Reliance Petroleum Project

8/14/2019 Reliance Petroleum Project

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Bechtel France SA

Reliance Petroleum LimitedJamnagar Refinery Complex

Specification

22960-3PS-E80-001

Electrical Design Criteria

1 08/11/96 Issued for DesignAccepted by Client

HJY RHB RHB/JJA

0 16-11-95 Issued for Approval HJY RHB RHB/JJA

A Aug 95 Issued for Review HJY BMW

Rev Date Revision By Chkd Appr Client

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Contents

Appendix A Project Specifications.

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Introduction

This specification defines the minimum basis of design of electrical installation for theReliance Petroleum Ltd, Jamnagar Refinery Complex. This specification shall beread in conjunction with other specifications prepared for this project and the

requirements of the applicable codes, standards, and regulations.

Codes, Standards and Regulations

Electrical systems design and installation shall be carried out in accordance with Indian Codesand Standards, in particular;

Indian Electricity Act, 1910

The Indian Electricity Rules, 1956

The Petroleum Act, 1934

The Petroleum Rules, 1976

The National Electrical Code

IS5572 - Classification of Hazardous Areas for Electrical Installations : Part

I Areas having Flaammable Gases and Vapours

These Codes and Standards will be supplemented by International Electrical

Commission (IEC) and British Standards (BS) where no Indian Standard existsor where the IEC or BS offer a design that is safe, modern and more costeffective.

Electrical equipment and materials manufacturing standards shall be in accordance with IECstandards, with the option for Indian manufacturers to offer equipment andmaterials manufactured to equivalent Indian Standards (IS).

Wherever Codes and Standards other than those of India are applied the necessary reviewand approval shall be obtained to ensure that they do not conflict with Nationaland/or local regulations.

Certification of equipment and materials for duty, rating, hazardous area use, etc. shall beobtained from recognised National or International testing authorities. Evidenceof the appropriate certification shall be obtained prior to commitment to

purchase.

Equipment of Indian origin selected for installation in hazardous areas shall have a testcertificate from the Central Mining Research Station (CMRS) and approvalcertificates from the Chief Controller of Explosives (CCE).


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Basic Conditions

The selection of electrical equipment shall be governed by fitness for purpose, safety,reliability, maintainability of spares and service, compatibility with specifiedfuture expansion, design margins, suitability for environment, economicconsiderations, and past service history.

The SI system of units shall be used.

English language shall be used for all drawings, texts and communications.

Equipment and Material Specifications

The equipment and material specifications listed in Appendix A shall be utilised in the designand purchase of the electrical power, earthing, lighting, instrument wiring,control and communication systems.

Service Conditions

Electrical equipment, materials and installation shall be suitable for operation and their designduty under site conditions as stated in the Basic Engineering Design DataSpecification document No. 22960-3PS-GA-001.

Equipment shall have a design life of at least 20 years.

Electrical equipment intended for outdoor installation shall have minimum protection toIP54,or IP55 if located in a hazardous area (in accordance with IEC 529). IP54 is

acceptable for Exd enclosures and floodlight fittings, and IP43 is acceptable forstreet lighting fittings.

Electrical equipment intended for indoor installation shall have minimumprotection to IP31 (in accordance with IEC 529).

Design ambient temperature is:

+ 40C for Equipment Located Indoors and lighting fittings located outdoors.

+ 435C for Equipment Located Outdoors

Equipment and materials shall be suitable for operation in service conditions typical of arefinery within a coastal environment in the tropics. The atmosphere is to beconsidered saliferous, sulphurous and dusty. The possibility of condensationexists, as experienced during large temperature variations in a humidenvironment.

Soil data required for the purpose of grounding calculations (soil electrical resistivity) andcable rating calculations (soil thermal resistivity) will be obtained from the projectsoil survey. In areas where the soil may become contaminated due tohydrocarbon spillage no electrical cables will be installed underground.

Design Calculations


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Calculations shall be made to substantiate the selection and sizing of electrical facilities, e.g.transformers, bus-duct, switchgear, and cables. The results of the calculationsshall be submitted to the Owner for review.

Calculations will include:

Plant and Unit Electrical Loads

Load Flow

Fault Calculations

Power Factor

Voltage Drops

Relay Settings

Cable Sizing

Earthing

Lighting Levels

Power Supply

Main Power Sources and Systems

The refinery will be self sufficient in main power generating capacity to satisfy the maximum

refinery load. In addition interconnections with the local utility system shall beprovided for export and import of electrical power as and when appropriate..

The necessary onsite electrical power will be generated by the use of gas and steam turbinedriven generator sets. The generators shall generate at a voltage of 11kV.

The main power generators shall be connected via individual 11/34.53kV step-uptransformers to the main 33kV distribution switchboard(s) which shall be locatedin the Main Receiving Substations 1 & 2 (MRS 1 and MRS 2)Power PlantSubstation.

The local utility interconnection shall be by means of four step down grid 220/34.5kV gridtransformers each rated 53MVA. having a total rating to provide back up supplyduring main generator downtime. The secondaries of the grid transformers will

be connected to the main 33kV switchboards.

A 220kV outdoor switchyard shall provide interconnection with the grid and thefour grid transformers.

Initially the outdoor switchyard will be operated at 132kV to provide atemporary connection to the local 132kV grid system.

Provision shall be made for integrating the future mega power plant in the overallelectrical distribution scheme (refer to one line diagram 22960-E51-RU772-001ESK-950-003).


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A Load Management scheme shall be provided to synchronise and control the load sharingbetween generator sets and also to initiate load shedding that may be necessary incase of any loss of generating set(s) or back up supply capacity.

