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HPCL, Visakh

DESIGN DATA-ELECTRICAL

ISSUED : 17/04/2009 / Rev E JOB NO. : 6261

TOYO ENGINEERING INDIA LTD.

DOC.No. A-6261-098-002 DHT PROJECT Page 2 of 26

TABLE OF CONTENTS

Sl. No. Title

Sheet No.

1 Site conditions

3

2 Details of Power Source

3

3 Power Supply Distribution System

4

4 Protection - metering, - control

6

5 Substation design

14

6 Equipment design

15

7 Cabling system

20

8 Earthing system

21

9 Lighting system

21

10 Electrical heat tracing system

23

11. Electrical equipment for hazardous Areas 23

12. Statutory Approval 26


HPCL, Visakh





1.0 SITE CONDITIONS

A. Equipment Design Temperature ( IS 9676) : 42 Deg C

B. Soil Resistivity : As per soil investigation report

C. Minimum Temperature(for battery sizing) : 10 Deg C

D. Elevation above Mean Sea Level : Less than 1000m above mean

sea

level.

E. Relative Humidity : 95 %

F. Seismic Zone : As per IS – 1893

2.0 DETAILS OF POWER SOURCE -- HOLD

2.1 Grid Incomer

A. Name of grid substation : 132kV GIS Switchyard

B. Number of feeders : One no. direct from grid &

through step down trafo.

One no. through 33 kV

GIS switchgear (spare)

C. Length of feeder / conductor size : km/ ___mm2 (Later)

D. Voltage : 33 kV

Frequency : 50 Hz

E. Min/max fault level : kA / kA (Later)

F. Design fault level / BIL : kA / kV (Later)

G. System neutral earthing : Later

H. Minimum load p.f. stipulated by supply authority. : Later

2.2 CPP and its configuration

A. Number / type of captive generators : 02 Gas Turbines +01 Steam

Turbine

B. Generator rating/voltage/power factor : STG-17MW/ 11kV / 0.8 p.f.


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GTG-2x31.5MW / 11kV / 0.8 p.f.

C. Parallel operation with grid : Yes

D. Type of Neutral Earthing : N G T

2.3 Emergency generator

A. Number / type of emergency generator : 03 Nos / Diesel

1 no. for GTG/1 no. for STG

1 no. for each S/S (hold)

B. Generator rating : KVA (min.) - Later

415 V/ 0.8 pf

C. Starting : Auto / Manual

D. Short time paralleling with grid system : No

3.0 POWER SUPPLY DISTRIBUTION SYSTEM

3.1 Voltage and frequency variation.

The following maximum variations shall be considered for equipment:

A. AC System

Voltage : +10%

Frequency : +3 %

B. DC System (at system output terminals)

Electrical Control, Critical Lighting etc. : +10% / -15%

Instrumentation Power Supplies : +10%

3.2 A. Primary HV distribution voltage : 33kV, 50Hz

B. Secondary HV distribution voltage : 6.6kV , 50Hz

C. Primary HV distribution system neutral Earthing : Solidly earthed

D. Secondary HV distribution system neutral Earthing : Resistance earthed

E. Auto/Manual transfer at HV : At 6.6 kV


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F. Auto/Manual transfer at MV with momentary : At 415V PCC and MCC

