ENGINEERING BASIS /

BASIC DESIGN / LOAD

LIST
TRAINING OBJECTIVES

 Project Engineering
 Data
 Design basis - Electrical
 Project Documents
 Load list
 Transformer sizing
ENGINEERING OF PROJECT ELECTRICAL
SYSTEM
• Preliminary Engineering Activities (FEED Documents)
Site data / Design Basis / Specifications / Data sheet / Layout / load list

• Proposal Engineering (Bidding)

• Project Execution
Basis Design / Detailed design

• Procurement

• Installation / Commissioning
ENGINEERING OF PROJECT ELECTRICAL
SYSTEM

PLOT PLAN

D:\Backup\C Drive\ONEDRIVE DOWNLOAD\PI-

170101\Petronas_Rapid\Feed Documents\Section D\Other Discipline
Section D\Plot Plan
ENGINEERING OF ELECTRICAL SYSTEM
1. Data

2. Design parameter

3. Design philosophies

4. The sequence of preliminary system design

5. Detailing the electrical system

6. Preparation of ‘as-erected- drawings’ & design manuals

DATA

• Data Pertaining to chosen site.

• Data Pertaining to process

• Information pertaining to the utilities.

• Other data
DATA PERTAINING TO CHOSEN SITE
• Data specific to the project-site such as:
maximum and minimum ambient temperature
average rainfall expected
altitude above MSL
maximum-wind-velocity
corrosive nature of atmosphere
dust concentration on area.

• The earth-resistivity & thermal conductivity of soil.

• Dimensions of crates that can reach site by road or by train.

• Environmental pollution, dust, corrosion etc.

• Is the proposed plant-location suitable for an out-door switch yard ?

• Earthquake co-efficient.
PROCESS RELATED DATA
• The tentative preliminary load-list is to be obtained from the process-consultants with
the critical and essential loads identified with the degree of required relative priority
indicated.

• Plot plan with the finished grade level of different tables.

• Details of co-generation proposed or captive generation needed to keep critical part

of the plant in operation during grid (EB) power-failure or during prolonged power and
demand-cuts. The type of load-shedding, load-limitation, and load-restoration
needed.

• Is a central monitoring and data-acquisition-center needed for Electrical system ?

• Degree of electrical system-security needed by the process way of power-transfer

(auto transfer scheme)
DATA REGARDING POWER SUPPLY BY THE
UTILITIES (EB) & EMERGENCY DG SUPPLY
• The Voltage at which power will be supplied by the utilities (The Electricity-Board).

• The power tariff rates for MD and consumption.

• The grid fault level at consumer's metering terminals.

• The location of the EB substation and length of EB's EHV line to the project.

• Will the EB install their own CTs and PTs for tariff-metering ?

• Is space needed for EB's tariff equipment in consumer’s Premises ?

• What is the protection that EB propose for the CB at their end of the line.

• Requirement of emergency power supply DG ? And its rating

DESIGN PARAMETER (DESIGN BASIS DOC.)
• Voltage Rating & Limits of Voltage drop.

• The demand factor & the Cushioning factors.

• Choice of type of HV and EHV system neutral earthing

• Short-time Rating of HV and LV Feeder Cables.

• Impulse Withstand levels for the insulation of windings etc.

• Lighting Lux requirement

• Earth resistance

• Installation data ( e.g. UG / Above ground tray)

• Cable entry
C:\Users\Sanket\Desktop\RANJAN PRESENTATION\LOAD LIST\DESIGN BASIS
DESIGN PARAMETER (DESIGN BASIS
DOC.)

ASSIGNMENT 1 :

Tabulate key design paraments in

excel based on above Design
basis
VOLTAGE RATING & LIMITS OF VOLTAGE
DROP
• Choice of voltage-rating for the larger HV-motors in the range of 250 kW to 6000 kW.

• Adoption of the permissible limits of steady-state voltage drops

• Adoption of the permissible limits of voltage-drops during acceleration of 415V

motors, to be maintained at motor terminals and at the MCC-bus.

• Choice of AC and DC control voltages and permissible limits of variation

SHORT-TIME RATING OF HV AND LV
FEEDER CABLES
• The designer has to choose the duration of short-circuit
withstand capability of HV and 415V motor feeder-cables
depending on whether it is a circuit-breaker-controlled feeder
or a "fuse-backed contactor" controlled feeder.

• For HV cables the duration chosen is between 0.2 and 1 sec.

depending on whether the HV feeder is "fuse-backed-
contactor" controlled or CB-controlled.

