DESIGN PHILOSOPHY STANDARD SPECIFICATION No.

$SlIfcil'lJde ENGINEERS FOR

~ fclI<Rc6 ~ INDIA LIMITED 6-51-0099 Rev. 4
(~~,,,,~) IA GOIII of India Unde'lalu"9j ELECTRICAL FACILITIES Page 1 of 25

DESIGN PHILOSOPHY
FOR
ELECTRICAL FACILITIES

REVISED AND ISSUED AS STANDARD

4 31.03.04
SPECIFICATION
REVISED AND ISSUED AS STANDARD
3 01.12.99 UAP AAN VPS AS
SPECIFICATION
REVISED AND ISSUED AS STANDARD
2 10.12.97 NPG VPS SG AS
SPECIFICATION
11.02.86 ISSUED AS STANDARD SPECIFICATION VPS GNT
Standards Standards
Rev. Prepared Checked Committee Bureau
Date Purpose Convenor Chairman
No by by
Approved by

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 DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
$5]fciltlltSe ENGINEERS FOR
~ fCll<Rcs -INDIA LIMITED 6-51-0099 Rev. 4
(>lRCI ~im::l'lll'"'l) (A Govt of India Undeltakmg)
ELECTRICAL FACILITIES Page 2 of 25

Abbreviations:

BIS Bureau of Indian Standards

OISD Oil Industries Safety Directorate
CCE Chief Controller of Explosives
CEA Central Electricity Authority
DGMS: Director General Mines Safety
IEC International Electro-Technical Commission
CMRI Central Mining Research Institute
UL Underwriter's Laboratory
CPRI Central Power Research Institute
IE Rules: Indian Electricity Rules

Electrical Standards Committee

Convenor: Mr. VP Sharma

Members: Mr. KV Subramanyam
Mr. SK Sood
Mr. SC Mittal / Mr. Vineet Aggarwal
Mr. A Ananthanarayan
Mr. CR MandaI
Mr. RP Goyal
Mr. R Chaudhury
Mr. UA Patro

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 DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
SSjtfdl~d. ENGINEERS
~ fclfctlc6 !iij INDIA LIMITED FOR 6-51-0099 Rev. 4
,...",. '-""?'Tffi?''''~) IA Govt of India Unde"akln9)
ELECTRICAL FACILITIES Page 3 of 25

CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 STATUTORY REQUIREMENTS

4.0 SYSTEM DESIGN PHILOSOPHY

5.0 EQUIPMENT DESIGN PHILOSOPHY

6.0 SUBSTATION DESIGN PHILOSOPHY

7.0 INSTALLATION DESIGN PHILOSOPHY

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 DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
SS]fcij~d. ENGINEERS
~ BrdlCs - INDIALIMITED FOR 6-51-0099 Rev. 4
1><Ri"~''''J'IlI'>l' fA Govt of India UndertakIng)
ELECTRICAL FACILITIES Page 4 of 25

1.0 SCOPE
This specification along with the applicable project design data shall form the basis for
developing detailed design and engineering for electrical facilities including electrical
power system, electrical equipment, plant communication system, fire alarm system and
electrical installation etc.

2.0 CODES AND STANDARDS

The main codes and standards, considered as minimum requirements, as applicable, are
as follows. Latest version of these shall be followed:-

IS-1646 Code of practice for the fire safety of buildings - Electrical

Installations.
IS-2309 Code of practice for the protection of buildings and allied
structures against lightning.
IS-3034 Code of practice for fire safety of industrial buildings -
Electrical generating and distributing stations.
IS-3043 Code of practice for Earthing.
IS-3716 Application guide for Insulation Coordination.
IS-5216 Guide for safety procedures and practices in electrical work
IS-5571 Guide for selection of electrical equipment for hazardous areas.
IS-5572 Classification of hazardous areas having flammable
gases and vapours for Electrical installations.
IS-6665 Code of practice for Industrial Lighting.
IS-3646 Code of practice for Interior Illumination.
IS-7689 Guide for Control of undesirable static electricity.
IS-7752 Guide for improvement of power factor consumer's
installations.
IS-8478 Application guide for on load tap changers.
IS-9676 Reference ambient temperature for electrical equipment
IS-10028 Code of practice for selection, installation and maintenance of
transformer.
IS-10118 Code of practice for selection, installation and maintenance for
switchgear and control gear.
IS-10561 Application guide for Power Transformer.
IS-11064 Guide for construction and use of rooms or buildings protected
by pressurization for installation of electrical apparatus for
explosive gas atmospheres
IS-12360 Voltage bands for electrical installations including preferred
voltages and frequencies.
IS-13234 Guide for short circuit calculations in three phase AC systems.
IS-13346 General Requirements for electrical apparatus for explosive gas
atmospheres.
IS-13408 Code of practice for the selection, installation and maintenance
of electrical apparatus for use in potentially explosive
atmospheres.
IS-14154 Electrical Apparatus with protection by enclosure for use in the
(part 1 and 2) presence of combustible dusts
IS-14774 Resistance trace heating in potentially explosive atmospheres.
(part 1and 2)
IS- 15142 Guide to the use of electrical apparatus for potentially explosive
atmospheres in the presence of combustible dusts
SP-30 National Electrical Code (NEC) - BIS Publication.
OISD-STD-110 : Recommended practices on static electricity

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 DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
SSilWl~a ENGINEERS
~ Bfcfl~5' INDIA LIMITED FOR 6-51-0099 Rev. 4
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ELECTRICAL FACILITIES Page 5 of 25

OISD STD-113 Classification of Area for electrical installation at Hydrocarbon

and handling facilities
OISD-STD-147 Inspection and safe practices during electrical installation
OISD STD-149 Design aspects for safety in electrical systems
OISD STD 173 Fire Protection System for Electrical Installations
OISD STD-180 Lightning Protection

IEC specifications shall be followed where equivalent Indian Standards are not available
in specific cases.

3.0 STATUTORY REQUIREMENTS

The latest version of the following statutory regulations shall be followed for design of
electrical system,
Indian Electricity Act.
Indian Electricity Rules.
The Factory Act.
The Petroleum Rules.
Requirements of other statutory bodies as applicable, e.g. CEA/ State Electrical
Inspectorate, CCE, DGMS

4.0 SYSTEM DESIGN PHILOSOPHY

4.1 General

The electrical system shall be designed to provide:

Safety to personnel and equipment both during operation and maintenance.
Reliability of Service.
Minimal fire risk.
Ease of maintenance and convenience of operation.
Automatic protection of all electrical equipment through selective relaying
system.
Electrical supply to equipment and machinery within the design operating limits.
Adequate provision for future extension and modification.
Suitability for applicable environmental factors.