50Hz alternating current electrical systems shall be provided as follows:

Main Power Generators 11kV 3 phase, 3 wire Neutral high res. earthed

Main Power Distribution 33kV 3 phase, 3 wire Neutral solidly low res.earthed

Secondary Power Distribution 6.6kV 3 phase, 3 wire Neutral low res. earthed

Emergency Power Distribution 6.6kV 3 phase, 3 wire Neutral low res. earthed

LV Power Distribution 415V 3 phase,. & N 4wire

Neutral solidly earthed

Lighting and Minor Loads 240V 1 phase,. & N 2wire

Neutral solidly earthed(Derived from 415V system)

Instrumentation 110240V 1 phase., &N 2 wire

1 poleNeutral solidly earthed

ContactorControl 240V 1 phase, 2 wire Neutral solidly earthed(Derived from 415V system)

Hand Lamps 24V 1 phase, 2 wire Centre point earthed

22110 Volt dc systems shall be provided for the following:

CircuitbBreakercControls

Emergency Lighting inside substationsLube system drivers (e.g. for GasTurbines)

Where special equipment has a requirement for power supplies other than those listed above,the equipment shall incorporate the necessary converters.

Emergency Power Sources and Systems

Emergency power onsite generating capacity shall be provided to satisfy the critical servicesnecessary to permit safe shutdown in the event of main power failure and toenable black starting of a main power generator.

The necessary electrical power shall be generated by the use of electrically started dieselengine driven generator sets, generating at a voltage of 6.6kV.


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Main emergency switchboards shall be provided at MRS 1 for the main refinery complex andalso at the major substation in the Marine Tank Farm. Emergency diesel enginedriven generator sets shall be provided on the main emergency switchboards andarranged to start up and connect to the busbar automatically should the normalsupply fail. Retransfer of load from emergency to normal on the main emergencyswitchboards, shutdown and periodic testing of the emergency generating sets

shall be manual operation.

From the main emergency switchboards emergency supply shall be distributed to all thesubstations either directly or indirectly via another substation.

For details of emergency distribution system see emergency system overall online diagram(s).The emergency power generator(s) shall be connected to eachsection of the main emergency power 6.6kV switchboard and shall be arrangedto start up and connect to the board automatically in the event that the normal

power feed(s) from the 33kV system fail.

Utilisation

Utilisation voltage for electric motors will be as follows:

Rating Utilisation Voltage

Up to 0.37kW 240V 1 phase

Above 0.37kW up to and including 1650kW 415V 3 phase

Above 1650kW 6.6kV 3 phase

For motors rated above 45000kW, consideration will be given to the use of33/11.5kV captive transformers connected directly to the 33kV system. Neutralof the 11kV system shall be low resistance earthed.

The kW break point between utilisation voltages may be varied for individualcases where thisthere willprovidegive an economical advantage.

Lighting and similar loads shall operate at 240V a.c. derived from a connection be connectedacross phase to neutral connection of a 415V 3 phase 4 wire systemvoltage(240V) from the same LV system. Primary distribution and switching for plant

area and street lighting may be by use of three phase four wire circuits.

AC Voltage and Frequency Tolerances

Steady State Limit

Non UPS

Voltage +/- 10%Frequency +/- 5%

UPPS

Voltage +6/- 1% (at equipment)Frequency +/- 1% feed via inverter

+/-5% feed via bypass transformer


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Transient Limit

Non UPS

Voltage +/- 20%Frequency +/- 5%

DC Voltage Tolerances

Voltage + 10%, - 15%

System Harmonics

The limitations of harmonic currents appearing on the system shall comply withthe British Electricity Council Engineering Recommendations G5/3.

Power Factor

Power factor correction will only be applied if electricity supply authority tariffs includes alow power factor penalty or due to system operation requirements such asstability, harmonics etc..

In general, power factor correction equipment shall only be provided on switchboards withpower factor below 0.85 lagging under normal design operating conditionsWherepower factor correction is required it shall be applied at process related 415Vswitchgear/motor control centres only.

Power Distribution

General

The firm capacity of the electrical supply and distribution system (generation, transformers,switchgear and cables), shall be capable of supplying continuously, 125% of the

peakload as assessed at the design phase of the project. The above mentioned125% may be reduced during design development, but on completion of the

project a margin of at least 10% spare capacity shall exist.

Where secondary selective systems are provided, each incomer shall be rated in accordancewith the above. However for transformers, this may be achieved by utilising theONAF rating, where it is economical to do so.

Main Power Distribution

The main 33kV power distribution switchgear shall be located in Main Receiving SubstationNos 1 & 2 (MRS 1 & MRS 2) .the captive Power Plant Substation.

The main 33kV power distribution switchgear will provide power at 33kV to majorsubstations located in process complexes, offsites, utilities, marine terminal and

jetty. 33/6.9kV transformers will be located at each major substation.

Satellite substations shall generally be fed from major substations by 6.6kV feeders.

LV power shall be provided at substations via local 6.6/0.433kV transformers.


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Duplicate power supplies will be provided to switchboards which supply loads which areessential to continuous operation of the facility.

Primary distributionTransmission of power at 33kV will be by direct buried cables except forfeeders to marine terminal and jetty which will be by 33kV overhead lines.Should the marine jetty be deleted and the ship loading berth become a sea

island, power for the loading berths shall be derived from diesel engine drivengenerators.

Emergency Power Distribution

Dedicated emergency power distribution feeders from the captive power plant emergency6.6kV switchboard shall supply LV emergency power switchboards in majorsubstations via local 6.6/0.433kV transformers.

Separate autonomous emergency power systems will be provided for the marine terminal andjetty.