Paralleling

G. Continuous Parallel operation of Incomers

- HV (33 kV) : Yes

- HV (6.6 kV) : No

- MV (415V) : No

H. Load shedding : Yes

I. HV motor voltage (above 160 kW) : 6.6kV AC, 50Hz, 3 Ph.

J. MV motor voltage (0.18kW and up to 160kW) : 415V AC, 50Hz, 3 Ph.

K. Power factor improvement capacitors : Later

L. Battery chargers ( Incomer Supply) : 415 V AC, 50Hz, 3 Ph

M. UPS System ( Incomer Supply) : 415 V AC, 50Hz, 3 Ph.

N. AC Lighting/Power Panels and Auxiliary Boards : 415V AC, 50Hz, 3 Ph

O. Welding Receptacles : 415V AC, 50Hz, 3 Ph

P. Bulk loads like Process Heaters etc. : 415V AC, 50Hz, 3 Ph

Q. Normal Lighting/Emergency Lighting : 240V AC, 50Hz,Single Ph.

R. Motors rated below 0.18 kW : 240V AC, 50Hz, Single Ph.

S. Convenience outlets : 240V AC, 50Hz,Single Ph.

T. DC Motor(e.g. emergency lube oil pump motor, etc) : 110V DC

U. MOVs : 415V AC, 50Hz,3Ph

V. Space heater for panels : 240V AC, 50Hz,Single Ph

3.3 A. Normal Instrumentation power supply : Refer Instrumentation design

basis

B. Critical instrumentation power supply : Refer Instrumentation design

basis

C. Instrumentation Shutdown system power supply : Independent system

D. Switchgear control, protection and : 110V DC

Critical lighting power supply

E. Input power supply for Plant communication : 240 V, AC, 50 Hz

System with battery back up

F. Input power supply for Fire alarm system : 240 V AC, 50Hz

with battery backup

G. Power supply to SCADA : 110V DC


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H Input power supply to Telephone system : 240V AC, 50Hz

With battery backup

4.0 PROTECTION - METERING – CONTROL

4.1 Control Philosophy

A. Protection Relays for Generator / Grid Incomers : On Switchgear Panel /

Control Relay Panel

B. Protection relays for HV switchgear : On Switchgear panel

C. HV Switchgear control : From switchgear / ECS /

From Generator Control and

Monitoring Panel

D. Numerical Protection/Control/Monitoring system for:

i) Grid Incomers : Yes

ii) HV Switchboard : Yes

iii) 415V PMCC/PCC : Yes

iv) 415V MCC : Yes

E. Microprocessor Based system for control interlocks :

And monitoring of Electrical power system

i) Human machine interface system- HMI : Yes

ii) Separate Operator Console : Yes

iii) Separate Engineering Console : Yes

iv) Data concentrator for each Substation : Yes -If relay or switchboard

makes are different (Separate

for HV and MV system)

v) Integration with higher level system : Yes

vi) Communication Protocol For Numerical : Yes

Relays

vii) Location of HMI : Later

viii) Common HMI for HV/MV system : Yes


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F. Limiting Conditions for Motor Start up

(Starting current limitation or method of starting)

i) HV Motors :As per engineering specification

for motors (case specific for

motor rated beyond 1000kW)

ii) MV Motors :As per Engineering specification

for motors

iii) Method of motor starting

For HV Motors (upto motor 1000kW) : DOL

For HV Motors (Beyond motor 1000kW) : Auto Transformer / Soft start /

Dedicated transformer /

VVFD

For MV Motors (upto motor 160kW) : DOL

G. Type of power isolation for remote transformers located away from HV

substation

i) Push button in transformer bay for tripping : No

remote breaker

ii) Local isolating load break switch panel in : No

switchgear room

iii) Local isolating breaker panel in switchgear : Yes

4.2 Relay protection system

4.2.1 Protection devices for power distribution system shall be as indicated below (Figure

inside bracket refers to note below) √ Applicable


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HV TRANSFORMER

FEEDER

OUTGOING

BREAKER

INCOMER RELAY DESCRIPTION RELAY

NUMBE R

(SECOND ARY

WINDING VOLTAGE > 3.3 kV

(SECOND ARY

WINDING VOLTAGE

≤ 0.433 kV)

HV

MOTOR

FEEDER

HV PLANT

FEEDER

MV

PCC/ PMCC

HV MV

PCC / PMCC

IDMTL over-current relay

51 √ √ - √ √ √(1) √

IDMTL earth-fault relay 51N √ (2) - - √ √ √ (1) √

51G backup earth-fault relay (secondary neutral)

51G

√ √ - - - - -

Motor protection relay with (50, 50N,46, 49, 50L/R,86,95).

99 - - √ -

√ (3) - -

Instantaneous restricted earth-fault relay (secondary side).

64R

-

X’mer bigger than

2 MVA

- - - - -

Instantaneous over-current relay

50 √ √ - - - - -

Instantaneous earth-fault relay

50N √ (4) √ - - - - -

Differential protection .relay

87 √ (5) - √ (6)

√ (7)

- - -

High speed tripping relay

86 √ √ √ √ √ √ √

Trip circuit supervision relay

95 √ √ √ √ - √ √ (8)

Transformer auxiliary relay

63 √ √ - - - - -

Under-voltage relay with timer .