4.2 Area Classification and Equipment Selection

4.2. 1 All the areas within the battery limits shall be classified for the degree and the extent of
hazard from flammable materials. Classification of hazardous areas shall be done in
accordance with Petroleum Rules, DGMS regulations (where applicable), IS-5572, IS-
14154, OISD standards and Process Licensors recommendations.

4.2.2 Following factors shall be considered for proper selection of electrical equipment for use
in hazardous area:
Area classification i.e. Zone.
Gas classification i.e. 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 i.e. Group - The characteristic of the dust involved.
Temperature classification - The ignition temperature of the gas, vapour or dust
involved or the lowest value of the ignition temperature if more than one
combustible material is present.

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 S3]1dl<Jd ~ ENGINEERS DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
~ 1Ct1dl~6 ~ INDIA LIMITED FOR 6-51-0099 Rev. 4
('IT''''H'RI'",,''''~) fA GolI! of India Undertaking)
ELECTRICAL FACILITIES Page 6 of 25

Environmental conditions in which apparatus is to be installed - The selected

electrical apparatus shall be adequately protected against corrosive and solvent
agencies, water ingress, thermal and mechanical stresses as determined by the
environmental conditions.

4.2.3 All 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) lEx (n)
type as per IS/IEe codes. Increased safety {Type Ex (e)} equipment shall not be used
in Zone-l areas. Ordinary industrial electrical equipment (even though permitted for
use in Div.2 area as per NFPA-70) shall not be used in Zone-2 areas. Type of
explosion protection to be used for individual equipment shall be as specified in the job
design data.

4.2.4 For pressurised electrical equipment {Type Ex (p)}, on failure of pressurisation system,
the following minimum actions shall be provided:

Area classification Minimum action to be taken

Zone-l Alarm and Switch-off.
Zone-2 Alarm

4.2.5 Electrical equipments for hazardous areas shall be certified by CMRI/ CPRII ERTL or
equivalent recognised independent test house such as BASEEFA I LCIE I PTB I UL I FM.
All equipment (indigenous and imported) shall also have valid statutory approvals as
applicable for use in the specified hazardous area. The indigenous equipment shall
conform to Indian standards and shall be approved by CCE/DGMS as applicable. All
indigenous flameproof equipments shall have valid BIS license and marking as required
by statutory authorities.

4.2.6 The hazardous area motors (Ex 'e' or Ex 'd') fed by variable frequency drives 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 with
frequency converters/ variable frequency power suppliers. In case of flameproof motors,
the motor and variable frequency drive combination may not need to be certified
together if direct temperature control by embedded temperature sensors are provided,
which will disconnect the motor.

4.3 Power System Design

The distribution system shall be designed in accordance with project specification taking
into account all possible factors affecting the choice of the system to be adopted such as
required continuity of supply, flexibility of operation, operational costs, reliability of
supply from available power sources, total load and the concentration of individual
loads.
Special attention is drawn to chapter X of IE rules, which includes requirements for
design of electrical system as applicable to Mines and oil fields installation.

4.4 Capacity of Electrical System

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.

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 $S]fdl'!]de ENGINEERS DESIGN PHILOSOPHY STANDARD SPECIFICATION No.

~ BldlCs - INDIA LIMITED FOR 6-51-0099 Rev. 4

t>lR1" ~ "".:J'l1l"1'l) (A Go" of India Undertaking)
ELECTRICAL FACILITIES Page 7 of 25

4.5 System Voltages

System voltages shall be as defined in Design data sheet.

4.6 Voltage Drops

4.6.1 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
PERMISSIBLE
Sl. No SYSTEM ELEMENT
VOLTAGE
DROP
a) Busduct or cable between transformer secondary and HV 0.5%
Switchboard or PCC/PMCC
b) Cable between PCC/PMCC and MCC or auxiliary
switchboard
i) MCC I Auxiliary Switchboard near PCC/PMCC 0.5%

ii) MCCI Auxiliary Switchboard situated remote from 2 to 2.5%

PCC/PMCC (Note-3)
c) Cables between HV Switchboard and HV Motor 3%
d) Cable between PCC/PMCC and motor 5.5%
e) Cable between MCC (situated near PCC I PMCC) and 5%
motors
f) Cable between MCC (situated remote from PCC I 3%
PMCC) and motors
g) Cable between Auxiliary Switchboard I LDB and Lighting 1 to 1.5 %
Panel (Note- 2)
h) Circuit between lighting panels and lighting points 4% (Note- 2)
i) DC Supply Circuit (Electrical Controls) 5%
j) DCDB to Control Room 2% (Note -1)
k) UPS outgoing circuit 5 % (Note - 1)

Note-l
Minimum voltage available across any instrument in the field shall be as per
instrumentation design basis. Distribution system for instrumentation supplies shall be
designed accordingly. In case of any conflict between electrical design basis and
instrumentation design basis, the latter shall govern regarding instrumentation power
supplies.

Note-2
In case of difficulty in achieving specified voltage drops in cables upto Lighting panel,
5 % drop from Auxiliary switchboard upto Lighting points may be permitted.

Note-3
Higher voltage drop may be permitted between PCC I PMCC and remote mounted
MCCI ASB, if overall voltage drop upto motor (from PCC I PMCC) is limited within
5.5%.

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 DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
SSilW1~d. ENGINEERS
Sfujr Br<Rcs ~ INDIALIMITED FOR 6-51-0099 Rev. 4
(>lR7! """"""l"'~) (A GOIII of India Undertaking)
ELECTRICAL FACILITIES Page 8 of 25

4.6.2 The maximum voltage drop at various buses during start-up of large motor and/or motor
reacceleration conditions shall be within the limits stated below·
MAX.
PERMISSIBLE
Sl. No SYSTEM ELEMENT OPERATING CONDITION
VOLTAGE
DROP
a) At the busbars of the Start -up of the large HV motor 15 %
worst affected with other loads on the bus or
Switchboard reacceleration of a group of HV
motors (Simultaneous start-up or
group reacceleration of HV
motors is not envisaged)
b) At the busbars of the Start up of large MV motor with 10 %
worst affected MV other loads on the bus, or
Switchboard reacceleration of a group of MV
(PCC/PMCC/MCC) motors.
c) Cables between HV Motor start-up or reacceleration 5 %
Switchboard and motor (Note-e)
d) Cables between MV Motor start-up or reacceleration 15 %
switchboard (Note-e)
(PCC/PMCC/MCC)
and motor

NOTES:

a) The voltage available at the motor terminals during start-up 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.

b) For medium voltage motors, the voltage available at the motor terminals must
not be less than 75 % of the rated value during start-up or reacceleration.

c) For high voltage motors, the voltage available at the motor terminals must not
be less than 80 % of the rated value during start-up or reacceleration.

d) Based on the sizing criteria as defined, including voltage drop criteria, Cables
for 415V motors shall be selected as per Cable sizing table indicated in Design
data.

e) Higher voltage drop in motor cables may be permitted, in case the conditions
given in Note a), b) and c) are complied.