Process interface buildings and satellite substations shall generally be fed from majorsubstations by dedicated 415V emergency power feeders.

Emergency power will be provided to vital loads which are defined as those which whenfailing in operation or failing if called upon to operate, can cause an unsafecondition or result in damage to the installation.

Permissible Voltage Drop In hCables

Main Feeders 1% at full rated current at receiving endterminals

Motor Feeders 5% at motor terminals for at full loadcurrent running condition.

15% at motor terminals forstartingcondition.

Secondary Feeders (lighting,small power and other lowvoltage circuits)

2% at full rated current at receiving endterminals

Lighting sub-circuits 5% at the furthestfutherest fitting

Where excessively oversized cables would result by applying the abovepermissible volt drops, each case is to be individually assessed taking the enduser requirements into account (e.g. for a main feeder to a transformer which is

provided with taps the volt drop in that feeder may exceed the above specified1% provided the increased volt drop can be compensated by the transformertap(s) and provided the transformer secondary voltage remains within specifiedtolerances from zero load to full load on the transformer).


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Substations

General

All substations shall be located strategically at load centres outside hazardousareas. Substation buildings shall be ventilatedair conditioned and shall generally

comprise elevated structures permitting the use of bottom entry switchgear withcable racking and trays below. 33kV Switchgear will be housed in a separateroom. Large batteries shall be housed in separate rooms but small batteries whenenclosed in ventilated equipment cabinets shall be permitted in the switchroom.An equipment access door shall lead directly to the outside from each switchroom. Internal personnel doors may connect adjacent rooms. Powertransformers shall be located at grade level in fenced enclosures adjacent to thesubstations and shall be provided with oil catchment pits pits and sunshades.BlastFire walls will be provided where required by codes and standards.

Heat sensitive electronic equipment shall be located in a separate room providedwith air conditioning.

Main Receiving(Power Plant) Substations (MRS)

Two Main Receiving SubstationsA main substation shall be provided adjacent tothe captive power generation plant. Each MRSThis substation willaccommodate twothe main 33kV power distribution switchboards, 6.6kV stationservices and emergency powerswitchboards, LV switchboards and motor controlcentres. MRS 1 shall also house the main emergency switchboard. The 33kVswitchgear shall be accommodated in a separate room. Load managementsystem hardware will alsobe accommodated in the Captive Power Plant ControlRoom.same substation.

Each main generator package shall be supplied complete with all the auxiliaryequipment such asshall incorporate a skid mounted control cabin accommodatingthe low voltage motor control centre,switchboards and all of the DC equipmentand batteries for the auxiliaries associated with the particular generator. LocalfFacilities shall be provided for starting the generator, for control ofsynchronising to the 33kV busbars and for loading the machine. Facilitiesy shallalso be provided to transfer control of starting, synchronising and loading of thegenerating set to a remote location (generator control room within the mainsubstation).

Plant Area Substations

Plant area substations shall be designated to be either a Major Substationsupplied with power at 33kV and housing both 6.6kV and LV systems, or asSatellite Substation supplied with power at 6.6kV (from one of the MajorSubstations) and which may house only LV distribution or both 6.6kV and LVsystems.

Utility Incoming Switchyard

A switchyard adjacent to the 33kV substation shall be provided for terminating

the utility incoming supply and to accommodate the four 220(HOLD)/34.53kVgrid transformers. Line isolators, line and transformer earthing switches andmetering transformers shall be provided at the high voltage side of the powertransformers. Switchyard services equipment together with the tap changer


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control, protection and tariff metering panels will eitherbe located inside MRSauxiliary rooms or inside a kiosk local at the switchyard.

Hazardous Areas

Hazardous Area Classification

Area shall be classified in accordance with the IS5572 - Classification ofHazardous Areas for Electrical Installations : Part 1 Areas Having FlammableGases and Vapours.

Equipment Selection

Electrical equipment shall meet the requirements of the Institute of PetroleumModel Code of Safe Practice : Part 15. The following equipment shall beselected.

Zone 1 Areasa) Flameproof or explosion proof, Ex(d) equipment

b) Pressurised, Ex(p) equipmentc) Intrinsically safe, Ex(ia) or Ex(ib) equipment

d)

Zone 2 Areasa) Non-sparking, Ex(n) equipment

b) Increased safety, Ex(e) equipmentc) Equipment complying with the requirements for

zone 1 area

Unclassified Areasa) Standard industrial equipment

b) Equipment complying with the requirements forzone 1 and 2 areas

Non Indian origin electrical equipment for installation in hazardous areas shall be typecertified by CENELEC approved testing authority. Electrical equipment ofIndian origin for installation in hazardous areas shall have a test certificate fromthe Central Mining Research Station (CMRS) and approval certificate from thechief controller of Explosives (CCE).

Equipment

Switchgear/Motor Control Centres

The 220kV switchgear shall be of the outdoor open type design with circuit breakers of theSF6 type and isolators of the open, air break type. Switchgear shall be inaccordance with specification 22960-3PS-EZ-001.

The main 33kV switchgear shall be of the air insulated, metalclad type with vacuum circuitbreaker and in accordance with specification 22960-3PS-ES-001.

6.6kV switchgear/motor control centres shall be of the air insulated, metalclad type with

vacuum circuit breaker and in accordance with specifications 22960-3PS-ES-002. All motors shall be controlled via circuit breakers. and EC-002. Feederswitches for motor drives up to approximately 4000kW shall be of the fused


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vacuum or SF6 contactor type. Larger motors, transformer and other feedersshall be supplied from circuit breakers.