• For 1.1 kV cables the duration chosen is from 0.1 sec. to 0.2
sec. It is preferable to select a lower value of 0.1 sec. for 1.1
kV cables.
DESIGN PHILOSOPHIES

• HV system
• Fire safety and ventilation
• 415 V System
• The degree of reliability needed for the control voltages
• The choice of earthing concepts and earthing conductors.
• The choice of lighting parameters and types of lighting.
DESIGN PHILOSOPHIES

• Choice of reactive-power compensation-techniques.

• Safety margin between impulse withstand level of the equipment and the
discharge level of the lighting Arrestors.

• Cabling : Cable tunnels or surface-trench or overhead cable-galleries.

• Standardisation of MCC-module control wiring for various ranges of motor

rating.
H.V. SYSTEM

• Type of HV-CBs to be used (Vacuum breakers or Vac- contactors or SF6-CBs OR

SF6-contactors or MOCBs ?)

• Ring Main system or Radial feeder system for HV distribution?

• Should each have 2 x 100% or 3 x 50% or 4 x 33% transformer capacities ?

• Should the power-transformer be Dy or Yy connected?

• Selection of system-security measures on basis of inputs from the Process-

consultant regarding degree of criticality of feeders, loads etc

• Is site-generation to be sized for export of power to grid or is export to be blocked

?
FIRE SAFETY & VENTILATION

• Type and degree of fire safetys- for Outdoor SS equipment, Substation

buildings, LCSS, tunnels, cable galleries, fire proof partitions, monitoring,
quenching and other provisions needed.

• Pressurised / forced air-ventilated substations or only air changes by exhaust fan

evacuation?
415 V SYSTEM : ISSUES TO BE DECIDED

• Should MCCs be located in Main SS where PCC is located or should MCCs

be located nearer the load groups ?

• Should electrical logic (sequencing and interlocking) be PLC controlled or

hard-wired electro-magnetic relay logic- controlled ?
THE SEQUENCE OF PRELIMINARY
SYSTEM-DESIGN
• The break-up of overall load-list into area wise load-list is to be taken up
first. The load-list area wise or department-wise, shop floor-wise, mill wise
or sub-plant wise.

• Further break-up of area-wise 415V motor-list into MCC-wise group lists.

The Max demand on an MCC is limited to 600 to 800 kVA, depending on
designer's discretion.

• Choice of location of Load-Centre-substations in the project-site-plan. The

LCSSs are located, to the extent possible, close to the load groups or
departments in order to limit the cost of 1.1 kV cabling and cable-galleries
THE SEQUENCE OF PRELIMINARY
SYSTEM-DESIGN
• The total maximum demand at the Main receiving Station (MSS)
calculated on basis of the drive demand factor, the group demand factors
for LCSS and the central diversity factor at MSS.

• The choice of number of transformers and capacity of the transformers to

meet the computed maximum demand, is to be made on basis of selection
of philosophy of spare capacity such as 2 x 100%, 3 x 50% or 4 x 33%
concepts for LCSS as
well as for MSS.

• The adequacy of transformer- rating to withstand the start of the largest

HV-motor is to be checked and established by calculations.
THE SEQUENCE OF PRELIMINARY
SYSTEM-DESIGN
• Preliminary selection of HV-cabling between MSS and LCSSs based on the
result of demand calculation.

• Preliminary Single-Line-Diagram (SLD) can now be drawn up to the

distribution-transformer or PCC bus indicating lumped 415 V loads and
tentative rating of HV motors based on the initial load list.

• Preliminary short-circuit calculation up to HV (LCSS bus) & MV (415-PCC)

buses can be undertaken, checking the short circuit withstand adequacy of
the HV cables.
THE SEQUENCE OF PRELIMINARY
SYSTEM-DESIGN
• Choice of the EHV Substation Layout.

• Should it be a Gas-Insulated-Substation (GIS) ?

• Should it be a conventional out-door-switchyard (ODSY) with fabricated

lattice steel-structures and ERW pipe-supports or RSJ/channel supports?

• Should it be a conventional yard (ODSY) but with concrete structure and

supports (prestressed or simply precast?)

• Should it be a clad-ODSY housed indoor for protection against saline

corrosion when located on seashore or from cement dust in an inland plant
or in a highly polluted chemical plant atmosphere?
THE SEQUENCE OF PRELIMINARY
SYSTEM-DESIGN
• Design of Duct bank, trenches, cable trays and tray supports.

• Freezing the layout of Duct bank, overhead cable galleries, cable trenches.

• This will be a long drawn out affair progressing slowly in stages and getting frozen
only at later stages as priority is usually accorded to the location of process
equipment.