27/2 - - - - -

√ (9) √ (9)

Check synchronizationrelay

25 - - - - -

√ (10) √ (10)


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4.2.2 Minimum protection relays for Synchronous generator (GTG/STG), Generator

transformer, grid power supply incomer and Synchronous motors shall be as follows √

Applicable.

RELAY

DESCRIPTION

NEMA

CODE

GENERAT

OR

GENERATOR

TRANSFOR

MER

HV/EHV

INCOM

ER

HV/EHV

TRANSF

ORMER

SYN

MOTOR

Distance protection 21 √

Synchronous check 25 √ √

Under voltage with timer 27 √ √ √

Reverse power 32 √ √

Low power flow 37 √

Loss of excitatior 40 √ √

Negative sequence 46 √ √

Over current 50 √ √

Earth fault relay 50N √ √

Over current 51 √ √

Voltage restrained 51V √ √ √

Earth Fault back up 51G √ √ √

Over current E/F 51N √ √ √

Over voltage with timer 59 √ √

VT failure 60 √ √

Auxiliary relay for transformer -

63TX √ √

Transformer Restricted Earth Fault

64R. √ √

Stator back up earth fault 64G √

Rotor Earth fault 64R √ √

Directional 0/C 67 √

Directional E/F 67N √

Under frequency/df/dt 81 √ √ √


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Tripping relay 86 √ √ √ √ √

Gen differential 87G √

Gen and Transformer differential

87GT √

Transformer differential 87T √

Feeder differential 87F √

Busbar differential and check

87B/87C

H √

Trip circuit supervision 95 √ √ √ √

Dead bus charging relay 98 √

Over fluxing 99 √

Note: In addition to the above protections Overall Differential Protection for Generator

and Generator transformer shall be provided.

Notes:-

1. 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.

2. Instantaneous earth fault (50N) shall be provided only for transformer with delta

primary.

3. For motor feeders rated above 55 kW, 50 elements shall not be provided for

contactor controlled feeders.

4. Directional IDMTL earth fault (67N) shall be provided for transformer with star

primary.

5. For transformers rated 5 MVA and above.

6. For motors rated 1500 KW and above.

7. For critical/long feeders and plant feeders connected to main power generation

and distribution bus. A plant feeder implies outgoing feeders from one

switchboard to another switchboard of same voltage level.


HPCL, Visakh





8. Trip circuit supervision relay 95 shall be provided as part of the numerical relay

for MV feeders wherever numerical relays are provided

9. Wherever auto-transfer feature is provided.

10. For switchgears where continuous or momentary paralleling of incomers is

envisaged, check Synchronizing relay shall be provided

11. 51G and 64R relays shall not be provided for input transformer of VFD system.

12. Bus tie feeders in HV switchboards shall be provided with. 51, 51N, 86 and 95

relays.

13. HV capacitor bank feeders shall be provided with 51, 51N, 59 (over voltage), 60

(neutral Displacement) 86 and 95 relays

14. 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

b. HV and MV breaker controlled motor feeders

c. Contactor controlled motor feeders with DC control supply.

15. One no. DC supply supervision relay (80) shall be provided for each incoming

DC supply to the switchboard.

16. One set of bus differential relays (87B) and bus wire supervision relay (95 B) for

each bus section shall be provided for

a. HV switchboards connected directly to generation buses

b. Remote HV switchboards directly connected to main generation switchboard.

17 In case of numerical relays, all relays shall be comprehensive units including all

protection, metering and control unless other wise specified

18. Under voltage and over voltage along with associated timer shall be part of the

Numerical relays.

19. Auto changeover logic between Incomers and bus coupler shall be built in the

numerical relay.


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20. 2 Nos of 86 relays shall be considered for HV and MV motor rated more than

55KW

21. Breaker control switch shall be hardwired type.

22. Stand by earth fault relay 51G shall be provided in the incomer of switchboard

fed from transformers and transformer and switchboard located remotely.

23. Restricted earth fault relay 64R shall be provided in the incomer of switchboard

fed from transformers having secondary voltage greater than 3.3KV and

secondary winding star connected. .

24. 51V voltage controlled over current relay shall be provided considering the rating

of the outgoing feeders with respect to the Incomer rating generally this relay

shall be provided where primary current of outgoing feeders is exceeding 40% of

the CT primary current of the incomer.

25. 415V DG set rated up to 500KVA shall have 51V, 51G, 40, 46, 86, 95, 80

protections unless other wise agreed with the owner.

