7.2.5: Cable trays shall be sized to allow 20% additional space for future
cables.
ii. Clause 7.2.14: MCTs shall be provided wherever the entry is above ground. And
where entry is below ground, sleeves (Laid in outward slope to avoid water entry)
shall be provided for electrical cables.
16.12 Clause 7.4 Lighting system
i. Non-plant buildings such as administrative building, gatehouses etc should be
provided with energy efficient CFL lamp fixtures.
ii. In plant buildings, control rooms should be provided with energy efficient CFL
lamp fixtures.

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