• Final Maximum demand and short-circuit calculations and final HV cable sizing
based on revisions in load list.

• The choice of control scheme wiring for the 415V motor feeders of various ranges
of ratings has to be frozen early so that the length of control cables, the number of
cores etc., can be estimated and quantified for tender purposes.
THE SEQUENCE OF PRELIMINARY
SYSTEM-DESIGN

• The initial choice of 1.1 kV cable sizes and preparation of tender BOQ.

• Preparation of Tender Documents .

DETAILING THE ELECTRICAL SYSTEM

• Preparation of Building Plan and Equipment Layouts for the ODSY, MSS and the
LCSSs.

• Final short-circuit analysis for freezing cable sizes and CB ratings.

• The selection of HV and 1.1 kV cabling for each motor feeder taking in to account:
the continuous current rating as well as the SC-withstand-capability needed
the voltage drop on account of the length of the feeder-cable which is known by this
stage.
DETAILING THE ELECTRICAL SYSTEM

• The detailed scheme-design of

change-over-schemes
control-schemes
Load-shedding-schemes
Auto-load-restoration schemes
Capacitor-switching schemes
Data-acquisition systems
Synchorinising-schemes
The scheme for interfacing site generated power with grid power etc.

• The review of vendor (manufacturer's) drawings for the equipment at MSS,

LCSS etc.,
DETAILING THE ELECTRICAL SYSTEM

• Cabling
Cable-tray routing and tray support design
Preparation of power and control-cable scheduling
Preparation of terminal connection schedules

• Preparation of detailed construction drawings for plant and project lighting.

• Interfacing captive power with grid

PREPARATION OF 'AS-ERECTED-
DRAWINGS' AND DESIGN MANUALS
• Final equipment-specifications as manufactured .

• Operating procedures for the Electrical system

• Write-ups on change-over-schemes, control-schemes for interlocking,

metering, sequencing, captive-power-interfacing, etc.,

• Safety aspects including fire-safety.

• Design parameters specifically adopted for the project

• Final load list

• Basic design philosophies

DOCUMENTATION

Refer to Document List

C:\Users\Sanket\Desktop\RANJA
N PRESENTATION\LOAD
LIST\DOCUMENT LIST
ELECTRICAL DESIGN - LOAD LIST

Produced by Electrical Engineering it shows all electrical loads assigned to each MCC or
Switchboard. It is a key document used as a basis by Electrical Design.

It is developed from the proposal stage through detailed design until all loads are
confirmed by vendor data. The example is a SmartPlant® Electrical database version.
ELECTRICAL DESIGN - LOAD LIST
ELECTRICAL DESIGN DELIVERABLES -
SINGLE LINE DIAGRAMS

The ‘Key’ electrical drawing shows the electrical system in a simple single line
format (the electrical equivalent of a P&ID)

Developed from the load list, vendor data , Design basis

ELECTRICAL DESIGN DELIVERABLES -
SINGLE LINE DIAGRAMS
ELECTRICAL DESIGN DELIVERABLES -
SCHEMATIC / WIRING DIAGRAMS

The next level down from the SLD shows a single circuit. Can be typical for more than
one item of similar equipment. May be by the MCC/Switchboard vendor.

