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Table of Contents
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Design Basis Memorandum
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Design Basis Memorandum
1.1 General
The design criteria shall be governed by the following principles:
a) Personnel and equipment safety.
b) Environmental conditions of the site.
c) Reliability of supply.
d) Redundancy built in electrical system.
e) Reduction of spaces, weights and cost.
f) Easiness of management, operation and maintenance.
g) Adequate flexibility for future installations and interchangeability.
h) Standardization and availability of components.
i) No risk of fire.
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Design Basis Memorandum
Note: Critical motors e.g. Lube oil supply or emergency requirement can be considered at 110 V
DC.
Permissible voltage and frequency variations are:
Steady state (long-term) voltage variation ± 5.0%
Steady state (long-term) frequency variation ± 2%
Power rating of single unit should be such that it can start the plant largest motor in worst case scenario.
Short circuit rating of switchgear should be such that all generation units are operating in parallel along
with WHR of 12 MW (to be confirmed later).
Each generating unit should be equipped with its individual control and protection panel. Load sharing
module and load management system should be provided by supplier.
Substations will be equipped with HVAC system. Fire alarm and detection system will be installed inside
substation building along with fire extinguishers.
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Design Basis Memorandum
Cable compartments
Bus bar compartments
Switching device compartment
Control compartment
Circuit breaker shall be operated by stored energy mechanism which is normally charged by electric
motor and can also be manually charged by handle in case of emergency operation.
All instrument transformers (CT & PT) shall meet the relevant IEEE standards.
Low voltage compartment shall be equipped with relevant monitoring, protective, alarm and controlling
facilities.
Earthing switch should be provided for each breaker which can only be operated in DE energized
condition.
Space heaters in each panel and ventilation fans should be provided where necessary.
The number of equipped spares provided in the MV Switchgear will generally be based on 10% of
installed numbers of feeders at each bus section, with a minimum of one of each type.
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Design Basis Memorandum
Draw out type air insulated LV switchgear will be used for low voltage distribution. Outgoing feeders will
be standard modules of different size and rating, thus providing interchangeability of modules.
Note:- Air Circuit Breakers should be equipped with ETU (Electronic Trip Unit) for protection against
thermal overload, over current, short circuit and ground fault.
Cable compartment shall be arranged at the side of each outgoing feeder section. Separate terminals
per outgoing feeder module shall be provided for incoming control, metering and auxiliary lines.
LV feeders will be provided with nameplate at the front side for identification. Door should be grounded
by separate grounding strips.
It should be provided with adequate clearance from live parts so flash -over cannot be caused by
switching, vermin, pests, etc.
At design inception, a 10% design contingency, and a 10% operating margin will be applied to the initial
total average demand, and the resultant figure will be used for the initial sizing of distribution
equipment (transformer).
The number of equipped spares provided in the LV Switchgear will generally be based on 10% of
installed numbers of each motor starter module and feeder size, with a minimum of one of each size.
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Design Basis Memorandum
The electrical distribution system will be designed to limit fault levels to the maximum calculated values,
and switchgear will be selected that has fault ratings equivalent to or in excess of these ratings. The
following table shows a preliminary assessment of expected short circuit levels. Actual calculations will
be based on actual equipment parameters and shall be updated during detailed design.
Miniature circuits breakers will provide outgoing circuit isolation and protection facilities.
All small power circuits feeding general purpose (convenience) outlets will have residual current
protection.
Power to the lighting chassis section of the distribution board will be switched through a photocell-
controlled contactor. An over-ride facility will be provided on the distribution board or elsewhere within
the electrical room, to enable manual switching of the lighting.
The lighting / small power Distribution boards shall be fed from main LV switchgear Panel.
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Design Basis Memorandum
During normal operation, the equipment served by the UPS shall be fed by the static
inverter. The inverter is fed from a rectifier unit fed by the mains and a float-charged
battery. The rectifier supplies the power to the inverter and the float-charging current
for the battery.
In the event of a mains power failure, there is no necessity to transfer any of the
electrical equipment as the inverter continues to be supplied with power from the
battery. When the mains power supply is restored, the rectifier unit supplies the
charging current for the battery and powers the inverter.
In case of failure of the inverter the static bypass switch (SBS) shall perform an
automatic transfer of the load from the inverter to the bypass source with no
interruption in power supply to the connected AC load.
The UPS systems will have dual incomers, one side being fed from the ‘normal’ 400V switchboard system,
and the other side and mains bypass transformer, being fed from the ‘Essential/Emergency’ 400V
switchboard bus.
During normal operation, the DC equipment is supplied with power by the rectifier set,
the battery being float charged. In case of mains power failure, the battery continues to
supply power to the electrical equipment. Upon restoration of the mains or feed from
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Design Basis Memorandum
The DC UPS system will consist of 2x100% rated rectifiers and 1x100% rated battery bank. The one
rectifier will be fed from the ‘normal’ 400V switchboard system, and the other from the
‘Essential/Emergency’ 400V switchboard.