4.7 System Earthing

System earthing for incoming supply and primary/secondary HV distribution system
shall be as per design data. The 415V system neutral shall be solidly earthed.

4.8 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 minimum period of one second. The
sizing of high voltage cables shall also be based on the short circuit withstand capacity

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 DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
SSilWl<lde ENGINEERS
Sfujr fCifcfJc6 ~ INDIA LIMITED FOR 6-51-0099 Rev. 4
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ELECTRICAL FACILITIES Page 9 of 25

for a minimum time period as dictated by the protection system as defined in Design
data, in addition to the maximum anticipated load current. .

4.9 Insulation System

The insulation of electrical facilities shall be designed considering the system voltage,
the system neutral earthing and the over voltages resulting due to system fault, switching
or lightning surges. Lightning arresters and surge absorbers shall be provided where
necessary.

4.10 Protection and Metering Schemes

4.10.1 The protective system shall be selected and coordinated to ensure the following:

a) Protection of equipment against damage, which can occur due to internal or

external short circuits or atmospheric discharges.
b) Uninterrupted operation of those parts of the system, which are not affected by
the fault.
c) Personnel and plant safety.

4.10.2 Protection relays shall be provided as specified in design data. In general, quick acting
relays (with time delays, if necessary) shall be used and all fault tripping shall be done
through high speed tripping relays

4.10.3 Metering shall be provided to keep a record of power consumption and supervision of
all concerned parameters like current, voltage, power, frequency, power factor etc. as
specified in Design data.

4.11 DC Power Supply

Independent DC power supply systems shall be provided for the following (unless
otherwise specified):

Plant shutdown system including DC instrumentation.

Electrical switchgear controls including critical lighting.

Each DC power supply system shall include charger-cum-rectifier, batteries and DC

distribution board. Battery back up time shall be as specified in Design data.

4. 12 Emergency Power Supply

The emergency power supply system, wherever envisaged, shall feed the following:
Electrical loads essential for the safe shutdown of the plant.
Emergency lighting.
Process plant instruments as required.
Communication equipment.
Fire detection and alarm systems.
D. C. Supply systems.
UPS Systems.
Fire fighting equipment excluding main firewater pump.
Loads critical for process, plant and personnel safety.

Emergency power supply could be from a different power source or Emergency

Generator as per Project Design Data. 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.

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 DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
$5llWi~d. ENGINEERS
Sfuir fCtfcffcs'
INDIA LIMITED FOR 6-51-0099 Rev. 4
(>lR1"~''''~) IAGolit of India Unde,tat<ing)
ELECTRICAL FACILITIES Page 10 of 25

The emergency generator shall, generally, not be required to run continuously in parallel
with the normal power supply system. However, short time paralleling facility shall be
provided for transferring load to normal power supply or other operational needs as
required.

4.13 Uninterrupted Power Supply (UPS)

Uninterrupted power supply system shall be provided, (as required) for meeting critical
loads that cannot withstand a momentary interruption in voltage (e.g. critical
instrumentation, control etc.). Separate battery bank shall be provided for UPS system.
Battery back up time shall be as specified in Design data.

4.14 Power Factor Improvement

Capacitor banks shall be provided, as specified in Design Data, to improve the power
factor to meet the minimum stipulated power factor by the power supply authorities.

4.15 Plant Communication System

4.15.1 It shall consist of the following:

Central exchange alongwith power supply system.
Master station along with loudspeaker, microphone etc.
Desk type call stations along with microphone and external loudspeaker for
installation in buildings.
Wall/column mounting type call stations for hazardous/safe areas with external
loudspeaker as per Operational requirements.

4.15.2 Paging speakers shall be suitable for installation in areas having high ambient noise
levels without compromising the audibility performance.

4.15.3 The construction of the exchange shall be designed to allow for atleast 10% expansion
for future additions without involving any major modifications in the system. The
exchange shall be fully wired for connecting the future field call stations (if shown) in
the speech diagrams.

4.16 Fire Detection and Alarm System

4.16.1 The Fire Detection and Alarm System shall be an independent system comprising of
individual break glass type manual call points, automatic sensors e.g. smoke and heat
detectors, main panel, zonal panel, hooter, battery, battery charger and other hardware.
The system shall be designed to provide audio-visual indication at the main panel to be
located in fire station and zonal panels, in control rooms. Repeater panels shall be
provided as specified.

4.16.2 The manual call points shall be provided at strategic locations with access of 60 m along
all exit routes and roads.

4.16.3 Electrical sirens shall be provided to cover entire plant area.

4.16.4 Hooters and exit lights shall be provided at required locations in the buildings.

4.16.5 Panel design and component selection shall be done for future extension upto 10% of
specified zones or one zone, whichever is maximum in each panel. The design of
common facility and hardware shall be provided for required future extension of zones.

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 DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
SSilfdl~d. ENGINEERS
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1>!Ri'f ~l"'JQlII>1) fA Govl 01 India UndertakIng)
ELECTRICAL FACILITIES Page 11 of 25

4.16.6 The fire detection system shall be interfaced with fire suppression system; wherever
specified.

5.0 EQUIPMENT DESIGN PHILOSOPHY

5.1 General
The equipment shall in general conform to ElL standard specifications. Equipments shall
be selected and sized as per philosophy given below:

5.2 Transformers

5.2.1 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.

5.2.2 In general kVA rating and percentage impedance of each transformer shall be selected
to limit the rated current and short circuit current to values which are within the current
rating and interrupting capacity of switchgear available.

Transformers rated more than 3150 kVA shall have provision for fan cooled rating,
unless otherwise specified.

The kVA rating shall be decided on the following basis and should be as far as possible
a standard value. Sizing shall include 10% margin for future load growth.

a) In systems having redundancy for transformers, with transformers without any

forced cooling, each transformer shall be rated equal to or greater than the 8 hour
maximum demand of the load plus 10% margin for future load growth.

b) In systems having redundancy for transformers, with transformers having forced

cooling, each transformer shall be rated equal to or greater than the 8 hour
maximum demand of the load plus 10% margin for future load growth (within 110%
of it's self cooled (ONAN) rating) and shall be fitted with automatic forced air
cooling fans.

c) Where redundancy in number of transformers is not provided, rating shall be equal

to or greater than 8 hour maximum demand plus 10% margin for future load
growth. Fan cooled rating, where applicable, shall be reserved as spare capacity for
further future load growth.

5.2.3 100% standby transformers shall be provided in all unit, offsite and utility substations,
unless otherwise specified.

5.3 Switchgear

5.3. 1 All switchgear and associated equipment fed from generators and transformers shall
have rating atleast equal to the rating of respective generators and transformers feeding
it, under any circuit configuration. Generator incomer shall be rated w. r. 1. maximum
power output of the generator set over entire operating temperature range. Transformer
incomer shall be rated atleast equal to forced cooled rating of transformer or 110% of
ONAN rating as applicable.

