Electrical Training Course

SYRIAN GAS COMPANY (SGC)
TRAINING COURSE
Electrical
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INDEX
1. ELECTRICAL SYSTEM DESIGN
2. SINGLE LINE DIAGRAM CRITERIA
3. MAIN ELECTRICAL EQUIPMENT
4. MAIN ELECTRICAL CALCULATIONS
5. ELECTRICAL PROTECTION AND CONTROL
6. EQUIPMENT AND CABLE RUN LAY-OUT
7. GROUNDING SYSTEM CRITERIA
8. LIGHTING
9. SAFETY AND AREA CLASSIFICATION
10. DOCUMENTS AND DRAWINGS
11. MATERIAL PROCUREMENT
APPENDIX A - PRINCIPLES OF ELECTRICAL ENGINEERING
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1. ELECTRICAL SYSTEM DESIGN
1.1. INTRODUCTION
When electric power stops flowing in a manufacturing plant, the plant’s

production stops. The plant owners may have invested money for the best of
plant facilities, the most modern production machines, have an ample inventory
o raw material, good product design, highly trained and efficient labour, and
everything else that is required to produce manufactured goods quickly and at
low cost.
However, if electric power is not available when and where needed in the plant,
then the owner’s investment in both plant and inventory is so much idle capital.
Because electric power is so important in any manufacturing process, the
electric power distribution system in the plant is the vital link that carries the
electric power from the utility supply point to the production machine that
keeps the plant’s production moving.
The electric power distribution system in a plant generally costs less than 2 to 5
per cent of the total plant cost, including process machinery. Since one gets so
much for so little from the investment in the plant power system, it pays to use
only the best practices and equipment to assume a maximum of profit from the
over-all plant investment.
The power system engineer who designs an industrial plant power distribution
system must rely on his technical engineering background, and also he must
exercise considerable engineering judgement, as all phases of industrial power
system engineering cannot be expressed in numbers or solved by formulas.
When decisions based on engineering judgement are required, the power system
engineer should always base his consideration on the best facts available and not
on vague hypotheses or information which does not apply to the specific
problems at hand.
1.2. GENERAL
The design of the electrical installation should be based on the reference code,
Over-all Planning (one line diagram), Safety, Economic factors, Future
expansion, Simplicity, Service Reliability, Selection of equipment and
Maintenance.
The philosophies to be employed will depend on the size and complexity of the
installation; those approved for a specific project should be set down clearly
during the project definition phase.
The electrical system and associated controls should be designed on the basis of
forming an integral part of the process plant facilities, as far as is practicable.
For example, on-site electricity generation by recovery of process heat energy
and integration of the electrical system controls with process control system
should be considered. Furthermore, due regard should be given to selection and
utilisation of efficient electrical equipment in order to reduce energy
consumption. The use of high efficiency/power factor electric drives, the use of
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VSDS for speed, flow or power control, the selection of low loss transformers,
etc. should be evaluated during the detail design and equipment procurement
stages of a project.
When designing electrical power systems, the following alternatives for the
electricity supply should be considered: own generation, public utility supply, or
a combination of these within the limits and possibilities given by the Principal.
The design and selection of power supply source should ensure a degree of
availability commensurate with the service required.
Generating sets should normally be in an electrically centralised location and the
distribution system arranged radially. Ring distribution systems should be
considered for residential/industrial facilities located at relatively large distances
from the power source or from each other.
A key line diagram of the electrical power system should be prepared and kept
up to date throughout the lifetime of the plant.
System studies and protection reports, etc., should be provided in support of the
design. Depending on the type, size and complexity of the installation, such
studies may comprise the following:
- Load-flow studies
- Fault level studies
- Transient stability studies under three phase fault conditions
- Dynamic performance studies under motor starting and/or loss of generation
conditions
- Protection grading studies, including relay setting schedules
- Harmonic distortion studies.
1.2.1. Over-all planning (single line diagram)
To obtain a power distribution system which is adequate to meet the service

reliability requirements of a plant and yet which is lowest in cost requires that
the power system engineer plans the power distribution system on an over-all
inclusive basis.
While the electrical system is installed in parts, such as substations, cables, bus,
switchgear, transformers, etc., the system nevertheless works as a complete
integral unit. The best way to get an over-all picture of the probable
performance of an industrial power distribution system is to make a one-line
diagram. This, on one small piece of paper, shows the system in its entirety. The
one-line diagram gives the power system designer a reasonable idea of what
service reliability will be and how the components of the system will fit together
electrically to serve the needs of the plant most effectively and economically.
There are many factors which must be considered in the over-all planning of a
power system. Some of the more important aspects to be considered are
discussed in the following.
1.2.2. Safety
One cannot put too much emphasis on safety. Electricity is becoming more and
more an integral part of our production lines. It is used in areas where all kinds
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of people work. The power system engineer is responsible for making the
systems as safe as possible. Building a substation structure with a fence around
it labelled “For Authorised Persons Only” is no safety guarantee. Authorised
personnel make mistakes too.
Three fundamental ideas help to build safe power systems:
1) Enclose all live conductors in grounded metal
2) Use only adequate circuit-protective equipment
3) Design the system so that working on energised conductors is not necessary.
Of course, there are other important safety points. But these are three which the
system design engineer can influence greatly.
1.2.3. Economics
Economics is a very important part of power engineering. The engineer must

compare systems on the basis of cost as well as other features. In making cost
comparison, it is important to include all parts of the system from the power
source down to and including the utilisation equipment.
Cost comparison should also include installation as well as equipment costs. To
illustrate: System A may require less transformer kva than system B. But the
connections of system A and other factors may require far more expensive
switchgear and more cable than system B. The increased cost of switchgear and
cable may more than offset savings in transformers. A comparison on the basis
of transformers only would give the wrong answer.
After a system has been selected, the equipment is chosen. Equipment Type I
may be so constructed that its selling price is lower than the price of equipment
Type II, which is more completely assembled at the factory.
On the other land, the increased field installation expense of Type I equipment
may more than offset the difference in price. Hence, both price and installation
cost must be considered to obtain the lowest over-all investment.
Always consider the cost of the completely installed system, not just the prices
of its components.
1.2.4. Plan for load growth
One of the greatest mistakes made in power system engineering is planning

without allowance for future expansion. Failure to plan for the future results in
extravagance, inflexibility, and complication. The use of electricity in most
plants increases. Even if new floor area is not added, more intensive
manufacture within a given area increases the amount of electricity 3 to 5 per
cent a year.
Our economy is still expanding, and as long as that takes place we are going to
have to manufacture more goods. The manufacture of more goods requires
expansion of existing facilities as well as new facilities.
It costs so little to plan and arrange for future load growth that it should be a
must for every plant. Some important items in this respect are to allow some
reserve in substation kva size over predicted present loads, to buy main
switchgear with a margin in interrupting rating to allow for increasing power
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supply to the plant, and last and perhaps most important, to select the proper
voltage, i.e., one high enough to permit growth without bottlenecks.
1.2.5. Simplicity
Make system simple. Many total shutdowns have resulted from complicated
system. Industrial operators do not get emergency switching practice every day.
If they have complicated systems, experience proves they are apt to make
mistakes in an emergency. These errors usually cause greater outrages than they
would with simple systems. Simple systems are easy to understand and easy to
operate during both normal and emergency conditions. The growing difficulty of
obtaining adequately trained personnel makes a simple power system derivable.
1.2.6. Flexibility
Plants change manufacturing processes from time to time. Where castings are
used today, welding may be used tomorrow. Process and product alike change
as demands and styles change. Any plant, and particularly a metal-fabricating
plant, should be designed with the idea that complete new process layout can
be made without requiring major changes in the electric distribution system.
Two great contributions toward flexibility are (1) the load-centre system with
small substations which may be added in small units as required and, if
necessary, moved, and (2) plug-in busway, which permits the installation of
permanent power distribution systems to which machine tools and other devices
are merely plugged in where necessary.
1.2.7. Service reliability
Service reliability in any plant is important. Most manufacturing processes are

on a production-line basis, so that a shutdown of any part of the line may hold
up an entire plant. Some processes in themselves require a very high order of
service reliability. High service reliability generally can be obtained in two ways.
One is by providing duplicate channels to route power to any load; the other is
by installing only the highest-grade electric equipment available, using the best
installation methods. It might be added that service reliability can be increased
through simplicity of system design, a fact that was emphasised previously.
1.2.8. Modernisation and expansion
When plant facilities have to be expanded or modernised, the engineer is

afforded an opportunity to design the ideal electrical system. First a one-line
diagram should be made of the system he would have if the plant were starting
new. Having made this plan, he should let it guide the future modernisation and
expansion. Existing equipment obviously cannot all be retired at once. But, as
additions and replacements of equipment are made, they should be on the basis
of being integrated into the ideal plan and not merely as replacements of
equipment in the old system.
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One of the most significant parts of the new program is selecting the proper
voltage not just riding along and trying to expand at existing low voltage.
1.2.9. Selection of equipment
The main fundamental in selecting equipment is to choose the best available. It

costs no more in the end and pays dividends in service continuity and lower
maintenance.
Some widely accepted principles are:
a) Use only metal-clad equipment at 15 kv and below
b) Choose non-flammable transformers
c) Use factory-assembled equipment for easier field installation and better co-
ordination
d) Be sure equipment ratings are adequate in every respect, i.e. voltage, current,
interrupting rating, etc.
Much of the advantage of the high-quality equipment can be lost if it is
carelessly installed and maintained.
1.2.10. Maintenance
Maintenance is largely in the hands of operators. However, the system designer

can aid in this problem by designing system that provide alternate power
channels, to permit one to be taken out for maintenance without dropping
essential loads. Use drawout equipment wherever possible to enable
maintenance on circuit-breaker elements to be done in a clean service shop. A
spare element should be specified to replace the one being maintained.
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1.2.11 Make a relay co-ordination study
The operator should check all equipment regularly. The system design engineer
can help by including suggested maintenance schedules in the data given to the
operator.
Relay settings can be selected by the design engineer to permit the operator to
set them properly. Most important of all, operation and settings of relays should
be regularly checked.
1.2.11. Things to check when designing the power system
The discussion of items in which proper judgement should be used to obtain a

power system best suited to a given plant could be expanded. However, the
foregoing points illustrate the basic thinking used by today’s power system
design engineers.
As a guide, here are things to check when designing a power system for an
industrial plant or building.
1.2.12.1 What is the nature and magnitude of the load?

Until the process and load requirements are known, one cannot intelligently
lay out a power system to meet the load requirements.
1.2.12.2 Where is the power coming from?

See the local utility early in the planning stages to see what problems there are
in power supply. Are there savings possible from by-product power generation
because of by-product fuel or use of large quantities of process steam?
These questions must be answered early in the study as well as other details of
what voltage is available and where is the nearest adequate utility line located
in relation to the plant site.
1.2.12.3 How much will the electric power system cost?

Estimates are usually required in the early stages. Be sure to make your
estimated realistic and not so low that you later find you have to cut corners to
stay within the appropriations.
1.2.12.4 What voltage levels should be selected for the plant primary system and low-
voltage system?
Consider load growth, economics, flexibility, etc. Usually 13.8 or 4.16 kv is
the most advantageous primary voltage and 380 volts the most all-around
satisfactory for low voltage.
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1.2.12.5 What circuit arrangement is best suited, i.e., radial, secondary selective, or
secondary network?
Consider service reliability as dictated by process, provision for maintenance
and possible load growth, flexibility required for process changes, etc.
1.2.12.6 What size substations are most economical?

General studies give the most economical range at 500 to 1500 kva at 380
volts secondary, but in a specific plant load density, load locations, primary
voltage, and many other facts affect the choice.
1.2.12.7 Secondary distribution

What type of feeders, cable or bus? How big should feeders be? How much
load per feeder? Should plug-in busway be used or are panel boards required?
How can adequate short-circuit protection be secured in the branch circuit
protective equipment?
1.2.12.8 Combined light and power system.

Usually combined light and power system are more economical, but the flicker
problem must be watched, particularly if welders are present. How big should
the 380-120 volt transformers be? Should they be single or three phase? If
fluorescent lighting is being used, can 220 volt ballast operating off 380Y/220
volt systems be used? Should lights be switched individually or in groups?
1.2.12.9 Are voltage regulating means required?

If the primary voltage varies too much, feeder or bus voltage regulators may
be required. Should there be load ratio control in the main transformers?
Individual regulators? Switched capacitors? Or secondary feeder regulators?
1.2.12.10 Short-circuit protection.

Do circuit breakers, fuses, fused switches, and motor starters have adequate
interrupting rating? Do circuit breakers, fuses, etc. have a margin to allow for
increases in plant supply? Is the system laid out so that additions can be made
without overstressing circuit breakers and fuses interrupting rating-wise?
1.2.12.11 Grounding
Experience has shown that system neutral grounding is desirable at all voltage
levels. Is the system properly grounded at the neutrals and are machine frames,
etc., properly grounded to earth?
1.2.12.12 Overcurrent protection.

Are there adequate overcurrent devices properly set to provide selective
tripping in the event of overcurrent conditions? Are the relays the simplest that
will do the job? Is there adequate backup protection? Do relays, circuit
breakers, and fuses operate selectively wherever practical? Are all parts of the
systems adequately protected against the effect of overloads?
1.2.12.13 Is the lightning protection adequate?
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Are the lightning arresters of the proper rating, and are they properly located
and grounded? Are the rotating machines adequately protected?
1.2.12.14 Are circuit properly metered to tell what loads are?

Is provision made for connecting portable meters where permanent meters are
not justified? Adequate metering is the only way one can check the system
performance and to check when loads reach the limits of apparatus ratings.
Remote metering, i.e., telemetering gives meter readings at centralised points
remote from the location of the meters.
1.2.12.15 Power-factor correction.

Can the power bill be reduced through reduction of vars? Can you increase
voltage and current-carrying capacity by using capacitors? Where should they
be installed? Should they be switched?
1.2.12.16 Supervisory control.

