Old Sample Electrical Base

DOC NO.
1061-SMI-E-DB-1001
PROJECT
CLIENT: SAUDI MARJAN INDUSTRIES, JEDDAH ,KSA 1061
NO.
SHEET NO. 1 of 31
PROJECT USED LUBE OIL RE-REFINING
EPC TITLE AND HYDROGENATION
CONTRACTOR: PLANT KINGDOM OF SAUDI
JEDDAH,
CHEMIE - TECH DMCC LOCATION
ARABIA
ELECTRICAL DESIGN BASIS
REVISION
A 04-04-2016 Issued for Review/Approval H.N.P D.P.B D.P.B

REVISION PREPARED CHECKED APPROVED
DATE DESCRIPTIONS
NO BY BY BY
SAUDI MARJAN INDUSTRIES,
JEDDAH, KSA ELECTRICAL DESIGN BASIS
Project No.: 1061 1061-SMI-E-DB-1001
Table of Contents
1. INTRODUCTION .................................................................................................................. 4
1.1. Project Summary.................................................................................................................. 4
1.2. Project Objective .................................................................................................................. 4
2. SCOPE OF WORK .............................................................................................................. 5
2.1. Definitions / Abbreviations .................................................................................................... 5
2.2. Statutory Requirements, Codes & Standards ....................................................................... 7
3. SITE CONDITION ................................................................................................................ 8
4. ELECTRICAL SYSTEM DESIGN ........................................................................................ 9
4.1. Plant Power Source Details .................................................................................................. 9
4.2. Supply System Parameters .................................................................................................10
4.3. System Earthing Details ......................................................................................................10
4.4. System Voltage and Circuit Parameters ..............................................................................11
4.5. Permissible Voltage Drops ..................................................................................................12
4.6. Protection Philosophy..........................................................................................................12
5. AREA CLASSIFICATION ...................................................................................................13
6. EQUIPMENT DESIGN PHILOSOPHY ................................................................................14
6.1. Transformer ........................................................................................................................14
6.2. Emergency Diesel Generator ..............................................................................................15
6.3. MV and LV Switchgear ........................................................................................................15
6.4. Power Factor Improvement System ....................................................................................17
6.5. LV Motor .............................................................................................................................17
6.6. DC System ..........................................................................................................................18
6.7. Uninterruptible Power Supply System .................................................................................19
6.8. Batteries ..............................................................................................................................20
6.9. Lighting System...................................................................................................................20
6.10. Socket Outlets .....................................................................................................................22
6.11. Local Control Station ...........................................................................................................23
6.12. Cable Glands ......................................................................................................................23
6.13. Earthing and Lightning Protection System ...........................................................................23
6.14. Cables and cable Tray ........................................................................................................26
6.15. Cathodic Protection System ................................................................................................28
6.16. Neutral Grounding Resistor .................................................................................................28
6.17. Low Voltage Bus duct..........................................................................................................28
ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 04/04/2016) Page 2 of 31

THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER
WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.
6.18. Overhead Lines (Package Items) ........................................................................................29

7. ELECTRICAL SUBSTATION/SWITCHGEAR BUILDING ..................................................30
8. INSTALLATION, TESTING AND COMMISSIONING ..........................................................31

1. INTRODUCTION
Saudi Marjan Industries has planned to setup a Used Lube Oil Re Refining Plant at
JEDDAH, K.S.A with Capacity of Distillation Plant to process 200 MT/day USED
LUBRICATING OIL Feed. The corresponding Feed Capacity of Hydro-treatment Unit is 170
MT/day.
Chemie-Tech DMCC has been appointed as an EPC contractor for Basic & Detailed
Engineering, Procurement & Supply, Installation, Testing and Commissioning of 200 MT/Day
Capacity Used Lube Oil Re-refining Plant at JEDDAH, K.S.A
Chemie-Tech DMCC, Dubai (EPC Contractor) has appointed M/s Green Industrial
Technologies (GIT-Greece) as a consultant for Basic Engineering of Hydro Treatment (HDT)
Plant.
1.1. Project Summary
Project Name Used Lube Oil Re-Refining Plant
Project Number 1061
Project Location JEDDAH, K.S.A
Comapany SAUDI MARJAN INDUSRIES
EPC Contractor Chemie-Tech DMCC
1.2. Project Objective
This Report describes the Used Lube Oil Re-Refining Plant Electrical Design basis for
SAUDI MARJAN INDUSRIES - ULO Re-Refining Plant’ located at JEDDAH, K.S.A. The
process is intended to Recover Lube Oil Base Stock (LOBS) as an intermediate product from
the used lubricating oil. The recovered LOBS will be sent to Hydro treatment process to
produce lube oil base stock of API Gr. II + Grade.
The process comprises of various unit operations for recovery of LOBS & purification in
Hydro treating plant.

This document shall form the basis for Design & Engineering of Electrical System Used Lube
Oil Re Refining Plant, also for the development of Detailed Engineering specifications.
The objective here is to resourcefully use the collected used lubricating oil for producing
recycled Base oil of API GR-II+ Grade. Through various processes we will be removing
contaminants like free solids, ash content, added additives, water, antifreeze, light ends / fuel
oils in order to reclaim 70-75 % lube oil base stock. A further process of refining (Hydro
treatment & fractionation) and blending is done to produce finished products and apart from
that by-products obtained from the process are asphalt residue and fuel oil which are also
saleable products.
Design Capacity:
The plant is designed to treat 200 MTPD Used Lubricating Oil (ULO) feed rate with stream
efficiency of 8000 hours per year with two planned maintenance of 12 days each & turndown
ratio of 50% of designed capacity.
2. SCOPE OF WORK
The purpose of this document is to set out a Basis of Engineering & Design of electrical
system of the project in respect of:
 Design Philosophy
 Electrical Parameters
 Equipment Requirements
 Safety Considerations
This document is intended as a guide for design engineering and to specify the requirements
for this project.
2.1. Definitions / Abbreviations
SHALL : Indicates a mandatory requirement

: Denotes an action or requirement which is not mandatory but strongly
SHOULD
recommended
S/S : Substation
ANSI : American National Standard Institute
BS : British Standard Institution
UPS : Uninterruptible Power Supply

AC : Alternating Current
DC : Direct Current
LV : Low Voltage
MV : Medium Voltage
Hz : Hertz
MCC : Motor Control Centre
MLDB : Main Lighting Distribution Board
PDB : Power Distribution Board
LDB : Lighting Distribution Board
ACB : Air Circuit Breaker
VCB : Vacuum circuit breaker
VFD : Variable Frequency Drive

APFC : Automatic Power Factor Correction
CT : Current Transformer
PT : Potential Transformer
ATS : Automatic Transfer Switch
MCCB : Moulded Case Circuit Breaker
SPN : Single Phase Neutral
DCDB : DC Distribution Board
PVC : Polyvinyl Chloride
XLPE : Cross (X) Linked Poly Ethylene
FRLS : Flame Retardant Low Smoke
IP : Ingress Protection
PLC : Programmable Logic Controller
SCADA : Supervisory Control and Data Acquisition System
FAT : Factory Acceptance Test
SAT : Site Acceptance Test
JB : Junction Box
LCS : Local Control Station

