Electrical Design Basis - Rev 0

DOCUMENT No.
6556-00-16-50-DB-01
Rev.0
ENGINEERING DESIGN BASIS

ELECTRICAL
Page 1 of 17

DESIGN PHILOSOPHY
5.7 ELECTRICAL
THIS DOCUMENT HAS BEEN APPROVED BY IOCL
10.02.05
IOCL Comments incorporated and issued for

implementation
02.11.04
Issued for clients comments/Approval
Rev.
No
Date
Format No. EIL 1641-1924 Rev. 1
Purpose
SA
RCS
AAN
SA
RCS
AAN
Prepared
by
Checked
by
Approved
by
Copyright EIL All rights

reserved

ELECTRICAL
%%$
1.0
Site conditions
2.0
Power Source Details
3.0
Power Supply Distribution System
4.0
Protection - Metering Control
5.0
Substation Design
6.0
Equipment Design
7.0
Cabling System
8.0
Earthing System
9.0
Lighting System
DOCUMENT No.
6556-00-16-50-DB-01
Rev.0
Page 2 of 17
10.0 Electric Heat Tracing System

11.0 Electrical Equipment For Hazardous Areas
12.0 Statutory Approval
13.0 Cable Sizes for MV Motors
14.0 Specific requirements
15.0 Attachments
16.0 Deviation to design philosophy

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DOCUMENT No.
6556-00-16-50-DB-01
Rev.0

ELECTRICAL
Page 3 of 17
The electrical design data defines the design requirements agreed by owner/clients in addition to
Design philosophy for electrical facilities no: 6-51-0099 Rev 4 (Any additional deviation must be
recorded as part of this document)
1.0
SITE CONDITIONS
A.
B.
C.
D.
E.
: 45C
Soil Resistivity
: Later (after the soil Resistivity test)
Minimum temperature. for battery sizing
: 10C
Equipment design temperature (IS 9676)
per IS-1893)
Altitude above mean sea level
2.0
POWER SOURCE DETAILS
2.1
General
A. Independent system or existing system

2.2
: Independent system
Grid Supply
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
2.3
: <1000 m
* Refer CPP design basis
Name of sub station / MW
: *
Number of feeders
: *
Length of feeder
:*
Type of conductor/ cable size
: *
mm
Voltage
: *
kV
Frequency
: *
Hz
Minimum/maximum fault level
: *
kA /
KA
Design fault level / Basic Insulation Level
: *
kA /
kV
System neutral earthing
: *
Minimum load power factor stipulated by
: *
Supply authority
:*
Parallel operation of incomers
: *
Yes/No
PLCC requirement
: *
Yes/No
CPP and its configuration
A.
B.
C.
D.
2.4
* Refer CPP Design basis
Number / type of captive generators
: *
/Steam, Gas turbine
Generator rating/Voltage/Power factor
: *
MW/ kV/ 0.8
Parallel operation with grid
: *
Yes /No
Neutral earthing
High resistance earthed
Emergency generator
* Refer CPP design basis (Emergency
A.
B.
C.
D.
E.
Number / type of emergency generator
:*
Generator rating/Voltage/Power factor
:*
kW/ V/ 0.8
Starting
:*
Auto / Manual
Short time para
:*
Yes/No
Paralleling with grid system
:*
Yes /No
power for lighting from existing PREP power plant)
2.5
Details of Existing System
3.0
Refer CPP design basis
POWER SUPPLY DISTRIBUTION SYSTEM
Based on PREP-IOCL design basis and DFR

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DOCUMENT No.
6556-00-16-50-DB-01
Rev.0

ELECTRICAL
Page 4 of 17
3.1
Voltage and frequency variation

AC System
i.
Voltage
ii.
Frequency
:
:
+6%
+3%
:
:
+ 10%
+%
Primary HV distribution voltage
33KV
Secondary HV distribution voltage
6.6 KV
Primary HV distribution system neutral earthing
Solidly earthed
Secondary HV distribution system Neutral
Resistance earthed
HV motor voltage
6.6KVabove 160KW & </= 6MW
MV motor voltage
415 VAC upto&including 160KW
Auto transfer at 6.6KV bus
Yes
Auto transfer at MV (At PCC Level)
Yes
Continuous Parallel operation of Incomers
B. DC System (at system output terminals)

i.
Electrical Control, Lighting etc.
2
ii.
Instrumentation Power Supplies
3.2
Utilisation voltage and operating philosophy
A.
B.
C.
D.
E.
F.
G.
H.
I.
HV
Yes /No (33KV-Yes, 6.6/11KVNo, 415V-No)
No
Yes/ No
Motors rated below 0.18 kW
240V AC, 1ph/ 415V AC 3ph
Battery chargers incoming power supply
415V AC, 3ph
UPS System incoming power supply
415V AC, 3ph
AC Lighting/Power Panels and Auxiliary