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5.3.2 Bus tie circuit breakers shall have rating higher of the following:
a) Largest incoming circuit breaker.
b) Maximum running load on either side of bus section.

The tie breaker rating shall not be less than the bus-bar current rating, unless otherwise
specified.

5.3.3 All other switchgears not directly fed from generator and transformers shall have rating
atleast equal to the maximum demand under any circuit configuration plus a provision
for 10% future load growth. Incomers of these switchgears shall be designed to cater to
the complete load including 10% margin for future load growth.

5.3.4 Spare outgoing feeders shall be provided in all switchgear. For HV Switchboards, the
number of spares shall be as indicated in SLD. For other switchboards (and where not
specifically indicated in SLD), at least one number of each type of outgoing feeder or
10% of each type of outgoing feeder, whichever is more, shall be provided as spare in
the switchboard.

5.3.5 Circuit breakers/contactors controlling motor feeders shall have a rating of atleast 125%
of the maximum continuous rating of the connected motors.

5.3.6 Separate feeders shall be provided in the switchboard for each load/motor. However, as
an exception maximum two numbers welding receptacles may be connected to one
power feeder.

5.3.7 All circuit breakers shall be of single break type having one pole per phase. Circuit
breakers for MV generator incomer shall be with four poles. Alternatively three pole
breaker with adequately rated air break contactor for neutral isolation may be provided.

5.3.8 In case of HV vacuum circuit breaker, surge suppressors shall be provided for outgoing
motor feeders, as a minimum.

5.3.9 Rated service short circuit breaking capacities (i.e. Ics) for all breakers and MCCBs
shall be equal to or higher than the maximum specified value of the short circuit current
at the point of installation. MCCBs with backup fuses shall not be acceptable.

5.3.10 Air circuit breakers (ACB) shall be provided in MV switchboards for all feeders rated
above 400 A and switch fuse units/MCCBs shall be provided for all feeders rated upto
400A.

5.3.11 Circuit breakers/Switch fuse units 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.

5.3.12 The switchboard components viz. 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 time of 1 second, unless otherwise
specified.

5.3.13 For motors rated above 5.5 kW, CT shall be provided in the switchgear for ammeter on
the local push button station.

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fA GOIII of India Unde,lal<,ng)
ELECTRICAL FACILITIES Page 13 of 25

5.3.14 The maximum rating of bus-bars for MCCs/ASBs/LDBs should preferably be limited to
800 Amps. Heavy duty type load break switches/ACB shall be used for incoming and tie
breakers and these shall have suitable mechanical interlocks.

5.4 Bus Duct

The rating of bus 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.

5.5 Neutral Grounding Resistor

The NGRs shall be rated to withstand the fault current for 10 seconds.

5.6 Batteries
Batteries shall be of adequate capacity to meet the back-up requirements as envisaged in
the duty cycle as well as to take care of future load growth of 10%. While sizing the
battery, temperature correction factor and ageing factor shall be considered in addition
to the maintenance factor. Batteries shall be complete with battery racks and
accessories.

5.7 Battery Charger and Distribution Board

5.7.1 The battery charger/rectifier shall feed the load and keep the batteries under fully
charged condition. Provision shall also be made for necessary boost charging/initial
charging of battery.

5.7.2 Each battery charger and DCDB shall be sized to cater to selected battery capacity.

5.7.3 Each DCDB shall have atleast 10% spare feeders for future use.

5.8 Uninterrupted Power Supply System

5.8.1 UPS system shall be sized to take care of the crest factor of the load current.

5.8.2 UPS system shall include a set of storage batteries, rectifier transformer, rectifier-cum-
charger, inverter, set of filter circuit, static switches, bypass transformer, facility for
manual transfer between inverter supply and bypass line, facility for bypassing inverter
and static switch for maintenance, AC Distribution board and other associated
accessories.

Under normal conditions, the rectifier-cum-charger shall feed the inverter and charge
the battery set. In case of mains failure, the battery shall supply the necessary power to
the inverter. The inverter in turn shall feed the load through the static switch. If the
inverters malfunction or get overloaded, the load shall be instantaneously transferred to
the bypass line through the static switch. Normally, the inverter shall be operated in
synchronised mode with the bypass line, and manual forward transfer or manual reverse
transfer shall be effected without any break. Automatic forward transfer, in case of
inverter malfunction shall be affected with a break not exceeding 4 milliseconds in
synchronous mode and 20 milliseconds in asynchronous mode.

5.8.3 Each branch circuit of the UPS distribution system shall have a fused disconnect switch.
The fuse shall be fast clearing type and the fuse rating shall be co-coordinated with the
rating of the UPS system. Normally the largest branch circuit load shall not exceed
25 % of the UPS system rating.

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 SS]fdi~d. ENGINEERS DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
~ fcUd"fcs ~ INDIA LIMITED
(0iR'n ~''''3'liT'>l)
FOR 6-51-0099 Rev. 4
IA Govt of India Undertakmg)
ELECTRICAL FACILITIES Page 14 of 25

5.8.4 Each UPS ACDB shall have atleast 10% spare feeders for future use by owner.

5.8.5 UPS shall be sized to cater to 10% future loads.

5.9 Motors

5.9.1 In general, three phase squirrel cage induction motors designed for direct on line starting
shall be used. Motors shall be totally enclosed, fan cooled type and suitable for
continuous outdoor use.

5.9.2 All motors shall be continuous maximum rated with possible exception of crane and
hoist motors, soot blowers, turbine/engine starting motors etc. which may be rated for
the envisaged duty cycle.

5.9.3 High voltage motors shall be suitable for starting under specified load conditions with
80 % of the rated voltage at the terminals and medium voltage motors shall be suitable
for starting under specified load conditions with 75 % of the rated voltage at the
terminals.

5.9.4 For heavy duty drives 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.

5.9.5 Induced voltage across the shaft ends of motor shall not exceed 250 mV (rms) for ball
and roller bearings and 400 mV (rms) for sleeve bearings. Wherever it exceeds the
specified limit, the non-driving end bearing shall be insulated from the motor frame to
avoid circulating current. The insulated bearing end shield or pedestal shall bear a
prominent warning.

5.10 HV Capacitor banks

5.10.1 The capacitor banks shall be. supplied with series reactor and RVT (residual voltage
transformer). The whole bank shall be suitable for outdoor location.

5.10.2 The capacitor bank in conjunction with series reactor shall provide minimum net kVAR
at rated nominal voltage. The insulation system shall be designed to withstand
continuous over voltage of 110%.