2.2. Statutory Requirements, Codes & Standards
The design and the installation shall be in accordance with established codes, good
engineering practices and shall confirm to the statutory regulations applicable in the country.
Latest ANSI standards are to be followed for all electrical equipment/ component design.
The main codes, standards and statutory regulations considered as minimum requirements
are as given below. Latest version of these shall be followed:
 American National Standards Institute (ANSI)

 American Petroleum Institute (API)
 National Electrical Manufacturers Association (NEMA)
 Institute of electrical & electronics engineers (IEEE)
 National Fire Protection Association (NFPA)
 National Association of Corrosion Engineer (NACE)
The design and terminology shall comply as a minimum with the latest editions of the
engineering codes, standards and practices as below. However system/equipment design
shall be in line with latest of all applicable standards-
Codes Description
ANSI 268 Letter symbols to be used in electrical technology
NEMA Electrical Motors
ANSI for Electric Power Systems and Equipment – Voltage Ratings
ANSI C84.1-2011.
(60 Hertz).
ANSI / IEEE
Instrument transformers: Current transformers
C57.13-2008
ANSI C57.12 Power Transformers
ANSI 12.13.01-
Electrical apparatus for Explosive gas atmospheres
2000
ANSI C37.9 Electrical relays
ANSI C136 Luminaires
Power cables with extruded insulation and their accessories for rated
ANSI 60502
voltages from 1 kV up to 30 kV
ANSI 60529 Degree of protection provided by enclosure
ANSI C37.20.1 Low Voltage Switchgear
Uninterruptible Power Systems (UPS)-Specification and Performance
NEMA PE 1-2012
Verification
NFPA 780 Installation of Lightning Protection Systems

Recommended Practice for the classification of Locations for

API RP-505 Electrical Installations at Petroleum facilities classified as Class-I,
Zone-0, Zone-1, & Zone-2.
IEEE 80 Grounding Considered for Industrial power system
ANSI C37.55-2002 Medium Voltage Switchgear
The System will be designed and built in accordance with the requirements of the all
applicable local codes and standards.
In case of any conflict / deviation amongst various documents the order of precedence shall
be as follows:
 Statutory Regulations
 Data Sheet
 Technical Specifications
 Tender and any other documents forming part of the Contracts
 Electrical Design Basis
 Referenced Codes & Standards
3. SITE CONDITION
Parameters Description Reference
Altitude from above Sea Level 17 Meter SAES-A-112 (Meteorological

and Seismic Design Data)
Average Ambient Temperature PDB_
39/18.1 /28.3 °C
(Max./Min./ Mean.) 1061-SMI-P-DB-1001
SAES-A-112 (Meteorological
Average Annual Temperature 28 °C
Average Daily Max. Temp. (hottest SAES-A-112 (Meteorological
33 °C
month) and Seismic Design Data)
Monthly Normal Max. Temp. (hottest SAES-A-112 (Meteorological
39 °C
month) and Seismic Design Data)
Design Ambient Temperature (Min. / PDB_
18.1 / 39 °C
Max.) 1061-SMI-P-DB-1001
Ground Temperature at 1m below
(HOLD) (HOLD)
ground (Min. / Max.)
Rainfall, Average Annual 57 mm
Rainfall Maximum in 24 hours 73 mm

151.2 KM/Hr. PDB_

Design Wind Velocity
(42.2 m/s ) 1061-SMI-P-DB-1001
Seismic Risk Class ZONE 2A PDB_

1061-SMI-P-DB-1001
Minimum Temperature for Battery
10 °C As per Standard
Sizing
Average Soil resistivity for Earthing 25 Ohm. At 1.5 Mt Report_SE16-01-030-Soil
& CP system Depth Investigation Report
Relative Humidity (Max./Min./ Mean.) 100 / 3 / 60 % PDB_
1061-SMI-P-DB-1001
Environment (HOLD)
HOLD details shall be confirmed later.
4. ELECTRICAL SYSTEM DESIGN
4.1. Plant Power Source Details

 Grid Supply
Normally the main incoming power supply to the Lube Oil Re Refining Plant is provided by
Electricity Company of K.S.A at a voltage and frequency level of 33kV, 3-Phase and 60Hz
from the 33kV Overhead Lines. The fault level at 33KV shall be 25kA for 3 second.
The supply will be received subject to agreement with the Grid Supplier on an overhead line
termination double pole structure with isolator, protection fuses & metering facility outside the
premises of the Lube Oil Re Refining Plant.
Within the premises of the Re Refining Plant site, 33KV Distribution Substation shall be
constructed & shall comprise of below listed Equipment:
 33KV MV Switchgear with VCB

 33KV / 4.16KV Distribution Transformer
 33KV / 0.48KV Distribution Transformer
 0.48KV Main PCC
 0.48KV DG. Set
 DG. Set AMF Panel
 Remote Tap-changer Control Panel
 Battery bank with charger
 Heat Tracing Panel
 Auxiliary Distribution Boards
A separate Electrical Room within the premises of the Re Refining Plant site shall be
constructed & shall comprise of below listed Equipment:

 0.48KV LV MCC with Incomer & Outgoing ACBs suitable for fault current 65kA for 1
second.
 VFD panels
 AC & DC UPS
 PLC / SCADA Panel
 Auxiliary Distribution Boards
 Normal Operation
In normal operation, all loads will be powered by the grid Power.
 Emergency Operation
In the event of complete power failure from the grid supply, the Diesel Generator will be started
automatically and some emergency plant load shall be transferred to D.G. Set through ATS.
Generator breaker will close automatically with time delay after stabilization of DG voltage and
frequency to feed power to the emergency load
One number 0.48KV Diesel Generator suitably rated for emergency power generation is
envisaged.
4.2. Supply System Parameters
: 33kV, 60Hz, 3-Phase, 3 wire (Provided by

Main Grid Supply
Electricity Company of KSA)
: 480V, 3-Phase Supply
Distribution Supply
277V, 1-Phase Supply
Voltage tolerance : ± 10%
System Frequency : 60Hz
Frequancy tolerance : ± 3%
System Power Factor : 0.9 (Assumed)
Design Fault Level: 33kV System : 25 kA for 3 Sec. (Max.)
Design Fault Level: 480V System : 65kA for 1 Sec.
4.3. System Earthing Details
33KV / 4.16KV Transformer

: Neutral Grounded through resistor (NGR)
(Secondary)
33KV / 0.48KV Transformer
: Solidly earthed Neutral
(Secondary)
480V Diesel Generator : Solidly earthed Neutral

277V System : Solidly earthed
DC System : Unearthed
4.4. System Voltage and Circuit Parameters
Sr.
System Description Voltage Level
No.
1 Grid Incoming Supply : 33KV ± 10% AC, 60 Hz ± 3%, 3 Phase, 3 Wire
: 0.92 Lagging (Minimum) as per statutory