415LV switchgear/motor control centres shall be in accordance with specifications 22960-3PS-ES-003 and EC-003. Motors rated up to and including 90kW shall becontrolled by fused contactors. Motors rated above 90kW shall be controlled by

air circuit breakers on Power Control Centres (PCC). Fuse switch circuits shallgenerallybe used for outgoing feeders up to and including 63 amps and fusedcontactors for circuits greater than 63 amps and up to and including 630 amps.Current ratings above 630 amps shall be supplied from air circuit breakers onPCC..

Emergency switchgear complete with automatic changeover facilities shall be provided whereappropriate in all the substations. Under normal operating conditions power tothe 415V emergency switchboards/MCCs shall be derived from the normalsupply network. Oona loss of normal supply the automatic changeover facilitieswill changeover the supply from normal to emergency. The retransfer of load

back from emergency to normal supply will be an automatic function.Emergency power will be provided by diesel engine driven, 6.6kV generators. Theemergency generators will be connected to a 6.6kV emergency switchboardlocated in the main substation in the captive power plant. Duplicate 6.6kVincoming feeders from the normal power system will be provided. Emergency

power will be distributed at 6.6kV throughout the refinery. At each majorsubstation 6.6/0.433kV transformer(s) and 415V emergency switchboard(s) will

be provided. Under normal conditions power to the 415V emergencyswitchboards will be derived from the normal 4l5V power supply system. Anautomatic change over facility will be provided to change over to the emergencysupply on loss of normal volts.

Separate emergency power systems will be provided in the Marine Terminal and for the Jettyfacility. Power will be provided by diesel engine driven, 6.6kV generators anddistributed similarly to that for the main refinery.

Where duplicate feeds are provided to 6.6kV and 415V , switchboards,gea ran automatictransfer scheme will be provided in order to switch to the alternative feeder if afailure occurs in one supply feeder. Protection shall be provided to preventtransfer in the case of a fault downstream of the circuit breaker. The automatictransfer systems shall be independent for each switchboardbusbar section andshall include time delay such that transfer takes place at the 6.6kV level beforetransfer at LV is effected. The timing shall also be adjusted such that switching

to the emergency supply feeder shall only take place if upstream transfers havefailed to restore the supply. Return to normal after main power restoration shall

be manual. Exceeding of switchgear fault rating during momentary parallelingshall be permitted.

Lighting and small power distribution switchboards shall be located in each substation, inother buildings and at strategic locations outdoors around the plant areas.Depending upon their application they shall be supplied either from photocellcontrolled or manually operated circuits on either the normal or the emergencyservices LV switchboards. The distribution switchboards shall be in accordancewith specification 22960-3PS-EK-001. The distribution switchboards shall be

suitable for indoor or outdoor use and the hazardous area classification in whichthey are to be situated. Distribution boards located in hazardous areas shall belimited to 18 single phase ways.


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Automatic motor reaccelaration/restarting following voltagepowerdips will not be providedunless dictated by process requirements..

Power system monitoring, control and protection will be in accordance with specification22960-3PS-EY-004. Emergency Shut Down (ESD) systems and emergencystops will be hard wired back to the switchgear/MCC.

Large motors fed via 33/11.5kV captive transformers will be controlled by 11kV switchgearconnected to the secondary side of the captive transformer. Both transformerand 11kV switchgear shall be located in the substation local to the motorcontrolled.

Power Transformers

Distribution power transformers shall be in accordance with specification 22960-3PS-ET-002.

Generator and grid transformers shall be in accordance with specification 22960-3PS-ET-

001.

Cooling arrangement of all transformers shall be ONAN.Where cost effective ONAN/ONAFtransformers will be provided (i.e. ONAN rating will match current loadrequirement with fan cooling (ONAF) fitted in future to provide for futureloads).

Automatic on-load tap changers shall be provided on the grid transformers and the maindistribution transformers located at the Marine Tank Farm major substation..

Power Factor Correction

Power factor correction will be applied only where dictated by para 7.7 above.

Where provided Ppower correction equipment shall be in accordance with specification22960-3PS-EA-002will only be provided should the power supply authorityimpose a low P.F. penalty within his electricity tariffs.

Consideration will be given regarding the alternative of using synchronous machines toimprove the overall system power factor of the plant at the point of gridconnection.

Neutral Earthing Resistors

Neutral earthing resistors shall be in accordance with specification 22960-3PS-EG-001.willbe provided to limit the earth fault current on each of the 33kV, 11kV and 6.6kVnetwork to an appropriate level.

Each earthing resistor will be rated to withstand the respective earth fault current for aduration of not less than 10 seconds. For 6.6kV system 250A, and for 11kVsystem 250A (except generation), see single line diagram(s) for details.

DC Supply Units

DC supply units shall be in accordance with specification 22960-3PS-ED-001.

DC supply Units shall be provided in each substation for:


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the Sswitchgear protection and tripping supplies

, and Ssubstation alarm annunciators panel(s)

Electrical load management system

Electrical distribution management system

See single line diagram(s) for DC system configuration.

DC supply units will be in accordance with specification 22960-3PS-ED-001.

AC Uninterruptible Power Supplies (UPS) Systems

AC UPS systems shall be in accordance with specification 22960-3PS-EUP-001.

AC UPS systems shall be provided as required in substations, process interface buildings andcontrol rooms to provide no break supplies to the following systems:

Distributed Control System (DCS)

Fire and Gas System

ESD System

Control panels where deemed appropriate

Essential instrumentation

Machine/Process Condition Monitoring System (e.g. vibration, analyser and

anti-surge).

PA/Alarm System

Talkback Intercom System

Telephone System

Radio System

CCTV System

See single line diagram(s) for ACUPS system configuration .

Busbar Trunkings

Busbar trunking shall be in accordance with specification 22960-3PS-EB-001.