Boards incoming power supply
415V AC, 3ph
J.
K.
L.
M.
N.
O.
P.
Q.
R.
S.
T.
U.
3.3
PCC/PMCC
4
Load shedding
Welding Receptacles
415V AC, 3ph
Bulk loads like Process Heaters etc.
415V AC, 3ph
Normal Lighting/Emergency Lighting
240V AC, 1ph
Power factor improvement capacitors
As required
Convenience outlets
240V AC, 1ph
DC Motor
Not envisaged
415V AC, 3ph
Normal Instrumentation power supply
V AC
Critical instrumentation power supply
V AC/ V DC
Shut-down system power supply
V AC/ V DC
Switchgear protection and Critical lighting

power supply
220V, DC
E. DC supply for instrumentation

F. Plant communication system power supply
Independent system
415V, Normal,
backup
G. Fire alarm system power supply
240V AC Normal
Motor operated valves
Utilization voltage for critical supplies
A.
B.
C.
D.
with
battery
(With battery back up)

2
Refer instrument design basis

More than 6MW, the motor shall be connected on 11KV through dedicated transformers
4
Refer DB Document, section 11 of advanced E&I for load shedding
5
Refer instrument design basis for voltage choice for instrument loads
3

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ELECTRICAL
Page 5 of 17
H. Annunciation panel power supply6

4.0
PROTECTION - METERING CONTROL
4.1
Metering for external power supply incomers
A. Summation metering
B. Trivector meter
4.2
V AC Normal/AC UPS
V DC (No separate Pnl)
Not applicable
:
Yes/No
Yes/No
Protection relays for HV switchgear
On Switchgear panel
HV Switchgear control
Local/ Remote/ ECS
Control Philosophy
A.
B.
C.
D.
Hard wired annunciation panel
No (Part of substation HMI)
:
:
:
:
Yes / No (Not applicable)

Yes
Yes
Yes
Numerical Protection/Monitoring system for
i.
ii.
iii.
iv.
EHV system
HV Switchboard
415V PMCC/PCC
415V MCC
E. Microprocessor based system for control interlocks :
Yes
and monitoring of electrical power system
i.
ii.
iii.
Human machine interface system-HMI :

Yes
Operator console
:
Yes
Engineering console
:
No, use LAP TOP instead
Data concentrator for each substation (Separate for HV and MV system)
8
:
Yes/ No
Interface with higher level control system:
Yes
F. Limiting Conditions for Motor start up

(e.g. starting current limitation or method of Starting)
9
i.
ii.
HV Motors
MV Motors
iii.
Method of starting for large HV motors :
iv.
Method of starting for large MV motors :
:
:
G. Type of power isolation for remote transformers10

i.
Load break switch in switchgear room :
ii.
Push button in transformer bay for tripping:
550% (No tolerance allowed)

600% up to 75KW, 550% above
75KW
Direct on line (refer foot note for
F(i)
Direct on line
No
for all transformers
Remote breaker
Hard wired annunciation panel is not proposed. Annunciation will be part of substation HMI
No grid backup is envisaged as per CPP design basis.
8
Separate data concentrators for HV and MV are not required for same make and type of relays
9
For motors greater than 2.5MW, maximum starting current shall be based on motor startup study
10
As 33KV switchboards are of rating 31.5KA and available in GIS, instead of local isolating panel, it is
suggested to provide push button station with lamp indication for trip of sending end breaker and requires
approval with CEA for implementation.
7

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6556-00-16-50-DB-01
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ELECTRICAL
Page 6 of 17
4.3
11
Relay protection system

Protection devices for power distribution system shall be as indicated below
Relay
number
51
Relay description
Feeder
IDMTL over-current relay
51N
Transformer
IDMTL earth-fault relay
(Secondary
winding
voltage
(Secondary
winding
voltage
> 3.3 KV)
< 0.433 KV)
Yes
Yes
Yes (7)
51G
51G
backup
earth-fault
(secondary neutral)
relay Yes
99
Motor protection relay with locked

rotor feature
No
(50, 50N,46, 49, 50L/R)
No
Motor
feeder
Outgoing feeder
Incomer
HV
HV
HV
MV
PCC/
MV PCC/
PMCC
PMCC
-
Yes
Yes
Yes
Yes
(4)
(13)
Yes
Yes
(4)
(13)
Yes (4)
Yes
Yes
No
No
No
No
No
Yes
No
Yes (8)
No
No
No
No
No
No
No
64R
Instantaneous restricted earth-fault Yes