Are there remote water-pumping stations or other loads that should be
controlled from the power house or some other central points? Supervisory
control will do it.
1.3. DESIGN AND ENGINEERING PRINCIPLES
1.3.1. Standards, codes and regulations

The design and engineering of the electrical installation should satisfy all
statutory requirements of the national and/or local authorities of the country in
which the electrical installation will be located.
The electrical installation should be suitable for the site conditions.
Where necessary special attention should be paid to the selection and
installation of electrical equipment suitable for seismic conditions.
Electrical equipment and materials should comply with the relevant defined
Code and principal specifications.
Generally IEC and/or national standards of the country in which the installation
will be located may be used for the design and engineering of the electrical
installation.
1.3.2. Operational safety and reliability
The design of the electrical installation should be based on the prevision of a

safe and reliable supply of electricity at all times. Safe conditions should be
ensured under all operating conditions, including those associated with start-up
and shutdown of plant and equipment, and throughout the intervening shutdown
periods.
The design of electrical systems and equipment should ensure that all operating
and maintenance activities can be performed safely and conveniently and should
permit periods of continuous operation . To fulfil the above requirements
provisions may be required for alternative supply sources and supply routes,
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spare/stand-by capacity, load shedding and automatic restarting schemes. The

simultaneous failure of two pieces of equipment should not be catered for.
The insulating and dielectric materials used in all electrical equipment should be
non-toxic and should not contain compounds that are persistent and/or
hazardous environmental contaminants, e.g. polychlorinated biphenyl (PCB’s).
The design of the electrical installation should ensure that access is provided for
all operational and maintenance purposes.
Special attention should be paid to provisional and temporary installations
required for the erection of permanent installations to ensure compliance with
basic rules for good working practice and safety and to cope with increased
hazards which are present in temporary installations.
1.3.3. Quality assurance and control

The design and the Engineering should be generally executed in compliance
with quality control and assurance systems which conform to the ISO 9000
series.
1.3.4. Design phases

Phase 1
- General Philosophy
- Single line diagram
Phase 2:
- Electrical load schedule
- Definition of main equipment
- Equipment data sheets
Phase 3:
- Equipment layout
- Cable run layout Earthing layout
- Lighting layout
Phase 4:
- Cable sizing
- Short circuit calculation
- Protection co-ordination
- Earthing calculation
- Lighting calculation
1.4. DESCRIPTION OF DESIGN METHODS

The basic principles applied in design of electrical installation are as follows:
a) To use data as soon as it becomes available within the company, taking

into due account its validity and variability.
b) To carry out design taking into account the validity of data obtained,
defining, in subsequent stages, general data, specific data and quantities.
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c) To use the electrical industry constructional standards which, in general,

establish equipment and material manufacturing types.
Taking into account the above mentioned points and on the basis of user data
coming from Process Department, as well as preliminary lay-outs coming from
Piping Department, a preliminary design will be prepared in Phase 1 and Phase 2
by defining the following:
- General arrangement;
-Electrical sub-stations;
- Selection of main electrical equipment types;
- Drawing up of material quantities in order to define the estimated amount for
orders.
This stage of the preliminary design involves the following:

a) Issuing of a few important drawings, which, however, cannot be considered as
final, like:
- Electrical plant philosophy;
- Single line diagram.
b) Issuing of specification with defined technical characteristics.
c) Drawing up of preliminary quantities;
d) Definition of open orders establishing the prices and technical characteristics
of the various components.
Subsequently, in phase 3 and phase 4, detailed design is carried out on the basis
of final users and final lay-outs. This involves the preparation of detailed
drawings from which final quantities are obtained.
The preparation of final drawings and material list and the approval of suppliers’
drawings are carried out during this stage in order to prepare all documentation
necessary for erection.
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2. SINGLE LINE DIAGRAM CRITERIA
2.1. INTRODUCTION
As already said in Chapter 1 the best way to get an over-all picture of the
probable performance of an industrial power distribution system is to make a
one-line diagram. From the design point of view this is the most important
document to be carried out by the Electric Department. In this Chapter the basic
criteria to be followed in order to obtain the best definition of the single line
diagram are outlined.
2.2. GENERAL PHILOSOPHY

On the basis of the preliminary list of users, their location and subdivision into
medium and low voltage the single-line diagram general philosophy is
developed. It outlines the distribution arrangement, the voltage levels and the
number of main sub-station. The following activities are involved:
- Establishing the operating conditions of the supply sources;
- Establishing primary distribution voltage levels;
- Establishing the main medium voltage and low voltage load centres;
- Establishing the main distribution system in accordance with the requirements
of plants to be supplied;
- Calculating short circuit levels;
- Carrying out the first power balance on the basis of which general sizing is
carried out, taking into account technical and economic factors.
The result of this first activity is a drawing showing the distribution philosophy,
this serving as a basis for all subsequent work.
This document will be updated step by step with the definition that will arise
during the detailed design activities and with the definition of all items and
equipment involved.
2.3. CIRCUIT ARRANGEMENT

Many circuit arrangement are possible, those commonly used can be resolved
into three basic arrangement or combination of them.
These basic arrangements are:
- Single Radial Distribution
- Double Radial Distribution
- Ring Distribution
These may be compared on many bases, but some of the more important
characteristics are:
- Cost
- Safety
- Flexibility
- Reliability
- Ease of expansion
- Simplicity etc.
2.3.1. Single Radial Distribution
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In the Single Radial arrangement there is only one primary feeder and one
transformer through which a given secondary bus is served and there is no
duplication of equipment. Thus in the majority of installation is the lowest cost
of all. It must be recognised, that in case of a fault on a cable or transformer,
service is lost until the fault is repaired.
Figure 1- Single radial distribution
2.3.2. Double Radial Distribution
Where greater flexibility and reliability is required, the single radial can be
modified doubling the system providing a normally open tie between the two
bus A and B. With this system any part of the electrical plant can fail or be taken
out of service for maintenance etc., and power can still be available at every
secondary bus. The correct arrangement is shown in figure 2.
In figure 3 three examples of double radial system solution to be avoided are
shown.
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Figure 2- Double radial distribution: correct single line diagram
a = only one feeder; b = only one MV bus-bar; c = only one LV bus-bar
Figure 3- Double radial distribution: solution to be avoided
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2.3.3. Ring Distribution
In the Ring Distribution system the breakers are arranged in a ring with circuit
connected between breakers. During normal operation, all breakers are closed.
The ring scheme is economical in cost, has good reliability is safe in operation,
is flexible and is normally considered as the best solution when we have a
number of substations. Protective relaying is more complex than of previous
schemes described.
Figure 4- Ring distribution
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2.4. ELECTRICITY SUPPLY FOR VITAL SERVICES
2.4.1. General
Electricity supplies of enhanced reliability and having duplicate energy source

should be provided to energise loads forming part of vital services. Such
supplies should, if required by the load, be uninterrupted on failure of one
energy source. Loads which can tolerate an interruption in the power supply but
which require restoration of the supply within a relatively short period of time
should be energised from an interruptible, maintained power source.
2.4.2. A.C. uninterruptible, maintained electricity supply
This is a power supply derived from two a.c. UPS units each of which
incorporates a battery to provide power in the event of failure of the mains
electricity supply. The power supply is uninterrupted in the event of mains
supply failure and is maintained throughout the battery discharge period.
An a.c. uninterruptible, maintained supply derived from a single a.c. UPS unit
may be considered for batch process plants where the normal plant power
supply is considered reliable.
A.C. UPS system philosophy and single line diagram
Under normal operating conditions, the load should be fed from the mains
through the Inverter and, therefore, the Battery charger should supply
contemporaneously both the Inverter and for the charge for the Battery:
actually, the battery will usually absorb only the float charge but, when
necessary, it should undergo an equalising charge (automatically or manually) in
order to restore the capacity lost during long periods of back-up operation.
In case of a mains voltage failure or an out of service of the Battery charger, the
Inverter should be supplied by the Battery for the whole period specified on the
Contract requirements, without any discontinuity of power supply.
When normal conditions are restored, the Battery charger should supply the
Inverter and in addition perform an automatic recharge of the Battery within the
time specified in the Contract requirements.
In case of an Inverter failure or if the output parameters (V, I, Hz) are out of
tolerance, the Static switch should automatically transfer the whole load to the
back-up line in a time not exceeding a quarter of a cycle (e.g. 5 milliseconds at
50 Hz).
When normal conditions have been restored for a reasonable time and
synchronism with the mains has been reached, the Static switch should transfer
the load back to the Inverter with transients within acceptable limits (see
Contract requirements).
Actually, the Inverter output frequency will be normally synchronised and
almost phased with the mains frequency, provided that this is within the
specified tolerances. Should the mains frequency exceed the tolerances, the
Inverter should operate in a frequency generated by itself; synchronisation will
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automatically occur when the mains frequency has returned within the limits
specified.
Figure 5- Typical single line configuration of an AC UPS system
2.4.3. D.C. uninterruptible, maintained electricity supply

This is a power supply that is derived from battery-rectifier units (d.c. UPS
units) or from rectifier units energised from one or more a.c. uninterruptible,
maintained supply sources (a.c. UPS units).
Such supplies should be considered for applications where the load is relatively
small and closely concentrated, or to supplement a.c. UPS systems (e.g. for fire
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alarm or communications systems). Due consideration should be given to the

allowable voltage drop at the consumer terminals.
Where an a.c. uninterruptible, maintained electricity supply is available and the
d.c. load does not exceed 15% of the a.c. supply capacity, the d.c.
uninterruptible, maintained electricity supply may be derived via duplicate
rectifier units fed from the a.c. UPS distribution switchboards.
Figure 6- Typical single line conf. of DC current switchboard (rectifier section)
2.4.4. Battery autonomy times
The batteries of UPS units should be rated to energise the relevant loads for not
less than:
- ½ hour for process plant shutdown
- 1 hour for utility plants
- 10 minutes for non process computer installations
- 3 hours for offshore plant shutdown
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- 8 hours for fire fighting, fire alarm systems and telecommunication systems.
The foregoing autonomy times should not be reduced even if an emergency
diesel generator is installed to provide back-up supplies to UPS units.
2.4.5. A.C. interruptible, maintained electricity supply
This is a power supply which is derived from the main distribution system but
which has back-up power supply, typically from an automatically started,
emergency diesel generator. The interruption in voltage on mains supply failure
is normally 10 to 15 seconds.
This category of supply is used typically for energising: electric motors
associated with cooling systems of enclosures housing process control and
instrument systems; analysers; emergency lighting etc.
If mains electricity failures of greater than one hour are a reasonably frequent
expectation, then consideration should be given to using the emergency
generator to energise the a.c. UPS units, thereby extending the duration of the
relevant supplies beyond the UPS battery autonomy times.
If the emergency generator is to be used to energise UPS units, then due
consideration should be given to the magnitude of the harmonic currents
required by the rectifier of each UPS unit to be energised, and to the consequent
voltage distortion created. To take into account the effects of such non linear
loads, it is recommended that the rating of the emergency generator be not less
than twice the rated output of the UPS unit.
Emergency generators should be arranged to start automatically on detection of
mains power failure and to take over the supply of power on closing of the
generator circuit breaker. Facilities should be provided to permit periodic on
load testing of emergency generators enabling the generator to be synchronised
with the mains supply. Each generating set have sufficient fuel storage capacity
for at least 8 hours full load operation
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3. MAIN ELECTRICAL EQUIPMENT
3.1 GENERAL
In order to realise the electrical system as it is defined on the single line diagram it is
necessary to identify the main items which constitute the plant. In the following
paragraphs these main items are defined in principle.
3.2 SWITCHGEAR
3.2.1 General
Switchgear and controlgear should be of the compartmentalised metalclad type

and should be designed to minimise any risk of developing a short circuit or
propagating a short circuit. The design should also be such as to ensure
personnel and operational safety during all operating conditions, inspections,
maintenance, during the connection of main, control and auxiliary cables and
during the equipping and commissioning of spare panels while the switchgear is
live and in operation.
Switchgear should only be installed when the switchroom civil and building
works are complete, so as to minimise the ingress of dust and dirt during or
after erection.
Switchgear foundations, including any inserts to be cast in, should be in
accordance with manufacturer’s drawings and should be level to within the
manufacturer’s specified tolerances.
Substation floors should be smooth and level to permit the handling of
equipment on rollers, regardless of whether cranage is provided.
3.2.2 HV substation
This equipment should be generally installed near the boundary fence and should
be suitable for a feeder system realised either by overhead power line or by H.V.
cable.
In principle a H.V. substation should be installed when the power source voltage
is over 132kV.
The substations can be divided into two different types and namely:
 outdoor type substation;
 indoor type gas insulated switchgear (GIS) substation.
Indoor gas insulated switchgear (GIS) is generally considered when available
space is limited or when environmental conditions would result in unreliable
operation of open terminal switchgear.
A main distribution transformer is generally included in the substation
equipment.
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3.2.2.1 Outdoor substation
22
3.2.2.2 Indoor substation
23
3.2.3 MV switchgears
24
3.2.4 LV switchgears
25
3.3 TRANSFORMERS
Oil-filled power transformers should be installed outdoor in a fenced-in area of

the substation. The fences should have at least two lockable gates.
Each transformer should have a minimum of 1 m clear space all round. Fire or
blast walls are not required.
For intake substations with large transformers, of 100 MVA and above, a blast
wall between the transformer bays should be provided.
Transformers should be mounted on a flat concrete base, those of the non-
sealed type should be surrounded by a gravel-filled or gravel-covered oil
catchment pit, which is sized to contain the total oil content of the transformer.
The catchment pit should be:
- connected to the oily water drains system in a wet climate
- arranged for pumping out by a suction tanker in a dry climate
- connected to the storm water drains system through an oil/water separator.
Transformer should be positioned and oriented in such a way as to minimise
cable crossing, especially when multiple single core cables are required.
The dielectric strength of the oil should be tested before it is used to fill or top
up the transformer. For the filling of the transformer an oil filter/heater pump
unit should be used. The transformer should be filled from the bottom drain
valve and air released at the top.
If a dry-type transformer does not have an integral metal enclosure, it should be
installed within an earthed, demountable metal barrier or fence of at least 1 m
high on all sides. The fence should have a lockable personnel access gate, which
should provide at least 1 m clearance from the extremities of the transformer
and its cable terminations to allow safe access for virtual inspection of the live
transformer.
The in-load tap-charger, should be stored energy operation type with
commutation resistance or reactance. The switch should be installed in its own
oil enclosure separated from the one of the transformer. If the enclosure is
connected to the transformer conservator, oil should be separated by a suitable
filter. The switch contacts should be in easy accessible position for revision and
possible replacement. The tap-changer should be equipped with a manual
control device by means of a removable handle and with an electric motor
driven control device foreseen fore remote control.
26
3.4 UPS EQUIPMENT
3.4.1 General
UPS equipment should be selected based on the preferred arrangement for a.c.
and d.c. uninterruptible, maintained electricity supplies for process control and
safeguarding systems.
Uninterruptible, maintained electricity supply distribution boards and the
associated UPS units should be located as close as possible to the loads
supplied.
3.4.2 A.C. UPS units
Two types of a.c. UPS units should be considered:

- static UPS units
- hybrid UPS units
the use of static UPS units up to 400 kVA unit rating is preferred on the
grounds of:
- lower capital cost
- smaller space and weight requirement
- low maintenance requirement
- adequate reliability
For loads requiring UPS units of higher rating, consideration should be given
either to sub-dividing the load into logically arranged groups, e.g. on a
geographical and/or plant unit basis, or to using hybrid UPS units.
Hybrid (static/rotary) UPS units are preferred in situations requiring duplicate
(redundant) UPS units to operate in parallel and provide a single a.c. source of
power to an indivisible load, e.g. at computer centres.
When supplied from a static a.c. UPS system, either direct or through rectifiers,
loads should be arranged such that their circuit fuse ratings are sufficiently low
to ensure the fuse exhibits cut-off in the event of a short circuit. To facilitate
this, fuse ratings should not exceed 10% of the rated output current of each
UPS unit. Load circuit fuse ratings exceeding 10% of the UPS rated current
should only be permitted if the mains supply frequency is sufficiently stable to
enable the UPS static bypass circuit to be relied on to operate the fuse in the
event of a load circuit fault.
3.4.3 D.C. UPS units
Conventional thyristor controlled bridge rectifiers should be used in d.c. UPS

units. However the switched mode power supply (SMPS) type of d.c. UPS unit,
up to a maximum unit rating of 3 kW, should be considered for applications
where a physically small unit is necessary because of space limitations, of where
the superior dynamic output response and lower ripple voltage are required by
the load. The use of switched diodes or battery cell tap regulation as a means of
controlling the output voltage of d.c. UPS units within the specified operation
27
limits is not preferred. The correct selection of battery capacity and provision of
redundancy should obviate this need.
3.4.4 Batteries
Three alternative types of battery that are technically acceptable for UPS duty:
- vented lead-acid batteries (Planté type)
- vented nickel-cadmium (Ni-Cd) batteries (pocket plate type)
- valve-regulated gas recombination type lead acid batteries complying
The lower capital costs and lower maintenance requirements associated with
valve regulated batteries and the fact that no dedicated battery room is required
normally provides an economic incentive to select this type of battery.
Notes:
1) Valve-regulated lead-acid batteries require no special ventilation as the
amount of gas normally produced can be safely dissipated in a naturally or
mechanically ventilated room (i.e. not gas-tight), housing other equipment.
2) The life expectancy of valve regulated lead-acid batteries is approximately
half that of the vented types, and consideration should be given to replacing
them after 7 years’s service.
Vented lead-acid or Ni-Cd batteries should be used where.
- battery capacities in excess of 400 Ah are required, so as to avoid the need to
connect batteries in parallel;
- where extreme temperature fluctuations are expected under normal operating
conditions, e.g. outside the range of 10-30°C.
For switchgear tripping and closing supplies, Ni-Cd batteries are preferred
because of their greater dependability in terms of being able to provide the
necessary tripping and closing power within the permitted coltage tolerances
and throughout the temperature variations experienced in substations, during
the (typically 20 year) life expectancy of the battery.
3.5 ELECTRIC MOTORS
3.5.1 General
The minimum/maximum power ratings of electric motors in relation to system

voltage are stated in the following table.
Switchboard nominal Maximum LV Minimum HV

voltages motor rating motor rating
LV and 3.0/3.3 kV 110 kW 132 kW
LV and 6.0/6.6 kV 185 kW 200 kW
The installation of LV motors of higher rating than the above mentioned maxima
may be justifiable where, for example, the installation of an HV system would
be avoided.
Any motor driven auxiliaries associated with the main motor or its driven
equipment should be fed from a nearby switchboard, which should have a load
28
classification equal to or better than the of the main drive. The auxiliary drives
should be connected to a section of the switchboard which is fed from the same
supply source and supply circuit as the main unit in order to obtain optimum
availability of the total system.
Asynchronous cage induction motors are preferred on account of their simple
robust construction and lower capital cost. Synchronous motors are more
efficient than asynchronous motors (of equal rating), but they have a higher
capital cost. The use of synchronous motors will normally be cost effective at
ratings exceeding 10 MW, depending on speed, manufacturer, etc. For low
speed applications and for installations in which power factor compensation is
beneficial, synchronous motors of less than 10 MW may be economically
justifiable. Synchronous motors should not be considered at ratings below 2
MW.
Consideration should be given to the quality and reliability of the power supply
when evaluating the use of synchronous motors for a particular application. The
greater ability of asynchronous motors to ride through voltage
depressions/interruptions may favour selection of this type of motor. Moreover,
the generation of pulsating torques by a synchronous motor during run-up may
need to be addressed by the driven equipment manufacturer.
3.5.2 Variable speed driver units (Synchronous converter cascade)
Each variable speed units realised by slip ring asynchronous motor, with
converter for recovering the slip energy should consist of the following:
a) slip ring asynchronous motor
b) starting rheostat, liquid type
c) rotor power converter unit consisting of: diode rectifier, air DC link reactor;
line commutation inverter
d) recovery transformer for adapting the inverter output voltage to the line
voltage
e) connection/disconnection devices for the starting rheostat and the energy
recovery unit in order to allow the automatic transfer from the starting phase
to the phase of speed regulation
f) short circuit contactor for the rotor winding in order to allow the operation at
the maximum speed with the energy recovery unit excluded.
29
3.6 GENERATORS
The rating, type and characteristics of the generating set should fulfil the
requirements imposed upon it by the electrical power system requirements,
whether operating in island mode, in parallel with other generating sets, in
parallel with a public utility or any combination of these.
The above requirements should take account of factors such as overload
capabilities, load throw-on/throw-off capabilities, real and reactive power
sharing, maximum speed deviations, maximum response times, reactances,
inertias, etc.
When the rated speed of the prime mover is less than or equal to 3000 or 3600
rpm, as appropriate, no gearbox should be installed.
The kVA rating of the generator should be selected by the prime mover
manufacturer in line with the specified requirements, such that the generator
does not limit the output of the prime mover over the specified operating
temperature range.
The generator rated power factor should be 0.8 lagging, unless otherwise
specified.
It will normally be used for interruptible, maintained electrical supplies, possibly
together with black-starting duties, rather than for base load generator services.
The rating of this emergences generating sets will normally be within the range
of 50 - 1000 kW, and supply an emergency LV switchboard. In sizing the
generating set, account should be taken of the related motor starting
requirements and UPS loads.
The generating sets should be suitable for unattended operation and for
automatic black--starting on detection of failure of the mains supply.
30
3.7 SOLAR POWER SUPPLY

The solar power supply is a solution feasible for small loads (< 2kVA) located in
isolated place, where the public network is not available.
Solar cells are tipically used in the line valve station (LVS) of the pipelines.
3.7.1 L.V.S. typical loads
LVS LOADS Public network Public network

available not available
Tower lighting 100W 100W
Telecomunication Radio system 100W 100W
Amplifier 50W 50W
Other 100W 100W
Instrumentation RTU 50W 50W
Field Instr. 30W 30W
Motor operated valve (MOV) 2500W -
Cathodic protection 1500W 200W
HVAC 500 -
Site lighting 1500W -
Total installed power 11kW 650W
If the public network is not available the best solution is to reduce as much as
possible the loads, by maintaining only the vital (uninterruptable) services and to
use the solar power supply. If the MOV is absolutely needed, then alternative
solutions have to be chosed.
Alternative solutions for the power source in LVS are: CCVT (closed circuit
vapour generator), TEG (thermoelectric generator), Gas generator, Diesel
generator.
The first three solutions are feasible just in case of gas pipeline. The Diesel
generator is not an appreciated solution because in the MOV I start = 10-15 In,
therefore the Diesel should be oversized and Diesels do not work properly if the
load is less than 40%.
3.7.2 Solar power design criteria

The factors to be taken into account for the design of the solar power supply
system are:
 Total load (continous + intermittent);
 Medium solar irradiation in the country of installation;
 Back-up period or autonomy of the system (Ah of the battery);
 Days necessary to recharge the batttery.
31
Example:
Total load = 650W  ILOAD = 650/24 = 27A.
Back-up period = 7 days  Battery capacity = 27*24*7 = 4536 Ah.
Days necessary to recharge the batttery = 21  IRECHARGE = 4536/ (10*21) =
21.6A considering that the recharge is done during the day.
ITOT = IRECHARGE + ILOAD = 49A  Rated power of the solar cells = 1176W.
On the equator line 1m2 = 100W; usually 1m2= 15W.

The average cost is 100$ per W.
SOLAR POWER
IRECH
ITOT
ILOAD
32
3. MAIN ELECTRICAL CALCULATIONS
3.1. ELECTRICAL LOAD SCHEDULE
3.1.1. Purpose of the electrical load schedule

The purpose of the electrical load schedule is:
- to establish the maximum power demand for the distribution network;
- to establish the power demand to size the emergency power generators.
The load schedule will also serve as input to studies such as voltage drop and
short circuit calculations.
3.1.2. Classification of loads

Electrical loads should be classified as performing a service which is ‘vital’,
‘essential’ or ‘not essential’.
4.1.2.1 Vital service
A vital service is a service which, when failing in operation or when failing if

called upon, can cause an unsafe condition of the process and/or of the electrical
installation, jeopardise life, or cause major damage to the installation.
A vital service is, by definition, a safety matter. Complete duplication of the
energy source, of the lines supply and of the equipment is necessary.
Examples: - One or more uninterruptable power supply (UPS) units to provide
electrical supply to process control systems.
- Power supply to emergency lighting and escape lighting.
4.1.2.2 Essential service
An essential service is a service which, when failing in operation or when failing

if called upon, will affect the continuity, the quality or the quantity of the
product.
An essential supply is, by definition, an economic matter. Therefore the
economics of partial or complete duplication of the energy source, of the lines
of supply or of the equipment, or the introduction of the automatic restarting or
changeover facilities etc., should be evaluated in relation to the consequences of
service interruptions.
Examples: - Product transport by means of duplicated pump sets with a view to
maintenance requirements of the pumps.
- Power supply to security lighting and plant area lighting.
4.1.2.2 Non-Essential service
A non-essential service is a service which is neither vital nor essential.

Examples: - Power and lighting supply of offices, residential areas, warehouses,
etc.
33
3.1.3. Load assessment and electricity consumption

A schedule of the installed electrical loads, the maximum normal running plant
load and the peak load, expressed in kW and in kvar and based on the plant
design capacity when operating under the site conditions specified, should be
prepared using the attached Standard Form. The latter should be completed and
updated regularly throughout the design stage of the project and should form
the basis for provision of the necessary electricity supply and distribution system
capacity.
The Standard Form gives the following formulae for determining the total
electrical loads:
- Maximum normal running plant load = x(%)E + y(%)F
- Peak load = x(%)E + y(%)F + z(%)G
where E = sum of all continuously operating loads
F = sum of all intermittent loads
G = sum of all stand-by loads
Values should be determined by the Principal for the diversity factors
appropriate to the type of plant. The values of the diversity factors x, y and z
must take account of the individual drives or consumer which make up the
continuous, intermittent and stand-by loads, respectively. For example, y(%)F
cannot be less than the largest individual intermittent drive or consumer.
NOTES:
1. Subject to the following considerations, the following default values could be
used for initial load assessment, or if the diversity factors have not been
finalised:
x = 100%
y = 30%
z =10%
2. A separate schedule should be prepared for each switchboard, the total of all
switchboards loads being summarised as required to arrive at the maximum
normal running and peak loads for each substation and for the plant overall.
All loads to be shed during an underfrequency condition should be identified
as such in the ‘remark’ column. All loads to be automatically restarted after a
voltage dip should be identified as such in the ‘restarting’ column.
3. The percentage of total intermittently operating load that contributes to the
maximum normal running load will depend on plant operation.
4. Depending on steam/electricity supply availability, the use of non-electrical
drivers for stand-by duties and the total number of units installed, only a
small number of the largest electrical stand-by units may have to be
considered when establishing the peak load.
5. Where a group of drivers operate as a unit, it should be considered as an
individual consumer.
34
3.2. SHORT-CIRCUIT-CURRENT CALCULATING
3.2.1. Short-circuit currents and their effects
If adequate protection is to be provided for a plant electric system, the size of