26. Generator rated above 500KVA shall be provided with protection 51V, 51G, 40,

46, 86, 95, 80, 64R as minimum. Additional protection shall be provided, which

merit the size and application of the generator in line with manufacturer /

package vendor’s recommendation and governing specifications / data sheets.

27. All relays upto PMCC level shall be numerical type.

4.3 The metering devices in EHV , HV and MV switchboards shall be as below:

Feeder Type A V Hz PF MW MWH Hour MVAR MVAH MVA.

-Run

EHV Incomer √ √ √ √ √ √ - √ √ √

EHV Bus Tie √ - - - - - - - - -

EHV Transformer √ - - - √ √ - - - -

EHV Bus PT - √ - - - - - - - -

HV Incomer √ √ √ √ √ (2) √ - √ (2) √ (2) √ (1,2)

HV Bus Tie √ - - - - - - - - - HV Transformer √ - - - √ √ - - - -

HV Bus PT - √ - - - - - - - - HV plant Feeder √ - - - - √ - - - -


HPCL, Visakh





HV Motor √ - - - - √ (kWh) √ - - - HV Capacitor √ √ - - - - - √ - - PCC/PMCC Incomer √ √ - √ - √ (kWh) - - - -

PCC/PMCC Bus Tie √ - - - - - - - - -

PCC Bus PT - √ - - - - - - - -

ACB Outgoing √ - - - - √ (kWh) - - - -

MV Motor (> 55 KW) √ - - - - - - - -

MCC/PDB/ASB Incomer

√ √ - - - - - - - -

MCCB/SFU Outgoing √ - - - - √ (kWh) - - - - (>= 250A)

LDB Incomer √ √ - - - √ (kWh) - - - -

DG Set - MV √ √ √ √ √ (KW) √ (kWh) √ - - -

4.4 Metering for generator and Generator transformer shall be according to the table

below. These shall, however, not be limiting.

Meter HV Generator Generator transformer

Ammeter 3nos √ √ Voltmeter with selector switch

√ √

MW meter √ √ MVAR meter √ MVA meter √ MWH meter √ √ MVARH meter √ Power factor √ √ Frequency meter √

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 5.5kW.

4) All metering shall be part of numerical relay in case of electrical system

having numerical relays unless specifically analogue / digital meters asked

for.


HPCL, Visakh





5.0 SUBSTATION DESIGN

5.1 HV/MV Substation

Main/HV MV MCC Room

Elevated with trays in cable cellar Yes Yes No

Elevated with internal trenches No Yes Yes

All top cable entry with trays below

ceiling

No No No

Pressurization against ingress of dust Yes(Note-2)

Yes(Note-2)

No(Note-2)

Air-conditioning for operator room,

UPS, Battery chargers, VFD, ECS,

SCADA and SS-71

Yes Yes No

Roof slab for

Power Transformer

Distribution transformer

Yes

Yes

Yes

Yes

-

HV capacitor bank Yes Yes -

Note: 1. For Main/HV Cables ,internal cable trenches in the cable cellar shall be

considered.

2. Except SS-71 all other substations / MCC room shall be pressurized.

5.2 Specific Equipment Locations

A. Batteries : Separate room in sub-station/control room

B. Battery charger : Air-Conditioned room in Substation /

Control Room

C. Thyristor Controlled Heater Panels/ : Air-conditioned room in Substation

VFD Panels

D. UPS System : Air-conditioned room in control

room /Substation

E. Operator station/SCADA/ECS : Separate Air conditioned room in

substation

F. Fire Alarm Panel : Air conditioned room in Control Room

G. Paging System Equipment : Air conditioned room in Control Room

H. Excitation & control panel : Air conditioned room in Substation


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for syn. Motor

I. Annunciation panel : Operator room in substation

J. Control relays panel / RTCC panel : Air conditioned room in Substation

K. Lighting Transformer : Switchgear room

6.0 EQUIPMENT DESIGN

6.1 HV Switchboard

A. Execution : Draw out

B. Type : Air insulated

C. Bus bar : Single bus

D. Circuit breaker type : SF6 / Vacuum circuit Breaker

E. Motor Control : Breaker ( 840 kW & above)

Vacuum contactor ( less than 840 kW)

6.2 Current Transformer (CT)/ Potential Transformer (PT)

A. CT Secondary

- Protection : 1A

- Metering : 1A

B. PT Secondary : 110 V AC

Note : Separate CT shall be provided for differential and restricted earth fault

protection relay.