2 Power Factor for the Plant
requirement of Electricity Company of KSA
3 Emergency Power Supply : Diesel Generator – 480V, 3Ph, 4 Wire, 60Hz
: 480 V ± 10% AC, 60 Hz ± 3%, 3 Phase + Neutral +

4 Plant Distribution
Earth
5 Plant Distribution : 4.16 KV ± 10% AC, 60 Hz ± 3%, 3 Phase
6 Control Voltage : 277 V ± 10% AC, 60 Hz ± 3%, 1 Phase, 3 Wire
UPS System
(for Process Control & : 277 V ± 10% AC,1 Ph, 3 Wire, 60 Hz ± 3%, &
Instrumentation
6 (24V ± 5% DC supply required for Instrumention
system, SCADA/PLC, F&G, packages shall be derived from 277V AC UPS
ESD, Fire alarm, supply)
Communication System, etc)
7 DC System : 110 V ± 10% DC
8 Welding Receptacles : 480 V ± 10% AC, 60 Hz ± 3%, 3 Phase + Earth
9 Lighting : 277 V ± 10% AC, 60 Hz ± 3%, 1 Phase, 3 Wire
10 Motor Power : 480 V ± 10% AC, 60 Hz ± 3%, 3 Phase

Control Supply for Motor
11 : 277 V ± 10% AC, 60 Hz ± 3%, 3 Phase
feeder
12 All Panel space heaters : 277 V ± 10% AC, 60 Hz ± 3%, 1 Phase, 2 Wire
13 Motor space heater : 277 V ± 10% AC, 60 Hz ± 3%, 1 Phase, 2 Wire
15 All Panel Indication Lamp : 277 V ± 10% AC, 60 Hz ± 3%, 1 Phase, 2 Wire
Tripping coil Voltage for
16 : 110 V ± 10% DC, 2 Wire
Breakers
Spring Charging Motor of MV
17 & LV Switchgears Breakers : 110 V ± 10% DC, 2 Wire
for Incomers

18 All LV contactor controlled : 277 V ± 10% AC, 60 Hz ± 3%,, 1 Phase, 2 Wire,

feeders control and indication (via control transformer)
19 All Numerical Relays : 110 V ± 10% DC, 2 Wire

All Panel Sockets & plugs
20 : 277 V ± 10% AC, 60 Hz ± 3%,, 3 Wire,
(Industrial type)
4.5. Permissible Voltage Drops
The maximum voltage drops in various sections of the electrical system under steady state
conditions at full load shall be within the limits stated in the following table:
Maximum
Sr.
System Description Permissible
No.
Voltage Drops
1 Cable between Grid Supply arrangement and VCB Panel 0.5%
2 Cable between VCB Panel and Transformer primary 0.5%
Busduct or cable between Transformer secondary and LV

3 0.5%
switchgear / PCC
4 Cable between MCC (situated near LV switchgear) and LV motor 5%
Maximum voltage drop for cables between MCC & LV motor

5 15%
during motor startup
6 Cable between LDB and Lighting panels 1-1.5%
7 Circuit between lighting panels and lighting points 4%

8 DC supply circuit (Electrical controls) 5%
9 UPS outgoing circuit 5%
4.6. Protection Philosophy
The protection system will be designed such that a faulty circuit is identified and disconnected
safely and quickly without adversely affecting the stable operation of other healthy circuits and
plant.
All the protection relays shall be numerical type (intelligent electronic devices) and shall
comply with ANSI Standard.
Typical protection relay applications as minimum are tabulated as follows:

Feeder Description Type of Feeder Relay Description
 IDMT Over current Relay -51

 IDMT Earth fault Relay -51N
33KV Switchgear with
Incomer Feeder  Under voltage Relay with Timer -27
VCB Panel
 Trip circuit supervision Relay -95
 High speed tripping relay - 86

Incomer Feeder (From  Instantaneous Over current Relay -50
LV Switchgear Transformer  Instantaneous Earth fault Relay -50N
secondary winding)  Under voltage Relay with Timer -27
 Trip circuit supervision Relay -95
 High speed tripping relay – 86

Outgoing Feeder (LV
LV Switchgear  Under voltage Relay with Timer -27
MCC)
 Motor Protection Relay with (46, 49,
59 Protection Relay)
 Under voltage Relay with Timer -27
D.G. Set Generator Protection
 Generator Protection Relay
 Reverse Power Relay -Anti motoring
protection -32
All numerical protection relays and other communicable meters shall have FO/RS485 port for
serial interface, the data of this relays shall be capable of transferring to SCADA/PLC via
Modbus communication or Ethernet over ANSI C12.22 protocols.
5. AREA CLASSIFICATION
Hazardous areas shall be defined in accordance with API-RP-505: Recommended Practice for
the classification of Locations for Electrical Installations at Petroleum facilities classified as
Class-I, Zone-0, Zone-1, & Zone-2.
Electrical equipment installed in the classified area shall be suitable for the area and taken into
consideration, during design of the plant equipment, the gases and chemical substances,
which shall be handled, processed or stored in the plant. Selection of equipment shall be made
in compliance with ANSI/UL Standards.
Electrical apparatuses suitable for use in classified areas with test certificates by an official test
laboratory / Notified body such as CESI for Italy, PTB for Germany, BASEEFA for England,
LCIE or INERIS for France, FM or UL for US and ATEX etc. will be considered.
The equipment suitable for Zone 1 area will be deemed suitable for zone 2 area.

6. EQUIPMENT DESIGN PHILOSOPHY
 General Criteria
All equipment will comply with project specification, data sheets and relevant ANSI code.
All equipment will be suitable for continuous operation at full load and will withstand the
thermal and electrodynamics stresses due to the specified abnormal conditions.
All ratings will be continuous at specified maximum ambient temperature.
Unless otherwise specified all components will have at least 20% extra capacity above the
expected load.
Insulation levels of the power system will be coordinated in accordance with ANSI standard.
Rated short duration power frequency withstand voltage and switching/lightning impulse
withstand voltage will take into account of system voltages and type of Earthing.
 Design Life
The equipment will be designed for an operational design life of minimum 30 years.
 Weather Protection
For Indoor Installations : IP 42
For Outdoor Installations : IP 55
6.1. Transformer
Transformers shall be hermetically sealed; mineral oil immersed with integral filling type of
either pad mount construction and double wound copper winding type suitable for installation
outdoor without additional weather protection.
Cooling shall be ONAN using oil. Non-degradable coolants shall not be used. Forced cooling
is not envisaged. Windings shall conform to vector group Dyn 11, as defined in ANSI.
The KVA rating (1x100%) shall be decided on the following basis and should be as far as
possible a standard value. Sizing shall include 25% margin for future growth in case of Power
Transformer and 40% margin for Distribution Transformer.
KVA rating and % impedance of each transformer shall be selected so as to limit the short
circuit current to values within the current rating and rupturing capacity of proprietary available
switchgear whilst also ensuring that the voltage drop in the system elements stays within
permissible limits. The transformer impedances shall comply with the applicable ANSI
standards unless otherwise required.
Main Power Transformer shall be provided with On-Load Tap changer on the primary (HV)
winding giving voltage variation of +/- 10%.
Distribution Transformer shall be provided with off circuit tap changer (OCTC) on the primary
(HV) winding with tap selection for (-) 5% to (+) 5% of rated primary voltage in steps of 2.5%.