5.11 Emergency Generator

5.11.1 The emergency generator set shall be designed to start automatically on power failure
and feed the selected loads. It shall be capable of taking care of the load variations (e.g.
the starting of the largest rated motor with specified base load). However, DG sizing
shall not include boost charging loads for UPS and DC system batteries (but shall only
include float charging and service loads). Moreover, Generator shall be designed to take
care of load Harmonics (current harmonics as per IEEE limits) without any derating.
For machines rated upto 1250kVA, harmonic distortion factor shall not exceed the value
given in IS-13364 Part-2. For machines rated above 1250 kVA, telephone harmonic
factor as per IS-4722 shall be applicable.

5.11.2 The regulation of generator voltage shall be automatic and necessary instruments for
metering viz., Ammeter, Voltmeter, frequency meter, kWH meter, power factor meter,
hour run counter etc. shall be included in control panel. Warning of abnormal conditions
shall be incorporated prior to automatic trip to prevent unnecessary shutdown.
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 DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
$Sllfdl~d. ENGINEERS
S@<ir ~r<Rcs ~ INDIA LIMITED FOR 6-51-0099 Rev. 4
(iiRi'f ~ 1m3'IlI'1'l) (A Govt of India UndertakIng)
ELECTRICAL FACILITIES Page 15 of 25

5.11.3 The unit shall be complete with necessary engine starting equipment, associated control
panel and shall be suitable for remote starting. Emergency Generator shall have auto-
starting arrangement but only with manual switching off feature. 'Fail to start'
annunciation shall be provided, in case the engine fails to start.

5.11.4 The load shall be automatically switched on to the generator only after the requisite
voltage build-up. The generator set shall be provided with all necessary protection
including protection against overloads, short-circuits, ground faults, etc. as applicable.

5.11.5 The Emergency generator set shall have atleast 10% spare capacity for meeting future
requirements.

5.12 Annunciation Panel

5.12.1 Audio-visual annunciation panels shall be provided, where specified in design data, to
monitor the switchgear and other electrical equipments.

5.12.2 Detailed annunciation schedule shall be based on but not limited to the following:

a) HV Switchgear
Breaker-wise fault trip alarm
Auto-changeover completed
Auto-changeover failure
Trip circuit status for each breaker
Differential relay operation alarm
Transformer trouble alarm
DC supply failure alarm (Bus wise)
PT secondary MCB trip alarm for all line and bus PTs.
Bus wire supervision alarm

b) MV Switchgear
Incomer/Bus coupler fault trip alarm
Auto-changeover completed
Auto-changeover failure
Bus-wise group fault trip alarm for outgoing feeder breakers
D.C. supply failure alarm (Bus-wise)
PT secondary MCB trip alarm for all line and bus PTs.

c) Operating status/fault conditions for UPS system.

d) Operating status/fault conditions for DC supply system.

d) Operating status/fault condition for DG sets.

e) Fault alarm for VSD panels

5.12.3 Annunciation panel shall be complete with acknowledge, test and reset pushbuttons.
10% spare windows for future use shall be provided in the panel. Generally,
annunciation panel shall be fed from the UPS system/ DC system.

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 DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
SSllfbi~d. ENC.INEERS
~ fClfcfJCs - INDIALIMITED FOR 6-51-0099 Rev. 4
1>iR" ~1fj1J'R!'>1' fA Govt of India UndertakIng)
ELECTRICAL FACILITIES Page 16 of 25

5.13 Cables And Wires

5.13.1 HV cables shall be dry cured XLPE insulated, extruded PVC sheathed, armoured type
with aluminum/copper conductors. All cables rated 3.8 kV/6.6 kV and above shall be
provided with both conductor screening and insulation screening.

5.13.2 MV power cables shall be PVC insulated, extruded PVC sheathed, armoured type with
aluminum/copper conductors. In general power cables with conductor size upto 16 mm-
shall be with copper conductor while aluminium conductor shall be used above 16 mm-.

5.13.3 The control cables shall be PVC insulated, extruded PVC sheathed, armoured type with
copper conductors. Special cables e.g. twisted pair or shielded control cables etc. shall
be used as applicable for numerical relays, VSDs etc. to suit selected equipment as per
equipment supplier's recommendations.

5.13.4 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 derating due to ambient air temperature, ground temperature, grouping and
proximity of cables with each other, thermal resistivity of soil, etc. shall be taken into
account.

5.13.5 Cables connected in parallel shall be of the same type, cross-section and terminations.

5.13.6 As an exception within substation areas, unarmoured cables may be used, if specifically
agreed upon.

5.13.7 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 areas shall not be permitted.

5.13.8 All incoming cables to switchgear/UPS/DC system/DBs and other equipment shall be
sized for maximum anticipated load including 10% future load growth. Cable for
capacitor banks shall be sized for 135 % of the rated capacitor current.

5.13.9 The incoming cable for heat tracing power distribution panel shall be with four cores,
the neutral conductor being of same size as the phase conductors.

5.13.10 All control cables shall have minimum 10% spare cores, except that control cables
having upto seven cores may have one core as spare.

5.14 Control Station

5.14.1 Each motor shall be provided with a control station in the field, unless otherwise agreed
upon.

5.14.2 The control station shall include the following equipment as per individual requirement:
Start!stop push button
Ammeter
Auto/Manual or Local/Remote selector switch
Cable glands
Indication lamps etc. (if specified).

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 ENGINEERS DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
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(A Govt of India Undertaking)
ELECTRICAL FACILITIES Page 17 of 25

5.14.3 Stop push button shall generally have stayput feature except in the case of critical drives
such as lube oil pump etc.

5.15 Convenience Receptacles

5.15.1 These shall have the necessary mechanical interlocks and earthing facilities. The
enclosure shall have suitable protection for site conditions specified (flame proof,
weather proof, dust proof, corrosion resistant, etc.).

5.15.2 Adequate number of welding receptacles shall be provided at suitable locations to ensure
accessibility with a 50 m length of trailing cable to any point in the process area. These
shall be rated for 60 A suitable for 415 V, 3 phase system with a scraping earth.

5.15.3 Adequate number of three-pin sockets for lamps and portable tools shall be provided at
suitable locations to ensure accessibility with a 15 m length of cable to all manholes of
process equipments and other important areas in the process units. These shall be rated
for 15A, 240 V single phase with earth connection. Hand lamps and portable tools shall
be earthed through flexible cords. In hazardous areas, flameproof hand lamps shall be
rated for 24V. Accordingly, 240/24V transformers shall be provided in the plug, unless
otherwise specified.

5.16 Actuators for Motor Operated Valve

MOVs shall be provided with integral starters. The necessary local/remote selector
switch, start/stop control switches or push buttons, torque limit switches etc. shall be
provided on actuator for local/remote control depending on the mode of selection. In
case of failure of torque limit switches, the mechanical design shall be adequate to stall
and trip the motor without damage. The control circuit may be A.C. operated for short
distance and D.C. operated for extended distances, where required. MOVs with 2 wire
control shall comply to job specifications and control supply shall be as specified
therein.