the electric power system must also be considered to determine how much
short-circuit current it will deliver. This is done so that circuit breakers or fuses
may be selected with adequate interrupting capacity (IC). This interrupting
capacity should be high enough to open safely the maximum short-circuit
current which the power system can cause to flow through a circuit breaker if a
short circuit occurs in the feeder or equipment which it protects.
The magnitude of the load current is determined by the amount of work that is
being done and bears little relation to the size of the system supplying the load.
However, the magnitude of the short-circuit current is somewhat independent of
the load and is directly related to the size or capacity of the power course. The
larger the apparatus which supplies electric power to the system, the greater the
short-circuit current will be.
Take a simple case: A 380-volt three-phase 20-hp motor draws about 30 amp of
current at full load and will draw only this amount whether supplied by a 25-kva
or a 2500-kva transformer bank. So if only the load currents are considered
when selecting motor branch circuit breakers, a 15 or 20 amp circuit breaker
would be specified.
However, the size of the power system back of the circuit breaker has a real
bearing on the amount of the short-circuit current which can flow as a result of
a short circuit on the load side of the circuit breaker. Hence, a much larger
circuit breaker would be required to handle the short-circuit current from a
2500 kva bank than from a 25 kva bank of transformers.
A simple mathematical example is shown in Fig. 1
These numbers have been chosen for easy calculation rather than a
representation of actual system conditions.
The impedance, limiting the flow of load current, consists mainly of 20 ohms
apparent impedance of the motor. If a short circuit occurs at F, the only
impedance to limit the flow of short-circuit current is the transformer impedance
(0.1 ohm compared with 20 ohms for the motor); therefore, the short-circuit
current is 1000 amp, or 200 times as great as the load current. Unless circuit
breaker A can open 1000 amp, the short-circuit current will continue to flow,
doing great damage.
Suppose the plant grows and a larger transformer, one rated at 1000 amp, is
substituted for the 100 amp unit. A short circuit at F1 (bottom in Fig. 1) will
now be limited by only 0.01 ohm, the impedance of the larger transformer.
Although the load currents is still 5 amp, the short-circuit current will now be
10,000 amp, and circuit breaker A must be able to open that amount.
Consequently it is necessary to consider the size of the system supplying the
plant as well as the load current, to be sure that circuit breakers or fuses are
selected which have adequate interrupting rating for stopping the flow of the
short-circuit current.
35
E = 100 V F In = 5A
Zt = 0.1  Icc = E/Zt = 1000A
E = 100 V F In = 5A
Zt = 0.01  Icc = E/Zt = 10000A
FIG. 1- Illustration showing that capacity of power source has more effect on
short circuit current than load.
Short-circuit and load currents are analogous to the flow of water in a

hydroelectric plant, shown in Fig. 2. The amount of water that flows under
normal conditions is determined by the load on the turbines. Within limits, it
makes little difference whether the reservoir behind the dam is large or small.
This flow of water is comparable to the flow of load current in the distribution
system in a factory.
On the other hand, if the dam breaks, the amount of water that will flow will
depend upon the capacity of the reservoir and will bear little relation to the load
on the turbines. Whether the reservoir is large or small will make a great
difference in this case. This flow of water is comparable to the flow of current
through a short circuit in the distribution system. The load currents do useful
work, like the water that flows down the penstock through the turbine water
wheel. The short-circuit currents produce unwanted effects, like the torrent that
rushes madly downstream when the dam breaks.
36
FIG. 2- Normal load and short circuit currents are analogous to the conditions
shown in the hydroelectric plant.
3.2.2. Sources of short-circuit currents
When determining the magnitude of short-circuit currents, it is extremely

important that all sources of short circuit current be considered and that the
reactance characteristics of these sources be known.
There are three basic sources of short-circuit current:
1. Generators
2. Synchronous motors and synchronous condensers
3. Induction motors
Al l these can feed short-circuit current into a short circuit (Fig. 3).
Generators are driven by turbines, diesel engines, water wheels, or other types
of prime movers. When a short circuit occurs on the circuit fed by a generator,
the generator continues to produce voltage because the field excitation is
maintained and the prime mover drives the generator at substantially normal
speed. The generated voltage produces a short-circuit current of a large
magnitude which flows from the generator (or generators) to the short circuit.
This flow of short-circuit current is limited only by the impedance of the
37
generator and of the circuit between the generator and the short circuit. For a
short circuit at the terminals of the generator, the current from the generator is
limited only by its own impedance.
Synchronous motors are constructed substantially like generators; i.e., they have
a field excited by direct current and a stator winding in which alternating current
flows. Normally, synchronous motors draw a-c power from the line and convert
electric energy to mechanical energy.
However, the design of a synchronous motor is so much like that of a generator
that electric energy can be produced just as in a generator, by driving the
synchronous motor with a prime mover. Actually, during a system short circuit
the synchronous motor acts like a generator and delivers short-circuit current to
the system instead of drawing load current from it.
The inertia of the load and rotor of an induction motor has exactly the same
effect on an induction motor as on a synchronous motor; i.e., it drives the motor
after the system short circuit occurs.
The initial symmetrical value of short-circuit current is approximately equal to
the full-voltage starting current of the motor.
FIG. 3 - Generators, synchronous motors, and induction motors all produce

short circuit current.
3.2.3. Example of calculation

Purpose of this calculation is the determination of the short circuit current in
point A of the power circuit illustrated in figure 4. The procedure of calculation
38
is simplified (for more details see IEC 909 standard), based on the following
condition.
4.2.3.1 Assumptions
- Three-phase bolted balanced short circuit only are considered

- Positive sequence impedance’s only are considered
- I”k = Ib = Ix is assumed where:
I”k : initial symmetrical short-circuit current
Ib : symmetrical short-circuit breaking current
Ik : steady-state short-circuit current
This assumption is motivated by the distance of fault points from network
supply generators.
- The calculated current are in RMS
- The data assumed for transformers,. motors, cables etc. are approximate
- For the 13.8 kV incoming line 250 MVA short circuit power has been
assumed
- The impedance of switchgear buses and circuit breakers are not considered,
as these valves are extremely small
250MVA 250MVA
FIG. 4- Simplified single line diagram
39
4.2.3.2 Calculation
System 13.8 kV Electrical Characteristics
13.8 kV Supply Network

- Rated voltage: Un 13.8 kV
- Short circuit capacity: S”k 250 MVA
- Short circuit current:
S" k 250

3U N 3.13
= 0.46 KA
- Equivalent network reactance: XN =
2
cU 1.1. (13.8) 2
N1

S" k 250
= 0.84
- The equivalent resistance of the network is considered to be negligible
Characteristics of the Cable C1 Feeding the Distribution Switchboard

- Cable type three-core
- Core cross section Sc1 95 mm2
- Length Lcl 150 m
3000
- Rated current carrying capacity: IC1 = = 125,5 A
3.13.8
- Load power factor cos 0.85
- Resistance per unit length rcl 0.256*10-3 /m
- reactance per unit length xcl 0.108*10-3 /m
- Total phase resistance
Rcl = Lcl*rcl 0.0384 
- Total phase reactance
Xcl=Lcl*Xcl 0.0162
2
I t 10.46 0.5 = 51.7 mm
- Minimum cross section admitted: S C1 = CC

K 143
Calculation of the short circuit current at point A
- Resistance of the fault circuit

RA = Rcl 0.0384 
- Reactance of the fault circuit
XA = Xr + Xcl = 0.84 + 0.0162 0.8562 
- Impedance of the fault circuit
Z A = R 2A  X2A = 0.857 
- Symmetrical fault current value
40
(without contributions of motors)

cU n 1.1 *13.8
I”k (A)=  = 10.23 KA
3.ZA 3.0.857
41
3.3. ELECTRICAL CABLES SIZING CALCULATION
3.3.1. Sizing of cables
Sizing of cables, in accordance with the current, should be calculated and

checked in order to define minimum section which satisfy the following
conditions:
- keeping voltage drop
- keeping temperature within limits permitted by the type of cable both under
normal operating condition and during overload or short circuit.
The range in which cross-section has been defined is the standard specified in
IEC 228.
3.3.2. Sizing on the basis of voltage drop

In order to ensure correct operation of the electrical system, in particular,
feeders to users, the voltage drop has to be verified.
The voltage drop during normal operation and motor starting condition has
been determined by the following relation:
3(Rcos  Xsen ).I n .L
V% = 100
Vn
where:
V% = voltage drop percent
R = cable resistance/km
X = cable reactance/km
I = current of user in normal or starting condition
L = cable length in km
= power factor
Vn = rated voltage
The voltage drop during motor starting condition has been verified also by the
following relation:
V% = 100. Pms/(Pms + Psc)
where:
Pms = motor starting required power (KVA)
Psc = short circuit power to the motor terminal (KVA)
Generally the voltage drop on the cables should be limited to:

a) 2% cables supplying switchboard
b) 5% cables supplying motors during normal operation
c) 15% cables supplying motor during start up
d) 2% cables for lighting circuits during normal operation
42
3.3.3. Thermal sizing

Thermal sizing has to be verified in order to ensure that cable operating
temperature do not exceed maximum temperatures permitted.
According to Standards, the capacity (Iz) of a line is the maximum value of the
current that, under permanent and specified conditions, the line can transmit
without the temperature of the conductors exceeding a specified limit value, in
relation to the type of insulation used.
The temperature limit value is an important parameter which must be
considered when determining the cross section of the conductors, together with
other factors such as minimum cross-sections, mechanical considerations,
voltage drops, resistance to the external environment, etc.
Regardless of their cross-section, the live conductors should be protected by
one or more devices which automatically cut off the circuit when a dangerous
overload or short-circuit is generated, unless the maximum current that can be
supplied by the power supply, does not exceed the capacity of the conductors.
Conditions take into consideration are as follows:
a) currents due to short-circuits
b) currents due to overloads
c) current during normal operation
4.3.3.1 Sizing on the basis of short circuit
Cables are characterised by the “adiabatic heating time”, i.e. the time during
which the heat produced by the current is accumulated inside the cable,
increasing the temperature, assuming no dissipation of heat outside the cable.
During a short circuit the thermal phenomena occurring in the cable are tipically
adiabatic, i.e. the increasing of the current is so fast that the cable has not time
enough to dissipate the heat produced by the current itself.
According to this the short-circuit protection devices fuses or circuit breaker
must cut-off the short-circuit currents before the heat absorbed by the cable
become dangerous. The short-circuit protection must operate within a time less
than that required to raise the temperature of conductors beyond the acceptable
limit.
Therefore in order to guarantee a correct sizing of cables it has to be checked
that I2t which passes through the limiting circuit-breaker or fuse is less than
maximum thermal energy of cable K2S2 under adiabatic condition.
I2t  K2S2
where:
I2t = Is the specific let-through energy by the protection device during
the time period “t” of the short-circuit
K2S2 = is the maximum heat that can be absorbed by the cable
S = cross section
I = short circuit current
t = protective device operating time
K = cable factor
4.3.3.2 Sizing on the basis of overload current
43
The sizing of cables in relation to thermal stresses has to be carried out for
circuit where there is a possibility of long duration overloading as motor
feeders.
There is a general rule that imposes installation of protection devices to cut off
the conductor overload currents before such currents cause overheating which
may damage insulation, connections, terminals or the external environment.
These devices can be installed at any point in the line, provided that the shunts
and plug sockets are not located ahead of them and the loine is thus protected
against short-circuits.
The overload protection device must not cut-off the circuit when short-term
overloads are generated during normal operation.
Here below we summarises the cases in which lines have been protected against
overloads.
1) Supply of several shunts or loads for which, during the design phase, the
contemporaneity coefficient was set to less than one
2) Supply of motors or user equipment which may create overloads
3) Supply of loads through plug sockets
4) Supply of lines installed in locations with explosion or fire risks.
The overload protection device has to be verified and coordinated with

the line according to the following rules:
IB  In  IZ
If  1.45  IZ
where:
IB and IZ are data relative to the line:
IB = current for which the circuit is designed
IZ = continuous current carrying capacity of the cable
while In and If are data relative to the protection device:
In = nominal current of the protection device
(for adjustable protective devices, the nominal current (I n) is the
selected setting current)
If = Current ensuring effective operation (tripping current) of
the protective devices (conventional tripping current in conventional
time for circuit breaker is 1.3 times the setting current (I n) as indicated
in IEC 947.4 code).
44
4.3.3.3 Sizing on the basis of normal operating conditions
In order to ensure that maximum permissible temperatures of cable are not

exceeded with a steady load, cable sizing in relation to thermal stresses during
normal operation is carried out using rated cable capacities (I ncx) as reference,
bearing in mind standard conditions defined in codes and which are generally as
follows:
a) for direct buried cables

- cable laid in one level
- ground temperature 20°C
- thermal resistivity of ground 100°C cm/W
- laying depth: 0.8 m for cables  kV
- 1.0 m for cables  1 to 15 KV
b) for overhead cables

- cables laid on one level
- air temperature 30°C
3.3.4. Definition of capacities in relation to installation conditions
Where cables are installed in conditions other than standard conditions the rated
capacities Inc have been modified by applying multiplication coefficients
(utilisation factors) which determine the rated capacity of the cable under actual
installation condition (Iz). This will be:
Iz = KU * Inc
Where KU is the general utilisation factor resulting from the product of the
following factors:
KT = ground or air temperature rating factor

KR = thermal resistivity rating factor or ground
KL = depth or burial rating factor
KD = duct laying rating factor
KA = water laying rating factor
KP = group rating factor
.. = any others
Values of various coefficients and factors are according Snamprogetti Standard