6.2. Emergency Diesel Generator
Essential services panel shall be feed from 480V Emergency Diesel Generator for which
rating shall be determined on the basis of essential loads.
480V Emergency Diesel Generator driven by battery started diesel engine with AMF panel
shall be provided.
The electrical loads of Essential services panel to be fed by emergency generator shall
consist of the following as minimum:
 20-25% lighting load
 Loads critical for process, plant and personnel safety
6.3. MV and LV Switchgear
MV Switchgear (33kV VCB Panel)
MV Switchgear shall be air insulated type with VCB and draw out feature. Switchgear
enclosure shall be robust metal construction, vermin & dust proof and shall have minimum
degree of protection IP55 suitable for outdoor installation. Each vertical section shall consist
of 1 no. of circuit breaker only.
MV Switchgear shall be as per standard ANSI C37.55-2002.
All switchgear shall have integral circuit earthing facilities suitably interlocked with the
switching mechanism.
Switchgear mechanisms shall be fully interlocked and provide shutters, door locks etc., to
prevent persons contacting live parts.
33kV circuit breakers shall be of the trolley mounted withdrawal type assembled to make up a
switchboard. A test position shall be incorporated. The interrupting medium shall be vacuum
circuit breaker.
All busbars and jumper connections shall be of electrolytic copper conforming to relevant
ANSI standards. They shall be adequately supported on suitable insulators to withstand
electrical and mechanical stresses due to specified short circuit currents. Busbar cross
section shall be uniforms, throughout the length of switch board.
VCB feeder shall be provided with numerical relays.
All cable connections and entries, including those of the low voltage cables, shall be made
from the bottom.
LV Switchgear:
LV Switchgear shall be located in non-hazardous area close to the load Centre in order to
reduce distribution losses, size and length of cables.

Low voltage switchgear will consist of incoming circuit breakers, motor starters, lighting and
power distribution board feeder, APFC units grouped together to form where appropriate a
Motor Control Centre of the cubicle type constructed to ANSI C37.20.1 and internal
separation shall be of Form-4. All operating mechanisms shall be between 300 - 1800 mm
height from the base of the panel.
LV Switchgear shall be metal enclosed, dead front, floor mounted, free standing type as per
applicable ANSI standards with the following features:
 Incomer and bus-tie Circuit Breakers shall be ACB, four poles, spring charged, horizontal
draw out electrically operated type single front design.
 LV Switchgear / MCC shall be fully draw- out (withdraw-able) double front type. However,
Air Circuit Breaker shall be of single front design.
 Distribution boards (PDB/LDB) shall be fixed type with a single front design.
 All the switch boards shall be suitable for future expansion on both sides and all bus bars
for all the switch boards shall be electrolytic grade copper and shall be fully insulated
unless otherwise specified.
 A minimum of 25% spare feeders or one no. of each rating and type on each side of the
bus section, whichever is the greater, shall be provided
 Circuit breakers / contactors controlling motor feeders shall have a rating of at least
125% of the maximum continuous rating of the connected motors.
 Motor starter shall have components listed by UL and applied according to NEC safe for
operator and shall provide adequate protection for the components. Motor starter
modules shall be fitted with ammeters for motors rated 37 kW and above.
 For feeders rated up to and including 630A, MCCBs shall be provided, for the feeders
rated above 630A, ACBs shall be provided.
 All incomer ACB feeder for LV switchboard shall be provided with numerical relays and
outgoing MCCB feeder in LV switchboard shall be with microprocessor based adjustable
type release for over current, short circuit, instantaneous and earth fault release. MCCBs
shall be provided tripping device with inverse time characteristic for overload protection
and instantaneous characteristics for short circuit protection & earth fault protection.
 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, unless otherwise specified.
 Provision shall be made for space heater supply of motors rated 30kW and above.
 LV switch board shall have metal enclosed horizontal main bus bar compartment running
at the top.

 Top entry bus duct as incomer for LV MCCs fed from Transformer rated 750kVA and
above shall be provided. Incomers for other boards shall be from Bottom entry. All other
cables shall be from Bottom entry.
 Control transformer of suitable rating shall be provided in each bus section in MCC for
control supply. Transformer shall be rated for 100% load requirement of entire panel.
 Thermostatically controlled space heater for each panels, maintenance sockets outlets,
panel illumination etc. shall be provided.
 All switchgear, modules shall be designed to have all safety features, not to have access
to live terminals and interlocks to ensure to protect accidental closing while racking in
and door opening while in service.
6.4. Power Factor Improvement System
An automatic power factor improvement system shall be considered on Busbar of LV

Switchgear. The system shall have capability to improve the overall power factor of the grid
supply to above 0.92 lag.
The power factor improvement system shall consist of:
 Capacitor banks
 Series Reactors
 Power cabinets with MCCB, busbars, feeders comprising fuses/breakers and power
contactors, control transformers, etc.
 Power factor correction relay
6.5. LV Motor
In general, three phase squirrel cage motors shall be totally enclosed, fan cooled type and
suitable for continuous outdoor use with protection IP 55. Wherever identified Motors shall be
suitable for direct on-line starting.
Motors up to 160KW shall be fed from 480V MCC and Motors above 160KW shall be fed from
4.16KV MV Switchgear.
Motor construction shall be as per NEMA and have premium efficiency class as per NEMA
MG-1.
The type of enclosure for motors (i.e. indoor/outdoor, industrial/non sparking/ flameproof)
shall be adequate for the application and area in which it is to be installed.
 Hot & Cold Start
Motors shall be designed to allow the minimum number of consecutive starts indicated below:

Min. no. of consecutive

Condition
starts
With initial temp. of the motor as ambient temp. (cold) 2
With initial temp. of the motor as full load operating temp. (hot) 1
Minimum locked rotor thermal withstand time at rated voltage shall be 10 seconds under cold
conditions and 8 seconds under hot conditions. The hot thermal withstand time at 100%
voltage shall be at least 5 seconds more than the starting time at 80% voltage. The starting
time of the motor shall be less than the hot thermal withstand time (time te in case of
increased safety motors) to facilitate application of conventional bimetal relays or thermal
release against locked rotor and overload conditions.
 Insulation
All motors shall have class F insulation with temperature rise limit to class B on a maximum
ambient temperature measured by resistance, in accordance with NEMA Standards, for all
parts of the machine windings.
Motors identified to be driven and controlled by a VFD shall be suitable for the required
variable speed range at a temperature rise within the permissible limits. All motors driven by
VFDs shall be suitable for inverter duty application and shall have embedded PTC thermistors
in the windings operating a thermistor trip relay in the VFD should the temperature of the
winding exceed the permissible limits.
VFD shall be interface with SCADA/PLC through serial link by either Modbus or Profibus
protocol.
Provision shall be made for space heater supply of motors rated 30kW and above.
6.6. DC System
DC Power supply system comprises the converters, battery banks and the Main DC
Distribution Boards (Main DCDBs).
System shall supply continuous 110V DC power to MV and LV switchgear and relays. The dc
power supply system shall be a fully redundant system consisting of two units operating in
parallel.
The DC UPS system shall comply with NEC. The DC UPS rectifier shall be IGBT/Thyristor
based three phase full wave rectification.
Each unit shall consist of one 100% Float-cum-boost charger with 100% loading capability but
operating at 50% load. Batteries shall be one common 100% sealed maintenance free Nickel
Cadmium battery bank placed in a separate well ventilated room on racks.
In case of normal power failure to the float-cum-boost chargers, each battery unit shall have
sufficient capacity to supply the total 110V DC system loads for 60 Minutes (1Hours.).
Under normal condition the Float-cum-boost charger will take care of all DC load connected to

its Main DCDB and keep the battery under charged condition. In case of failure of normal
supply, battery will feed the DC load requirement. Retransfer of load on resumption of normal
supply will be done without interruption of supply to loads.
AC input to the DC system shall be 480V ± 10%, 3 phase, and 60Hz ± 3% from the plant LV
Switchgear.
Each battery charger and DCDB shall be sized to cater to selected battery capacity.
Each DCDB shall have at least 10% spare for future loads. All the DB’s shall have cable entry
at the bottom.
The battery chargers shall have intelligent monitoring / metering system and shall display the
capacity of the battery, battery voltage, rectifier voltage and current and events and alarms
and communicable for remote monitoring.
6.7. Uninterruptible Power Supply System
Uninterruptible Power Supply system comprises the converters, static inverters, static
automatic transfer switch, battery banks, and Isolation transformer with voltage stabilizer in
bypass along with maintenance by pass switch along with AC & DC distribution Board.
One complete Uninterruptible Power Supply System consisting of two parallel units (for
redundancy) shall be provided for powering the plant Process PLC, FGS, instrument package
equipment system, and local control panels.
The inverter shall be transistorized (IGBT) type or with the latest proven technology. All
components shall be of a high quality and reliability that satisfy the requirements of a secure
AC power to vital equipment with respect to performance.
Rectifier shall be Thyristor base three phase full wave rectification.
The system input shall be 3 phase, 480V ± 10%, 60Hz ± 3%, Output shall be 277V ± 10%
AC,1 Phase, 60Hz ± 3% & 24V ± 5% DC. Harmonic filters shall be considered at input side, if
required. System total harmonic distortion (THD) content shall be not exceeding 5%,
conforming to IEEE-519.
UPS system shall consist of two parallel units (each including a 100 % converter, a 100 %
solid state inverter,) with one common 100% sealed maintenance free 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.
Both units shall operate in parallel, each shall provide 50% load but each shall have 100%
loading capability. Battery backup time shall be 60 Minutes (1 Hours).for the complete
system.
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.

Usually, the two UPS units will operate in parallel and share total load requirement equally.
On failure of inverter of one of the UPS the other UPS will start feeding 100 % of the load
automatically without any interruption. In case of failure of both the inverters, the bypass
mains will take care of 100 % of the load through static bypass switch automatically without
interruption. Forward and reverse transfer of load will be done automatically and without any
interruption of supply to loads.
Each UPS shall have at least 10 % spare feeders and the UPS shall be designed to cater
additional 10 % for future loads.
6.8. Batteries
Sealed maintenance free Nickel Cadmium Batteries shall be of adequate capacity to meet the
backup requirements as envisaged in the duty cycle. While sizing the battery, temperature
correction factor, and ageing factor shall be considered in addition to the maintenance factor.
Battery backup time shall be 60 Minutes (1 Hours).for the complete system.
6.9. Lighting System
Plant lighting will be broadly classified into 2 categories:
 Normal lighting
 Emergency Lighting
Power for normal and emergency lighting shall be drawn from the LV Light Distribution
Boards (LDB). The LDB protected with MCCB in incomer and outgoing with MCBs with ELCB
protection
Generally 20-25% of the total lighting fixture shall be fed from AC emergency lighting via
480V Emergency Diesel Generator.
During normal operation normal and emergency lighting shall be fed from normal power
source. On failure of normal power supply, emergency lighting shall be transferred to
emergency power supply source.
The lighting design and installation will be in accordance to ANSI Standard..
Lighting installation will be designed to provide an average sustained illumination level not
less than the values tabulated below.
Location Lux (average)

Process & Utilities areas
Pumps, collectors, separators areas 70 to 85 at grade
Ladders and stairs 45 at floor level
Instruments, Local boards 150 at 1 m level

Storage area
Tanks (ladder, gauge area) 15 at grade
Manifold area 10 at grade
Loading area
General area 70 to 85 at grade
Tank loading point 250 at 1 m level

Street & fence lighting
Main road 15 at grade
Secondary road 10 at grade
Fences 10 at grade
Buildings
Administrative buildings Office 300
Control rooms 500
Electrical rooms 300
Instrumentation rooms 400
First aid room 500
Lockers rooms – showers - toilets 150
Laboratories 500
Workshops 300
Fire station 150
Gate house 250
Stairs 150
Exits 100
Pantry 400
Car park 12 at grade
Fittings to be installed in hazardous area shall be suitable for the Zone specified and certified
by a notified body.
Indoor Lighting System
Lighting system will consist of fluorescents lighting fixtures for indoor lighting of non-process
buildings, and control room. Battery room shall be provided with chemical resistant fixtures.
HPMV lamp shall be used for bay lighting in Process building/Shop floor. A maintenance

factor of 0.8 shall be considered for illumination level calculation for indoor areas.
Outdoor Lighting System
External area lighting will consist of Flood light High-Pressure sodium Vapour (HPSV) lamps
rapid re-strike type. Telescopic tubular hot dip galvanized high masts shall be provided for
illumination of tank farm/general areas. Where feasible street lighting poles may be avoided
where lighting high masts provide adequate illumination, Street lighting will be standard
luminaries, 277V±10%, on galvanized steel pole. For High mast & street lighting HPSV
luminaries shall be used.
All fittings to be installed outdoors shall have ingress protection of IP65 and shall be
weatherproof and have a guard. All Light Fittings, JBs shall be so located to have easy
maintenance approach. A maintenance factor of 0.65 shall be considered for illumination level
calculation for outdoor areas.
External lighting will be automatically controlled by Photoelectric cell or timer.
Wiring Type
Process plant/Shed & Outdoor area Armoured cable