relay (secondary side)
50
Instantaneous over-current relay
Yes
Yes
No
No
No
No
50N
Instantaneous earth-fault relay
Yes (6)
Yes
No
No
No
No
87
Differential protection relay
Yes (1)
No
Yes (2)
Yes (3)
No
No
No
86
High speed tripping relay
Yes
Yes
Yes
Yes
Yes
Yes
Yes
95
Trip circuit supervision relay
Yes
Yes
Yes
Yes
No
Yes
No
63
Transformer auxiliary relay
Yes
Yes
No
No
No
No
27/2
Under-voltage relay with timer
No
Yes
(5)
Yes (5)
Yes
Yes(9)
(14)
25
Check synchronisation relay
(9)
NOTES:
1. For transformers rated 5 MVA and above.
2. For motors rated 1500 kW and above.
3. For critical/long feeders and plant feeders connected to main power generation and
distribution bus.
4. These relay functions can be substituted by inherent releases. At remote substations where
DC supply is not envisaged, 415V switchboard shall have inherent releases instead of
relays.
5. Wherever auto-transfer feature is provided.
6. Instantaneous earth fault 50N shall be provided only for transformer with delta primary.
7. Directional IDMTL earth fault 67N shall be provided for transformer with star primary.
8. For motor feeders rated 55 kW and above.
9. For switchgears having bus transfer scheme, where continuous or momentary paralleling is
envisaged, check synchronising relay shall be integrated with overall paralleling scheme.
10. The bus tie feeders in HV switchboards shall be provided with 51, 51N, 86 and 95 relays.
However MV bus tie shall not have any protective relays.
11. HV capacitor bank feeders shall be provided with 51, 51N, 59 (over voltage), 60 (Neutral
displacement), 86 and 95 relays.
12. In case of HV switchboards with parallel operation of incomers, following additional relays
shall be provided:
a. One set of 87B (Bus differential) and 95 B (Bus wire supervision) for each bus
section.
b. 67 and 67N (Directional IDMTL over current & earth fault) relays for the incomers.
13. The following feeders shall be provided with timers for delayed tripping on bus under
voltage while the under voltage relay shall be common for the bus
a. HV and MV capacitor feeders
11
Generator protection requirement shall be covered separately in respective EPCC document.

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DOCUMENT No.
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ELECTRICAL
Page 7 of 17
14.
15.
16.
17.
4.4
b. HV and MV breaker controlled motor feeders or contactor feeders with DC control

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

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ELECTRICAL
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6556-00-16-50-DB-01
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Page 8 of 17
5.0
SUBSTATION DESIGN
5.1
EHV Switchyard
Not applicable
A. Type
B. Structure
C. Bus material
5.2
: String bus / Tubular bus

: Galvanised / Painted / RCC
: Aluminium / Copper
HV/MV Substation
Description
HV *
MV
Elevated with trays in cable cellar
Yes
No
12
Raised with internal trenches
Yes
All top cable entry with trays below ceiling
No
No
Yes
Pressurisation against ingress of dust
Yes
Yes13
Air-conditioned room for operator
Yes
No
Roof slab for
Power transformer
No
No
Distribution transformer
No
No
Note:
1. * Substation with long high voltage switchboards having substantial amount of cabling work
2. Battery room shall be preferably located in corner side at first floor of the substation
building.
5.3
Specific Equipment Locations
A. Batteries
Electrical switchgear batteries
UPS batteries
B. Battery charger for electrical system

Battery charger for instrumentation
C.
D.
E.
F.
UPS System
: Air conditioned room in control room
Lead-Acid and Nickel-Cadmium
: In separate rooms
Annunciation panel
Not envisaged/ HMI

annunciation
Operator
substation
Single/Double
Minimum oil/SF6
EQUIPMENT DESIGN
6.1
EHV Switchyard
to have
room
in
NOT APPLICABLE
A. Bus bar system

B. Circuit breaker type
C. Isolator type
: Pantograph/ Semi pantograph/ Centre rotating/ Centre break
HV Switch-board
A.
B.
C.
D.
6.3
: In substation air conditioned room

: In Control room along with UPS.
Variable speed drive panels/Thyristor control panel : Air-conditioned room in substation
6.0
6.2
: Separate room in sub-station

