1017 EL DBS 101 - Rev.1

ELECTRICAL DESIGN BASIS
DOC. NO.: 1017-EL-DBS-101 CLIENT: Kukdo Chemical India Pvt. Ltd. SHEET NO.: 1 OF 22
PROJECT NO.: 1017 PROJECT: KDCI-KI Project REV.: 1
Document No: 1017-EL-DBS-101
1 16.01.2019 Issued for Engineering VS AC AC

0 05.10.2018 Issued for Review VS AC AC
PREPARED CHECKED APPROVED
REV. DATE PURPOSE
BY BY BY
TABLE OF CONTENTS
1.0 INTRODUCTION 3
2.0 SCOPE 3
3.0 STANDARDS 3
4.0 STATUTORY REQUIREMENTS 3
5.0 SYSTEM DESIGN PHILOSOPHY 4
6.0 EQUIPMENT DESIGN PHILOSOPHY 9
1.0 INTRODUCTION
Kukdo Chemical Co. Ltd. is a company based in South Korea having the largest manufacturing
capacity of Epoxy based resin in the world. The company is in the business for last 46 years and
have various specialty epoxy based products like hardener, polyol etc. Recently, they have started
their Indian business as Kukdo Chemical India Pvt. Ltd. and acquired land in Dahej for their maiden
manufacturing plant.
KDCI proposes to execute these grass root manufacturing facilities at Dahej in two phases. In the first
phase, Plant-1 will be installed along with storages, utilities, waste water treatment and admin
building.
2.0 SCOPE
2.1 This specification along with the applicable project design basis / data form the basis for
developing detailed design and engineering for electrical facilities including electrical power system,
Electrical Equipment , Electrical Installation etc.
Electrical items such as 11 KV 4 pole structure, HT CICO panel, Distribution transformer, lighting
panel transformer, HT cable / CT- PT, Emergency DG set with AMF panel, LT PCC panel, BUS-duct,
MCC panel, PDB panel, Motors, Power & Control cables, LCS / Lugs / Glands , Earthing and Lighting
fixtures are as required for Phase I. If client intends to decide about Phase II, it can be discuses &
finalized during discussion.
3.0 STANDARDS
3.1 All electrical equipments shall be in conformance with Central Electrical Authority (CEA) Regulations
& Indian Electricity Rules 1956 (IER 1956) as applicable. Any other regulatory design requirements
and approvals needs to be followed where ever applicable.
3.2 Employ the standards, as applicable, in the design as per relevant specification
a. Oil Industries Safety Standards (OISD)
b. Bureau of Indian Standards (BIS or IS)
c. International Electro-technical Commission (IEC) Standards (wherever relevant IS

standards are not available )
d. IEEE standards (wherever IS / IEC standards are not available).
e. National Association of Corrosion Engineers (NACE) Recommended Practice for Cathodic

Protection
f. NFPA standards as part of fire proofing and design of substation buildings.
Metric SI system of units shall be applied to all dimensions and documents.
4.0 STATUTORY REQUIREMENTS

4.1 Indian electricity Act
4.2 Indian Electricity Rules
4.3 The Factory Act

4.4 Oil Mines Regulations
Requirements of other statutory bodies as applicable, e.g. Central Electricity Authority (CEA) / State
Electrical inspectorate, CCE, DGMS.
5.0 SYSTEM DESIGN PHILOSOPHY

5.1 General
The Electrical system shall be designed to provide.
a. Safety to plant, personnel and equipment during operation and maintenance
b. Reliability of service
c. Flexibility of operation and maintenance
d. Minimal fire risk
e. Reliable Protection system through selective relaying system.
f. Adequate provision for future extension and modification
g. Effective power management and load shedding
h. Low harmonics in the system as per standards
i. Rated performance at applicable environment factors (Project specific)
5.2 Area Classification and Equipment Selection
5.2.1 Hazardous classification of areas and installations shall be in accordance with IS 5572 / IEC 61241,
OISD standards and Oil mines regulations act. All the area within the battery limits shall be classified
for the degree and the extent of hazard from flammable materials.
5.2.2 Following factors shall be considered for proper selection of electrical equipment for use in hazardous
area.
 Area classification as per Zone