6.0 SUBSTATION / MCC ROOM DESIGN PHILOSOPHY

6.1 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.

6.2 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 atleast
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.

6.3 MV sub-stations and MCC rooms shall be elevated by compacting the soil so that
• The finished floor level shall be above the approach road level to the building.
• The finished floor level shall be minimum 1000 mm above the surrounding grade
level.
• The bottom of the cable trench within sub-station is minimum 150 mm above the
surrounding grade level.

6.4 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

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 $Silfbl'lJ~ •
ENGINEERS DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
~ fclfcffCs'W' INDIALIMITED FOR 6-51-0099 Rev. 4
'>m'" ~I"'~) fA GolII of India Undertaking)
ELECTRICAL FACILITIES Page 18 of 25

be provided with double door system with an airlock lobby. The Sub-station shall also
have an emergency door opening outwards.

6.5 Sub-station wall adjacent to the transformer bays and walls separating transformers shall
be 355 mm thick (inclusive of plastering) in case of brick construction or 230 mm thick
in case of RCC construction.

6.6 Sub-station building shall be without any columns within the switchgear room to ensure
optimum space utilization, unless otherwise specified.

6.7 Battery banks shall be located in a separate adequately ventilated room in the sub-station
buildings, alongwith the necessary exhaust system and water connection with sink.
Floor of the battery room and walls upto 1.5 m height shall have acid/alkaline resistant
protective epoxy coating. Light fittings in this room shall be chemical resistant type.
However, separate battery room is not required in case of VRLA batteries.

The battery rooms shall be provided with minimum two exhaust fans and louvered
opening in opposite wall/door.

6.8 UPS system and other power electronics equipment e.g. variable speed drive panels
shall be located in air-conditioned room, unless otherwise specified.

6.9 Sub-station shall have fire extinguishers, first aid boxes and other safety equipment as
per statutory requirements. Insulating mats of required voltage rating shall be provided
in front of switchboards.

6.10 Separation walls between transformers in all substations and safe inter transformer
distances for switchyard transformers shall be as per clause 5.3.11 & 5.3.12 of OISD-
Std-173.

6.11 Equipment like transformers, neutral grounding resistors, reactors and 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.

6.12 In order to prevent oil, whether from a small leakage or outflow from transformer tank,
from reaching and polluting the water bearing stratum, transformers shall have the
following provisions, depending on the oil capacity of the transformer

6.12.1 Oil Capacity upto 2,000 litres:

Transformers installed adjacent to sub-station/buildings or in Switchyards shall be

provided with a layer of 100 mm deep stones of about 40 mm granulation, all around the
transformer, for a width of 20 % of the transformer height or with a minimum width of
about 800 mm.

6.12.2 Oil Capacity exceeding 2,000 litres:

Transformers installed adjacent to sub-station/building or in Switchyards shall be

provided with oil containing pits.

The oil containing pit may be shaped as per OISD standard 173. The pit shall extend all
around the transformer for a width of 20 % of the transformer height, with a minimum
width of about 800 mm. In case oil capacity exceeds 9,000 litres, in any chamber,

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 DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
$5jIWl'2Jd ~ ENGINEERS
~ fCtfcRc6 ~ INDIALIMITED FOR 6-51-0099 Rev. 4
Iffi<'" ~1"'JQi7»l) IA Go\'! 01 India Undertaking)
ELECTRICAL FACILITIES Page 19 of 25

provision shall be made for draining away of any oil, which may escape or leak from
the tanks, to a waste oil tank.

6. 13 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:

si, No LOCATION CLEARANCE

a) Front clearance for HV switchboard 2500 mm
b) Front clearance for all other switch boards/panels 2000 mm
c) Rear clearance for panels having maintenance Less than 200mm or more
access from front only than 750 mm
d) Rear clearance for panels requiring maintenance 1500 mm (HV swbds) &
from rear 1000 mm (MV swbds)
e) Side clearance between two switch boards or from 1000mm after considering
nearest obstruction space for future panels as
per cl. 6.16)
f) All around clearance for transformers 1000 mm
g) All around clearance for NGR 1000 mm on two sides,
200 mm on other two
sides
h) All around clearance for capacitor bank/ series 1000 mm
reactor
i) Battery rack to wall clearance for
- Single row, single/double tier 100mm
- Double row, single tier 100mm
- Double row, double tier 750mm
j) Battery rack to rack clearance 750mm
k) Head room clearance below busducts or any other 2000 mm
overhead equipment
1) Front clearance for wall mounted equipment 1000 mm
m) Front clearance for operation station / 2500 mm
annunciation/control panel

Vertical clearance above the top of the highest equipment shall be minimum 1500mm
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.

6.14 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 The DG sets shall be preferably located in a separate building other than the substation,
in a safe area to reduce noise level in substation. However in case the same is located in
the substation building, the DG set foundation shall be structurally delinked from the
slab/floor of the rest of the substation building. Exhaust of diesel engine shall be kept

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 DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
$Jj)Wl~d. ENGINEERS
~ fclrdlcs ~ INDIA LIMITED FOR 6-51-0099 Rev. 4
(Offi?"[ ~'Il1~) fA Govt of India Undertaking)
ELECTRICAL FACILITIES Page 20 of 25

away from the process/hydrocarbon handling areas and diesel day tanks shall be located
outside the DG room. Suitable ventilation system shall be provided to avoid heat
accumulation in the DG room.
6.16 Fire protection for transformers and switchgear room shall be provided to comply to
requirements of OISD-STD-173.

7.0 INSTALLATION DESIGN PHILOSOPHY

7.1 General
The installation work for equipments, cabling system, earthing system and lighting
system shall generally conform to ElL standard specifications and installation standards.

7.2 Cabling System

7.2.1 Cabling system for various areas shall be as specified in Project design data. Total
cable route connected to FW pump/motors starting from main receiving substation to
FW pump house shall be directly buried underground.

7.2.2 The cable trenches shall be sized depending upon the number and voltage grade of
cables. The trenches in hazardous areas shall be filled up with sand. Where
underground cables cross road ways, pipe sleepers at grade etc. they shall be protected
by being drawn through sleeves/ducts to provide a permanent crossing.

7.2.3 RCC cable trenches shall be sealed against ingress of liquid and gases wherever the
trenches leave or enter a control room or substation. Pipes laid for mechanical
protection shall be sealed at both ends. In case of direct burial, cable route markers
shall be installed at 30 m interval all along the cable routes and where the direction of
cable trench changes. Additionally, markers shall be provided at cable straight through
joint locations.

7.2.4 Above ground cables shall be well supported on cable trays and suitably protected
against mechanical damage. Routing shall be decided to avoid interference with hot
surfaces or places subject to undue fire risk.