Used by construction for connection of wiring at motors and electrical equipment. Also
used by Commissioning and Client for maintenance operations
ELECTRICAL DESIGN DELIVERABLES -
SCHEMATIC / WIRING DIAGRAMS
ELECTRICAL DESIGN DELIVERABLES -
STANDARD DETAILS
Shows the typical installation of an item of E/I equipment or system component.
May need modification to suit project conditions and/or local codes and regulations
ELECTRICAL DESIGN DELIVERABLES -
EQUIPMENT LAYOUTS
• Shows the physical layout
of electrical equipment
with dimensions.
• Equipment is modelled
in the 3D PDS using
Equipment Modelling.
• Used by construction
to accurately position
equipment on site.
ELECTRICAL DESIGN DELIVERABLES -
CABLE TRAY / TRENCH LAYOUT
Shows the physical
layout of E&I cable
trays and/or
trenches with
dimensions.
Designed in the 3D
PDS model using
EE Raceway, often
one of our biggest
inter-discipline
interface
challenges. Used
by construction to
install the cable
trays.
ELECTRICAL DESIGN DELIVERABLES -
CABLE ROUTING / POWER & EARTHING
LAYOUT
Shows the routing of
power and Earthing
cables and
associated items
such as earth
electrodes.
Used by
construction (with
the cable schedule)
to route cables and
install associated
items.
References
installation standard
details.
ELECTRICAL DESIGN DELIVERABLES -
LIGHTING & SMALL POWER LAYOUT
Shows the physical
layout of luminaries
(lighting fittings) and
socket outlets with
circuit details.
Used by
construction (with
the dist. board
schedules) to install
the luminaries and
socket outlets.
References
installation standard
details
ELECTRICAL DESIGN DELIVERABLES -
CABLE SCHEDULES
Separate Electrical and
Instrument cable
schedules - generated
either from SmartPlant®
Electrical or SmartPlant®
Instrumentation or other
database.
Lists cabling
requirements for the E&I
installation. ( E&I
equivalent of the piping
Line List)
Shows cable numbers,
cable types, lengths,
destinations, glands,
voltage levels & routing
details.
ELECTRICAL DESIGN DELIVERABLES -
TERMINATION DIAGRAMS
Can either be generated from the
SmartPlant® databases in a
report format or created as CAD
drawings.
Shows the terminals, wire
numbers & the order in which
cable cores are to be connected
at junction boxes, cabinets and
panels.
Used (in conjunction with the
cable schedule) by Construction
to install & terminate cables both
in the field & within buildings &
packages.
ELECTRICAL DESIGN DELIVERABLES -
HAZARDOUS AREA CLASSIFICATION
The Hazardous Area Classification drawing
is a collaboration with Mechanical and
Process and shows the extent of any
hazardous areas. On a Process Plant the
hazardous areas are usually caused by the
presence of flammable liquids and gas. The
drawings are used to ensure that
equipment which may ignite flammable
gases is located wherever possible in ‘safe’
or non-hazardous areas. Where equipment
must be located within the hazardous area
the equipment (including mechanical
equipment under new ATEX regulations)
must be manufactured and certified, such
that it will not cause heat, sparks or
excessive energy that may ignite any gases
present.
ELECTRICAL DESIGN DELIVERABLES -
OTHER DOCUMENTATION
Instrument Mounting Details and Electrical Details
Junction Box Frame Schedules & Details
Junction Box Schedules
Interconnection Diagrams
Cable Block Diagrams
Logic Diagrams
ELECTRICAL DESIGN ACTIVITIES
MTO & Material Control

Vendor Drawing Review

Interdiscipline Squad Checks

Design Specifications

E&I Contract

Construction Support

As-built Drawings
INTERFACES
Load List, Single Line Diagrams, Electrical
Electrical Eng Equipment.
Specifications, Contracts, Design/Drawing
verification.

Instrument Index, DCS, ESD, Fire & Gas, Telecoms

Control Systems Eng Philosophy/Specifications, Data Sheets, Heat Traced
Instruments.

Substation/Control Building, location, design, size &

CSA layout. E&I Equipment foundation design.
Underground E&I ducts, above grade support
steelwork for IPB, Circuit Breaker, Cable Trays, etc.

Input to RFQs, scope of E&I work, vendor data,

Mechanical location of vendor furnished E&I equipment, Qty &
type of electrical supplies and interface points.
INTERFACES

Input to RFQs, scope of E&I work, vendor data, location of

Mechanical vendor furnished E&I equipment, Qty & type of electrical

Piping Plot Layout, Space reservation for cable trays and trenches,
Heat Traced lines, PRDS, metering , in-line instruments.

Process Equipment List, P&IDs, Control Philosophy, Hazardous Area

Classification, SIL.

E&I Installation Contract, Construction Support,

Construction
Technical Queries, As-builts

Commissioning Home office/site support

INTERFACES

Client Operations, Project, Engineers

Document Control (DC) Document review matrix, document issue system, Squad
checks

Project Controls Estimating, Progressing (EZTrac), Manhour Control,

Project Management Schedule
AUTOMATION TOOLS
3D PDS® (EE Raceway & Equipment Modeling) / PDMS

Microstation® (2D drawing production) / Auto Cad

SmartPlant® Electrical

SmartPlant® Instrumentation

MaterialManager®

Aveva

Various equipment manufacturer programs e.g., for lighting and electrical trace heating
design
SEE THE BIG PICTURE
Consider what effects your equipment will have on other disciplines.
Example, this transformer will require good plot access and sufficient
plot space at its final location to enable the heavy haul contractor
deliver and position the transformer in place.
RISK - DEVIATING FROM THE CONTRACT
• Understand what is required by the Contract for your discipline

• Ensure equipment, materials and design match what is required by the

Contract. If you exceed the Contract requirements it’s Contractor’s/
Consultants money, not the Clients you are spending!

• Don’t do something just because that’s the way you did it on the last
project.

• Aim for the lowest cost, safe solution that complies with the Contract.