In general power connections exceeding 1000 amps will be carried out using busbar trunking.

Relay Panels and Protective Devices

The metering, protection and control equipment associated with the 220kV switchgear shallbe housed in dedicated relaypanels located in a relayroom within located MRS1.Main Substation.


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Thebus zone protection equipment associated with the 33kV switchgear shall be housed indedicated panels located in the relay room within the respective MRS.

With the exception of 220kV and 33kV switchgear all other protective devices and metersshall generally be housed within the switchgear cubicles.

The metering, protection and control equipment associated with the gassteam and steamgasturbine driven generating sets shall be housed in dedicatedpanels located insidethe auxiliary room within each MRS or Captive Power Plant Control Roomrespectively.respective local control cabin.

All other protective devices and meters shall be housed within the switchgearcubicles.

Alarm Annunciators

Alarm annunciators shall be in accordance with specification 22960-3PS-EY-003.

All fault tripped and equipment malfunction signals occurring within switchgear, MCCs andother electrical equipment shall be wired into an alarm annunciator panel situatedin each substation. A common summary alarm signal from each annunciator shall

be fed into the DCS where it shall bring up a substation fault alarm in the MainControl Room.

Certain alarms shall be fed into the electrical distribution management systemwhich shall bring up an alarm in the CPP Control Room.

Interfaces with Process Control Systems

Process control interfaces between the DCS and MCCs shall be by a communications datalink.

Certain switchgear signals shall be connected into the DCS for remote status monitoring ofthe electrical system.

EnergyLoad Management System

The Energy Management System shall combine both load management and electricaldistribution system management functions.

Load management shall be in accordance with specification 22960-3PS-EY-002

and electrical distribution management in accordance with specification 22960-3PS-EY-004.

Load management shall monitor and facilitate control of the main power generation,synchronising and load shedding at the 33kV level. Its functions shall includeautomatic load sharing, load shedding, grid transformer tap changer control,33kV breaker control and system parameters/status monitoring.ency genera

The electrical distribution management shall provide monitoring and control (exceptemergency system) of the complete electrical power distribution system. Thisincludes breaker control, status monitoring and fault reporting of the distribution

circuit breakers and monitoring of systemparameters such as voltage and power.


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The communication between the substations and the management system shall eitherbe viaoptical fibre serial links or hardwired.

The system shall have the facility to be monitored from the main Control Room via the DCSserial link communication network.The system shall also have the facility to communicate with the Refinery

Information Management System (RIMS)..

The main Energy Management System and Electrical Distribution Management Systemequipment shall be located in the Captive Power Plant Control Room.

Variable Speed Drives

Variable speed drives equipment shall be in accordance with specification 22960-3PS-EVP-001 .

The use of variable speed drives, shall be considered on an economic and technical basissubject to process requirements.

Converter equipment shall be located inside the substation, except the associatedtransformers and reactors, which shall be located outside within atransformer/reactor bay adjacent to the substation..

Motors and Motor Control Stations

Motors generally shall be of the squirrel cage induction type and in accordance with

specifications 22960-3PS-EM-001 and 22960-3PS-EM-002. LV motors shallnormally be selected to have ratings in accordance with the preferred ratedoutput values of the primary series as listed in IEC 72.

Motor enclosures shall be selected to suit the site conditions. As far as is practical, motorsshall have totally enclosed fan cooled (TEFC) enclosures. Larger machines willgenerally have separate internal and external air circuits (CACA or TETC).).

All motors above 30kW shall will be fitted with 240V AC rated anti-condensation heaters.Winding heating utilising 24V AC shall be provided for all motors rated 30kWand below.

Motors for use in hazardous areas shall be fully certified as follows:

Area Certification

Zone 1 6.6kV motors Ex(d) or Ex(p)

LV motors Ex(d)

Zone 2 6.6kV motorsEx(n) orEx(d) (with Ex(d) or Ex(e) Terminal box) orEx(p)

LV motors Ex(n) orEx(d) (with Ex(d) or Ex(e) Terminal box) orEx(n)


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Each motor shall be provided with a start/stop control station installed on suitable steelsupport adjacent to the motor. Exception being the critical drives such asemergency D.C. lube oil pumps for the gas turbines.

Start/stop control station shall have stay put stop and lock-off stop features (padlocking).

Start/stop control stations for motors rated above 30kW and motors driving agitatorscompressors and blowers shall be provided with ammeters. Ammeter shall haveconnection to CT (1 amp secondary) located within the motor starter.shalle thecontrol gear. Othermotors below 30kW driving agitators, compressors lowersshall also provide

Start/stop control stations for all fin-fan and cooling tower fan motors shall be located atgrade.a aA lock-off stop push button shall be located adjacent to each fan motor.

Motors having automatic process control shall be provided with control stations

incorporating Hand/Off/Auto selector switch (padlockable in Off position).

Motors which can be started from more than one location shall be provided with controlstations with Local/Off/Remote selector switch (padlockable in Off position).

Motor operated valves and electric cranes shall be fully equipped with integral control gear.

Earthing System

Earthing systems shall provide low impedance earth paths for earth faults, static dischargeand lightning protection.

Power system earthing, lightning protection and equipment bonding shall be by a commonsystem. All units shall be bonded together to form a single continuous earthingsystem.