 Gas classification as per Group – The characteristic of the gas or vapour involved in
relation to the ignition current or minimum ignition energy and safe gap data.
 Dust classification as per Group. – The Characteristic of the dust involved
 Temperature classification – The Ignition temperature of the gas, Vapour or dust involved or
the lowest of the ignition temperature if more than one combustible is present.
 Environment condition in which apparatus is to be installed – the selected electrical
equipments apparatus shall be adequately protected against corrosive and solvent
agencies, water ingress, thermal and mechanical stresses as determined by the
environmental conditions.
5.2.3 All the electrical Equipment installed in hazardous areas shall be selected as per IS-5571 and IS
14154 and shall meet the requirements of relevant IS and statutory regulations. However, electrical
equipments for Zone 2 areas as a minimum shall be EX (e) / EX (n) type as per IS/ IEC codes.
increased safety type Ex(e) equipment shall not be used in zone 1 areas. Type of explosion
protection to be used for individual equipment shall not be as specified in the job design data.
5.2.4 As far as possible Pressurised electrical equipments need to be avoided as along as other alternative
is available. In case using pressurised equipment (Type Ex (p)) then on failure of pressurisation
system, the following minimum actions shall be provided.
1. For Zone 1 the equipment needs to switched off and alarm needs to be initiated.
2. For Zone 2 Alarm needs to be initiated
5.2.5 All electrical equipment to be used in classified areas shall be certified by CMRI / CPRI / ERTL
or equivalent recognized independent test house such as BASEEFA / LCIE / PTB/UL / FM. All
equivalent (Indigenous and imported) shall also have valid statutory approvals as applicable for use in
the specified hazardous area. The indigenous equipment shall confirm to Indian standards and shall
be approved by CCE/ DGMS as applicable based on mines non mines application. All mines
application shall be under DGMS jurisdiction and shall be defined based on project condition in
design basis.
5.2.6 The hazardous area motors (Ex (e), or Ex (d) fed by variable frequency drive shall be certified as a
combination for the specified location by independent test house and shall have valid statutory
approvals. Non-sparking (Ex (n) motors shall not be used were solid state starters / VFD’s are used
for separating purpose of the motor. In case of flame proof motor and variable frequency drive
combination may not be certified together if direct temperature control by embedded temperature
sensors are provided which will disconnect the motors.
5.3 Power system Design
5.3.1 The power distribution shall be designed in accordance with project specification taking into account
all possible factors affecting the choice of the system to be adopted such us required continuity of
supply, flexibility of operation, operating cost, reliability of supply from available power sources, total
load and the concentration of individual loads.
5.3.2 Power supply shall be at 11 KV & Power distribution system including emergency power shall be
discussed & finalized during Electrical discipline meeting.
5.4 Capacity of Electrical system
5.4.1 All the components of the electrical system shall be sized to suit the maximum load, under the most
severe operating conditions. Accordingly, the maximum simultaneous consumption of power, required
by continuously operating loads shall be considered and an additional margin shall be taken into
account for intermittent service loads, if any. The amount of electrical power consumed by each
process unit shall be calculated for its operation at the design capacity. System design shall permit
direct on line starting of all motors unless specified otherwise.
5.5 System voltages
Power distribution within plant 11 KV + 6%, 3 ph, 3 W, 50 Hz + 3%,
415 V + 10 %, 3 ph, 4 W, 50Hz + 3%.
230 V, +/- 6 %, 1 Ph, 3 W system for Lighting and

Small power
1 230 V, Ph-Ph +/-2% for Hazardous area Lighting
( To be referred with Design basis / SLD of
specific projects )
Utilization voltage (250W <= Motors / 415V + 10 %, 3ph, 4W, 50 Hz + 3%,

Heaters
resistance grounded
<= 160KW , Welding socket outlet)
Lighting, Space Heaters, Single phase socket 230V + 6%, 1 ph + N, 3 W, 50 Hz + 3%,

outlet solidly grounded
Charging of HV Switchgears and 415 V 110V+ 10%, DC, 2W, Ungrounded

Breaker*
415 V contactor feeders control and 230V+ 6%, 1ph+N, 2W, 50 Hz + 3%, solidly
grounded
indication supply
UPS system 230 V+ 1%, 1ph, 50 Hz + 1%
Process Control & Instrumentation system 230 V + 1%, 1ph+N, 50 Hz + 1%, (from UPS
System)
* 415 V switchgear control power supply can be 230 V, 2 ph, 50 Hz, where 110 V DC is unavailable.
230 V, 2 ph, 50 Hz supply shall be derived from the Switchboard’s Control Power Transformer (CPT).
Load factor of 0.7 & 0.8 should be considered for process loads & utility loads respectively.
5.6 Allowable Voltage Drop
The maximum allowable voltage drops, as a percentage of the system During Normal Operating and
Start up
Maximum
Sl. Operating
System Description Permissible
No condition
voltage drop
1 Main Bus Stabilized 0.5 %
2 Bus duct or cable between transformer Stabilized 0.5 %

secondary and HV switch board
3 Cable between PCC / MCC and MCC or auxiliary Stabilized 0.5 % 2 to 2.5 %
Switch board (Note 3)
MCC / Auxiliary switch board near PCC / MCC
Remotely located MCC / Auxiliary switch board to
PCC / PMCC
4 Cable between PCC / PMCC and motor Stabilized 5%
5 Cable between MCC and motor Stabilized 5%
6 Circuits between lighting panel and Lighting points Stabilized 4%
7 DC supply circuits for electrical systems Stabilized 5%
8 From Main UPS DB to furthest consumers Stabilized 2%
9 Startup of large MV motor with other loads on the 15 %

bus, or reacceleration of a group of MV motors
10 Cables between HV switch board and Motors Motor startup or 5%