: Separate room in control room
Execution
Drawout (Fixed for GIS-33KV)
Bus bar system
Single/(Double bus for GIS)
Circuit breaker typ
SF6/Vacuum
Motor Control
Breaker/ Vacuum contactor
1/5A
Current Transformer (CT)/potential Transformer (PT)
A. CT Secondary
14
Protection
12
HV cables in cable cellar shall be laid in trenches filled with sand

Pressurization not required for remote MCC room located in safe area
14
1A Protection CT for differential, REF protection; Separate CT for differential/ REF protection
13

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ELECTRICAL
Page 9 of 17
Metering
B. PT Secondary
6.4
1A (No separate metering CT

except Metering CT for motor
PB stn
:
Transformers (Power/distribution)
110 V AC
15
Transformer
Vector
group
Tap changer
Soak pit
Main power transformer
Yyo/Dy1
OLTC
Yes
Generator unit transformer
Ynd 11
Off-circuit
Yes
Intermediate power transformer
Dyn 11
OLTC/Off-circuit
Yes / No
Dedicated (e.g. for VFD)16
As Reqd.
Off-circuit
Yes / No
Distribution transformer
Dyn 11
Off-circuit
No
Preferred
(kVA)
rating
(< 2000 KVA)
6.5
MV Switchboard
A. Execution
i.
ii.
iii.
iv.
v.
PCC / PMCC
Breaker panels
Contactor feeders
MCC
ASB
LDB
Motors
PMCC
MCC
17
Type of switchboard for package
:Draw out/Single front

:Drawout, single / Double front
:Drawout, single / Double front
:Drawout /Fixed, single/Double Front
:Drawout /Fixed: single/Double Front
: Above 55KW Upto&Including 160kW
: Upto and including 55 kW
: Compartmentalised/Fixed type
vi.
B. Motor Starter Type
i.
Contactor and switch fuse with overload relay: Up to 22 kW
ii.
Contactor, switch fuse and overload relay with: Above 22 up to 55 KW
iii.
iv.
v.
vi.
vii.
CBCT for earth fault protection

Contactor and switch fuse with motor protection relay
:
Above 55 up to 160KW
Air circuit breaker with motor protection
:
No
Contactor and MCCB with overload relay:
No
Contactor, MCCB and overload relay with CBCT:No
for earth fault protection
CT for remote metering
:
Motor rated above 5.5KW
C. Motor Controls18
i.
Auto / Manual switch
: Near motor/Switchgear/control room
ii.
Local/remote switch
iii.
Normal / Standby switch
iv.
Process interlock
: PLC /relay panel/switchgear
v.
Reacceleration equipment
: PLC /relay panel/switchgear
vi.
Control voltage for Contactor Starter :
240V AC
vii.
Control supply for contactor starter
:
Control transformer.
viii.
Separate transformer for each bus section:
Yes/No
15
Rating of Power and intermediate transformers, OLTC requirement including vector grouping of all
transformers shall be decided during basic engineering based on KSLD attached with FEED.
16
To be finalized based on licensors recommendation
17
Package like AC plant MCC, Bagging plant MCC etc
18
6.5C(i to iv): Operating philosophy and location of controls shall be as per process and instrumentation
design basis.

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ELECTRICAL
Page 10 of 17
6.6
Motors
Motors
High voltage
415 volts
IP55/IP54
Enclosure:
Indoor
IP55/IP54
Outdoor
IP55
IP55
Insulation class
F (Temp. Rise limited to B)
Terminal box
Phase segregated/ Phase separated / Phase insulated
Anti-condensation heater
Yes
30 kW and Above
Additional canopy (outdoor motors) Yes
Yes
Design
voltage
variation
6 % / 3%
frequency 6 % / 3%
Note: Motors for MOV actuator shall have F class of insulation with temperature rise limited to
class-B.
6.7
UPS System
A.
B.
C.
D.
E.
F.
G.
H.
I.
6.8
: 50% /100%
Type of redundancy
: Parallel redundant/Hot standby
Back-up time
: 120 minutes
Inverter bypass transformer
: Static
Bypass transfer control
: Auto / Manual
Separate fault diagnostic unit
: Yes/No
Battery type
: Lead acid/Ni-Cd/VRLA
Type of UPS
: IGBT/Transistorised
Battery execution
/servo controlled
: Single bank up to 600 Ah/Parallel bank above 600 Ah
Communication System
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
6.9
Redundancy
Plant Communication System