6.3 Transformers (Power / Distribution)

Main power transformer Later OLTC

Generator unit transformer Later Off-circuit

Intermediate power transformer Dyn 11 Off-circuit / OLTC

Dedicated ( e.g. for VFD) As Reqd Off-circuit

Distribution transformer

( =< 2000 KVA)

Dyn 11 Off-circuit


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6.4 MV Switchboard

A. Executions

i. PCC / PMCC

Breaker panels : Draw out , Single front

Contactor feeders : Draw out , Single/ double front

ii. MCC : Draw out , Single/ double front

iii. PDB /ASB : Draw out, Single/ double front

iv. LDB : Draw out, Single/ double front

v. Motors

PMCC : Above 55 kW and up to 160kW

MCC : Up to and including 55 kW

vi. Type of switchboard for small package : Draw out , Single front, of approved

(AC system, pressurization system etc,) make

B. Motor Starter Type

i. Contactor and switch fuse with overload relay : Upto 22 kW

ii. Contactor, switch fuse and overload relay : Above 22kW Upto 55 kW

relay with CBCT for earth fault protection

iii. Air circuit breaker with motor : Above 55 kW Upto 160 kW

Protection relay

iv. CT for remote metering : Motor rated above 5.5kW

C. Medium Voltage Outgoing Feeder Type

i Switch fuse : Up to 100 A

ii Switch fuse with Contactor and CBCT : Above 100A and up to 400A

for earth fault protection

iii MCCB with Contactor and CBCT : 100A and up to 400A

for earth fault protection

iv MCCB : 250A and up to 400A

v Air circuit breaker with protection relay : Above 400A


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D. Motor Controls : As per process requirement

i Auto / Manual switch : Control Room/ field / switchgear / control

panel

ii. Local/remote switch : Control Room/ field / switchgear / control

panel

iii. Normal / Standby switch : Control Room/ field / switchgear / control

panel

iv. Process interlock : DCS / PLC / Switchgear

v. Reacceleration equipment : DCS / PLC / Switchgear

vi Control supply for earth fault relay : 110V DC/240V AC

in contactor feeder

vii Control supply for contactor starter : 240V AC , By control transformer

viii Separate transformer for each bus section : Yes

6.5 Motors

Motors High voltage Medium voltage

Enclosure IP55 IP55

Insulation class F (Temp. Rise limited to B)

F (Temp. Rise limited to B)

Terminal box Phase insulated/ Phase separated/ Phase segregated

-

Anti-condensation heater Yes Above 30kW

Additional canopy (outdoor motors)

Yes Yes

FRP Material

Design voltage / frequency variation

± 10%, ±3% ± 10/%, ±3%

Combined voltage / frequency variation

± 10% Any combination of above

± 10% Any combination of above


HPCL, Visakh





6.6 UPS System

A. Redundancy : 100%

B. Type of redundancy : Dual Redundant type

C. Back-up time : 30 minutes

D. Inverter bypass transformer : Static /Servo Controlled

E. Bypass transfer control : Auto / Manual

F. Battery type : Ni-Cd

G. Separate fault diagnostic unit : Yes/No

H. Type of UPS : IGBT / Transistorized

I. Battery execution : Single upto 600 Ah.

Parallel bank above 600 Ah

J. Spare Margin : 20 %

K. Isolation Trafo at Input and Output : Yes

L. Battery : Single Battery bank with 1 x 100%

loading

6. 7 Communication System

A Plant Communication System : Yes

B. Telephone System : Yes

C. Interface of communication system with FA system. : Yes

D. Interface with PA and Telephone System : Yes

E. Battery type : Ni-Cd

F. Battery backup time for telephone system : 60 Minutes

G. Battery backup time for Plant communication System: 60 minutes

6.8 Fire Detection & Alarm System

A. Type : Analogue addressable

B. Name of building to be provided with detectors : Sub-station, control rooms

Major non-plant buildings

C. Type of manual call point : With telephone facility

D. Detection System : Break Glass / Smoke

and Temp. Detector.