reacceleration
11 Cables between MV switch board Motor startup or 15 %

reacceleration
Note 1: Higher voltage drop may be permitted between PCC / PMCC and remote mounted MCC/
ACB; if overall voltage drops up to motor (PCC to motor) is limited within 5.5 %
Note 2: The Voltage available at the motor terminals during startup must be sufficient to ensure
positive starting or reacceleration of the motor (even with the motor fully loaded, if required), without
causing any damage to the motor
Note 3: For medium voltage motors, the voltage available at the motor terminals must not be less
than 85 % of the rated value during startup or reacceleration.
Note 4: For high voltage motors, the voltage available at the motor terminals must not be less than 85
% of the rated value during startup or reacceleration.
5.7 System Earthing
System earthing for incoming supply and primary / secondary HV distribution, LV distribution system
shall be as per design data / SLD of specific project and statuary regulation of that particular
operating area.
Electrical earthing system shall be designed considering earth resistivity achieving earth grid
resistance less than 1 ohm or less. Instrumentation earth grid resistance shall be less than 5 ohms.
5.8 Short Circuit Capacities
Each short circuit interrupting device shall be designed to have rated service short circuit breaking
capacity (Ics) equal to or higher than the maximum value of short circuit current calculated, at its
location. The related switchgear and bus – ducts shall withstand the above maximum available fault
current for a maximum period of one second. The sizing of high voltage cables also be based on the
short circuit withstand capacity for a minimum time period as dictated by the protection system, in
addition to the maximum anticipated load current. Earth conductors to be sized based on fault
currents.
5.9 Insulation system
The insulation of electrical facilities shall be designed considered the system voltage, the system
neutral earthing and the over voltages due to system fault, switching or lightning surges. Lightning
arrestors shall be provided wherever necessary. Lighting / Surge arrestors shall be provided
wherever necessary.
5.10 Protection and Metering schemes
5.10.1 The protective system shall be selected and coordinated to ensure the following
 Protection of equipment against damage, which occur due to internal or external short circuits
or atmospheric discharges
 Uninterrupted operation of those parts of the system, which are not affected by the fault
 Personnel safety
5.10.2 Protection relays shall be numerical based smart and communicable type relays. In general, quick
acting relays (with dime delays, if necessary) shall be used and all the fault tripping shall be done
through high speed tripping relays.
5.10.3 Metering shall be provided to keep record of power consumption and supervision of all concerned
parameters like current, voltage, frequency, power factor etc as specified.
5.11 DC Power Supply
Independent DC Power supply system shall be provided for the following (Unless otherwise
specified)
5.12 Emergency Power supply
The emergency power supply system, wherever envisaged, shall feed the following:
 Essential Electrical loads

 Emergency lighting
 DC supply system
 UPS System
 Loads critical for process, plant and personnel safety

 Emergency power could be from a different power source or Emergency generator. Where
emergency generator is envisaged emergency power supply shall be made available within
a time period of 30 seconds from the instant of failure of normal supply / under voltage
system activated. Manual start provision shall be provided in the system.
5.13 Power Factor Improvement
Capacitor banks with Harmonic control Panel shall be provided to improve the power factor in order to
meet the minimum stipulated power factor by the power supply authorities. Contactor switching type
APFC Panel with Harmonic control Panel shall be provided with 6 / 8 / 12 steps APFC relay.
5.14 Harmonics Elimination
Design consideration and equipment selection needs to carried out to reduce the overall harmonics
within 5 % in the system by following ways
 Harmonics needs to reduce at the source of generation like VFD, UPS etc.
6.0 EQUIPMENT DESIGN PHILOSOPHY

6.1 General
The equipment shall in general confirm to QPSL standard specification. Equipments shall be selected
and sized as per philosophy given below:
6.2 Transformers
6.2.1 All transformers except lighting transformers shall be three phase, oil immersed, double wound type
suitable for outdoor use, unless otherwise specified. Lighting transformers shall be dry type unless
otherwise specified.
6.2.2 Transformers rated more than 2000 KVA shall have provision for fan cooled rating unless otherwise
specified to increase the rating from the normal specified rating. Distribution transformer as per IS
1180.
6.2.3 Unless otherwise specified dry type transformers shall be used for lighting transformers.
6.2.4 Main transformer should be of OLTC type (on load tap changer). This will facilitate to control voltages
at secondary side without disturbance.
6.2.5 Provision of Harmonic control through APFC (Automatic power factor control) panel.
6.3 Switch Gear
6.3.1 All switchgear and associated equipment fed from generators and transformers shall have rating at
least equal to the rating of respective generator and transformers feeding it, under any circuit
configuration. Generator incomer shall be rated to the maximum power output of the generator set
over entire operating temperature range. Transformer incomer shall be rated equal to forced cooled
rating of transformer or 110 % of ONAN rating as applicable.
6.3.2 Bus tie circuit breakers shall have rating higher of the following
 Largest incoming circuit breaker