Telephone System
19
Yes
Yes
Telephone system and plant communication system :
Separate/Integrated
No. of intercom and external P&T lines
Later By IOCL
Battery type for telephone system
Sealed Lead acid (SMF)/ VRLA
Battery type for plant communication system
Sealed Lead acid battery/ VRLA
Battery backup time
120 min for both systems
Interface of Communication system with fire alarm system:
Yes
Interface of PA and telephone system
Yes
Type of communication system
Digital microprocessor based
Fire Detection and Alarm System
A.
B.
C.
D.
E.
F.
G.
Type
: Conventional/Analogue addressable
Name of buildings to be provided with detectors
: All buildings except watch tower
Battery type
:Sealed Lead acid (SMF)/Ni-Cd/VRLA
Battery backup time
:48hrs. (Normal) + 120 minutes. (Alarm)
Detection System
: Break Glass/ Smoke, Heat, linear beam
Type of manual call point
: With/Without call back facility

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

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Page 11 of 17
H. Power supply for Siren

I. Any specific requirement of range
6.10 DC System
A. Battery type
i.
Switchgear Protection, control
Control and critical lighting
Instrumentation System
Diesel Engine Starting
21
DC Motors
ii.
iii.
iv.
B. Battery back up time

i.
Switchgear Protection
Control, Lighting
Instrumentation
Diesel Engine Starting
DC Motors
ii.
iii.
iv.
: 415 V AC/DC normal supply

: 10 Km diametrical
: Lead acid/Ni-Cd/VRLA(automotive type)
:120 minute when no DG back up and
30 minutes where DG set is available
: 30 /60/120minutes
: 10Starts (FW pumps)& 6 Starts others
: refer foot note
6.11 Variable frequency drive

22
i.
Type of inverter
23
ii.
Number of pulse
iii.
By pass feature required
iv.
VFD rated output voltage
:
:
:
:
See foot note

6/12
Yes
As per licensor/FEED reqt.
6.12 Cables
The power and control cables shall have the following minimum cross sectional areas:
A.
B.
C.
D.
E.
24
Medium voltage power cable
25mm (Al)/2.5 mm (Cu)
Control cables
2.5 mm (Cu)
2.5 mm (Cu)
0.9 mm dia (Cu)
1.5 mm (Cu)
25
Lighting
Communication system
26
Fire alarm system
7.0
CABLING SYSTEM
7.1
Cable details
Design Criteria
High voltage27
Loads located beyond 1 km
1Core/ 3 Core Cable
Cable
Loads located 200-1000 m
1-Core/ 3 Core cable
1-core cable/ 3-core cable
Load located up to 200 m
3 Core Cable
Cable / Bus trunking
Loads beyond 1 kA rating
Bus duct / cable
Bus duct /1 core cable
Recommended limiting size of multi-core

cable (mm)
300
300
Short-circuit withstand time (seconds)
0.2 (Outgoing)/0.60 (Plant)/1.0

(Incomer)
N.A.
Insulation voltage grade
Earthed for both 33KV and

6.6KV system
Earthed
Type of cable insulation
XLPE
PVC
415 volts
21
DC motor application is not envisaged

Licensors recommendation/ EIL equipment specification shall apply
23
6 or 12 pulse rectifier as per manufacturers standard and as required for meeting EIL equipment
specification requirement.
24
Cable for motor above 110KW shall be sized considering copper cable.
25
1.5 mm Cu conductor PVC Insulated wire shall be used in conduit with proper colour coding for building
lighting.
26
Cable sizes for PA and FA systems are indicative. These shall be finalised later as per the manufacturers
recommendation
27
1Core or 3 Core HV cable shall be decided during basic engineering based on load and distance
22

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Page 12 of 17
High voltage27
415 volts
Fire pump
Yes/No
Yes/No
Plant communication
Yes/No
Armour for cables inside the substation
Yes/No
Yes/No
Design Criteria
28
Fire survival (Resistant) cable
7.2
Cable laying philosophy
A. Process area29
B. Offsite paved area30
C. Offsite unpaved area
:Overhead cable tray /RCC trench-sand filled
D. Type of cable trays

E. Special requirements
:Galvanized prefabricated / Site fabricated and painted
:Above Ground cable tray on sleeper/overhead rack/ RCC trench

:Above Ground cable tray (on sleeper/ overhead rack) / directly
buried. (see footnote against point 7.2 above)
:Cables for fire water system shall be taken on exclusive route
through underground trench starting from main substation in case
applicable
F. Road Crossings for under ground cables31