7.2.5 Cable trays, racks and trenches shall be sized to allow for 10 % space for future cables.
Cable installations shall provide minimum cable bending radii as recommended by
cable manufacturer. Separate trays shall be provided for HV cables, MV power,
control and plant communication cables. However, where specifically agreed upon in
exceptional cases, HV and MV power, control cables may be laid together, with a
barrier plate separating HV and MV cables.

7.2.6 Separate cables shall be provided for AC and DC signal/control circuits, except for
cables to Local control stations/ local control panels.

7.2.7 Cables connected in parallel shall run together so that their length remains the same.

7.2.8 Type of cable tray and accessories shall be as specified in Design data. For tray system
design, in addition to self load and wind forces, following guidelines for design shall be
considered.
a) Maximum Support span 3000 mm

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 ENGINEERS DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
~f2Udlc5
lOiR1'f~''''~)
INDIALIMITED FOR 6-51-0099 Rev. 4
fA Govt of India Vndellakong)
ELECTRICAL FACILITIES Page 21 of 25

b) Cable load for

i) 150 mm wide cable tray 30 kg/linear meter
ii) 300 mm wide cable tray 60 kg/linear meter
iii) 600 mm wide cable tray 75 kg/linear meter
iv) 750 mm wide cable tray 75 kg/linear meter.

c) In addition to this, 70 kg concentrated load at center span shall be

considered. All structural steel design shall be as per Indian Standards.

7.2.9 Bends, tees, reducers, crosses, droppers etc. shall have the required bending radii as
required for various cable sizes with a minimum of 300 mm.

7.2.10 All cables shall carry the cable tag numbers for easy identification.

7.2. 11 Instrument cables, communication cables and Fire alarm cables for addressable analog
systems shall preferably not be laid in the same trench/ tray along with electrical
cables. In case these are laid in the same trench/ tray, a clearance of minimum 300 mm
from electrical cables shall be provided. The overall cable layouts shall be designed for
minimum interference between signal and power cables.

7.2.12 The armour and semiconductor screen of single core cables shall be earthed at one end
(except for short cable lengths). The continuity of armour and semi conductor screen
shall be broken at each joint. The unearthed end of armour and screen shall be insulated.

7.3 Earthing System

7.3.1 It is recommended that all electrical equipment be suitably earthed. Earthing system
shall, in general cover the following:
• Equipment earthing for personnel safety.
• System neutral earthing
• Protection against Static and Lightning discharges.
• Separate clean earth system for Instrumentation, DCS, ECS etc. as per specified
requirements

7.3.2 Plant earthing design shall generally be carried out in accordance with the requirements
of Indian Electricity Rules and IS : 3043. The earthing system shall have an earthing
network with required number of earth electrodes connected to it. The following shall
be earthed:
• System neutral
• Current and potential transformer secondary neutral
• Metallic non-current carrying parts of all electrical apparatus such as transformers,
switchgears, motors, lighting / power panels, terminal boxes, control stations,
lighting fixtures, receptacles etc.
• Steel structures, loading platform etc.
• Cable trays and racks, lighting mast and poles.
• Storage tanks, spheres, vessels, columns and all other process equipment.
• Electrical equipment fencing (e.g. transformer, yard etc.)
• Cable shields and armour.
• Flexible earth provision for wagon, truck.
• Pump handling Hydrocarbon if its base Plate is separate from motor's base plate.
• Turbo driven pump handling hydrocarbon

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 $5iIf(ij~a. ENGINEERS DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
s&W fCUdlc6 . , INDIALIMITED
(......,.~""~)
FOR 6-51-0099 Rev. 4
IA GoY! of India Undertaking)
ELECTRICAL FACILITIES Page 22 of 25

7.3.3 Unless adequately connected to earth elsewhere, all utility and process pipelines should
be bonded to a common conductor by means of earth bars or pipe clamps and
connected to the earthing system at a point where the pipelines enter or leave the
hazardous area except where conflicting with the requirements of cathodic protection.

7.3.4 Where installed, lightning protection shall be provided as per the requirements of IS:
2309. Self-conducting structures having metal thickness of more than 4.8 mm may not
require lightning protection with aerial rod and down conductors. They shall, however,
be connected to the earthing system, at least, at two points at the base. OISD-STD-180
may be referred for details on lightning protection

7.3.5 The resistance values of an earthing system to the general mass of earth should be as
below:
• For the electrical system' and equipment a value that ensures the operation of the
protective device in the electrical circuit but not in excess of 4 Ohms. However, the
generating stations and large sub stations, this value shall not be more than 1 Ohm.
• 10 Ohms in the case of all non-current carrying metallic parts of major .electric
apparatus or any metallic object. For lightning protection, the value of 5 ohms as
earth resistance shall be desirable but in no case it shall be more than 10 ohms.
• Earthing of Tanks shall comply to OISD-STD-173
• All joints in pipelines, valves, plants, storage tanks and associated facilities and
equipment for petroleum shall be made electrically continuous by bonding or
otherwise; the resistance value between each joint shall not exceed 1 Ohm.
Pipeline runs / installations having cathodic protection shall be governed by Rule-
109 of Indian Petroleum Rules-2002.

7.3.5.1 Earth rods and conductors shall be designed to cope with the conditions imposed. The
earth conductor shall be adequately sized to carry the applicable maximum earth fault
current without undue temperature rise. All joints shall be protected against corrosion.

7.3.5.2 All the electrical equipment operating above 250 volts shall have two separate and
distinct connections to earth grid. Transformers shall be provided with two dedicated
earth electrodes for earthing of neutral and transformer tank earthing.

7.3.5.3 All earth connections should be visible for inspection to the extent possible. In all
cases, connection to earth should be made in accordance with IS : 3043.

7.3.5.4 For further details on earthing installation practices, refer OISD-STD-147 and OISD-
STD-149.

7.3.6 The main earthing network shall be used for earthing of equipment to protect it against
static electricity. An independent earthing network shall be provided for lightning
protection and this shall be bonded with the main earthing network below ground,
minimum at two points.

7.3.7 An approach for removing fire or explosion danger is to provide means for adequate
dissipation and prevention of accumulation of static electricity, thereby ensuring that
static discharges do not occur. One of the methods to eliminate risk of static electricity
build up is grounding and bonding.

The subject of Static accumulation caused by flow of petroleum products and the
mitigation methods are dealt in detail in OISD-STD-II0 and same should be referred.

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I A GOIit of India Undertaking)
ELECTRICAL FACILITIES Page 23 of 25

7.3.8 Normally earthing system shall comprise of main earth grid alongwith suitably located
disconnecting plates to provide multiple earth connections between earth grid and
equipment and for connections between main earth grid and electrodes.
All connections shall be adequately secured against loosening.
Connections between earth electrode and the disconnecting plates shall be done by GI
strip. Connection between the disconnecting plate and various equipment shall be done
by GI strip, GI wire or GI wire rope.

7.4 Lighting System

704.1 Plant lighting system shall comprise:

i) Normal lighting
ii) Emergency lighting
iii) Critical lighting.