 Maximum running load on either side of the bus section
6.3.3 All other switch gears not directly fed from generator and transformers shall have rating at least to the
maximum demand under any circuit configuration plus a provision for 10 % future load growth.
Incomers of these switch gears shall be designed to cater to the complete load including 10 % margin
for future load growth.
6.3.4 All HV switch gear up to 11 KV shall be air insulated and VCB / VC for individual feeders depending
upon the utility.
6.3.5 Spare outgoing feeders shall be provided in all the switch gear. For HV switch boards the number of
spares shall be as indicated in SLD.
6.3.6 For other switch boards (and where not specifically indicated in the SLD including HV switch gear) at
least one number of each type of outgoing feeders or 10 % of each out going feeder whichever is
more shall be provided as spare in switch boards
6.3.7 Separate feeders shall be provided in the switch board for each load / motor. However as an
exception maximum two numbers of welding receptacles may be connected to one power feeders
looped from the first to second receptacles.
6.3.8 Circuit breakers / contactors controlling motor feeders shall have a rating of at least 125 % of the
maximum continuous rating of the connected motors.
6.3.9 All circuit breakers shall be of single break type having one pole per phase.
6.3.10 In case of HV vacuum circuit breaker, surge suppressors shall be provided for all out going feeders.
6.3.11 All High voltage feeders and incomers shall have Numerical protection relays according to their
service like transformers, generators, motors.
6.3.12 Rated service short circuit breaking capacities (Ics 0 for all breakers and MCCB‘s shall be equal to or
higher than the maximum specified value of short circuit current at the point of installation. MCCB with
backup fuses are not acceptable.
6.3.13 Air circuit breakers (ACB) shall be provided in MV (415 Volts and below) switch boards for all feeders
rated from 800 A and MCCB ‘s shall be provided for all feeders rated below 800 Amps.
6.3.14 Circuit breakers for capacitors shall have a current rating of at least 135 % of the capacitor rated
current. Circuit breakers capability to interrupt applicable capacitive current shall be specifically
verified.
6.3.15 The switch board components like circuit breakers, Main horizontal and vertical bus bars, bus bar
joints, bus bar supports etc shall be designed to withstand the maximum specified short circuit current
for a minimum of 1 second.
6.3.16 For motors rated above 15 KW, CT shall be provided in the switch gear for ammeter on the local push
button station.
6.3.17 The maximum rating of bus bar for MCC / ACB / LDB should preferably be limited to 800 amps. ACB
shall be used for incomers and the tie breakers and these shall have suitable mechanical interlocks.
6.3.18 Control room to interface with Instrumentation via marshalling cabinet.
6.3.19 All feeders shall include as a minimum on /off indicating lights and trip indication.
6.3.20 All outgoing feeders will have earth fault protection.
6.3.21 Tropical protection for PCC / PMCC / MCC.
6.3.22 Thermostatically controlled space heater for panels.
6.3.23 All the switch boards Suitable for future expansion on both sides.
6.3.24 Bus bars for the switch boards shall be copper unless otherwise specified.
6.3.25 The vertical / horizontal / tap off bus bars shall be insulated and all joints shall be shrouded with high
thermal capability non flammable shrouds.
6.3.26 The short circuit capacity of current transformers shall be in accordance with the short circuit capacity
of the switchgear.
Unless otherwise specified the switchgear shall be expandable on either sides.
6.3.27 PCC / MCC feeders should have LOTO facility with pad locking arrangement.
6.3.28 PCC should have facility to monitor H.T. & L.T. voltages.
6.3.29 Panel identification details like feeder name, cable size and number of runs etc., shall be painted at
the rear side of the panel to prevent opening of wrong feeder during maintenance. This is a part of
erection contractor activity & shall be included in their scope.
1 6.3.30 Control voltage for MCC & motor push button station shall be 230 V.
6.3.31 Motor feeders shall be with SFU / MCCB / MPCB, contactor & thermal overload relay.
6.3.32 PCC I/Cs – provide separate A+AS, V+VS only.
6.3.33 Starter for motors rated less than 40 HP shall be DOL starter & motor rated 40 HP & above shall be
Star-delta.
6.3.34 Both incomers (Normal supply + DG) shall be provided with mechanical interlock (2 lock with 1 key).
6.3.35 230 V control bus shall be run through the switchboards and these will be derived from Dry type cast
epoxy, control transformer 415 V, 3 Ph / 110 V, 1 PH.
6.3.36 All MCC shall be fixed type. However ACB feeders shall be draw-out type.
6.4 Bus Duct
6.4.1 LV bus ducts will be provided for interconnection of the 11/0.440 kV transformers and above from the
transformer secondary to the 415 V PMCC/PCCs.
6.4.2 Non phase segregated, self-cooled type, 3 phase, 4 wire.
6.4.3 Copper bus bars with heat shrinkable PVC Sleeves.
6.4.4 Enclosure will be fabricated from 3mm thick (min) aluminum sheets for ratings above 3000A and
2mm thick (min) sheet steel otherwise.
6.4.5 Seal-off bushings with wall frame assembly wherever the bus duct crosses wall from outdoor to indoor.
6.4.6 The Rating of the bus bar ducts connected to breakers shall have same continuous and short circuit
rating as that of breakers. Similarly bus ducts connecting to two bus sections shall have same
continuous and short circuit rating as that of main bus bars
6.4.7 Neoprene rubber bellows for enclosure wherever expansion joints are provided.
6.4.8 The outdoor portion of the bus bar shall be minimum IP 55 with canopy for rain protection.
6.4.9 The adopter box on both ends of the bus duct shall be designed as part of the bus duct.
6.5 Electric Motors
6.5.1 In general, three phase squirrel cage motors designed for direct online starting shall be used. Motors
shall be totally enclosed, fan cooled type and suitable for continuous outdoor use.
6.5.2 All motors shall be continuous maximum rated with possible exception of crane and hoist motors,
soot blowers, turbine starting motors etc which may be rated for the envisaged duty cycle.
6.5.3 High voltage motors shall be suitable for starting under specified load condition with 80 % of the rated
voltage at the terminals and medium voltage motors shall be suitable for starting under specified load
condition with 75 % of the rated voltage at the terminals.
6.5.4 For heavy duty motors such as reciprocating compressor / agitator / crusher etc. high starting torque
motors shall be provided and starting time shall be limited to ensure adequate protection by motor
protection relays.
6.5.5 Energy efficient motors shall be used and efficiency class shall be IE2.
6.5.6 Full length motor canopy (FRP type) shall be provided.
6.6 Control Station
Motors shall be controlled in the field at the motor location. Local control station philosophy as per
SLD.
Motor control station (push button) should have lockable OFF facility. All push button stations to be
installed with canopies (preferably FRP) & equipment number name plate on the canopy.
6.7 LED Lighting Systems