Battery banks will be sized to provide 4hrs backup power on loss of AC supply.
Name plates shall be placed on the outside of each transformer identifying the service by name and
equipment number. In addition, nameplates shall identify each device on the instrument panel and
other devices such as instrument transformer, fuse etc. inside the enclosure.
Transformer MV connections will be via cables. Transformers will be equipped with No Load Tap changer.
The voltage adjustment range would be ± 5.0%.
The distribution transformer shall be sized to supply for the maximum demand of LV loads connected to
the associated switchgear plus 20% spare capacity for future expansion at ambient temperature.
The transformer kVA rating shall be chosen as far as possible in accordance with the standard sizes as
per IEC 60076 recommendations.
Rectifier
DC link
Inverter
Regulating Devices
Control Devices
Monitoring facilities
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Design Basis Memorandum
Harmonic Filters
Control and monitoring shall be microprocessor based. The operator panel serves the entering control
parameters and indication and alarm values shall be accessible from front of cabinet.
Motors shall be equipped with local control stations with padlock facilities in the off position. Where
motors are fitted with anti-condensation heaters, a heaters safety switch shall be installed adjacent to
the motor remote control unit. Local isolators, if used, shall have padlock facilities in the off mode.
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Design Basis Memorandum
Diesel Engine
Generator
Air intake and exhaust air system
Starting system (Battery and Charger)
Control and Monitoring functions
It should be able to start automatically within reasonable time after occurrence of blackout.
Generator should be three phase synchronous type with brushless exciter suitable for parallel operation
with other generators / grid.
Output voltage of generator should be 415 V with power rating based on 0.8 inductive power factor.
Fuel system should be designed with day fuel tank having capacity of 10 hours continuous operation at
rated load.
1.18
A dedicated PLC based load management system shall be provided to achieve smooth operation of
simultaneous operation of generators. It shall also handle the load management in case of generator(s)
tripping.
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Design Basis Memorandum
All cables for outdoor installation buried will have steel wire armour construction. Cables for indoor
installation laid in cable tray can be unarmored.
Cable glands shall be suitable for the type of cable.
All cables for outdoor installation buried will have steel wire armour construction. Cables for indoor
installation laid in cable tray can be unarmored.
Cable glands shall be suitable for the type of cable.
Earthing cables
Earthing cables shall be stranded copper conductor, PVC sheathed, colored yellow/green.
Instrument Cables
Copper conductor shall be used. PVC insulated cable shall be used. Cables sheathing insulation will be
flame-retardant as per IEC60332-3-24, Category C.
Analog cables shall be shielded with individual pair and overall shielding.
Cable glands shall be suitable for the type of cable.
Cable Sizing
The cable shall be sized based on the thermal limits in normal service conditions, and the maximum
allowable voltage drops in the circuit.
The current carrying capacity (thermal limit) of cables in normal service conditions shall take into
account the de-rating due to the laying conditions or grouping.
The current rating of the circuit for cable sizing shall be as follows:
The transformer primary and secondary cables shall be rated based on a current equal to the
rated current of the transformer.
The cables to switchgear and/or panel boards without step down transformer shall have a
current carrying capacity equal to the maximum demand of loads connected to the
switchgear/panel board.
The motor feeder cables shall be sized based on the 100% of motor nameplate rated current.
All the remaining cables not mentioned above shall have a current carrying capacity equal to the
maximum current demand of continuous duration.
Cable arrangement shall be in general so designed that the de-rating factor due to grouping of cables
shall not be less than 0.6 for above ground installation and 0.4 for underground installation.
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Design Basis Memorandum
Power cables shall be run in a continuous length from the power source to the load.
MV and LV single core cables shall be laid in trefoil groups with 150 mm spacing between trefoils. On
trays or racks MV cables shall be segregated from the LV cables.
Cables shall be installed underground in trenches in a single layer as far as possible. Power, control, and
instrument cables will be buried minimum 600mm below grade and MV cables will be buried minimum
750mm.
Underground cable routes shall be designed to avoid close pipe crossings and adjacent runs with
underground pipelines, i.e. a clear distance of at least 300 mm between cable and pipe (including
insulation) shall be maintained. Cables should cross underneath buried pipelines except where the
depth measured at the top of the pipeline is more than 1 meter.
Appropriate cable route markers shall be used to indicate the underground cable laying. Cable tags shall
be used to identify the cables in the trenches or in the cable trays at both ends of the cables.
Intermediate tags shall be used at every 30m distance from the electrical room end to the consumer
side. The tags shall also be used on either end of the road crossing for underground cabling.
At road crossings and cables emerging from floors or soil rigid PVC conduits shall be used for mechanical
protection.
All penetrations of underground cables into the electrical room walls shall be through conduits suitably
sealed (silicon foam) to be water tight.
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Design Basis Memorandum
Cables shall be installed mainly on extra heavy duty execution of hot dipped galvanized steel ladder type
trays in accordance with BS. The cable tray as specified NEMA class 20B is minimum requirement. For
branches from the cable tray or when cable are small number, cables shall be installed on hot dip
galvanized perforated cable tray or steel conduit.