6776.84.
45
3.3.5. LV cable sizing: design phases

1) Calculation of the load current IB.
2) Selection of the setting current of the protective device: IN = 1.1 IB.
3) Choice of the cable  Determination of INC = standard condition rated
capacity.
4) Calculation of KU  IZ = KU INC . = continuous current carrying capacity of
the cable Usually KU = 0.5  0.6.
5) Verification of the relationships:
IB  In  IZ
If  1.45  IZ
where:
If=Current ensuring effective operation (tripping current) of the protective
devices in conventional time
6) Verification of V% during both normal and starting conditions.
7) Verification of: I2t  K2S2 with K =140 for PVC and K=180 for rubber.
46
4. ELECTRICAL PROTECTION AND CONTROL
4.1. INTRODUCTION
4.1.1. General
An electrical power circuit, which pertains to a generation, distribution of user’s

system is always integrated with an electrical protection circuit.
The electrical circuit protection has the function of interrupting at pre-
established points the electrical circuit to limit the effect of faults and to stop
faults occurring.
Protective relays are the brain of the electrical protection circuit.
In this respect, their choice is a critical step in the Power Systems Design and
Development.
The selection of protective devices is based on:
- The Safety of Personnel and Equipment (Sensitivity of detection, response
speed)
- The Quality and Continuity of the Electrical Supply (Fault Determination,
Special Directional Protection, Automatic transfer, Fast clearing times to
improve System Stability....)
The optimisation of the Power Systems Reliability and Safety, dictates the use
of independent stand-alone relays located within close proximity of the power
circuit breakers on which they operate.
A protection diagram in the form of a single line diagram should be prepared for
the complete electrical power system to indicate the type and location of all
protective devices, and associated transformers to be provided. Based on this
drawing, an electrical protection report should be prepared which should
demonstrate the adequacy of all protective systems in fulfilling the above
requirements. The protection report should include at least a description of the
system and of the system operating modes on which the settings have been
based, together with relevant short circuit current calculations, single line
diagrams for each part of the system, tabulated relay settings and co-ordinated
relay and fuse characteristics, etc., plotted in graphical form.
The minimum generation and/or minimum supply capacity conditions should be
at least representative of those conditions which can arise during normal
operation of process units, production facilities and their utilities. The
protection of distribution systems during more extreme conditions, such as
those occurring at the time of starting up generating plant and utilities, may be
catered for by appropriate adjustments of protection relay settings.
47
4.1.2. Current and potential transformer
The insertion of sensible elements either for the protection (relay) or for
measurement (instruments) of current and high voltage, is made possible by
inserting a measurement transformer in which the primary windings are run by
the full load taken into consideration, while on the secondary windings loads of
smaller values but proportional to the primary winding can be obtained. These
transformers are Current Transformer (CT) and Potential Transformer (PT)
depending on the function given on the secondary signal proportional to the
current or primary voltage.
4.1.3. Protection relay
These are sensible electrical equipment and depending on the values are
different from those normally used. Depending on the fixed time parameters
(setting) they can automatically intervene or signal.
The protection relay can be:
- Direct: for full load;
- Indirect: when CT and PT are inserted;
- Time Dependent: time intervention depend on the load value;
- Time Independent: intervention at fixed time;
- Directional: sensible to the direction of the load;
- Adirectional: not sensible to the direction of the load.
4.1.4. Types of relays and their function
The most common types of relays, their function and where they are normally
applied are as follows:
Thermal Relay : intervenes in overload conditions and is applied and breaks the
outgoing supply of motors in order to avoid overloading.
Maximum Current Relay : intervenes for overload but more frequently for short
circuit to rapidly interrupt the part at fault; these are generally applied at
outgoings.
Differential Relay : intervenes if a fault exists in the protected part which is

delimited and in extremely short times; they are applied for protection of
transformer, generators, bars and exceptionally for cables.
Earthing Relay : intervenes and/or signals on earth fault; these are applied for
motors, transformers, generators.
Power Relay : intervenes if the power exceeds a certain value; these are applied
on generators.
48
Voltage Relay : intervenes if the voltage exceeds or decreases a predetermined

value; these are applied to generators or bars of switch boards.
4.1.5. International numbering of main types of relays
Number Function
25 Synchronising or synchronism check device
27 Undervoltage relay
30 Annunciator relay
32 Directional power relay
35 Brush-operating, or slip-ring short-circuiting device
40 Field relay
43 Manual transfer or selector device
46 Reverse-phase or phase-balance current relay
47 Phase-sequence voltage relay
49 Machine or transformer thermal relay
50 Instantaneous overcurrent or rate-of-rise relay
51 A.c time overcurrent relay
59 Overvoltage relay
63 Pressure switch
64 Ground detector relay (e.g. for machine)
71 Level switch (e.g. Buchholz relay 71+80)
80 Flow switch (e.g. Buchholz relay 71+80)
81 Frequency relay
86 Lockout relay
87 Differential protective relay
91 Voltage directional relay
92 Voltage and power directional relay
49
4.2. EQUIPMENT PROTECTION
4.2.1. Typical application of protective relays
5.2.1.1 Electrical circuit protection of :

 a network with low impedance neutral earthing;
 MV/LV transformer;
 HV/MV transformer;
 Diesel generator;
 Turbo-alternatot;
 Induction machine with Pn < 300kW;
 Induction machine with 300kW <Pn< 2MW;
 Induction machine with Pn > 2MW;
 Synchronous machine with 5MW < Pn < 1MW;
 Synchronous machine with Pn > 5MW;
 Special system.
50
4.2.2. Protection of cable feeders
Cable feeders for HV sub-distribution should be controlled and protected by

circuit breakers in conjunction with phase short circuit and earth fault protective
relays.
Differential protection should be provided on all HV feeders which can be
operated in parallel, or where instantaneos fault clearance time is required.
Cable feeders for LV sub-distribution should be controlled and protected by
fuse-switch combinations or by moulded case circuit breakers (MCCB)
incorporating short circuit and earth fault protective devices. The MCCB should
co-ordinate with outgoing circuit protective devices on the receiving end sub-
distribution switchboard.
The rating of any fuse protected LV circuit which derives a supply from a
distribution switchboard should not exceed 25% of the rating of a supply
transformer which energises the switchboard. Where the rating of the fuse
protected LV circuit exceeds the above-mentioned value, and in order to ensure
proper co-ordination with the earth fault protection in the transformer
secondary neutral-earth connection, one of the following devices may have to
be fitted in addition to fuses:
- A latched contactor with a d.c. trip coil, operated by a core balance earth
fault protection relay with the necessary time delay. The operating
characteristics of the earth protection relay should be co-ordinated with the
upstream as well as the downstream protection characteristics
- A contactor with d.c. hold-in coil and the above protection
- An air circuit breaker, also with the above protection.
Similarly, the rating of any fuse protected LV circuit which derives a supply
from a distribution switchboard should not exceed 50% of the rating of fuse
protected LV circuit which energises the switchboard. This is to ensure that the
circuit protective devices can be fast operating and selective in isolating short
circuits.
4.2.3. Protection of overhead line circuits
Overhead lines of primary distribution feeders should be controlled and

protected by circuit breakers in conjunction with phase short circuit and earth
fault protective relays. When distance protection is employed it should be
provided in conjunction with overcurrent and earth fault protection, the latter
serving as back-up protection. The selection of protection should be subject to
circuit interconnections, methods of system earthing and general service
conditions.
Protection against the effects of lightning by means of earth wires and lightning
arresters (surge diverters) should be provided. Earth wires may be omitted only
after approval by the Principal. Lightning arresters should be provided with
counters.
51
Three phase auto-reclosure schemes should be considered in relation to the

general service conditions.
4.2.4. Protection of UPS equipment
Feeders to rectifiers and UPS equipment should be controlled and protected by

a fuseswitch or an MCCB incorporating short circuit and earth fault protection.
Sub-distribution circuits fed by d.c. or a.c. UPS systems should be fuse
protected.
4.2.5. Protection of electric heaters
Control and protection of LV electric heaters should be by means of a fused

switch or an MCCB supplemented with a contactor if required. For fuse ratings
or MCCB trip settings exceeding 100 A, earth fault protection should also be
provided. Over temperature protection should be provided by at least two
thermocouples located in the area of highest anticipated sheath temperature.
When static converters are required to control the heater output, they should be
equipped with the following as a minimum:
- incoming voltage monitoring
- fuse protection for the semi-conductor devices
- over temperature in the converter panel.
4.2.6. Protection of power and convenience outlets
Each LV power and convenience outlet circuit should be protected by phase

short circuit protective devices and by current-operated earth leakage protective
devices, i.e. residual current circuit breakers (RCCB). The RCCB operating
current should be 30 mA for circuits of less than 125 A and 300 mA for circuits
equal to or greater than 125 A. The operating time should not extended 30 ms.
4.2.7. Protection of other electrical equipment
Local isolating switches should be provided for electric process heaters, motor
operated valves (MOV’s), trace heating systems, cathodic protection
equipment, etc., and should be located near to the equipment or on their
pertaining control panels. Where automatic control is required for such
equipment and its controlgear is located in the substation, then this should be
accomplished with an RCU similar to those used for motor control.
52
5. EQUIPMENT AND CABLE RUN LAYOUT
5.1. SUBSTATION AND SWITCH BOARD BUILDINGS
In general sub-station buildings should be completely closed buildings in order

to prevent penetration of dust. These should be located outside the hazardous
area.
Battery banks should be installed in a separate room, provided with exhaust fan.
All electrical items in battery room should be of Ex-d execution suitable for
hydrogen and should be fed from emergency network. Eye wash facility should
also be provided in battery room.
Sub-station buildings should be provided with at least one personnel door and
one-equipment door (double door). The equipment doors should accommodate
the largest assembled unit of equipment using standard size doors with
removable panels, if required. Doors preferably should be located at apposite
ends of the sub-station building. All doors should have suitable gaskets to
prevent the dust entry. Windows should be eliminated.
Oil filled transformers where required should be located outside the sub-station
building and arranged to minimise the length of secondary cables and provide a
minimum clearance of 1000 mm from the building wall.
A minimum clearance of 1000 mm should be provided between transformers.
Clearance should be measured from transformer extremities. Suitable concrete
pads with rails should be provided for mounting the transformers. Pads should
be with oil pit of suitable dimensions to contain the oil of the unit. The oil pits
should be connected to a common collection system suitable to accommodate
the oil quantity by the largest unit.
Lighting fixtures for sub-station and store/workshops etc. should be industrial
type with fluorescent tubes suitable for indoor installation. In control room
where false ceiling is provided recessed typing lighting fixtures should be
installed. Conductors in workshop and sheds etc. should be laid in galvanised
steel conduits fixed on wall (surface type).
In other buildings such as control room, switchgear room etc. Conductor should
be laid in concealed G.S. conduits.
Minimum clearance around equipment should be as follows:
Behind switchgear 1500 mm (H.T.)

1000 mm (L.T.)
Between equipment ends or 750 mm

Between equipment ends & wall
Operating aisle 2500 mm
53
5.2. CABLE LAYOUT
5.2.1. Cable segregation - general
Segregation within the new cable installations should comply with the following
requirements:
- Power systems operating at different voltages and control, protection and

instrumentation circuits for separate units or plant should be run in separate
cables routes.
- A minimum 300 mm spacing should be maintained between measuring and

control cables at voltages of 60 V and below and low voltage power cables.
- A minimum 300 mm spacing should be maintained between power cables and

control cables at voltage above 60 V.
- A minimum 600 mm spacing should be maintained between medium voltage

power cables and control cables at voltages 60 V and below.
5.2.2. Cabling within buildings
The cabling facilities with the plant building and building structures should be as
generally shown on the specification drawings and comprising:
- A full cabling basement under the electrical plant annexe of the main
pumping station
- structural cable trenches within the pumphouses of the main and booster
pumping stations
- walkthrough cable galleries extending between the main pumping station

electrical annexe and booster pumping station and between the electrical
annexe and the main power supply transformer compound.
All cables installed within the pumping station building and on building
structures should be run on cable ladder and cable tray support systems.
The cable tray installations should be designed to maintain the specified cable
segregation, adequate general cable spacing for load rating factors, and to
ensure a minimum of 15% spare space is provided on all trays and ladders after
completion of the cabling installation.
The tray and ladder systems should ensure adequate working access is provided
to the completed cabling installation, to other plant, and for safe personnel
access to the walkthorugh cable galleries and basement.
Where cables enter or leave buildings and structures cable access holes should
be sealed to form a positive and permanent waterproof barrier. Cable entry
54
sealing should be by a proprietary galvanised steel frame mounted transition

seal assembly for multiple cable entry or by sealing individual cable entry holes
by an approved sealing compound.
5.2.3. External cabling
General external cable routes are indicated on the Drawings
All external cabling within the site boundary of the pumping station, should be
installed in ducted cable systems.
The cabling installations outside the station site boundaries should be direct
buried. The 380 kV cable route between the JPS1 transformer compounds and
Desalination Plant should be generally as indicated on the Drawings. The cable
installation should be direct buried over the general route length..
The depth of burial of the cable route to the route protective cable tiles should
be not less than 1.500 mm. The 380 kV cable installation should maintain a
segregation of at least 1000 mm between the parallel power cable circuits,
between the power cables and the associated control cable circuits, and to all
other buried services and structures.
Auxiliary and control cables should be laid to a buried depth to cable centre not
less than 600 mm. All power cables below 380 kV should be laid to a depth of
not less than 900 mm.
For all external cable installations the Contractor should be responsible for:
- conducting all site surveys necessary to establish and verify the location of all
existing buried services and structures against available installation records
- all route excavations for buried and ducted cable systems
- the provision of all duct systems including drawpits
- the backfilling of excavated trenches and reinstatement of ground and

finished made up surface areas to the requirements of the specification.
55
6. GROUNDING SYSTEM
6.1. GENERAL
The word “grounding” is commonly used in electric power system work to

cover both “system grounding” and “equipment grounding”.
System ground: A system ground is a connection to ground from one of the

current-carrying conductors of a distribution system or of an interior wiring
system.
Equipment ground: An equipment ground is a connection to ground from one
or more of the non-current-carrying metal parts of the wiring system or of
apparatus connected to the system. As used in this sense, the term equipment
includes all such metal parts as metal conduit, metal raceway, metal armor of
cables, outlet boxes, cabinets, switch boxes, motor frames and metal enclosures
of motor controllers.
6.2. SYSTEM GROUNDING
6.2.1. Ungrounded system
The term ungrounded system is used to identify a system in which there is no

intentional connection between the system conductors and ground. However, in
any practical system, there always exists a capacitive coupling between the
system conductors and ground. Consequently, the so-called “ungrounded
system” is in reality a “capacitively grounded” system by virtue of the
distributed capacitance from the system conductors to ground.
Two principal advantages are attributed to ungrounded systems. The first is
operational. The first ground fault on a system causes only a small ground
current to flow, so the system may be operated with a ground fault present,
improving system continuity. The second is economic: no expenditures are
required for grounding equipment or grounted system conductors
Ground detectors on an ungrounded-neutral system will indicate the existance
of a ground fault but will not give its location. Several devices are available for
determining the approximate location of ground faults. Such devices are
admittedly helpful, but they do not provide the complete answer. Some time is
still required to locate and remove the faulty feeder from service for repair.
These devices do nothing to prevent the occurrence of the fault.
56
6.2.2. Grounded system
The term grounded system is used to identify a system in which there is the
intentional connection of the system neutral conductor to the ground. The
neutral to be grounded is readily available in the source transformer, having
wye-connected windings in all modern system.
The advantages of operating an industrial power system grounded compared
with operating it ungrounded may be one or more of the following:
1) Reduced operating and maintenance expense
a) Reduction in magnitude of transient overvoltages
b) Improved lightning protection
c) Simplification of ground-fault location
d) Improved system and equipment fault protection
2) Improved service reliability
3) Greater safety for personnel and equipment
The relative weight of these advantages varies with system voltage classes and
to a lesser degree with installation conditions.
7.2.2.1 Methods of system neutral grounding