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E. Battery back up time : 48 hrs

F. Qty of siren and location : Later

G. Power supply for siren : Uninterrupted

H. Siren range : Later

6.9 DC System

A. Battery type

i) Switchgear Protection, Control & critical lighting : Ni-Cd

ii) Instrumentation System, DC System : Ni-Cd

iii) Diesel Engine Starting : Lead Acid Type

iv) DC Motors : Later

v) Fire alarm system : Ni-Cd

vi) Plant communication system : Ni-Cd

vii) Telephone system : Ni-Cd

B. Battery back up time

i) Switchgear Protection & Control : 120 Minutes

ii) DC Motors : Later

iii) Instrumentation : 30 Minutes

6.10 MV /HV Variable Frequency Drive

i) Type of inverter : Current / Voltage

ii) Number of pulse : Minimum 12 Pulse

iii) By pass feature required : Yes

iv ) VFD rated output voltage : Later

6.11 Cables

The power and control cables shall have the following minimum cross sectional areas:

a) Medium voltage power cable : 16 mm2 (Al.)/ 2.5mm2 (Cu)

b) Control cables : 2.5 mm2 (Copper)

c) Lighting : 2.5 mm2 (Copper)

d) Communication system : 0.9 mm dia (Copper)

e) Fire alarm cables : 1.5 mm2 (Copper)


HPCL, Visakh





Note: 1) For lighting inside the buildings, minimum1.5 mm2 copper conductor, PVC

insulated wire shall be used in conduit system (for circuit and point

wiring), with proper colour coding. 2) All power cables upto 10 mm2 shall be copper. 3) Cable sizes are of equipment manufacturer indicative only and these

shall be finalised as per the communication of the equipment manufacturer

7.0 CABLING SYSTEM

7.1 Cable details

Design Criteria High Voltage 415 Volt

Loads located beyond 1km Cable Cable

Loads located 200-1000 m 1 -core cable/ 3-core cable

1-core cable/ 3 & 31/2-core cable

Loads located up to 200 m Cable Cable / Bus trunking

Load beyond 1kA rating Bus duct /1 core cable Bus duct /1 core cable

Recommended limiting size of multi-core cable (mm2)

300 300

Short-circuit withstand time (seconds)

0.3(Outgoing)/0.60 (Plant)/ 1.0 (Incomer)

N.A.

Insulation voltage grade Earthed for 33kV and Unearthed ( Rest)

Earthed

Type of cable insulation XLPE XLPE

Type of cable insulation during Later -

Fire survival (Resistant ) cable Fire pump Fire proof MOV Plant communication

No - -

No No No

Armoured cables inside the substation

Yes Yes

7.2 Cabling System

A. Process area : RCC trench

B. Offsite paved area : Above Ground cable tray on

sleeper/Overhead rack / RCC


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trench

C. Offsite unpaved area : Above Ground cable tray (on

sleeper / Overhead rack) /

directly buried.

D Type of cable trays : Galvanized prefabricated

F. Road Crossings for underground cables : PVC Pipes / Cable culvert

G. Road Crossings for above ground cables : Overhead cable bridge/culvert

Note: Plant communication, fire alarm and telephone cables shall be laid in

overhead cable trays / instrumentation trenches as far possible. In case

these are not available, cable shall be laid along berm of the roads.

8.0 EARTHING SYSTEM

A. Earth electrode :GI Pipe B. Main earth loop material :GI strip

C. Substation earth loop :GI strip

D. Above Ground Earthing : Copper conductor PVC insulated cable

9.0 LIGHTING SYSTEM

9.1 Supply System

A. LDB at each substation : Yes

B Lighting transformer required : Yes

C. Lighting transformer voltage ratio : 415 / 415V

9.2 Control Philosophy

A. Outdoor Area : Auto / Manual

B. Street lighting : Auto / Manual

C. Outdoor process area : Auto / Manual

D. Process building : Auto / Manual / Centralized / Local

E. Auto control : Synchronous timer / Photocell


HPCL, Visakh





F. Lamp type for outdoor lighting :HPMV(Normal)/MLL(Emergency)

/Incandescent type for (critical

lighting)