1
6.7.1 Plant lighting will be broadly classified into 2 categories
 Normal lighting
 Emergency lighting
Normal and emergency lighting will be on 230V / 230 AC (phase-Neutral) Supply, under normal
conditions; both emergency and normal lighting will be fed by normal power source. On failure of
normal supply, emergency lighting loads will be fed from emergency power source supply.
In the event of normal power failure, emergency lighting may be provided to facilitate safe shutdown
of the plant, access to fire fighting facilities and escape route for safe evacuation of plant operating
personnel. Emergency lighting will be 20-25% of normal lighting load.
6.7.2 415 / 230 V, 3 ph, 50 Hz lighting transformer of adequate capacity will be used to feed AC lighting
circuits. Lighting transformers shall be located inside floor/wall mounted Sub Lighting Distribution
Boards.
6.7.3 Lighting power distribution shall be through Main Lighting Distribution Boards (MLDBs). MLDBs shall
receive 415 V, 3 ph, 50 Hz supply from PMCC / PCC / MCC and distribute to lighting fixture in each
building. MLDBs shall have 415 / 230 V, 3 ph, 50 Hz lighting transformer of adequate capacity.
6.7.4 Separate panel boards are provided for indoor and outdoor lighting. Enclosure of indoor panel boards
will have min IP 4X protection and outdoor panel boards will be housed outdoors in an IP 55
enclosure.
6.7.5 Lighting methods and material shall be suitable for the area classification in which they are to be
installed.
6.7.6 Indoor Lighting
a. Each lighting circuit load shall not exceed 2000 VA (230 V, 1 ph + N).
b. 28 Watts, decorative, mirror optic, low glare, high power factor, surface mounted LED Lamp
fixture for MCC Room and offices.
c. Industrial type, slotted reflector, open bottom in utility areas.
d. Lighting for Control Room will be 43 Watts LED, 600 x 600 mm Mirror optic Recesses mounted
light fixture.
e. Switching will be local double pole toggle devices.
6.7.7 Outdoor Lighting
a. Each lighting circuit load shall not exceed 6000 VA (230 V, 3 ph).
b. Control is photocell / timer switching with manual override of 3 pole contactors fed from 32 A.
c. 32 Amp, 3 pole outdoor panel board circuit breakers. Cable size for exterior lighting circuits shall
2
be a minimum of 3/C 6mm cu. However, final lighting feeder sizes shall be determined after all
de-rating and voltage drop factors are considered, especially the extended distances involved.
d. Aircraft warning lights shall be provided for structures of height 30 meters and above such as
communication tower and flare stack as per Directorate General of Civil Aviation (DGCA)
regulations.
e. Process Plant, Staircase and exterior lighting will be wall / back mounted compact with side
hinged cover, aluminum housing, epoxy finish, 230 V ballast suitable for 45 W LED lamp in well
glass fixture.
f. Flood lighting fixture will be die cast aluminum, multi-tap ballast; yoke mount with slip fitter
adapter 150 W LED mounted on 12 m galvanised steel poles, 2 per pole.
g. Street lighting will be standard cobra head luminaries, 230 V ballast, 100 W LED, on a 9m
galvanized steel pole.
6.7.8 Levels of illumination for the design of lighting systems shall be based on the illumination intensities.
Some of the values are summarized as given below:
Area Description Minimum Lux Level
Above pumps & sampling points 80 lux
Walkway , corridors 20 lux
Coal storage, crusher, coal handling plant 20 lux
Plant area 200 lux 1
Q.C. LAB – Instrument & chemical lab 150 lux
Tanker filling area 100 lux
Above drum filling station 100 lux
Office 100 lux
MCC Room 200 lux
Control Room 300 lux
Canteen kitchen 200 lux
Canteen serving room 200 lux

Remarks: All above values are finalised on the basis of Factory act, IS6665 & USDAW (Union of
shop, distributive and allied workers) Guidelines.
These are in-service values after applying a maintenance factor of 0.7 and a utilization factor
depending on the type of the fixture.
6.7.9 ELCB to be provided to all lighting distribution board.
6.8 Socket Outlets
6.8.1 Single phase socket outlets shall be fed at 230 (ph-N). Three phase socket outlets / welding
receptacles shall be fed at 415 V, 3 ph+ N supply.
6.8.2 Receptacles will have necessary mechanical interlocks, suitable protections for site conditions and
earthing facilities. All receptacles will have looping facility.
6.8.3 Substation, Control Room and Office Rooms will have decorative type receptacles, with ELCB
(100mA sensitivity) controlled socket, 230 V, 1 phase 15 A, 3 pin at 20 meter interval.
6.8.4 In outdoor area, 415 V, 63 A, ELCB (100mA) controlled TPNE welding socket spaced 50 m apart.
6.8.5 A maximum of two welding receptacles will be connected in one circuit.
6.8.6 All outdoor socket outlet/ receptacles will be of flameproof (Ex ‘d’) construction and rated for
temperature class T3, gas group IIA / IIB.
6.8.7 All receptacles specified above shall have interlocked type and provided with one matching plug.
6.8.8 All receptacles shall have looping facility.
6.8.9 All the sockets shall have cable entry at the bottom / top.
6.9 Earthing and Lightning Protection
6.9.1 Earthing systems power system neutral earthing and plant earthing.
Power system neutral earthing employs following methods:
a. Solid earthing for 11 kV / 6.6 kV system
b. Solid earthing for 415 V.
6.9.2 Plant earthing design will generally be carried out in accordance with the requirements of Indian
Electricity Rules and Code of Practice for Earthing BIS 3043.
6.9.3 Earth fault protection relays shall be provided for HV / LV distribution systems.
6.9.4 The resistance value of plant earthing system will not be more than 1 Ohm.
6.9.5 Main earth grid conductor will be used below ground. Above ground green / yellow PVC insulated
copper conductors GI shall be used.
6.9.6 Earth electrode of 65 mm diameter 3 m GI pipe electrode.