The methods of grounding system neutral can be divided into two general
categories: solid grounding and impedance grounding. Impedance grounded
may be further divide into several subcategories: reactance grounding,
resistence grounding and ground-fault neutralizer grounding. Fig. 1 shows
examples of these methods of grounding.
Generally an impedance grounding instead of a solid grounding allows to reduce
the fault current and the transient overvoltages.
57
Fig 1- System Neutral circuit and equivalent diagrams for ungrounded and various types
of grounded neutral systems
58
6.3. EQUIPMENT GROUNDING
6.3.1. General
For the earthing of electrical systems, equipment and structures, each

installation should have one common earth grid connected to the ground. The
earth grid should comprise stranded copper earthing cables with green/yellow
PVC sheathing.
The earth grid should extended throughout the plant in the form of a plant earth
ring with branch interconnections to the equipment and structures to be earthed,
and l form part of a single earth grid for the whole site.
The connection to the ground of this earth grid can be carried out by connecting
it to:
1) 2 or more earth electrodes, where earth electrode means a bare conductor
embedded in the earth;
2) one ring of bare conductor buried in the earth;
3) one grid of bare conductors consisting of a system of horizontal earth
electrodes (a number of interconnected, bare conductors buried in the earth).
The third solution is the most used for big plants.
An ideal grounding should provide a near zero resistence to remote earth; in any
case the earth resistance should be low enough to ensure the operation of all
electrical protective devices.
Earth electrodes should be made of galvanised steel pipe or another suitable
material which guarantees low resistance and long life. Copper electrodes
should not be used in areas with impressed current cathodic protection.
The connections between electrode heads and conductors should be so executed
that easy inspection and testing of the earth resistance of individual electrodes
is possible, without disconnecting the earthing conductors from one another.
6.4. EARTHING REQUIREMENTS FOR SUBSTATIONS, SWITCHROOMS

AND CONTROL ROOMS
The main substation earth ring comprising the connections to the earth
electrodes, and the wall mounted earth bars should have a cross sectional area
such as to be capable of conducting for 1 s the maximum earth fault currents
that can arise.
Note: For the purpose of sizing earthing conductors, all system neutral points
should be assumed to be solidly earthed.
Branch earth conductors connected to individual switchgear and controlgear
assemblies should be sized so that their total cross sectional area is capable of
carrying the rated short circuit current capacity of that particular assembly.
Rated short circuit current and Total conductor size mm2

duration
59
20 kA/1s 70
25 kA/1s 70
31,5 kA/1s 120
40 kA/1s 150
50 kA/1s 240
63 kA/1s 240
80 kA/1s 300
Note: For the large conductor sizes, two smaller conductors of equal or greater
total cross-section may be used, e.g. for standardisation or ease of handling.
6.4.1. Earthing of plant equipment and structures

The metallic enclosures of electrical equipment should be bonded to the plant
earth ring. The metallic enclosures of non-electrical equipment, e.g. vessels,
should also be bonded to the plant earth ring or be provided with their own
duplicate earth electrodes; in the latter case, the combined resistance to the
general mass of earth should not exceed 10 .
Plant earthing ring conductors should have a cross-sectional area of 70 mm2.
The cross sectional area of branch conductors connecting equipment and
structure to the plant earth ring should be:
- to metallic enclosures of HV electrical equipment: 70 mm2
- to metallic enclosure of LV electrical equipment, having a supply cable cross-
sectional area 35 mm2 : 70 mm2
- to metallic enclosures of LV electrical equipment, having a supply cable
cross-sectional area 35 mm2: 25 mm2
- to control panels, etc. 25 mm2
- to non-electrical equipment exposed to lightning e.g. tanks, columns and tall
structures: 70 mm2
- to other non-electrical equipment: 25 mm2
60
61
6.4.2. Electronic equipment
Special attention should be paid to the electronic system earthing, if required for
computers and control systems.
Computer systems and instrumentation DCS equipment should be earthed
separately from the electrical earth system. The metallic housing of such
electronic equipment should be connected to the main earth.
This separate earth system, called the “clean earth”, “instrument earth” or
“computer earth”, as relevant, can be one or a number of separate and
independent earth systems depending on manufacturers’ requirements. For
instrumentation DCS equipment the clean earth system is designated as the
instrument earth and is intended for the earthing of the instrument power supply
isolating transformers, signal cable screens, etc.
The instrument clean earth system typically consists of screened copper earth
conductors connecting the DCS equipment and/or isolating transformer neutral,
possibly via earth test/grouping busbars, to dedicated earth electrodes which
should have a resistance to the general mass of earth not exceeding 2 . The
clean earth electrode(s) should be of the same type as those used on the electric
earthing system but should, in addition be placed in a non-galvanised steel line
pipe for a depth of 4 m to shield the electrode from surface earth stray currents
which may cause unwanted interference.
Since in some locations it is difficult to achieve the maximum resistance
specified above, the clean earth system should be interconnected with the
electrical earthing system to make use of the latter’s low resistance, realisable by
virtue of the vast interconnected array of earth electrodes around the plant. The
connection should be made by means of a high frequency choke in parallel with
the surge arrester.
62
63
6.5. SAFETY IN GROUNDING
6.5.1. Basic problem

In principle, a safe grounding design has two objectives:
1) To provide means to carry electric currents into the earth under normal and
fault conditions without exceeding any operating and equipment limits or
adversely affecting continuity of service;
2) To assure that a person in the vicinity of grounded facilities is not exposed to
the danger of electric shock.
6.5.2. Typical shock situations

People often think that any object grounded can be safely touched, assuming
that the earth potential is constantly equal to zero. This is a misconception; in
fact the earth potential during a fault is a function of:
 earth resistence of the grounding system;
 magnitude of the fault current;
 distance between earth surface and earth electrodes;
 earth resistivity.
A typical surface potential profile during a line to ground fault in a plant having
a station grounding grid is shown in figure
The Ground Potential Rise during a fault is defined as the maximum voltage
that a station earth electrode (or the station grounding grid) may attain relative
to a distant grounding point assumed to be at the potential of the remote earth
(zero potential).
The value of this voltage is: GPR = RG x profile
Figura 1 - Surface potential
IG during a line to ground fault
with: RG = earth resistence and IG = magnitude of fault current.
64
The basic shock situations in a grounded station are due to the following
voltages:
 Step Voltage, defined as the difference in surface potential experienced by a

person bridging a distance of 1m with his feet without contacting any other
object.
 Touch Voltage, defined as the potential difference between the ground
potential rise and the surface potential at the point where a person is
standing, while at the same time having his hands in contact with a grounded
structure.
 Mesh Voltage, defined as the maximum touch voltage to be found within a
mesh of a ground grid.
 Transferred Voltage, defined as a special case of touch voltage where a
voltage is transferred into or out of the substation.
In figure 9 the above mentioned basic shock situation are shown:
65
66
6.5.3. Maximum allowable step and touch voltage
The safety of a person depends on preventing the critical amount of shock

energy from being absorbed before the fault is cleared and the ststem de-
energised.
The magnitude and duration of the current conducted through a human body at
50 or 60 Hz should be less than those that cause ventricular fibrillation.
On the basis of studies on the fibrillating current the National Codes tried to
establish a Step Voltage and a Touch Voltage limit.
The maximum allowed step and touch voltages according to IEEE Std. 80-1986
are here below reported.
7.5.3.1 Permissive body current limit
The magnitude and duration of the current conducted through a human body 60
Hz should be less than those that cause ventricular fibrillation.
The duration for which 60 Hz current can be tolerated is determined by the
following formula:
IB = K/ ts (EQ 4)*
where:
K = SB = 0.157
SB= empirical constant related to the electric shock energy tolerated by a certain
percent of given population.
ts = duration of the current exposure
Fibrillation current is actually a function of individual body weight, as illustrated

in Figure 1. This shows the relationship between the critical current and body
weight.
Dalziel's more recent studies on which (EQ 4) is based, lead to the alternate
value of k = 0.157 and S B= 0.0246 [A2 s].as being applicable to persons
weighting 70 kg. Thus,
IB = 0.157/ for 70 kg body weight (EQ 6)*
67
7.5.3.2 Step voltage and touch voltage limit
a) Maximum allowed step voltage
ES70 : tolerance step voltage for human with 70 kg body weight

E S70 =  RB  R2 FS   I B (EQ 23)*
b) Maximum allowed touch voltage
ET70: tolerance touch voltage for human with 70 kg body weight

ET70 =(RB + R2FP )  IB (EQ 25)*
RB: Resistance of human body from hand to-both-feet of from hand-to-hand or

from one foot to the other foot = 1000 .
R2FS: Resistance of ground between the two feet in series.

R2FS = 6 (EQ 14)*
68
R2FP: Resistance of ground between the two feet in parallel.

R2FP = 1,5 (EQ 15)*
6.6. LIGHTNING AND STATIC ELECTRICITY
6.6.1. General
Lightning protection system should be installed if required in accordance with

local regulations. In the absence of such regulations, the need for lightning
protection should be determined, and the system, where required should be
designed and installed in accordance with the reference codes.
For the purpose of facilitating a low impedance lightning discharge path to
earth, earth electrodes should be located near the base of elevated structures
requiring lightning protection. The electrode(s) should be connected to the
structure to be protected and interconnected with the plant earth ring by 70 mm2
earth cables.
The combined resistance to the general mass of earth of the electrodes provided
for lightning protection should not exceed 10  when isolated from the plant
earth ring.
Metal structure e.g. tanks, vessel, etc. do not require additional protection
beyond the earthing requirements specified above.
6.6.2. Equipment and Structures to be considered
Equipment and structures can be separated into five classifications for their need
of lightning protection.
1) The first class needs very little or no additional protection. The only real
requirements for these is that they be effetively connected to a suitable
grounding electrode. This class included:
a) All metal structures except tanks or other enclosures of flammable
materials
b) Water tanks, silos, and similar structures, constructed largely of metal
c) Flagpoles made of conductive material
2) The second class consists of buildings with conducting surfaces and non
conducting framework, such as metal-roofed and metal-clad buildings. This
type requires the addition of down conductors to connect the exterior roof
and cladding to suitable grounding electrodes.
3) The third class consists of metal-framed buildings with nonconductoring
facings. These need the addition of conducting air teminals suitably located,
connected to the frame, and projecting beyoin and above the facing to act
as the loightning terminal points, eliminating puncture of the facing.
4) The fourth class consists of nonmetallic structures, either framing or facing.
These require extensive protection treatment. Included are:
a) Buildings of wood, stone, brick, tile, or other nonconducting materials,
without metal reinforcing members.
69
b) High stacks and chimneys. Even with reinforcing members, these should
have full lightning protection treatment of air terminals, down
conductors, and grounding electrodes.
5) A fifth class consists of iterms of high risk or loss consequences, which
normally receive full lightning-protection treatment, including air terminals
or diverters, down conductors, and grounding. These include:
a) Buildings of great aesthetic, historical, or intrinsic value
b) Buildings containing readily combustible or explosive materialas
c) Structures containing substances that would be dangerous if released by
the effects of a lightning stroke
d) Tanks and tank farms
e) Power plants and water pumping stations
f) Transmission lines
g) Power stations and substations
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7. LIGHTING
7.1. BUILDING LIGHTING
7.1.1. Illuminance levels
The building internal lighting design shall take into account:
- the operating environment

- the type and style of architectural finish
- the activities to be performed in the areas
- access for equipment maintenance
- operating life
The minimum service illumination levels shall be in accordance with values

listed below.
In no case shall the illumination be below that necessary to perform work or
other essential activity in any particular location.
Lighting shall be provided in all building areas, to provide the following
illuminance levels which, unless otherwise specified shall be at ground level:
AREA Illuminance
(lux)
Offices 500
Control rooms 500
Switchgear and electrical equipment rooms 300
Pump rooms 250
Auxiliary plant rooms and areas 150
Warehouse/storage areas 150
Warehouse working areas 250
Workshop 300
Corridors 150
Toilet areas 150
Mess rooms 300
Cable basement and galleries 100
Transformer bays 150
Cooling plant room 250
Surge vessel plant room 250
Scraper station building 250
Pipeline valve building 250
Battery equipment rooms 250
External areas at building entrance doorway 50
Walkways adjacent to buildings 50
Chambers (where shown on the drawings) 50
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Lighting control
Separate switching control shall be provided for each room or area lighting.
Switching shall be provided adjacent to the room or area doors and entrances
multiple switching or push button/contactor control shall be provided to areas
having more than one entrance.
Exterior lighting for building entrances and walkways shall be controlled by
internal switches adjacent to the respective building doorways.
7.1.2. Emergency lighting
General area emergency lighting shall be provided in the main pumping station
buildings and building areas to permit personnel access to control rooms, and
other plant rooms where essential working access is necessary to the main and
auxiliary plant installations and control equipment in the event of loss of the
pumping station main power supplies.
The general area emergency lighting shall comprise area sections or specific
circuits of the main building lighting installation that shall be automatically re-
energised from the pumping station essential power distribution power system
and emergency standby power generator in the event of loss of normal main
power supply.
Emergency escape lighting
Independent emergency escape lighting installations shall be provided to permit