Surface conduit wiring above false
Non plant building with/without false
ceiling & Canceled conduit wiring on wall below false
Ceiling / Control room
ceiling
Surface conduit / Armoured cable in G.I perforated
Substation (Switchgear Room)
trays
Wiring for lighting in outdoor area shall be done with armoured cable run along the columns/
Platform & structures.
6.10.Socket Outlets
Enclosure of the convenience receptacle shall be suitable for site conditions such as weather
proof, dust proof, flame proof, corrosion resistant etc. Necessary interlocks and earthing
facilities shall be provided as per safety requirements. These receptacles shall be provided at
selected locations in the plant.
For office buildings, 277V, 13A/15A twin socket outlet will be provided for PC, monitors and
printer from UPS supply. 277V, 13A/15A, socket outlets will be provided in each room from
normal supply for general purpose. In halls, one socket for each 10m of the hall periphery will
be provided.
Apart from the above power outlets will also be provided for Pantry appliances, water coolers,
refrigerators and Lab.
Welding outlets (480V-3ph-63A-4P+E) will be provided at suitable location near major

equipment like Pump house, Process area etc. to provide power for portable equipment at
inspection and maintenance point.

Substation will have industrial type receptacle while Control Room and Office rooms will have
decorative type receptacles, with ELCB (sensitivity range 30mA-300mA) controlled socket,
277V, 1 phase, Neutral & Earthing,13A/15A,3Pin.
All receptacles shall have looping facility & shall have cable entry at the bottom.
6.11.Local Control Station
All motors will be provided with local control stations each having START (Green)/STOP
(Red) pushbuttons. The stop position is stay put type with pad lock facility.
The local control stations shall be of aluminium alloy (LM6) construction, Enclosure of the
control station shall be suitable for site conditions such as weather proof, dust proof, flame
proof (Ex-d), corrosion resistant etc. LCS located outside shall have minimum IP-65.
Local/Remote (Hand - Auto) selector switch shall be provided in LCS.
LCS cable gland shall be provided by the vendor properly coordinated with the cable size and
shall be of high quality. Cable glands shall be brass compression type with isometric threads.
6.12.Cable Glands
All cable glands shall be made of nickel chromium plated brass and shall have ISO metric
entry threads with 1.5mm pitch. The same type and make of cable glands shall be used
throughout the installation.
Cable glands shall be dual certified for EEx de for installing in hazardous area and industrial
type weatherproof for installing in safe area. Glands shall be provided with an integral
permanent sealing device to prevent water ingress at the armour clamp. Each gland shall be
supplied complete with an IP66 entry thread seal and a brass locknut. Cable shrouds shall not
be required. Cable glands shall be double compression type.
6.13.Earthing and Lightning Protection System
Entire electrical system envisaged for the terminal, shall follow earthing installation practice in
accordance with the provisions of the relevant NFPA-70. For the Earthing calculation purpose
IEEE 80 shall be followed.
The earthing system will protect the electric network and assure personal safety in case of an
electric failure and against static charges.
Earthing system in general cover the various earthing system listed below.
 Cable armoring (multi-core power cables)
 Generator and Transformer neutral points.
 Substation building ground busbars.
 MV and LV Switchboard/MCC/PDB ground buses.
 Main Lighting DBs (MLDB), High Mast, Security tower

 Motor / generator machine frames.
 Metallic structure of building and metallic reinforcement of concrete building Pipe rack
steel.
 Frames of skids.
 Tanks, vessels, towers, stack
 Lorry tanks during loading, if necessary
 Base plate of rotating machinery
 All non-current carrying metallic structures
 Metal fences, gates, side rails
 Separate clean earth system for Instrumentation. I.e. SCADA / PLC Panel as per
specified requirements.
Main earth grid will be provided around substation and main plant area. It will consist of buried
copper conductor connected to rods driven earth pits at several points.
Size of copper conductor shall be calculated based on the system fault level. Copper
conductor shall be laid at a depth of not less than 500 mm below ground level. Earth pit will
consist of 16 mm dia., 3m long copper clad steel rod. The main earthing ring shall be
extended to earth bus to connect parts of all electrical equipment and machinery at two
separate and distinct earth connectors.
All product and water tanks shall be adequately protected against lightning strokes, by
connecting them to the earth grid with adequate size of Cu earth continuity conductors.
Depending on the tank diameter following number of cleats shall be welded on the tank body
with application of bituminous paint at welded joint-
Tank Diameter (D)

Earthing Connection
in meters
≤ 20 2 Nos. at 180°
20 ≤ D ≤ 30 3 Nos. at 120°
30 ≤ D ≤ 40 4 Nos. at 90°
40 ≤ D ≤ 50 5 Nos. at 72°
50 ≤ D ≤ 60 6 Nos. at 60°
In addition to tank earthing at base, Internal floating roof tanks will provided with earthing on
floating roofs. This is to ensure that the floating roof is of the same potential as the tank shell
and thus reduce the chance of potential spark and to allow a path to earth in the event of
lightning strike.
Earthing resistance of the grid shall be measured after connecting all the earth electrodes to

the grid. Value of resistance of earth grid to the general mass of earth shall be as follows:
 For electrical system and equipment, a value that ensures operation of the protective
device in the electrical circuit but not in excess of 5 ohms.
 For lightning protection, value of resistance of 5 ohms as earth resistance shall be

desirable, but in no case it shall be more than 10 ohm.
 Overall grid resistance shall be less than 5 ohm.
Below ground earthing is carried out by Thermit welding and above ground earthing through
compression type lugs. Cadmium coated nuts and bolts are to be used at tapping points
where welding is not envisaged. Lighting fixtures and receptacles shall be earthed through the
extra core provided in the lighting circuit / cable for this purpose.
Recommended earthing Conductor sizes are indicated in the table below:
Equipment Size of Earthing copper cable

Metallic enclosure of electrical equipment having a supply Half of the phase
cable with cross section more than 35 sq.mm conductor
Metallic enclosure of electrical equipment having a supply 16 Sq.mm Multi-stranded Cu
cable with cross section more than 16 sq.mm and up to green/yellow flexible PVC
35 sq.mm insulated cables
Metallic enclosure of electrical equipment having a supply
same as phase
cable with cross section more than 6 sq.mm and up to 16
conductor
sq.mm
6 Sq.mm Multi-stranded
Metallic enclosure of electrical equipment having a supply
Cu green/yellow flexible
cable with cross section 6 sq.mm and less
PVC insulated cables
Storage tanks (vertical & horizontal) Cu green/yellow flexible
Pipe racks, vessels & heat exchangers Cu green/yellow flexible
Small equipment & instruments Cu green/yellow flexible
Push button station Cu green/yellow flexible
Lighting Poles Cu green/yellow flexible
Lightning Protection
Lightning protection will be provided to equipment, structure and buildings which are higher
than 20 meters or as per the risk index analysis worked as per NFPA 780.