The earthing systems in the high voltage switchyard, substation and power plant shallcompriseeach consist of a buried grid of galvanised mild steel flat bar bondedtogether and sized to suit the maximum earth fault current for 1 second plus a50% corrosion allowance. Earth electrodes providing the requisite value ofresistance to the general mass of earth electrodes shall be installed adjacent totransformers and generators and throughout plant areas to ensure that the

requisite value of resistance between equipment and the general mass of earth isobtained. The electrodes shall be bonded to the earthing grids throughdisconnecting links which will permit periodic maintenance testing. Connectionsfrom the earthing grid rising above ground to local metalwork and electricalequipment shall be carried out using PVC covered aluminium cablegalvanisedsteel wire. All large equipment items shall be bonded to earth in at least two

places.

The design of the earthing grid within the high voltage switchyard shall ensure that step andtouch voltages remain within code requirements.All other units shall have a

buried continuous earth ring of mild steel flat bar encompassing the unit area.

The mild steel bar shall similarly be designed to carry maximum earth faultcurrent for 1 second plus a 50% margin for corrosion. Connections to localmetalwork and equipment shall be carried out as described above.


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A separate earthing system shall be provided for the earthing of instrumentation system insideeach area.

Earthing and bonding of jetty shall be designed and installed in accordance with relevantstandards. Pipe and/or hose connections between ship and the jetty shall be

provided with insulation flanges or joints. Gangways shall be insulated from the

ship by means of insulated rollers. Electrical equipment on the jetty shall bebonded to the shore earthing system regardless of whether or not the jetty iscathodically protected.

Earthing and bonding at road and rail loading facilities shall be designed and installed inaccordance with the relevant Codes and Standards. Bonding clamps with Ex(d)isolators shall be provided for bonding between tanker and fixed installation.

The metallic enclosures of all electrical equipment shall be bonded and earthed to thecommon earthing grid.

In hazardous areas or where the equipment contains a hazardous liquid, the metallic

enclosures of non electrical equipment, vessels, tanks, structures, etc., shall bebonded and earthed to the common earthing grid.

Maximum values of resistance of equipment earthing systems to the body of earth shall be asfollows:

General Electrical Earthing 1 ohm

Earthing for Lightning Protection 10 ohms

Instrument Clean Earth 1 ohm

Intrinsically safe Earth 1 ohm

However, a lower resistance value may be necessary to ensure proper operationof the earth fault protection.

Lightning protection shall be provided for all non metallic and all metallic noncontinuouslywelded structures over 20 metres high.

Earthing of lighting and small power systems shall be by means of an earth conductor integralwithin cable or conduit. Power circuits shall be earthed by separate earth wireconnected to the earthing grid.

Lighting

General Lighting

Lighting in industrial plant hazardous and non hazardous areas shall generally be by means ofhigh pressure mercury vapour wellglass twin lamp fluorescent luminairiesmounted on the structures, directly beneath beams, or on platform mounted

poles. Alternatively, where available to be sourced within India fluorescentluminaires may be provided.

Where required, gGeneral lighting for open areas within non hazardous area industrial plants

where required shall be by means of 250 or 400 watt high pressure sodium(SON) floodlight luminairies mounted on adjacent structures or on strategically


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located floodlight columns. High mast floodlighting (using 1000W SON)installation shall also be used where appropriate.

Where required general lighting for open areas within hazardous area industrial plantsrequiredshall be by means of 400 watt high pressure mercury vapour floodlightluminaires mounted on adjacent structures or on strategically located floodlight

columns.

High bay type 250 or 400 watt high pressure sodium luminairies shall be used in appropriatenon hazardouslocations such as compressor houses, warehouses, workshops etc.

Lighting in industrial buildings such as substations, workshops, warehouses, canteens, etc.shall be by industrial type ceiling or trunking mounted, twin lamp, fluorescentluminairies.

Lighting in administration building offices, instrument roomscontrol rooms and similarlocations shall be by flush ceiling mounted fluorescent luminairies of a typecompatible with the building architectural finishes. Control Room luminaires

shall be of the low glare mirror optic type.

The following average intensity levels, measured 1m above the floor level in a horizontalplane, shall form the basis for the lighting design:

Type of Location Lux

Control Room - general lighting 400 - 700

- rear of instrument panels, aux. and panel rooms. 250

- outside, near entrances 150

Pump and compressor houses, at or near equipment 100150

Switchrooms and PIBs etc. 150

Furnace and boiler areas 510

Outdoor operational areas 510

Outdoor non operational areas 103*

Stairways, platforms and walkways 510

Road/Rail loading gantries 50

Rail siding coupling/uncoupling areas 10

Rail storage sidings generally 51*

Road truck parking areas 53*Drawing offices 700

Offices 400

First-aid rooms 400

Toilets and locker rooms 150

Workshops - interior generally 250

- exterioroutside 50

Stores - interior between racks 150

- material yards 5*

- bulk storage operating areas 50Refinery Tank FarmsTank farms 5*0.5*

Marine Area Tank Farms 5*


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Jetty approaches 105*

Roads/main access 5*

Roads minor 53*

Complex Entrance GatesFence 50*No specific

lighting provided

* At gradeEmergency Lighting

Emergency lighting shall comprise two categories:

Category 1: No break lights, comprising fluorescent luminaries with integral battery/charger or alternatively central battery fed tungstenluminairies. They shall have 1 hour autonomy

Category 2: Short break lights, fed from the emergency generators.

Luminaires may be of the tungsten or fluorescent type.

The number of emergency luminaries in relation to normal luminaries shall be as follows:

Type of location Category 1 Category 2

Process area - 10%

Utility area - 20%

Machinery rooms (Workshops) 5% 25%

Road/Rail loading gantries - 10%Switch rooms, equipment rooms and instrumentshelters (including process interface building PIBs)

5% 25%

Off plot tankage areas andppump stations - -

Control and medical rooms 10% 40%

Administration buildings and offices 5% -

Fire exit doors from buildings 100% -

Road and Parking area Lighting

Road and parking area lighting shall be provided by means of 250, 400 or 1000 watt highpressure sodium luminaries mounted on 10 metre columns or 20 metre highmastfloodlighting columns. This lighting shall be connected to the normal powersupply system.