6.9.7 Earthing of HV motors will be provided by connection to the main earth grid. LV motors, cable trays,
metallic equipment, enclosures and other items will be connected to the main earth grid conductors.
6.9.8 A separate ground system for the Instrumentation, DCS, ECWS etc shall be established as specified
requirements. The UPS shall be grounded to this system ground bus. The resistance of this
grounding system shall not exceed 5 ohm.
6.9.9 The following shall be connected to ground system at one location
a. Cable armoring (single core power cables)
b. Metallic enclosures of electric equipment including cable boxes, local control stations etc
c. Lighting poles
d. Lighting fittings and control panels
e. Lightning protection ground rods
6.9.10 The following shall be connected to ground system at two locations:
a. Cable armoring (multi-core power cables)
b. Generator and Transformer neutral points
c. Transformer tank bodies
d. Substation building ground bus bars
e. High Voltage Switchboards and PMCC / MCC / PCC ground buses
f. Motor / generator machine frames
g. Buildings (metallic parts / piles, 1 per corner)
h. Pipe rack steel
i. Frames of skids
j. Tanks, vessels, towers, stacks
k. Base plate of rotating machinery
l. All non-current carrying metallic structures
m. All metallic structure / units
n. Metal fences, gates, side rails etc ( Shall be earthed at every 3 meters and wherever the fence
direction changes )
o. All metallic structure / units including permanent access ladders
6.9.11 Grounding cable joints shall be:
 Compression type below grade

 Bolted or compression type joints (above ground).
6.9.12 Lightning protection will be provided to equipment, structure and buildings which are higher than 30
meters or as per the risk index analysis worked as per IS 2309. For lightning protection, the value of 5
Ohms as earth resistance will be desirable.
6.9.13 Lightning protection system shall consist of air rods, down conductors and ground rods. Air rods shall
be of fully stainless steel (316). Installed as follows:
a. Drive a 3 m long ground rod 1m from the structure; connect the rod to the unit with minimum
2
70 mm green / yellow insulated copper conductor.
2
b. Connect the rod to the plant system ground grid with a 70 mm bare copper conductor routed
below grade.
c. Repeat this procedure at each unit.
6.9.14 All earth pits shall be chemically treated type.
6.9.15 Earth pit numbers, location, earth resistance value, date of testing to be put on all earth pits.
By erection contractor. Will be specified in erection contract.
6.9.16 Layout of all earth pits showing connection with equipments (like transformer, generator, motors,
plant equipment) to be prepared.
6.9.17 H.T., L.T., Lightening arrestor, Equipment Earthing & Instrumentation earthing to be kept separate.
Body & neutral earthing of transformer & generators connected to respective earth pits to be identified
& marked properly.
6.9.18 Motors, push button stations should be connected to earth with PVC flexible copper wire with lugs on
both sides.
6.10 AC Distribution Boards
6.10.1 This section covers main and sub distribution boards required for distribution of 415 V for non-motor
loads, 230 V / 230 V (UPS) / 110 V DC power for loads and lighting.
6.10.2 Indoor use, metal clad, vertical self-standing or wall mounting type, with min. IP 4X enclosure in
Substation / PMCC room and for other places min. IPW 55.
6.10.3 Generally single incomer with associated protection and control logic.
6.10.4 Generally for incomers and feeders MCCBs will be used.
6.10.5 Single front, fixed-out type construction.
6.10.6 Copper bus bars with heat shrinkable PVC Sleeves.
6.10.7 Identical breaker / contactor will be interchangeable.
6.10.8 Top or bottom entry cables as incomers and feeders.
6.10.9 Tropical protection for AC / DC Distribution Boards.