the safe evacuation of personnel from all buildings and building structures in the
event of loss of main power supplies.
The emergency escape lighting shall:
- indicate clearly and unambiguously the escape route from all areas within the
buildings;
- illuminate the escape routes to allow safe movement towards and out of the
exits.
The emergency lighting installation shall comprise system of independent self
contained non-maintained bulkhead fluorescent luminaries with integral
battery/charger/inverter equipment with minimum 3 hour operational duty.
Emergency luminaries located above or adjacent to escape exits and doorways
shall have illuminated labels described EXIT in both English and Arabic.
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7.2. EXTERNAL LIGHTING
External site services installations shall be provided which shall comprise the
following independent systems:
- site roadway lighting
- site security lighting
- gatehouse and site entry checkpoint lighting and associated services
- supplementary area lighting
7.2.1. Site road lighting
A road lighting system shall be provided to illuminate all roadways within the
pumping station site.
The road lighting system shall provide a maintained average surface illuminance
on all roadway and parking areas of not less than 15 lux. The ratio between the
maintained average and minimum point surface illuminance shall be not greater
than 3:1.
The column mounted luminaires shall imcorporate low pressure sodium or
mercury vapour discharge lamps and shall be of the side entry included
overhanging pattern with integral lamp control gear, weatherproof diecast
aluminium body, with hinged access cover and high impact polycarbonate
diffuser.
The columns shall be sized not less than 100 mm from the road kerb edge with
extended brackets to locate the luminaries at the road kerb.
The columns shall be hot dipped galvanized steel with low level cable
termination chamber accessible through lockable front cover plates. The column
cable terminations shall comprise fully insulated TP+N termination blocks for
the loop-in termination of the main power cable between columns, and insulated
internal fuses cut-out or MCB and neutral connections for the luminaries
circuits. Internal column wiring shall be in PVC insulated and sheathed cable.
Each column and luminaries shall be positively earthed and bonded to the cable
armour or protective conductor in an approved manner. An earthing ring of
sleeved stranded copper conductor shall be buried around the concrete
foundation of each pole and will be connected to it.
The columns shall be mounted in precast concrete foundations with PVC lined
cable entry ducts.
The road lighting system shall be supplied from independent MCB controlled
sub-circuit distribution feeders with single power source derived from the
pumping station “Essential services” 400/230 volt 60 Hz distribution system.
Road lighting shall be automatically contactor switched, controlled by an
adjustable electronic solar time switch with 12 hour integral battery standby
power supply, and overriding photocell switching circuit. Manual switching
facilities shall also be provided with auto/manual control selection.
The sub-circuit distribution equipment, contactor and time switch control
equipment shall be incorporated in the pumping station 400 volt essential series
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distribution switchgear or provided as a separate independent auxiliary

switchgear assembly.
The auto/manual control selection and manual switching controls shall be
located in the station control room.
The photo-cell shall be externally mounted on the south face of the main
pumping station building. The photo-cell controls shall be adjustable between 2
and 100 lux.
7.2.2. Perimeter security lighting
A security lighting system shall be provided to illuminate the complete perimeter

of the pumping station site.
The security lighting system shall comprise a full independent installation
consisting of column mounted low pressure sodium luminaries to illuminate a 10
metre wide internal corridor within he complete site perimeter fence line.
The security lighting installation shall comply with the Specification general
clauses and shall also comply with the requirements of the relevant clauses of
the Security and Safety Directives standard document SSD-13 appended to this
Specification.
The perimeter security lighting shall be supplied from independent MCB
controlled sub-circuit distribution feeders with duplicated power sources
derived from the pumping station “essential services” 400/230 volt 60 Hz
distribution system.
The security lighting shall be automatically contactor switched, controlled by an
adjustable electronic “solar” time switch with 12 hour integral battery standby
power supply and overriding photo-cell switching circuit.
Manual overriding switching facilities incorporating auto/manual control
selection and indicating lamp for an “auto control failed” alarm shall be
provided in the station control room.
The sub-circuit distribution equipment, contactor and time switch control
equipment shall be incorporated in the pumping station 400 volt essential
services distribution switchboard or provided as a separate independent
auxiliary switchgear assembly.
The photo-cell shall be externally mounted on the south face of the main
pumping station. The photo-cell shall be adjustable between 2 and 100 lux.
Each column and luminaries shall be positively earthed and bonded to the cable
armour or protective conductor in an approved manner. An earthing ring of
sleeved stranded copper conductor shall be buried around the concrete
foundation of each pole and shall be connected to it.
The columns shall be mounted in precast concrete foundations with PVC lined
cable entry ducts.
7.2.3. Gate house and site entrance services
The following electrical services and facilities shall be provided at the gate
house and site entrance:
- entrance area external flood lighting
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- electrically operated road barriers
8.2.3.1 External floodlighting
Independent area lighting shall be provided to illuminate the roadway and

walkway areas of the site entrance. The illuminated area shall extend from the
ends of the inner arms of the site perimeter fence, and from the line of the
entrance gate to 1 metre beyond the vehicle barrier. The defined area shall be
illuminated at a minimum surface illuminance of 50 lux.
The area lighting shall comprise a minimum two mercury or low pressure
sodium vapour flood lights either column mounted or bracket mounted from the
gate house building. The flood lights shall be of type and construction
compatible with the roadway and perimeter secure fence lighting installations.
8.2.3.2 Road barriers
Two electrically operated barriers each with manual operation override shall be
provided across the incoming and outgoing roadways, adjacent to the gate
house.
Raise and lower controls for barrier electrical operation shall be located within
the gate house.
7.2.4. Supplementary area lighting
Supplementary external site area lighting shall be provided to provide safe

operational or maintenance access to the following external plant areas:
- surge vessel plant area
- cooling plant area
- valve chamber areas
The lighting installation shall provide a minimum service illuminance of 50 lux
to the general plant areas and to any specific locations within the plant areas
necessary to provide safe personal access for emergency plant operation or
maintenance. Areas where routine operational access are required shall be
illuminated to 150 lux.
The area lighting shall be provided by mercury or low pressure sodium vapour
discharge floodlights which shall be either column mounted and or bracket
mounted from the local building structures. Additional lighting for local plant or
access stairway or walkways illumination shall be by bulkhead pattern
luminaries.
The supplementary area and plant lighting shall be from service distribution
boards or MCB feeder circuits incorporated in the respective auxiliary plant
control switchboards or adjacent building electrical services distribution
switchgear.
The supplementary area lighting shall be locally manually controlled.
Cabling for area lighting shall be PVCSWAPVC multicore type.
Cabling to column mounted floodlighting shall be direct buried.
Cabling for building structure or plant mounted lighting shall be installed on
cable trays.
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7.3. INDOOR LIGHTING DESIGN CRITERIA
One of the tasks of a lighting designer is to determine the required number of

luminaries of an interior with known parameters that will meet the design
objectives. This can be done by applying the BZ method (method of total
luminous flux).
7.3.1. Calculation Of Necessary Total Luminous Flux
Firstly the designer has to calculate the room index Kr :

L xW
Kr = , where:
Hm (L + W)
Room length = L [m];
Room width = W [m];
Mounting height = Hm = Ht - Hs - 0.85 [m];
Room heigth = Ht [m];
Suspension heigth = Hs [m];
Working plane = 0.85 [m].
Then, on the basis of the interior colours, the designer has to assume a value for
the reflectance of ceiling, walls, floor. Typical values can be:
Reflectance of Ceiling = Rc = 0.7;
Reflectance of Walls = Rw = 0.5;
Reflectance of Floor = Rf = 0.2;
Once Rc, Rw, Rf and Kr are known, from table 1 the utilisation factor UF can
be determined.
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Table 1 - Utilisation factor UF

Rc 0.70 0.50 0
Rw 0.50 0.30 0.10 0.50 0.30 0.10 0
Rf 0.20 0.20 0.20 0.20 0.20 0.20 0
Kr = 0.6 0.36 0.33 0.30 0.36 0.33 0.30 0.28
Kr = 0.8 0.42 0.38 0.35 0.41 0.38 0.35 0.33
Kr = 1 0.48 0.44 0.41 0.46 0.44 0.41 0.39
Kr = 1.25 0.52 0.48 0.45 0.50 0.47 0.46 0.43
Kr = 1.5 0.56 0.52 0.49 0.54 0.50 0.48 0.46
Kr = 2 0.60 0.56 0.53 0.56 0.54 0.52 0.49
Kr = 2.5 0.63 0.59 0.56 0.58 0.56 0.54 0.51
Kr = 3 0.65 0.61 0.59 0.60 0.58 0.56 0.53
Kr = 4 0.67 0.64 0.62 0.61 0.60 0.58 0.55
Kr = 5 0.69 0.67 0.65 0.63 0.62 0.60 0.57
Environmental factors, aside from the characteristics of the light source, must
be given consideration in the lighting calculation. Therefore an appropriate
depreciation factor f has been introduced. This factor can be derived from table
2.
Table 2 - Depreciation factor
Luminaries type Surroundings Fluorescent tubes Fluorescent tubes
“office” “workshop”
Clean 1.27 1.33
Open luminaries Suburbs 1.33 1.42
Centre of town 1.42 1.48
Dirty 1.48 1.54
Clean 1.27 1.27
Ventilated through Suburbs 1.33 1.33
reflector Centre of town 1.42 1.42
Dirty 1.48 1.48
Clean 1.27 1.27
Dustlight luminaries Suburbs 1.33 1.33
Centre of town 1.42 1.42
Dirty 1.48 1.48
Non-ventilated Clean 1.33 1.50
luminaries with Suburbs 1.39 1.61
plastic bowl Centre of town 1.54 1.69
Dirty 1.61 1.78
Ventilated Clean 1.33 1.45
luminaries with Suburbs 1.39 1.54
louvre or plastic Centre of town 1.54 1.61
plate Dirty 1.61 1.69
Recessed luminaries Clean 1.33 1.39
with louvre or Suburbs 1.39 1.48
plastic plate Centre of town 1.54 1.54
Dirty 1.61 1.61
Note: The tabled values are for Rw=0.3 and cleaning once a year. For Rw=0.5
the values must be increased by 0.04.
77
After having determined the Depreciation Factor it is possible to calculate the

total luminous flux necessary to obtain the required illuminance level:
ExLxW
TOT = f [lumen]
UF
where E = required illuminance [lux]
7.3.2. Calculation of necessary number of luminaries
The required number of luminaries is:
TOT
N=
n x LAMP
where LAMP = flux per lamp;

n = number of lamps for luminaries.
7.4. COMPUTER AIDED LIGHTING DESIGN
Nowadays lighting calculations are made with ease and a lot of saved time by
the use of computer. The designer will simply input the calculation parameters
and the result will be displayed on the monitor for evaluation.
Design offices consider this tool a necessity since the lighting designs required
in a simple project involved different applications which, if done manually, will
take a lot of time.
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8. SAFETY AND AREA CLASSIFICATION
8.1. SAFETY PRINCIPLES
Installations in which flammable materials are handled or stored should be

designed, operated and maintained so that any releases of flammable material,
and consequently the extent of hazardous areas, are kept to a minimum,
whether in normal operation or otherwise, with regard to frequency, duration
and quantity.
In the case of maintenance activities other than those of normal operation, the
extent of the zone may be effected but it is expected that this would be dealt
with by a permit-to-work system.
In emergency situations, reliance should be placed on the isolation of unsuitable
electrical equipment, shut-down of the process, isolation of process vessels,
containment of spillages and, if possible, the provision of additional emergency
ventilation.
In a situation in which there may be an explosive gas atmosphere, the following
steps should be taken:
a) eliminate the likelihood of an explosive gas atmosphere occurring around the
source of ignition, or
b) eliminate the source of ignition.
Where this is not possible, protective measures, process equipment, systems and
procedures should be selected and prepared so the likelihood of the coincidence
of a) and b) is so small as to be acceptable. Such measures may be used singly if
they are recognised as being highly reliable, or in combination to achieve an
equivalent level of safety.
8.2. HAZARDOUS AREAS CLASSIFICATION
An area in which an explosive gas atmosphere is present, or may be expected to

be present, in quantities such as to require special precautions for the
construction, installation and use of apparatus is defined as an hazardous area.
Hazardous areas are classified into zones based upon the frequency of the
occurrence and duration of an explosive gas atmosphere, as follows:
 Zone 0 - An area in which an explosive gas atmosphere is present
continuously or for long periods.
 Zone 1 - An area in which an explosive gas atmosphere is likely to occur in
normal operation.
 Zone 2 - An area in which an explosive gas atmosphere is not likely to occur
in normal operation and, if it does occur, is likely to do so only infrequently
and will exist for a short period only.
8.3. AREA CLASSIFICATION OBJECTIVES
79
Area classification is a method of analysis and classifying the environment where

explosive gas atmospheres may occur so as to facilitate the proper selection and
installation of apparatus to be used safely in that environment, taking into
account gas groups and temperature classes.
In most practical situations where flammable materials are used, it is difficult to
ensure that an explosive gas atmosphere will never occur. It may also be
difficult to ensure that apparatus will never give rise to a source of ignition.
Therefore, in situations where an explosive gas atmosphere has a high likelihood
of occurring, reliance is placed on using apparatus which has a low likelihood
of creating a source of ignition. Conversely, where the likelihood of an
explosive gas atmosphere occurring is reduced, apparatus constructed to a less
rigorous standard may be used.
It is rarely possible by a simple examination of a plant or plant design to decide
which parts of the plant can be equated to the three zonal definitions (zones 1, 1
and 2). A more detailed approach is therefore necessary and this involves the
analysis of the basic possibility of an explosive gas atmosphere occurring.
The first step is to assess the likelihood of this, in accordance with the
definitions of zone 0, zone 1 and zone 2. Once the likely frequency and duration
of release (and hence the grade of release), the release rate, concentration,
velocity, ventilation and other factors which affect the type and/or extent of the
zone have been determined, there is then a firm basis on which to determine the
likely presence of an explosive gas atmosphere in the surrounding areas. This
approach therefore requires detailed consideration to be given to each item of
process equipment which contains a flammable material and which could
therefore be a source of release.
In particular, zone 0 or zone 1 areas should be minimised in number and extent
by design or suitable operating procedures. In other words, plants and
installations should be mainly zone 2 or non-hazardous. Where release of
flammable material is unavoidable, process equipment items should be limited to
those which give secondary grade releases (a release which is not expected to
occur in normal operation) or, failing this (that is where primary or continuous
grade releases are unavoidable), the releases should be of very limited quantity
and rate, In carrying out area classification, these principles should receive
prime consideration. Where necessary, the design operation and location of
process equipment should ensure that, even when it is operating abnormally, the
amount of flammable material released into the atmosphere is minimised, so as
to reduce the extent of the hazardous area.
Once a plant has been classified and all necessary records made, it is important
that no modification to equipment or operating procedures is made without
discussion with those responsible for the area classification. Unauthorised action
may invalidate the area classification. It is necessary to ensure that all equipment
affecting the area classification which has been subjected to maintenance is
carefully checked during and after re-assembly to ensure that the integrity of the
original design, as it affects safety, has been maintained before it is returned to
service.
8.4. HAZARDOUS AREA EXTENSION
80
Generally the extent of an hazardous area is mainly affected by the following