Rail Siding Lighting

High mast floodlighting shall be utilised in areas where trains are coupled or uncoupled, inswitching areas and on the loading/unloading areas and their sidings. Apart fromthe loading gantries, the rail siding lighting shall be fed from the normal power

system only.

Tank Farm Lighting


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High mast floodlighting columns sited in non hazardous locations outside of tank farm bundwalls shall be utilised. Local lighting may be provided as necessary in areas ofregular plant operational activity.

Lighting Control

Outdoor lighting circuits shall generally be controlled by photo electric cells. Manualoverride shall be provided to permit maintenance.

Indoor lighting shall be controlled locally by suitably located switches.

Power and Convenience Outlets

415 volt, 63 amp, TP&N+E Power outlets shall be provided in workshops and at strategiclocations in industrial and plant areas such that all principal equipment locationscan be reached by use of 50 metres of extension cable.

240 volt, 16 amp, SP&N+E Convenience outlets shall be provided throughout the industrialareas such that all principal equipment locations can be reached by use of 25metres of extension cables.

Convenience outlets for hand lamp supplies with integral transformer, rating - 100VA, 240/24Volts (centre point earthed), shall be provided near to the manholes of vessels,tanks columns etc.

Sufficient 240 volt, 13 amp, SP&N+E Convenience outlets shall be provided in all domesticand administrative buildings, PIBs, switch and equipment rooms, and workshopsand offices.

All outlets located within hazardous areas shall be certified for such locations.

Cable and Cable Installation

Cable Types

Power cables and control cables may have XLPE or PVC insulation selected on economicconsiderations, and in accordance with relevant specifications 22960-3PS-EW-001. Instrumentation cables shall be selected in accordance with relevantspecification 22960-3PS-EW-002s.

Conductors 16 sq. mm and greatershall generally be may be either ofaluminium or(C coppermay be selected on economic orand technical considerations). Conductorssmaller than 16 sq. mm shall be copper.. Aluminium and copper conductors shallnot both be used on the same circuit.

All cables used above or below ground in industrial areas shall have non hygroscopic fillers,wire armouring, and PVC overall sheath.. Additionally, cables used undergroundin hydrocarbon processing or storage areas shall have a lead sheath.

Unarmoured cables and wires may be used where proper mechanical protection (e.g. metallic

conduit) is provided or where sheathed cables are installed above ceilings orbelow floors in non industrial locations. Concealed metallic conduits shall beused for buildings where appropriate.


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Cables for critical services shall be of the fire resistant type in accordance with IEC 331.

Cables for conduit installation shall be PVC insulated single conductor.

Earthing of lighting and small power systems shall be by means of an earth conductor integralwith the cable or conduit.

Cable Installation

Thepreferred method of cable installation is for cables to be installed above ground laid onracks and trays within dedicated levels of overhead piperacks and on the sleepersof low level pipeways.

In certain instances cables may be routed underground, these include:

high voltage distribution cables and associated control cables

cables entering or leaving buildings

cables in areas where ground contamination is unlikely and economic

consideration precludes the erection of special cable supports

cabling within the power generation area

feeder cables to satellite substations.

Cables routed underground shall be direct buried within offsite areas and installed in formedconcrete trenches within process areas.

33kV cables shall be laid in a single layer at 300mm centres and at a minimumdepth of 900mm below grade.

6.6kV cables shall be laid in one or two layers at 150mm centres and at aminimum depth of 500mm below grade.

415V cables may be laid in up to three layers at 150mm centres and at aminimum depth of 500mm.

Control cables and light loaded cables may be grouped together or laid betweenloaded cables.

All cables shall be laid on a sand bed with well compacted sand around andabove. Concrete or earthenware tiles shall be laid above the cables in unpavedareas, tiles are not required where cables are laid in formed concrete trenches.Trenches shall be sized to allow for a future 20% increase in cabling.

Where cables leave the main trenches and for road crossings they shall be run in duct banksof concrete encased PVC ducting.

Where cables rise above grade to equipment they shall be protected by metallic kick sleeveup to 150 mm above grade and from there shall be run on rack or tray or secured

by some other suitable means.

Control and communications signals between the refinery andcables along the pipelinewayleave to the marine area will be carried via fibre optic cables, installed as part


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of the 33kV overhead line system .and jetty shall generally be laid direct buriedadjacent to the 33kV overhead lines.

Cables shall be installed with spacing to minimise derating but consistent with the total spaceavailable.

All underground cables shall be fitted with substantial identification bands at terminations, at30m intervals over their entire length, at all points where they enter and leaveducts, and at changes in cable direction etc. The identification band shall showthe complete cable number.

Suitable route markers shall be provided to indicate trench locations and shall be located at50 m intervals and where the trench changes direction. When the trench is within

paved areas, red coloured coversconcrete paving, shall be used to mark cableroutes.

Cables shall be in one length where practical but underground joints may be installed whennecessary. Cable joints shall be recorded and their locations marked accurately

on as built drawings.

When cables pass through a building foundation, ducts or an opening in the foundation shallbe used to permit entry.

Adequate segregation shall be maintained between different services. In general, power andinstrumentation/telecommunication cables shall not be laid in the same trench. Aseparation of 600mm shall be maintained between parallel runs of instrument andelectrical cables.

Above ground cables shall be supported by cable racks or trays. Power cCables shall

generally be laid on racks or trays in a single may be bunched in a maximum oftwo layers. Control cables may be bunched together. Cables shall besecuredcleated at required intervals.