G. Road Crossings for above ground cables
8.0
:Overhead cable bridge/culvert/ERC
EARTHING SYSTEM
A.
B.
C.
D.
E.
Earth electrode
: GI pipe
Main earth loop material
: GI strip
Substation earth loop
: GI strip
EHV switchyard earth grid
: Not applicable
Lightning system
: As per IS2309
9.0
LIGHTING SYSTEM
9.1
Supply System
A. Centralised with separate transformer32

B. At each substation with separate transformer
C. Separate metering required
9.2
:PVC Pipes /Cable culvert
: Yes/No
: Yes /No
: Yes/No
Control Philosophy
A.
B.
C.
D.
E.
F.
Outdoor yard
: Auto/Manual/centralised (ECS)/Local
33
Street lighting
: Auto/Manual/centralised(ECS)/Local
Outdoor process area
: Auto/Manual/Centralised (ECS) / Local
Process building
: Auto/Manual/centralised/Local
Auto control
: Yes-Synchronous timer/photocell/ No
Lamp type for outdoor lighting
: HPMV-Process area/HPSV-Street light,

FLM/
(Incandescent
type
for
DC/emergency Critical lighting)
G. Panel execution
34
: Lighting transformer fed LDB with OG

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

reserved
DOCUMENT No.
6556-00-16-50-DB-01
Rev.0

ELECTRICAL
Page 13 of 17
H. ELCB at Incomer of lighting and Power panels35

9.3
AC Emergency Lighting
A. Name of process plants

B. Name of buildings
C. Power supply
9.4
: All process Unit except U&O Pump stn

: All buildings- Plant and non plant
: As per CPP design basis
DC Critical Lighting For Escape
A.
B.
C.
D.
9.5
: Yes/No
Name of process units

36
: All process units
Name of building
: All buildings (see footnote)
Power supply
: 220V DC
DC lighting for remote substation
: (See foot note)
Wiring Type
A. Process plant / Building / Shed

B. Large service building
C. Buildings with false ceiling
: Armoured cable
: Concealed/ surface conduit
: cables/Surface conduit above false
Ceiling
D. Substation (Switchgear Room)

E. Substation (Cable Cellar)
F. Other buildings
9.6
: METSEC channel
: Surface Conduit/armoured cable
: Concealed/Surface, conduit/
cable(armoured/ unarmoured).
Specific Lighting Requirements
A.
B.
C.
D.
E.
F.
Aviation lighting
Navigation lighting
Yes /No
Yes/No
37
Security lighting for peripheral road at boundary wall :
Yes/No
Type of control gear for HPMV/HPSV Lamps
Separate/Integral
Control gear box location
Accessible level if separate
Type of flood light mast
30 m Telescopic fitted tubular
10.0 ELECTRIC HEAT TRACING SYSTEM

A. System Design Basis
: Product Classification /System approach
35
ELCB shall be provided at sub distribution feeder at LDB for lighting panels for AC as well as DC lighting.
All buildings except remote buildings not having DC supply shall be provided with DC lighting for escape.
For buildings where DC supply is not available, portable DC light for escape to be provided.
37
To be provided on watch towers through search light
36

reserved

ELECTRICAL
DOCUMENT No.
6556-00-16-50-DB-01
Rev.0
Page 14 of 17
11.0 ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS

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

Ex-e/Ex-n
MV Motors
Ex-d
Ex-d
Ex-e/Ex-n
HV Motors
Ex-d / Ex-p
Ex-d/ Ex-p
Ex-p/Ex-e/Ex-n/
Ex-e/Ex-n
Push Button Station
Ex-d
Ex-d
Ex-d
Ex-d
Motor Starters
Ex-d
Ex-d
Ex-d
Ex-d
Plug & Socket
Ex-d
Ex-d
Ex-d
Ex-d
Welding Receptacle
Ex-d
Ex-d
Ex-d
Ex-d
Lighting Fixtures
Ex-d
Ex-d
Div.2 Ltg.
Div.2 Ltg.
(IS-8224)
(IS-8224)
i. Lighting fitting
ii. Control Gear Box
Ex-d
Ex-d
Ex-e/Ex-d
Ex-e/Ex-d
Junction Boxes
Ex-d
Ex-d
Ex-e/Ex-n
Ex-e/Ex-n
i. Light fitting
Ex-d
Ex-d
Ex-d
Ex-d
ii. Transformer Unit
Ex-d
Ex-d
Ex-d
Ex-d
iii. Plug & Socket
Ex-d
Ex-d
Ex-d
Ex-d
Break Glass Unit
Ex-d
Ex-d
Ex-d
Ex-d
Ex-d
Ex-d
Ex-d
Ex-d
Hand Lamps
(Fire Alarm System)