parameters:
 Release rate of gas or vapour;
 Intrinsic (physical and chemical) properties of the flammable material at
process conditions;
 Ventilation;
 Climatic conditions and topography.
The extension of hazardous area is normally carried out taking into account the
above mentioned parameters and according to National Standard.
When the National Standard is not available the most common Standards
applied are:
- IP section 15
- API RP500
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9. DOCUMENTS AND DRAWINGS
9.1. GENERAL
All necessary drawings documents and reports relating to the design of the
electrical installation and for its operation, and all necessary drawings required
for the installation and interconnection of equipment and cabling should form
part of the design package.
Such information should be updated when alterations to the design are made
and should include additional information that is required during erection or
may be required for future maintenance, troubleshooting and operation.
As built drawings should be prepared for the project covering all parts of the
electrical installation.
9.2. DESIGN DRAWINGS
Full detailed construction drawings should be provided so that the site

construction contractor can install all electrical equipment with no additional
design effort.
Vendor information and details should be incorporated in the design package as
soon as it becomes available.
a) Single line diagram
The single line diagrams should detail the main circuitry and its earthing
systems. It should also indicate the instrument transformers, relays, meters, etc.,
for the control, protection and operation of the equipment together with
electrical data such as voltage, current and impedances.
A single line diagram of a.c. and d.c. interruptible and uninterruptible,
maintained electricity supply systems should be provided. The single line
diagram should detail for each system the system configuration, earthing
arrangements, UPS and emergency generator ratings, the equipment number,
function, location, nominal voltages, maximum load, number and type of battery
cells and battery autonomy time.
b) Block diagram
The block diagram should show the basic control and protection systems
defining the protection, control, trip and alarm functions to be fulfilled at the
different locations. It should also indicate the reference signals and controls
needed and all the auxiliary supplies required such as air, luboil, cooling water,
electrical auxiliary supplies, etc.
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c) Switchgear drawings
The following schedule and drawings should be provided for each HV and LV
a.c. switchboard:
- switchboard specification, as appropriate
- circuit/schematic or control diagram, showing all circuit details in a
schematic form to control a motor or other power device, and all information
necessary for the identification and connection of the components and wiring
- interconnection/connection diagram showing the external connection details
of a switchgear panel, relay box, or junction box, etc.
- block diagram showing the interconnection of the various equipment of a
power system in a diagrammatic manner
- swithboard layout showing the basic information needed for the construction,
i.e. the switchboard outline dimensions, and the switchboard front outline
layout.
Note: Some of these drawings should be prepared by the equipment vendor.
d) Layout drawings
A substation/switchroom layout drawing shows the physical location and the

civil provisions to be made for installing all transformers, switchgear and other
electrical power, lighting, earthing and auxiliary equipment located in a
substation. The cable runs and support system should also be shown. Space
requirements for future switchgear, correct location and dimensions of transits
in the substation floor for existing and future switchgear should be shown.
Power, lighting, earthing, substation, and trench layout drawings should
identify:
- all major process equipment by their item number
- all electrical equipment and cables by their equipment and cable numbers.
The power layouts should show all power cabling, identified by cable numbers,
lighting supply cables up to the main junction boxes, and the power and
convenience outlet distribution board feeder cables.
Earthing layout should show the main earthing grid, branch connections, earth
electrodes, earth bars and conductor size for both the electrical earthing system
and the instrument clean earth system.
The cable trench layout should the physical location of all underground cable
trenches, underground pipes and ducts.
Cross-sectional arrangement drawings should be provided for all cable trenches,
ducts and above ground cable routes showing the location and number of each
cable along the routes.
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e) Construction drawings (typical details)
Construction detail drawings should show typical construction and mounting

details of the power, lighting and earthing installations which cannot otherwise
be shown on the layouts.
f) Area classification drawings
The area classification drawings should show the classification of the areas with
respect to gas or vapour or dust explosion hazard, and should include sectional
elevations where needed for clarity.
g) Vendor drawings
Vendor drawings should be provided to show as a minimum all the information

specified in the relevant equipment and specification purchasing order.
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10. MATERIAL PROCUREMENT
10.1. GENERAL
In order to proceed to purchase some material equipment the following

activities should be performed:
10.2. PREPARATION OF TECHNICAL DOCUMENTATION FOR RDA
The PSL prepares the copies agreed, in accordance with the purchase planning,
and sends to ACQ the documentation necessary to request bids for the materials
to be purchased.
This documentation generally comprises the following:
- Index of contents
- Data sheet
- General specification
- Project specification including codes and standards applicable
- IDS (inspection data sheet)
- Supplier documents requirement lists complete with delivery times
- Performance guarantees
- Definition of inclusions and exclusions
- The supplier is generally required to list the spare parts for both
commissioning and start-up
- Request for special references
10.3. TECHNICAL EVALUATION
10.3.1. Purposes and objectives
The purpose of the work process are to:

- ensure that the products offered meet the technical/management
requirements;
- identify any deviations or deficiencies, and have the bid updated if necessary;
- examine the technical and management acceptability of any alternatives and
evaluate their impact on the project;
- check that the supply schedule of materials and documents is compatible with
the project scheduling;
- provide ACQ with a synthetic and complete summary of the acceptability (or
not) of the bid, including the alternatives.
85
10.3.2. Bid evaluation
When all bids are received the ACQ deportment declare close the bidding
activities and send all received bids to the ESID department for the bid
evaluation.
- If necessary, a preliminary examination of the bids can be made in agreement

with ACQ and PM to define a vendors short-list, in order to examine in more
detail only the bids that are of actual interest both technically and
economically.
- When examining the bids, all deficiencies or deviations from the requirements
should be highlighted, in order to provide objective reasons for negative
appraisal.
Positive aspects should also be highlighted, and all alternatives should be
evaluated.
Any delivery dates that are not compatible with the project schedule should
also be highlighted.
- For correct and exhaustive bid evaluation, additional information should

normally be collected by contacting the vendors, compatibly with the
schedules dates for issuance of the PT.
- To evaluate the aspects concerning different specialist disciplines, the PSL

asks the competent PSL for comments or evaluations; the latter will forward
their comments in writing, in accordance with the procedures and by the
dates agreed upon.
- Deviations from the specified requirements may be accepted, provided that

exhaustive reasons are given in the PT; in particular, it should be
demonstrated that the plant functionality, reliability and safety are not
affected.
Should any deviation involve Employer’s requirements or approved
documents, the Employer’s approval should be obtained through the PM.
- The PT should be conclusive, i.e. should provide ACQ with a clear indication
of the bids that are considered suitable for placing the order; if necessary, the
notes should detail the conditions and/or information required, for example:
formalization of bid updating after clarifications, acceptable alternatives
and/or parts to be included in the order (among those offered), other aspects
that can be defined during the negotiations without further technical
evaluation
86
10.3.3. Preparation of technical evaluation (PT)
- The PT is prepared by the competent PSL or by another specialist authorised

by the same technical department.
- If no details are indicated on the bid, this means that the bid complies fully
with the specified requirements.
If the acceptance depends on specified conditions these should be
exhaustively detailed in the notes.
- If the bid is not considered acceptable the reasons should be specified in the
notes.
For example, the bid is considered inadequate and therefore not acceptable
when it does not include the requirements of the technical specifications, or
when it lacks essential data for proper evaluation, after the vendors have
been explicitly contacted.
In general, technical noncomformances should be clearly indicated, especially
for major equipment of technical/economic importance (e.g. compressors,
boilers, reactors, etc.).
The notes in the PT should clearly indicate the degree of compliance of the
bid with the requirements to be met.
Special attention should be paid to the vendor’s specific references regarding
the product offered.
Any differences between the various supplies, due to better performance,
easy construction and erection, different inspection and testing requirements,
should be quantified in economic terms.
10.3.4. Verification and approval
The PT should be verified by personnel independent of those having direct

responsibility for the preparation, and authorised by the department manager on
the basis of their specific technical competence.
In particular, the verification concerns the completeness and correctness of the
PT, and will be formalised by a signature written.
The PM write his own evaluations on the bids that are considered technically
acceptable; in particular, the PM may recommend (for placing the order) one or
more vendors among those that are positively evaluated in the PT, and state the
reasons therefore.
If contractually required, the PM will submit the PT to the Employer for
information and/or approval.
GEM - for inspections
87
PROMET - for “Package engineering” of the cathodic protection plants.

During this phase the PSL can contact the Supplier to point out any
discrepancies and/or oversights in the offer, request updates and examine any
variants and alternatives proposed and options.
The “Technical Evaluation” is then issued on special forms, indicating the
acceptability and composition of the basic supply and specifying the additional
and/or optional supplies.
As a general note, the following are specified in the technical evaluation when
applicable:
- penalties for consumption and/or performance
- documents subject to penalties and/or tied to instalments of payment
- contractual requirements linked to performance requested by Customer and/or
Third-parties.
The PT is sent to the PM.
10.3.5. Preparation of technical documentation for Order
The PSL starts the activity for issuing the technical Order documentation when
the order issued by ACQ has been received. This activity consists in updating
the documentation in accordance with the supply defined and agreed with the
Supplier as described in the technical opinion and/or negotiation records.
The technical documentation for the order also shows the name of the Supplier
and the order number and is sent with a field letter to: Supplier, GEM, ACQ,
PM, Uts involved.
10.3.6. Management of Supplier Documents
After the order has been issued, the Suppliers send the documentation requested
at the times planned.
The PSL checks, that the documentation delivery schedule is respected,
instigating the necessary expediting when required, informing the GEM
Department.
The PSL checks the documentation and sends the interdisciplinary
documentation to the other Uts for the checks and/or comments in their areas of
responsibility.
Any comments are made “in red” on the “MASTER” copies managed by the
PSL, who stamps the documents with the following:
- “Valid for construction except where marked in red”

- signature
- date
88
The PSL sends a cop of the documentation marked in this way to:
- The Supplier, so that he can revise the document in accordance with the
comments and subsequently issue it again
- The Customer, when requested or considered necessary.
This procedure may be repeated several time before arriving at the final
issue.
Having checked that the Supplier has taken the comments into account and
revised the document, the PSL stamps the document with the following:
- “Valid for construction”
- signature
- date
The said documentation, considered final, is numbered (Snamprogetti

identification) following the Department procedures, approved by the PSL (date
signature and revision) and distributed to the involved Departments.
10.3.7. Other activities
- Evaluation of spare parts bids for operation.

When foreseen, the PM sends to the PSL the spare parts offer (SPIR form or
similar) sent by the Supplier, requesting a technical evaluation.
The said evaluation is sent to the PM for subsequent actions.
- Revision and/or update of internal documents in accordance with definition of

supplies as per order.
- Witness to tests and inspection in workshop.
The Department provides any support required by the GEM Department during
the workshop tests and inspection on main equipment and in the event on any
cases of non-compliance.
89

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SYRIAN GAS COMPANY (SGC)

1. ELECTRICAL SYSTEM DESIGN

2. SINGLE LINE DIAGRAM CRITERIA

3. MAIN ELECTRICAL EQUIPMENT

4. MAIN ELECTRICAL CALCULATIONS

5. ELECTRICAL PROTECTION AND CONTROL

6. EQUIPMENT AND CABLE RUN LAY-OUT

7. GROUNDING SYSTEM CRITERIA

9. SAFETY AND AREA CLASSIFICATION

10. DOCUMENTS AND DRAWINGS

11. MATERIAL PROCUREMENT

APPENDIX A - PRINCIPLES OF ELECTRICAL ENGINEERING

( Gli allegati sono nel volume fatto per la commessa SHOAIBAH )

( Riportare come intestazione di pag. i logo di commessa usati nelle SPC o

1. ELECTRICAL SYSTEM DESIGN

When electric power stops flowing in a manufacturing plant, the plant’s

1.2.1. Over-all planning (single line diagram)

To obtain a power distribution system which is adequate to meet the service

Economics is a very important part of power engineering. The engineer must

1.2.4. Plan for load growth

One of the greatest mistakes made in power system engineering is planning

1.2.7. Service reliability

Service reliability in any plant is important. Most manufacturing processes are

1.2.8. Modernisation and expansion

When plant facilities have to be expanded or modernised, the engineer is

1.2.9. Selection of equipment

The main fundamental in selecting equipment is to choose the best available. It

Maintenance is largely in the hands of operators. However, the system designer

1.2.11 Make a relay co-ordination study

1.2.11. Things to check when designing the power system

The discussion of items in which proper judgement should be used to obtain a

1.2.12.1 What is the nature and magnitude of the load?

1.2.12.2 Where is the power coming from?

1.2.12.3 How much will the electric power system cost?

1.2.12.6 What size substations are most economical?

1.2.12.7 Secondary distribution

1.2.12.8 Combined light and power system.

1.2.12.9 Are voltage regulating means required?

1.2.12.10 Short-circuit protection.

1.2.12.12 Overcurrent protection.

1.2.12.13 Is the lightning protection adequate?

1.2.12.14 Are circuit properly metered to tell what loads are?

1.2.12.15 Power-factor correction.

1.2.12.16 Supervisory control.

1.3. DESIGN AND ENGINEERING PRINCIPLES

1.3.1. Standards, codes and regulations

1.3.2. Operational safety and reliability

The design of the electrical installation should be based on the prevision of a

spare/stand-by capacity, load shedding and automatic restarting schemes. The

1.3.3. Quality assurance and control

1.3.4. Design phases

1.4. DESCRIPTION OF DESIGN METHODS

a) To use data as soon as it becomes available within the company, taking

c) To use the electrical industry constructional standards which, in general,

This stage of the preliminary design involves the following:

2. SINGLE LINE DIAGRAM CRITERIA

2.2. GENERAL PHILOSOPHY

2.3. CIRCUIT ARRANGEMENT

2.3.1. Single Radial Distribution

Figure 1- Single radial distribution

2.3.2. Double Radial Distribution

Figure 2- Double radial distribution: correct single line diagram

a = only one feeder; b = only one MV bus-bar; c = only one LV bus-bar

Figure 3- Double radial distribution: solution to be avoided