Normal and emergency lighting shall be fed by AC supply (415/240V, three phase four
wire except in case of Mines and Oil fields where it shall be in line with Chapter X of
IE rules and statutory requirements) while critical lighting shall be fed by DC supply.
Additional precautions as per Chapter X of IE rules to be adopted in mines and oil
fields shall not apply to apparatus above the ground level except where such apparatus
may directly affect the safety of the persons employed in underground mines, open cast
mines and oil fields.

704.2 All emergency and DC critical lighting ( if specified) fixtures and associated Junction
Boxes in Hazardous areas shall be Flameproof type.

704.3 Normal lighting system shall provide enough illumination so as to enable plant
operators to move safely within the accessible areas of plant to perform routine
operation including reading of field instruments, operation of all valves etc. and to
carry out all the necessary maintenance and adjustment to equipment.

70404 Areas requiring AC emergency lighting shall include, but not be limited to, the
following:

- All Areas requiring DC critical lighting.

- Strategic locations in process, utility areas where specific safety/shutdown operation
are to be carried out.

Generally 20-25 % of the total lighting fixtures shall be fed from AC emergency supply.

7 04.5 Areas requiring DC critical lighting shall include, but not be limited to, the following:
- Control rooms
Substations
DG shed
Central fire station
Fire water pump house
First aid center

Adequate number of self contained portable hand lamps and battery operated emergency
lighting units shall be provided for immediate use for buildings where no DC supply is
available.

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 DESIGN PHILOSOPHY STANDARD SPECIFICATION No.
$SilWi~d. ENGINEERS
~ tafdlcs • INDIALIMITED FOR 6-51-0099 Rev. 4
IIiRi" ~l"'~) (A GOIII of India Undertaking)
ELECTRICAL FACILITIES Page 24 of 25

7.4.6 During normal operation, both emergency and normal lighting shall be fed by normal
power source. On failure of normal supply, emergency lighting load shall be
transferred to emergency source after the start of DG set. Critical (DC) lighting shall be
normally kept 'OFF' and during failure of AC power, battery bank shall feed the critical
lighting system.

7.4.7 HPMV lamps shall generally be used for outdoor plant lighting. Keeping in view the
restrike time lag and to avoid complete darkness in case of a voltage dip/black out
condition necessary incandescent lamps may be judiciously distributed throughout the
plant area. Fluorescent lamps shall be used for indoor lighting for non-process buildings
and control room. Safe area street lighting and area lighting may employ sodium vapour
lamps. All chemical handling facilities including battery rooms shall be provided with
chemical resistant fixtures. Low pressure sodium vapour lamps shall not be installed in
hazardous areas. DC critical lighting shall employ incandescent lamps. Tall structures
shall have aviation obstruction lighting as per statutory requirements.

7.4.8 Telescopic tubular high masts shall be provided for illumination of tank farm/general
area. Where feasible, street lighting poles may be avoided where lighting high masts
provide adequate illumination. The high masts shall be of continuously tapered
polygonal cross section and fabricated out of steel plates. The masts shall be provided
with motorised racking mechanism for lowering and hoisting lantern carriage.

7.4.9 Lighting system shall consist of lighting transformers, lighting distribution boards
(LDBs), lighting and power panels, fixtures, junction boxes etc. as specified. All
outdoor lighting shall be automatically controlled by means of photoelectric
cell/synchronous timers with manual overriding control as specified. Lighting and power
panels shall be fed from LDB through 433/433V, Dynll, dry type lighting transformer
having taps upto ±5 %. (Refer clause 7.4.1 above for Mine and Oil fields installations).
The lighting and power panels shall be provided with MCB and ELCB as incomer and
Miniature Circuits Breakers (MCBs) for outgoing feeders control and protection of
lighting circuits. MCBs shall not be loaded beyond 80% of rated capacity. A minimum
of 25 % of miniature circuit breakers of each panel shall be left as spares. In general, the
load on each circuit shall be limited to 1.5 kW. In areas having less lighting load,
lighting transformer can be avoided.

7.4.10 Lighting Lux Levels

Lighting system design shall be based on illumination levels as specified below:

Area LUX
- Roads and tank farm 20
- Pump house, Sheds 100
- Main operation platforms and access stairs 60
- Ordinary platforms 20
- Process area, pipe racks, heat exchanger 60
- Heater, cooling tower, separators etc.
- Switchgear room 200
UPS/ Operator room 300
- Cable cellar 70
- Battery room 150
- Control room, Laboratory 500
- Switchyard 20
- Warehouse 100
- Office 300
- Compressor area 150
Format No. 8-00-0001-F1 Rev. 0 Copyright ElL - All rights reserved
 S6ilfOl~d. ENGINEERS
~ fcUdlc5 =
INDIA LIMITED
(0!Rn """"'" ""~) IA Govt of India Undertakong)
DESIGN PHILOSOPHY
FOR
ELECTRICAL FACILITIES
STANDARD SPECIFICATION No.

6-51-0099 Rev. 4
Page 25 of 25

7.4.12 Lighting design shall conform to relevant Indian and International Codes and
Standards, IES Hand Book ·and shall take into consideration the requirements from
point of view of safety and ease in operation and maintenance. A maintenance factor
of 0.8 shall be assumed for lighting illumination level calculations for normal areas.
However for dusty areas, maintenance factor as per relevant codes and standards shall
be considered.

7.4.13 Wiring for lighting and convenience outlets in outdoor areas shall be carried out with
PVC armoured cables run along the column/platforms and structures. The armoured
cable shall enter lighting fixture/JB through double compression gland for safe area,
Ex(e) or Ex(n) equipment and through flameproof glands for Ex(d) equipment. Suitable
mechanical protection shall be provided for lighting fixtures (e.g. wire guard).

7.4.14 Adequate number of ceiling fan points shall be provided in Administration Building,
Offices, rooms allocated for operating and maintenance personnel etc.

7.4.15 Two pole isolation devices shall be used for controlling lighting fixtures and sockets in
hazardous areas to isolate phase as well as neutral. (For all Mine and Oil field
installations refer clause 7.4 .1 above).

7.4.16 For buildings with false ceiling, concealed conduit wiring shall be used below the false
ceiling and surface conduit wiring above the false ceiling.

7.4.17 Adequate number of pull boxes shall be used to aid wire pulling and inspection. No
joints shall be allowed inside these pull boxes.

7.4.18 Battery room shall have fixtures mounted on wall in order to facilitate easy replacement
of fused lamps. Switches controlling the lighting fixtures and exhaust fan shall be
installed outside the battery room.

7.4.19 Locally mounted lighting fixtures on platforms, walkways, stairs shall be installed in
such a way that relamping can be done without the use of ladders.

Format No. 8-00-0001-F1 Rev. 0 Copyright ElL - All rights reserved