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

reserved
DOCUMENT No.
6556-00-16-50-DB-01
Rev.0

ELECTRICAL
Page 15 of 17
12.0 STATUTORY APPROVAL
Statutory Authority for Electrical Installation

Hazardous area equipment
:
:
Central Electrical Inspectorate

CCE
13.0 CABLE SIZES FOR MV MOTORS

i. Direct on line (D.O.L) start motors (2/4 pole motors)38
Motor Rating
Cable Details
Number of runs
No. of cores
per run
Conductor material
Conductor
mm
Below 3.7 KW
Cu
2.5
3.7 KW
Cu
5.5 KW
Cu
7.5 KW
Cu
10
9.3 KW
Cu
16
11 KW
Cu
16
15 KW
Cu
16
18.5KW
Al
35
22 KW
Al
35
30 KW
Al
50
37 KW
Al
70
45 KW
Al
95
55 KW
Al
120
75 KW
Al
185
90 KW
Al
95
110 KW
Al
120
125/132 KW
Cu
120
160 KW
Cu
120
size
ii. Cable sizes for motors not confirming to above table e.g. for 2/4 poles motors, extended distance,
reduced voltage starting, low speed motors, shall be worked out on case to case basis.
iii. Cables sizes as indicated above are applicable for a distance up to 350m maximum and for 2/4
poles motors fed from MCCs located near PCCs and PMCCs.
iv. Cables for lighting shall be used to allow the following voltage dips
Street lighting
:10%
DC critical lighting
:5%
14.0 SPECIFIC REQUIREMENTS

i.
Canopy shall be provided for all out door equipment.
ii.
Substation shall be sized to ensure 2 nos panel extension on each bus section
iii.
iv.
v.
vi.
vii.
for all HV/ MV switchboards except GIS.

Dummy panel shall be provided in switchboards wherever there is expansion
joint in the building.
If signal cables for DCS interface with substations are envisaged, these shall be
laid in separate trays/ trench. However in exceptional cases signal cables may
be laid in electrical trench, properly cleated on trench wall allowing 300mm gap
with other power cables in the trench.
For building engineering, each office room, in addition to switch/ socket for
lighting design, shall be provided with minimum 2 nos telephone sockets and 2
number LAN socket at two different location as duly approved during detailed
engineering.
Modular type switches/sockets in main control room and all non plant buildings
shall be modular type.
Lamps shall be standardized for the purpose of inventory in hazardous area
lighting as below.
38
Cable sizes given in the table are indicative and standardized for inventory and are the minimum sizes. The
cable size as required to meet voltage drop criteria shall be provided.

reserved

ELECTRICAL
DOCUMENT No.
6556-00-16-50-DB-01
Rev.0
Page 16 of 17
Well glass normal Lighting : 70W HPMV lamps for well glass fittings
Flood Lighting
: 250W HPMV lamps for flood lighting
Critical lighting
: 100W GLS lamps
15.0 ATTACHMENTS
Design philosophy for Electrical Facilities
6-51-0099
Rev 4
16.0 DEVIATION TO DESIGN PHILOSOPHY

Document number 6-51-0099 rev 4
The requirement given under engineering design basis document shall be overriding. However
following job specific requirement are highlighted as deviation to Design Philosophy of Electrical
facilities document number 6-51-0099.
16.1 Clause 4.6.1 Voltage drop

i.
b(ii) MCC/Aux switchboard situated remote from PCC/PMCC 2%
ii.
d - Cable between PCC/PMCC to motor- 5% during normal running
16.2 Clause 4.11 DC Power supply
i.
DC power supply system for electrical controls and for critical lighting shall be
separate. For electrical controls and instrumentation, DC system shall be dual
redundant with single set of battery and for critical lighting, DC system shall be
non redundant.
16.3 Clause 4.15.3 Plant communication system-capacity for future expansion

i.
Exchange supplied shall be fully wired for hardware, power supply, software etc
ii.
for the capacity as required with spare capacity of 20% field call stations with no
future modification in exchange hardware/ software.
Exchange shall have required hardware for communication between two
exchange of the same make
16.4 Clause 4.16 Fire detection and alarm system

i.
Cl 4.16.5 : Spare fire alarm loop for future shall be 20% or 1number whichever is
ii.
maximum. Each loop shall be engineered to provide the flexibility to add 20%
additional detectors in future, if required.
Cl 4.16.6 : The status for actuation of fire suppression system shall also be wired
to fire alarm panel to annunciate at central fire alarm monitor.
16.5 Clause 5.3 Switchgear