6.10.10 Thermostatically controlled space heater for panels.
6.10.11 10 % spare feeders shall be provided in DB’s.
6.10.12 All the DB’s shall have cable entry at the bottom / Top.
6.11 Uninterruptible Power Supply (UPS) System
6.11.1 Uninterruptible Power Supply system comprises the converters, inverters, static automatic transfer
switch, battery banks, constant voltage by-pass transformer with maintenance by pass switch and
Main UPS Distribution Board.
6.11.2 One complete Uninterruptible Power Supply (UPS) system consisting of two parallel units (for
redundancy and by-pass arrangement both) shall be provided for powering the plant DCS, FGS, SIS
and I/Os.
6.11.3 The system input shall be 3 phase, 415 V± 10%, 50 Hz+ 3% , Output shall be 110 V ± 1%, 1ph, 50 Hz
± 1%.
6.11.4 UPS system shall consist of two parallel units (each including a 100% converter, a 100% solid state
inverter, 100% nickel cadmium battery bank, static automatic transfer switch), and a constant voltage
by-pass transformer with maintenance by pass switch. Batteries to be placed in a separate well
ventilated room on racks.
6.11.5 Both units shall operate in parallel, each shall provide 50% load but each shall have 100% loading
capability. Battery backup time shall be at least 30 minutes for each battery unit and total of 1 hours
for the complete system.
6.11.6 Under normal condition, the converter will feed the inverter load requirement through static switch and
keep the battery under charged condition. On failure of supply to converter, the battery will start
feeding the inverter load requirements automatically without interruption. Reverse transfer on
resumption of normal power will also be automatic. The inverter will be operating in synchronization
with the bypass mains within specified voltage and frequency limits.
6.11.7 UPS shall be fed from 415 V Auxiliary board.
6.11.8 Ingress protection of panels shall be IP55.
6.11.9 UPS system shall be sized to take care of the crest factor of the load current.
6.11.10 Each branch circuit of the UPS distribution system shall have a fast acting MCB with auxiliary contact
for alarm in each circuit of distribution. The MCB shall be fast clearing type and the MCB rating shall
be coordinated with the rating of the UPS system. Normally the largest branch circuit shall not exceed
25% of the UPS system rating.
6.11.11 Each UPS shall have at least 20 % spare feeders and the UPS shall be designed to cater additional
20% for future loads.
6.11.12 Since the batteries are sealed maintenance free those can be kept along with UPS in a room with air-
conditioning system
6.12 Cables
6.12.1 HV cables shall be dry cured XLPE insulated, extruded PVC sheathed, armored type with Aluminum
conductors. All cables rated for 3.8 / 6.6 KV above shall be provided with both conductor screening
and insulation screening.
6.12.2 MV power cables shall be XLPE insulated, extruded PVC sheathed, armored type with Aluminum
conductors.
6.12.3 The control cables shall be PVC insulated, extruded PVC sheathed, armored type with copper
conductors.
6.12.4 The cables shall be sized based on the maximum continuous load current, the voltage drop, system
voltage, system earthing and short circuit withstand criteria as applicable. The de rating due to
ambient air temperature, ground temperature, grouping and proximity of cables with each other,
thermal resistivity of soil etc shall be taken in to account.
6.12.5 Cables connected in parallel shall be of the same type, cross section and termination.
6.12.6 All power and control cables shall be in continuous lengths (unless otherwise agreed upon) without
any splices or intermediate joints. The cables used for lighting and wires in conduits shall have
appropriate junction boxes with adequately sized terminals. Unless otherwise agreed, cable joints in
hazardous area shall not be permitted.
6.12.7 Outer PVC sheath of all cables used shall be flame retardant type conforming to category AF as per
IS: 10810.
6.12.8 The cable shall have a low smoke or zero halogen property. The minimum Oxygen Index shall be 29.
6.12.9 All incoming cables to switch gear / UPS/ DC system / DB’s and other equipment shall be sized for
maximum load including 10 % future load growth. Cable for capacitor banks shall be sized for 135 %
of the rated capacitor current.
6.12.10 Maximum cross section area for multi core cables is 300 mm 2 and 630 mm2 for single core unless
otherwise agreed upon.
6.12.11 All control cables shall have minimum 10 % spare cores.
6.12.12 Cables shall be designed to Bureau of Indian Standards (BIS).
6.12.13 The armor for single core cables shall be of non magnetic material.
6.12.14 Conductors of all sizes of cables shall be stranded.
6.12.15 6.6 KV and 11 KV cables shall be Unearthed UE grade where as the 33 KV and 415 V cable shall be
Earthed (E) grade.
6.12.16 As far as possible all cables to be laid on overhead cable tray instead of underground.
6.12.17 All cables are FRLS, XLPE type only.
6.12.18 Cable passing from one room to the other shall be sealed with non-combustible material or shall be
coated with fire retardant compound to prevent spread of fire from one room to the other. The above
recommendations are applicable to all the cable passes from one room to the other.
This is applicable to all the panel rooms.
6.12.19 Normally all cables shall be laid on cable trays supported above the pipe rack and near the motor,
power cable to the motor shall be underground (near the motor: GI sleeve).
6.13 Cable Tray/ Cable Duct 1

6.13.1 Common Hot dip GI fabricated cable duct for electrical and instrument cables with separation shall be
considered for main cable route and branch route shall be with perforated GI cable trays with Hot dip
GI cover.
6.13.2 Cable Duct shall be supported at least 1 M & cable trays shall be supported at 2 M interval.
6.14 Equipment Enclosures
6.14.1 All equipment shall be entirely suitable for the site service conditions as specified in specifications and
shall be protected against dust, humidity, sulfurous and atmosphere and designed to obviate the
entry of vermin and insects.
6.14.2 The degree of protection for enclosures shall be according to IEC 60529 and IEC 60144 as follows:
 Indoor equipment : IP 4X
 Outdoor Equipment : IP 55
6.15 Electrical Substation Buildings
6.15.1 The sub-stations shall be located in a safe area close to the load center. Proper access shall be
provided/ ensured for operation/ maintenance of indoor and outdoor equipment.
As per KUKDO requirement: 200 kVA Dry type Transformer, Main VCB panel will be provided in
Substation room above material storage room. 1250 kVA Dry type Transformer, Plant PCC panel will 1
be provided in Plant MCC room.
6.15.2 The substation layout will be in conformance with the Indian Electricity Rules, 1956 / Central electrical
authority (CEA) regulations with latest amendments, Regulations of Statutory Authorities such as
Chief Electrical Inspector to Govt. and Oil Industry Safety Directorate Recommended Practices 116,
118 and
149. However the below guide lines shall be followed as minimum.
6.15.3 HV sub-station floor shall be raised above grade level and the space below the switchgear room shall
be utilized as cable cellar. The cable cellar floor shall be at least 300 mm above the approach road
level and shall be paved and cemented. The cable cellar shall have a minimum clear height of 2.5 m
and shall house all cable trays and their supports. Transformer floor shall be at least 150 mm above
the approach road level.
6.15.4 In addition to the entry to substation for operating personnel, a separate entry of minimum 3 m x 3 m
with rolling shutter shall be provided for drawing in all equipment for installation. The main entry for
operating personnel for pressurized substations shall be provided with double door system with an
airlock lobby. The Sub-station shall also have an emergency door opening outwards.
6.15.5 Battery banks shall be located in a separate adequately ventilated room in the sub-station Buildings,
along with the necessary exhaust system and water connection with sink. Floor of the battery room
and walls up to 1.5 m height shall have acid/alkaline resistant protective epoxy coating. Light fittings
in this room shall be chemical resistant and flame proof type. The battery rooms shall be provided
with minimum two exhaust fans and louvered Opening in opposite wall / door.
6.15.6 UPS system and other power electronics equipment e.g. variable speed drive panels shall be located
in air-conditioned room, unless otherwise specified.
6.15.7 Sub-station shall have fire extinguishers, first aid boxes and other safety equipment as per statutory
requirements. Insulating mats shall be of synthetic rubber and required voltage rating shall be
provided in front of switchboards.
6.15.8 Equipment like transformers, HV capacitor Banks shall be located in bays adjacent to the sub-station
building. All bays shall have well drained floor, surfaced with gravel or other suitable material.
6.15.9 The following clearances will be maintained around equipment as minimum, unless specified
otherwise:
Sl. NO Description Clearance
1 Front clearance for HV Switchboard 2500 mm
2 Front clearance for other switch boards 2000 mm
3 Rear Clearance for HV switch board 1500 mm
4 Rear clearance for other switchboard which 1000 mm