Lightning protection system shall consist of air rods, down conductors and ground Copper
rods. Air rods shall be of fully stainless steel Early Streamer Emission (ESE) type tested in a
high voltage laboratory in accordance with NFC-17-102.
6.14. Cables and cable Tray
Electrical Cables:
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 Laying
condition 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.
MV cables shall be dry cured XLPE insulated, extruded PVC sheathed, steel wire armoured
type with copper conductors. All cables rated for 1 kV and above shall be provided with both
conductor screening and insulation screening. Outer PVC sheath of all cables used shall be
flame retardant type conforming to ANSI.
All LV power & Lighting cables shall be with stranded copper conductor with XLPE insulation,
PVC inner sheathed, steel round wire armoured, PVC outer flame retardant (FRLS) sheath
and construction as per ANSI.
The control cables shall be PVC insulated, extruded PVC sheathed, steel round armored
type, outer FRLS sheathed with copper conductors. Special cables like twisted or shielded
control cables etc. shall be used as applicable for numerical relays, VFD etc. to suit selected
equipment as per equipment supplier’s recommendation
All earthing cables shall be Multi-stranded Copper conductor, flexible PVC insulated, colored
Yellow/Green, for above/underground use.
All power and control cables shall be in continuous lengths without any joints subject to
availability of drum length. The cables used for lighting and wires in conduits shall have
appropriate junction boxes with adequately sized terminals. Cable joints in hazardous areas
shall not be permitted.
In case of difficulty in connecting the cables to instrument or relay terminals, minimum cross
section may be reduced to 1.5 Sq.mm copper. For lighting inside the building, minimum 2.5
Sq.mm copper conductor, PVC insulated wire shall be used in conduit system (for circuit and
point wiring), with proper color coding.
Cable Tray and Cable laying philosophy:
 General:
Cables will be in general laid above ground on cable trays and or directly buried as per the
convenience at each location.
Cable trays will be hot dip galvanized steel ladder type. Covers will be provided for protection
against direct sunlight, rain water and mechanical damage.
Electrical cables will not be laid in the same trench, tray or conduit with the instrument and

communication cables.
Cable trenches, Trays and PVC duct banks will have 20% of spare space for future cables.
Multi-core HV cables will be arranged in a single layer with one cable diameter spacing
between them. Single core HV cables shall be arranged in trefoil formation in single layer,
with one trefoil cable diameter spacing between them.
 Buildings:
In the plant buildings, sub stations, control rooms, etc. cables will generally be laid on cable
trays supported on overhead metal structures, trenches, cable cellars, basement or along
building structures, walls, ceilings, etc.
In other non-plant buildings, power cables shall be laid in FRP cable trays/UPVC conduits. In
the false ceiling area, cables shall be laid above false ceiling and vertical dropper below the
false ceiling shall be concealed in wall. In the non-false ceiling area vertical trays shall be
provided with cover.
 Outdoor Underground Area:
In unpaved areas cables will be in general directly buried on a layer of sand and covered by
sand.
In paved areas cables will be laid in concrete trenches filled with sand and covered with
concrete slab or will be laid in PVC pipe/conduits in concrete duct bank.
For road crossing cables will be laid in PVC sleeves in concrete duct bank.
Cables will be identified with corrosion resistant cable strips, showing the cable numbers,
every 10m and at both side of road crossing, where ever transition from underground to
above ground and vice versa. A warning system of plastic strips will be provided above the
top level of all cables run in trenches. For unpaved areas cable trench markers will be
provided at grade over the cable trenches to show clearly the extent and the run of the
cables.
 Outdoor Aboveground Area:
Cables will be laid on hot-dip galvanized cable trays (ladder type) or in heavy PVC conduits.
Cable trays will be bolted to steel structures and walls or to adequately sized tray supports
and shall be routed on dedicated tiers of the pipe racks and on sleepers to equipment.
 Cable Tray:
The trays shall not show deflection / bend / deformation after laying of cables.
For terminal area, all cable trays and accessories shall be prefabricated, 2 mm thick hot
dipped Galvanized Iron ladder trays with rungs at 300 mm interval. Maximum width of trays
will be 600mm.Collar height will be 75 mm. The maximum length of single cable tray shall be
3000 mm.

For tray system design, in addition to self-load and wind forces, following guidelines for de-
sign shall be considered.
Support span - 2000 mm for horizontal & 1500 mm for vertical tray supports. Nuts, bolts and
any other hardware to be used in cable trays shall be stainless steel/cadmium coated.
Fastening of cables in cable ways shall be done with UV resistant (Black) PVC cable ties.
Cable trays used in the outdoor areas shall be provided with covers on top layer, for
protection from rain water & mechanical damage.
A horizontal clearance of 300 mm shall be maintained between instrumentation, signal cable

and electrical power/control cables.
For all cable trays stacked vertically, there shall be a minimum vertical working clearance of
300 mm from the top of the lower tray to the bottom of the tray above.
The trays shall be supported at appropriate intervals both vertically and horizontally, as
required by the cable tray manufacturer’s design criteria.
6.15.Cathodic Protection System
Cathodic protection will be provided for tank external bottom plates and Buries pipe line with
impressed current cathodic protection.
A CP specialist shall be engaged during the detailed engineering stage to confirm the extent
of the cathodic protection required. It shall be designed and implemented by the CP
specialist. Responsibly of engaging the services of the CP specialist shall be included in the
scope of the EPC contractor.
6.16.Neutral Grounding Resistor
The Neutral Grounding Resistor (NGR) shall be rated to withstand the fault current and shall
be out door type with IP 55 enclosure. The NGR element shall be stainless steel / ni-chrome.
6.17.Low Voltage Bus duct
LV bus ducts will be provided for interconnection of the 33/0.48kV transformer rated 750KVA
& above from the transformer secondary to the 480V LV Switchgear.
Non-phase segregated, self-cooled type, 3 phase, 4 wires with copper bus bars with heat
shrinkable PVC Sleeves.
Enclosure will be fabricated from 3 mm thick aluminum sheets for ratings above 3000A and 2
mm thick sheet steel otherwise. The Indoor portion of the bus duct shall be minimum IP42
and the outdoor portion of the bus duct shall be minimum IP55. The adopter box with flexible
bus bars on both ends of the bus duct shall be designed as part of the bus duct.
Bus bar supporting insulator shall be made of SMC (Sheet molding compound). Bus bar shall
be supported at regular intervals on insulator made of high dielectric strength. Non
hygroscopic, non-inflammable material with tracking index equal to or more than that defined
in standard.