Cable trays may be installed without removable top covers allowing adequate ventilation except where:
Mechanical damage of the cables is likely to occur during plant maintenance.
Oil or chemical spillage or dirt accumulation can be expected.
The cable shall not run close to parallel hot lines or large high temperature surfaces. Whenever
practicable, a 300 mm spacing shall be maintained.
6.3 kV and 400V cables are preferably installed on the separate tray. Where they are installed on the
same tray, the metal plates (diverters) shall be fixed between 6.3 kVand 400Vcables.
Duct bank system shall be used for road crossing. Duct bank shall be PVC or non-metallic pipes encased
in concrete of at least 50 mm thickness.
The top of the concrete encasement shall be at least 600 mm below grade where the duct banks cross
the road. Burial depth of duct bank may be reduced where duct bank is installed free from the heavy
loads.
1.20 Lighting
Lighting Distribution
Normal lighting will be fed from small power distribution board connected to 400V Switchboard.
Normal lighting will be photocell controlled, with manual override facilities.
Essential lighting will also be power fed from the 400V LV switchboards. However each of these
luminaries will be fitted with a battery pack that will provide 1hour of power for one tube of the fitting.
These luminaries will be positioned to illuminate escape routes and emergency exits.
In open and laydown areas, floodlights will be utilized. Floodlights will be high pressure sodium type.
Metal halide may also be considered as an alternate.
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Design Basis Memorandum
Fluorescent luminaries will operate at 230VAC. Floodlights will operate at 230VAC voltage, and any
requirement to balance loads across the three-phase distribution system.
The design will allow for a maintenance level of 0.7. Illumination levels are at 1.0 meters above floor level.
Area Lux
Process area. 150
Stairways, walkways, instrument stands. 50
At front of switchboards, local control panels, controller cabinets. 300
General lighting in switch room, instrument equipment room. 200
Electrical Room, Instrumentation Cabinet Room and Central Control Room. 400
Outdoor tank areas. Open Yards 30
Offices, first aid areas, reading areas. 500
Storerooms, warehouses. 75
Generators
Following protections shall be considered for the generators:
h) loss of excitation
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Design Basis Memorandum
Transformer Feeders
Following protections shall be considered as minimum:
LV Motors
Following protections shall be considered as minimum:
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Design Basis Memorandum
1. Load Flow
2. Ground Fault and Neutral Grounding Resistor w.r.t charging current of cables
3. Short Circuit
4. Protection Coordination
5. Motor Start
6. Harmonics
7. Arc Flash
Earthing network shall be developed with separate earthing pits and network for electrical and
instrument systems.
Control System
Each engine and generator will be equipped with its independent PLC for protection and control of the
unit. Local Auxiliary panels will be provided with each unit for operation through field.
Spare capacity of minimum 10% shall be kept for all the control system components.
The Control System will be located in the Control room where it will provide HMI interface to the
operator and communicate with the following devices/systems.
All field devices Plant
Package Monitoring signals via data communication links for alarms and indications.
Local HMI Interfaces/Control Stations in the field shall be provided where necessary for smooth plant
operations.
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Design Basis Memorandum
Each control system shall be capable to handle the following control and supervisory tasks, as a
minimum:
Field Instrumentation
The field devices comprise all electrical equipment in the field necessary for accurate analogue and
digital measuring required for the control and supervision of the plant which shall also include closed
circuit TV for burner, cooler and mill feed systems. The field instrumentation shall be SMART, HART
devices. Field instrumentation shall be generating 4~20 mAmp signals and transmitted to Central
Control Station for treatment. All instruments shall be provided with isolation valves. Manifolds will be
considered where necessary. Instruments installed in potentially explosive environment shall be suitable
for respective ATEX zone application.
Field devices must be of proven design and make and must meet the environmental conditions
prevailing in the plant. They must be, as far as possible, of the same make and type. The standardization
shall cover, as a minimum the instrument selection (e.g. sizes, materials, manufacturers etc), instrument
installation and hook-ups (e.g. sizes, connections, tubing and fittings etc.), instrument cables and
junction box (e.g. types, sizes etc.)
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Design Basis Memorandum
Junction Boxes:
All junction boxes, unless otherwise specified, shall be of heavy duty polyethylene, stainless steel or
fibre enforced plastic with swing doors, and shall have a minimum protection of IP65 and where
required certified to explosion protection.
The front cover of all junction boxes shall have a permanently attached nameplate, on which the
junction box tag number is engraved. The box tag number shall also be noted inside the permanently
mounted part of the box.
Instrument/Electrical wiring should be such to avoid any interference and noise from Junction Box till
Control Room.
Inspections
Inspections of Electrical and Instrument equipment shall, as minimum, conform to agreed inspection
plan agreed between EP Contractor and the Client during EP contract.
Commissioning
Commissioning of critical equipment shall be supervised by the OEM engineer and shall be incorporated
and planned accordingly.
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