G. ELCB at Incomer of lighting and Power Panels : Yes

H. Lighting switch ON/OFF push button at substation entry : Yes

9.3 AC Emergency Lighting

A. Name of process plants : Later

B. Name of buildings : Later

C. Power supply : From Emergency Generator

9.4 DC Critical Lighting for Escape

A. Name of process plants : Later

B. Name of buildings : Later

C. Power supply : 110 V DC

D. DC lighting for remote buildings : Form 110V DC System

9.5 Wiring Type

A. Process plant / Building / Shed : Armoured cable

B. Large service building : surface conduit

C. Buildings with false ceiling : cables/Surface conduit above

false ceiling

` D. Substation (Switchgear Room) : METSEC channel /

Concealed conduit

E. Substation (Cable Cellar) : Surface Conduit / Armoured

cable

F. Other buildings : Surface cable Armoured


HPCL, Visakh





9.6 Specific Lighting Requirements

A. Aviation lighting : Yes

B. Type of control gear for HPMV/HPSV lamps : Separate

C. Control gear box location : At accessible level

D. Type of flood light mast : High mast lighting. /Flood

Lights

10.0 ELECTRIC HEAT TRACING SYSTEM

A. System Design Basis. : Product classification / system

approach

.

11.0 ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS

11.1 The electrical equipment for hazardous areas shall be selected as per lS-.5571 and

petroleum rules. The minimum requirement is summarized below

Equipment ZONE-1 Gas Group

IIA, IIB

ZONE-1 Gas Group

II C

ZONE-2 Gas Group

IIA, IIB

ZONE-2 Gas

Group IIC

MV Motors Ex “d” Ex “d” Ex “e”

Ex “e”

HV Motors Ex “d” / Ex “p” (Refer note-2.9)

Ex “d” / Ex “p” (Refer note-2.9)

Ex “e”

Ex “e”

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


Lighting Fixtures

Light fitting Ex “d” Ex “d” Ex”nR” / Ex”d”

Ex”nR” / Ex”d”

Control Gear Box

Ex “d” Ex “d” Ex”d” Ex”d”


HPCL, Visakh





Junction Boxes Ex “d” Ex “d” Ex – e /Ex -d

Ex – e /Ex -d

Hand Lamps Ex “d” Ex “d” Ex “d” Ex “d” Light fitting Ex “d” Ex “d” Ex “d” Ex “d”

Transformer Unit


Plug & Socket Ex “d” Ex “d” Ex “d” Ex “d” Break Glass Unit (Fire Alarm System)


Lighting panel / power panel


Transformers Hermetically sealed with surface temperature not exceeding 200°C

Notes:

1.0 The electrical equipment for hazardous areas shall generally be suitable for gas

group llB and temp 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.

2.0 As additional safety features, the following requirements for electrical

equipment shall be followed:

2.1 All electric motors for agitators/mixers and metering, pumps handling flammable

material shall be flameproof type irrespective of the area being classified as

zone-2 or zone-1

2.2 All electric motors ‘for vertical sump pumps handling flammable material shall

be flameproof type.

2.3 Irrespective of the area classification (whether zone-1 or zone-2), all lighting

fixtures within the storage areas shall be flameproof type.

2.4 Irrespective of the area classification (whether.zone-1 or zone-2), all motors

and lighting fittings within the pump house (station) near the offsite tank farm

and within the loading/unloading gantries shall be of flameproof type.


HPCL, Visakh





2.5 All emergency/critical lighting fixtures and associated junction boxes in

hazardous areas (whether zone-1 and zone-2) shall be flameproof type.

2.6 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.

2.7 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

- 100% standby system for ventilation.

- Location of MCC/local panels in adjacent separate room Instrumentation

to be flameproof type or hermetically sealed.

-. AC plant room motors with type e’ protection.

- Lighting in AC plant room suitable for zone-2 area.

2.8 Process 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.

2.9 All motors for hazardous area Zone-1shall be flameproof type. Pressurized

motors may be provided in case flameproof motors for the required rating are

not available.

2.10 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.

2.11 All 6.6kV motors in hazardous areas (whether zone-1 and zone-2) shall be

Ex”d” type. In specific cases where flameproof motors in required kW

rating and RPM is not available Ex"p" type motor may be acceptable.


HPCL, Visakh





2.12 For Zone II, gas Group IIA,IIB and IIC if the offered MV motor is Ex'e' type

then the Risk Assesment for motors according to IS 6381:2004 and

IEC:60079-7(2001) shall be done by the vendor without any implication in

price, Or otherwise Vendor can offer Ex" d ' type motor.

12.0 STATUTORY APPROVAL :-

Statutory Authority for electrical Installation : State Electrical Inspectorate /

Central Electrical Inspectorate

Statutory authority for hazardous area : CCOE

Date post:	13-Feb-2018
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