Both Bus bar and supports shall be adequately sized and braced to withstand dynamic and
thermal stress expected due to the specified short time rating. Seal-off bushings with wall
frame assembly wherever the Busduct crosses wall from outdoor to indoor.
The Rating of the bus ducts connected to breakers shall have same continuous and short
circuit rating as that of breakers.
Neoprene rubber bellows for enclosure wherever expansion joints, transformer end, panels
end are provided.
6.18.Overhead Lines (Package Items)
In general the main components of an overhead line like conductor, supports, insulators,
cross arms and all related equipment shall be designed to provide adequate protection
against the adverse effects of all prevailing site conditions.
The design of an overhead line should take into account local utility practice in determining
the type of construction and the selection of materials.
 Conductors :
Phase and earth conductors shall be aluminium alloy, although ACSR (Aluminium Conductor
Steel Reinforced) may be considered & shall be complying with ANSI H35.1. Galvanised steel
may also be considered for earth conductors.
 Supports :
The support may either be wooden poles, steel pole or lattice steel tower as determined on
economic basis after satisfying the technical design parameters. Wooden poles shall comply
with ANSI standard. Steel poles & tower shall comply with relevant national standard.
 Insulators :
Post insulators and pin insulators shall be glazed porcelain, complying with ANSI/NEMA C29.
They shall be used in suspension insulation strings at higher voltages and in tension insulator
string at all voltages.
The insulators profile and insulator creep age length shall be selected to suit the site
conditions.
 Steel Components :
All steel components, including fasteners shall comply with the relevant international standard
and shall be hot dip Galvanised.
 Lightning Arresters:
Lighting Arrester shall be complying with NFPA-780 applies to non-linear metal-oxide resistor
type surge arresters without spark gaps designed to limit voltage surges on AC power circuits.
Lighting Arrester shall be installed as every cable termination.

7. ELECTRICAL SUBSTATION/SWITCHGEAR BUILDING
The substation building will consist of switchgear room and transformer bay. The switchgear
room will house LV Switchboard, MCC, auxiliary switchboards, UPS & battery bank and
Distribution Boards.
The sub-station 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. Layout of
the substation shall comply with the requirements of the latest versions of relevant standards
The Substation shall have a minimum two access points, one entry suitably sized to
accommodate equipment / normal entry and the second for emergency exit. Both exits shall
be fitted with a proprietary panic bar. The doors will be equipped with anti-panic handles and
will open outward.
The switchgear room floor will be elevated such that the floor level of the building will be 1.8
meter above the site FGL (ground level) to allow trenches below switchboards for cabling.
The Substation shall be sized to accommodate all electrical loads identified and to give
adequate clearances between items of equipment for ease of maintenance. Space for two
adjacent panels for future extension on each side of each switchboard shall be provided.
The Substation shall be designed for mounting on raised columns to provide access for the
installation of cables to the equipment. All switchgear panels shall be arranged to permit all
cables to enter from below.
Transformer bay & neutral grounding resistor (if any) will be outdoor type separated from
substation building with firewalls Fence & gate.
Sub-station wall adjacent to the transformer bays shall be 355 mm thick (inclusive of
plastering) in case of brick construction or 230 mm thick in case of RCC construction.
Batteries of UPS and DC Power Supply System shall be located separately in well ventilated
room provided with an exhaust fan and heat detectors.
The substation building shall be sized to maintain adequate clearances between equipment
for ease of maintenance. The following minimum clearances around various equipment shall
be maintained:
Sr. No. Location Clearance
1 Front clearance for HV switchboard 2500 mm
2 Rear clearance for HV switchboard 1500 mm
3 All around clearance for transformer 1000 mm

1000 mm on two sides,
4 All around clearance for NGR
200 mm on the other
5 Diesel generator set to wall 1500 mm

6 Clear height of bus-duct from FFL 3000 mm
Rear clearance for LV switchboard which

7 1000 mm
require Maintenance from rear
Rear clearance for panels having Less 200 mm
8
maintenance access from front only Or more than 750 mm
Front-Front of 2 switchboards facing each
9 2000 mm
other
1000 mm after
Side clearance between switch boards or
10 considering space for
from nearest obstruction
future panels
11 Minimum substation building free height 3500 mm
The substation shall be provided with portable fire extinguishers, safety signs, First-aid box
etc. in accordance with international safety requirements.
8. INSTALLATION, TESTING AND COMMISSIONING
Installation of all electrical equipment shall be carried out with high standard or workmanship,
neat routing/layouts, and clearances/access as per recommendations by the manufacturers,
standards and good engineering practices.
After installation the system equipment shall be tested for pre-commissioning test as
recommended by the manufacturers & established practices. Further, commissioning tests
shall be conducted to prove agreed performance within specified tolerance, temperature rise,
noise and vibration.


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DOC NO.

ELECTRICAL DESIGN BASIS

A 04-04-2016 Issued for Review/Approval H.N.P D.P.B D.P.B

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 04/04/2016) Page 2 of 31

6.18. Overhead Lines (Package Items) ........................................................................................29

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 04/04/2016) Page 3 of 31

1.1. Project Summary

Project Name Used Lube Oil Re-Refining Plant

Project Number 1061

Project Location JEDDAH, K.S.A

Comapany SAUDI MARJAN INDUSRIES

EPC Contractor Chemie-Tech DMCC

1.2. Project Objective

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 04/04/2016) Page 4 of 31

2.1. Definitions / Abbreviations

SHALL : Indicates a mandatory requirement

BS : British Standard Institution

UPS : Uninterruptible Power Supply

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 04/04/2016) Page 5 of 31

MCC : Motor Control Centre

MLDB : Main Lighting Distribution Board

PDB : Power Distribution Board

LDB : Lighting Distribution Board

ACB : Air Circuit Breaker

VCB : Vacuum circuit breaker

VFD : Variable Frequency Drive

ATS : Automatic Transfer Switch

MCCB : Moulded Case Circuit Breaker

SPN : Single Phase Neutral

DCDB : DC Distribution Board

PVC : Polyvinyl Chloride

XLPE : Cross (X) Linked Poly Ethylene

FRLS : Flame Retardant Low Smoke

PLC : Programmable Logic Controller

SCADA : Supervisory Control and Data Acquisition System

FAT : Factory Acceptance Test

SAT : Site Acceptance Test

LCS : Local Control Station

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 04/04/2016) Page 6 of 31

2.2. Statutory Requirements, Codes & Standards

 American National Standards Institute (ANSI)

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 04/04/2016) Page 7 of 31

Recommended Practice for the classification of Locations for

ANSI C37.55-2002 Medium Voltage Switchgear

Parameters Description Reference

Altitude from above Sea Level 17 Meter SAES-A-112 (Meteorological

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 04/04/2016) Page 8 of 31

151.2 KM/Hr. PDB_

Seismic Risk Class ZONE 2A PDB_

HOLD details shall be confirmed later.

4. ELECTRICAL SYSTEM DESIGN

4.1. Plant Power Source Details

 33KV MV Switchgear with VCB

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 04/04/2016) Page 9 of 31

In normal operation, all loads will be powered by the grid Power.

4.2. Supply System Parameters

: 33kV, 60Hz, 3-Phase, 3 wire (Provided by

Design Fault Level: 33kV System : 25 kA for 3 Sec. (Max.)

Design Fault Level: 480V System : 65kA for 1 Sec.

4.3. System Earthing Details

33KV / 4.16KV Transformer

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 04/04/2016) Page 10 of 31

277V System : Solidly earthed

4.4. System Voltage and Circuit Parameters