Cable racks and trays material shallbe fabricated from steel and hot dipped galvanised afterfabrication.suitable for the environment in which they are used. Considerationwill be given to the use of hot dip galvanised steel, stainless steel and GRP.

Cable racks and trays shall be enclosed by removable top covers allowing adequateventilation in the following situations:

Mechanical damage of cables is likely to occur during plant maintenanceactivities.

Oil or chemical spillages on the installation can be expected.

Covers are required for sun shields

Power (and associated control) HV, LV, and instrumentation/telecommunication cables shallbe run in their own racks. HElectricalV cables shall be where practical separatedby at least 60750mm from instrumentation and telecommunication cables exceptat switchgear/MCC an substations..

All cables shall be terminated using an approved compression cable gland which shall be ofnickel platedbrass except for single core cables where aluminium glands shall beused. All cable entry threads shall be BS conduit (ET) to BS 31.


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Alternative feeders to substations shall follow separate routes as far as is practical. Generallyunderground cables shall be in separate trenches (e.g. on opposite sides of roads)or if this is impractical shallbe separated by at least 1 metre.

Wiring for lighting, small power and telecommunication systems within non industrialbuildings shall be single core pvc insulated copper conductors run in screwed,

seamless, metallic conduits. Conduits shall be chased into the blockwork of wallshaving a plastered finish, elsewhere conduit installations shall be surface runclipped to brickwork, concrete or structural steel. All outlet boxes shall be steeland approved for either surface mounting or flush mounting system.

Within plant areas and in all hazardous areas, lighting and small power cablesshall be multicore pvc terminated using compression type cable glands.Wiring in

buildings for lighting, small power and telecommunication may be installed inconduits. Metallic seamless conduit shall be used in industrial areas but plasticconduits are acceptable in non industrial buildings.

Aircraft Warning Lights and Navigational Aids

Aircraft warning lights shall be installed on high chimneys and structures as required byinternational and local regulations.

Navigational aid lighting shall be installed on the Jetty as required by international and localregulations.

Electrical Trace Heating

Where necessary electrical trace heating shall be provided for process pipelines. As far as is practical, suitably certified self regulating heating tapes shall be employed.Special types of heating (e.g. skin effect, impedance or induction heating) may beemployed in particular applications.

Cathodic Protection

Appropriate application shall be made of either impressed current or sacrificial anodemethods of cathodic protection for buried or immersed structures, vessels, pipesand tank bases. The responsibility for the design and installation of the ground

beds shall be under the scope of the specialist sub contractor. The design of thejetty cathodic protection system, if any, shall take account of the leakage currentto the shore earthing system.

Standardisation

For ease of maintenance and to limit the spare parts inventory, it is intended that as far as ispractical, each class and category of electrical equipment shall be of the sametype and supplied by the same manufacturer wherever it is used on the refinery.

When similar classes and categories of electrical equipment are included in packages, vendorsshall be required to purchase the same standard types.


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Installation

The installation of the electrical and instrument cables and equipment will be carried outunder one or more subcontracts. Main equipment, cables and bulk materials will

be free issue to the installation subcontractor but minor installation materialsincluding fixings, brackets, steelwork for site fabricated supports, cable tray

below 100mm wide, conduit and conduit wiring, sand for cable bedding andcover, cable tiles, trench markers and all consumables will be supplied under thesubcontract.


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Appendix A

Project Specifications

Specification No. Description

22960-3PS-E80-002 Electrical Installation And Testing

22960-3PS-E80-003 Electrical Requirements For Packaged Equipment

22960-3PS-E80-004 Electrical Power System Studies

22960-3PS-E80-005 Captive Power Plant Design Criteria

22960-3PS-E80-006 Electrical Design and Installation for Electrical Equipment of Buildings

22960-3PS-EA-002 Power Factor Correction Equipment

22960-3PS-EA-003 Navigational Aids

22960-3PS-EA-004 Overhead Line Equipment

22960-3PS-EB-001 Busbar Trunkings

22960-3PS-EC-001 415V Outdoor SwitchgearSwitchracks

22960-3PS-EC-003 415V Motor Control Centres22960-3PS-ED-001 DC Power Supply Units

22960-3PS-EG-001 Neutral Earthing Resistors

22960-3PS-EH-001 Electric Trace Heating

22960-3PS-EK-001 Distribution Boards

22960-3PS-EM-001 LV Motors

22960-3PS-EM-002 HV Motors

22960-3PS-EMG-001 AC Synchronous Generators

22960-3PS-EMG-002 Diesel Engine Driven Generators

22960-3PS-EQ-001 Cathodic Protection

22960-3PS-ES-001 33kV Switchgear

22960-3PS-ES-002 6.6kV Switchgear

22960-3PS-ES-003 415V Switchgear

22960-3PS-ET-001 Generator and Grid Transformers

22960-3PS-ET-002 Power Distribution Transformers

22960-3PS-ET-003 LV Transformers

22960-3PS-EUP-001 AC UPS Units

22960-3PS-EVP-001 Variable Speed Drive Systems

22960-3PS-EW-001 HV and LV Cables

22960-3PS-EW-002 Instrumentation Cables

22960-3PS-EY-001 Generator Control Panel

22960-3PS-EY-002 Load Management System

22960-3PS-EY-003 Substation Alarm Annunciators Panels

22960-3PS-EY-004 Electrical Power, Control, Protection and Monitoring

22960-3PS-EY-005 Thyristor Control Panels for Electric Heaters

22960-3PS-EZ-001 HV Open Type Switchgear

Date post:	30-May-2018
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