requires Maintenance switch board
5 Rear clearance for MV switchboard and other 200 mm or more than 1000
panels which requires no Maintenance on the rear mm.
side and the panels rear is not having any openings
6 Side clearance between switch boards or from 1000 mm after considering

nearest obstruction space for future panels as
specified.
7 Clear height of bus-duct from FFL 3000 mm
8 Head clearance 2000 mm

9 Battery rack to wall for clearance for -
Single row / double tier 100 mm
Double row, single tier 100 mm
Double row, double tier 750 mm
10 Front clearance for wall mounted equipment 1000 mm
11 Front clearance for operation station 2500 mm

annunciation / control panel
12 Front-Front of 2 switchboards facing each other 2000 mm
13 2 nos. draw-out ACB’s are in front of each other 2500 mm
Note: Vertical clearance above the top of the highest equipment shall be minimum 1500 mm
measured from bottom of roof slab (except transformer bay where same shall be 1000 mm) and
minimum 500 mm measured from the bottom of the lowest roof beam.
However for the areas with false ceiling, minimum clearance of 750 mm shall be provided between
false ceiling and top of any equipment.
6.15.10 In all Substations/ MCC rooms, space for future extension of switchboards shall be provided. One
panel extension space on each side (for each Bus section) or two panel extension space on one side
(in exceptional cases) shall be provided for all HV Switchboards, PCCs, MCCs and ASBs. In addition,
space for future extension of the substation/ MCC room building shall be considered, as specified in
Design data.
6.15.11 The switches, lighting, sockets, and equipment in substation buildings and battery rooms shall be as
per drawings, specifications, and IS/IEC standards.
6.15.12 Batteries of UPS and DC Power Supply System shall be Ni-Cd type & located separately in AC room.
6.15.13 Battery room and ventilation arrangement and approved by Client.
6.15.14 Sub-station building & other MCC rooms shall have cable cellar or else and all panels shall be with
bottom / Top cable entry.

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ELECTRICAL DESIGN BASIS

ELECTRICAL DESIGN BASIS

Document No: 1017-EL-DBS-101

1 16.01.2019 Issued for Engineering VS AC AC

a. Oil Industries Safety Standards (OISD)

b. Bureau of Indian Standards (BIS or IS)

c. International Electro-technical Commission (IEC) Standards (wherever relevant IS

d. IEEE standards (wherever IS / IEC standards are not available).

e. National Association of Corrosion Engineers (NACE) Recommended Practice for Cathodic

Metric SI system of units shall be applied to all dimensions and documents.

4.0 STATUTORY REQUIREMENTS

4.2 Indian Electricity Rules

4.3 The Factory Act

4.4 Oil Mines Regulations

5.0 SYSTEM DESIGN PHILOSOPHY

The Electrical system shall be designed to provide.

a. Safety to plant, personnel and equipment during operation and maintenance

c. Flexibility of operation and maintenance

d. Minimal fire risk

e. Reliable Protection system through selective relaying system.

f. Adequate provision for future extension and modification

g. Effective power management and load shedding

h. Low harmonics in the system as per standards

i. Rated performance at applicable environment factors (Project specific)

5.2 Area Classification and Equipment Selection

 Area classification as per Zone

2. For Zone 2 Alarm needs to be initiated

5.3 Power system Design

5.4 Capacity of Electrical system

5.5 System voltages

Power distribution within plant 11 KV + 6%, 3 ph, 3 W, 50 Hz + 3%,

415 V + 10 %, 3 ph, 4 W, 50Hz + 3%.

230 V, +/- 6 %, 1 Ph, 3 W system for Lighting and

Utilization voltage (250W <= Motors / 415V + 10 %, 3ph, 4W, 50 Hz + 3%,

Lighting, Space Heaters, Single phase socket 230V + 6%, 1 ph + N, 3 W, 50 Hz + 3%,

Charging of HV Switchgears and 415 V 110V+ 10%, DC, 2W, Ungrounded

UPS system 230 V+ 1%, 1ph, 50 Hz + 1%

5.6 Allowable Voltage Drop

1 Main Bus Stabilized 0.5 %

2 Bus duct or cable between transformer Stabilized 0.5 %

4 Cable between PCC / PMCC and motor Stabilized 5%

5 Cable between MCC and motor Stabilized 5%

6 Circuits between lighting panel and Lighting points Stabilized 4%

7 DC supply circuits for electrical systems Stabilized 5%

8 From Main UPS DB to furthest consumers Stabilized 2%

9 Startup of large MV motor with other loads on the 15 %

10 Cables between HV switch board and Motors Motor startup or 5%

11 Cables between MV switch board Motor startup or 15 %

5.7 System Earthing

5.8 Short Circuit Capacities

5.9 Insulation system

5.10 Protection and Metering schemes

5.11 DC Power Supply

5.12 Emergency Power supply

 Essential Electrical loads

 Loads critical for process, plant and personnel safety

5.13 Power Factor Improvement

5.14 Harmonics Elimination