i.
Cl 5.3.4 : Each HV Switchboard (above 415V and except 33KV) shall have
ii.
minimum 2 numbers spares of each type. (i.e. type like transformer feeder, motor
feeder, plant feeders etc)
Cl 5.3.4 : Each MV Switchboard (Up to 415V) shall have 20% spares of each
type ( Spares in each MCC shall however be 20% subject to 1 number of each
motor feeder module )
16.6 Clause 5.7 Battery charger and Distribution board

i.
Cl 5.7.3 : Each DCDB shall have 20% spare feeder for future use.
ii.
DCDB outgoing feeders for critical lighting shall be provided with ELCB.
16.7 Clause 5.8 Uninterrupted power supply system
i.
Cl 5.8.4: Spare feeders in ACDB shall be 20% for future use with minimum of 1
ii.
number of each rating.

Cl 5.8.5 : UPS shall be sized to have 20% spare capacity on calculated load for
future loads.
16.8 Clause 5.13 Cable and Wires

i.
Cl 5.13.6 : No unarmored cable shall be used.
ii.
Cl 5.13.10 : Control cables shall have 1core spare upto 6core requirement and
20% or 2 core whichever is maximum for cables having requirement above 6
cores.

reserved

ELECTRICAL
DOCUMENT No.
6556-00-16-50-DB-01
Rev.0
Page 17 of 17
iii.
iv.
For 4-20mA signal interface between switchboards and DCS, screened cable
shall be used.
Cl 5.13.7 : Cables laid for hazardous area shall not have any joints.
16.9 Clause 5.14 Control stations

i.
Cl 5.14.1 : Each motor shall be provided with local control station. If specified per
process or equipment control requirement, local control station can be part of
local control panel.
16.10 Clause 5.16 Actuators for motor operated valves

i.
MOV shall have separately mounted actuator in area of high vibrations. In
particular the MOVs for Cooling water application shall have separate actuator
located near the valve for local actuation.
16.11 Clause 7.2 Cabling System

i.
Clause 7.2.5: Cable trays shall be sized to allow 20% additional space for future
ii.
cables.
Clause 7.2.14: MCTs shall be provided wherever the entry is above ground. And
where entry is below ground, sleeves (Laid in outward slope to avoid water entry)
shall be provided for electrical cables.
16.12 Clause 7.4 Lighting system

i.
Non-plant buildings such as administrative building, gatehouses etc should be
ii.
provided with energy efficient CFL lamp fixtures.

In plant buildings, control rooms should be provided with energy efficient CFL
lamp fixtures.

reserved

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DOCUMENT No.

ENGINEERING DESIGN BASIS

ENGINEERING DESIGN BASIS

THIS DOCUMENT HAS BEEN APPROVED BY IOCL

IOCL Comments incorporated and issued for

Issued for clients comments/Approval

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights

ENGINEERING DESIGN BASIS

Power Source Details

Power Supply Distribution System

Protection - Metering Control

10.0 Electric Heat Tracing System

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights

ENGINEERING DESIGN BASIS

: Later (after the soil Resistivity test)

Minimum temperature. for battery sizing

Equipment design temperature (IS 9676)

POWER SOURCE DETAILS

A. Independent system or existing system

* Refer CPP design basis

Name of sub station / MW

Type of conductor/ cable size

Minimum/maximum fault level

Design fault level / Basic Insulation Level

System neutral earthing

Minimum load power factor stipulated by

Parallel operation of incomers

CPP and its configuration

* Refer CPP Design basis

Number / type of captive generators

/Steam, Gas turbine

Generator rating/Voltage/Power factor

MW/ kV/ 0.8

Parallel operation with grid

High resistance earthed

* Refer CPP design basis (Emergency

Number / type of emergency generator

Generator rating/Voltage/Power factor

Short time para

Paralleling with grid system

power for lighting from existing PREP power plant)

Details of Existing System

Refer CPP design basis

POWER SUPPLY DISTRIBUTION SYSTEM

Based on PREP-IOCL design basis and DFR

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights

ENGINEERING DESIGN BASIS

Voltage and frequency variation

Primary HV distribution voltage

Secondary HV distribution voltage

Primary HV distribution system neutral earthing

Secondary HV distribution system Neutral

6.6KVabove 160KW & </= 6MW

415 VAC upto&including 160KW

Auto transfer at 6.6KV bus

Auto transfer at MV (At PCC Level)

Continuous Parallel operation of Incomers

B. DC System (at system output terminals)

Utilisation voltage and operating philosophy

Yes /No (33KV-Yes, 6.6/11KVNo, 415V-No)