• Don’t undertake additional work without raising a deviation and getting

projects approval.
PURPOSE OF LOAD LIST (LOAD
SCHEDULE) & SUMMARY SHEETS
• Distribution of Electrical loads sorted by switchgear buses and DBs

• Summarizes the maximum and peak load calculations for the project

• Proper loading of the transformers & switchboards

• Optimally sizing the transformer & switchboards

• EDG sizing
DEFINITION ……………

• Continuous load( C ) : Loads which are continuously in operation under normal

plant operation

• Intermittent load ( I ) :Loads which are powered for intermittent operation for
intermittent pumping, storage , loading etc., Example : Loading/unloading
pumps, MOVs

• Standby load ( S) :Loads which are spare/back up to the continuous and

intermittent duty loads.

• Diversity factor : It is a factor that depends upon the operating cycle and shall
be normally applicable to power feeders

• Load type : M-Motor, H-Heater, F-Feeder, L-Lighting

DEFINITION ……………
• Absorbed Normal: This is the mechanical power absorbed by the load
and is less than the rated kW load.

• Load Factor : This is the ratio of the absorbed Normal kW to the rated load
kW and which gives an indication about how much percentage the
consumer is loaded.

• Rated kW : This the standard motor rating nearest to the Final mechanical
load including design margin.

• Efficiency & Power factor: These are the standard values to be obtained
from motor manufacturers at various percentage of loads. For heater loads
this shall be considered as 1. For Lighting loads, efficiency shall be
considered as 1.
BASIC DESIGN DATA

• Equipment list from process

• Various packages loads(static, rotating & HVAC) from mechanical

• Instrument loads for UPS & non-UPS supply

• Telecom loads for UPS & Non UPS supply

• Cathodic protection from Metallurgy

• HSE Loads

• Voltage levels of the plant –As per Electrical design basis & Key SLD
TYPICAL ELECTRICAL LOAD SCHEDULE &
SUMMARY SHEET

C:\Users\Sanket\Desktop\RANJAN PRESENTATION\LOAD LIST\LOAD LIST AND

SLD
SLD FOR LOAD LIST
ASSIGNMENT 2

PREPARE YOUR OWN LOAD LIST

DRAW SLD AND CONSIDER MOTOR, LIGHTING, SMALL
POWER LOAD.

CALCULATE TRANSFORMER RATING

TRANSFORMER SIZING

kVA Rating

Transformer kVA rating reqd.(min) = Peak kVA * Load growth margin * Future
spare margin
Load growth margin & Future spare margin shall be considered as per Client’s
spec and if nothing is specified, 10% margin

•Final rating taking into account transformer losses is selected based on the
standard ratings as indicated in IEC60076-1

% Impedance
Minimum short circuit impedance shall be selected from Table-1 of IEC 60076-5
based on the standard transformer rating . Manufacturer’s tolerance to be applied
as per IEC -60076-0
TRANSFORMER SIZING

Short circuit capacity

The Selected impedance value with the tolerance to be verified by
performing short-circuit study and shall be decided based on the
satisfactory study results

Voltage drop criteria

Permissible voltage drop at the switchboard bus shall be verified for
the largest motor starting condition with all the base loads in operation
by load flow studies.
Rated kVA capacity of the transformer shall then be determined based
on the above.

Voltage ratio
Secondary voltage is normally higher than the system voltage to take
care of the voltage regulation from no load to full load condition.
TRANSFORMER SIZING
Vector group
Vector groups of transformer are as indicated in IEC-60076-1 Annexure-D
However preferred vector groups are as follows:
Distribution transformers( Step down) Dyn11
Generator transformer (step up) YNd1
EHV to MV step down transformer Yd1 with ZN yn1(for Grounding &
secondary)
distribution
EHV to MV step down transformer Yd1 with ZN (for grounding)

Type of cooling
For various cooling methods refer IEC 60076-2 and normally used cooling
methods are
Distribution transformer(<10MVA) ONAN
Distribution transformer(>10MVA) ONAN/ONAF
 TRANSFORMER SIZING

Tap Changer

For Grid transformers/Generator transformer ON load tap changer(OLTC)

For Distribution transformer OFF Circuit tap changer(OCTC)

Taping range (Normal) +5% to -5% in steps of 2.5%

+10% to -10% in steps of 5%

EDG SIZING

kVA Rating

EDG kVA rating reqd.(min) = Peak kVA * Load growth margin * Future
spare margin
Load growth margin & Future spare margin shall be considered as
per Client’s specification and if nothing is specified, 20% to 25%
margin to be considered

Voltage and frequency

Terminal voltage shall generally match with the utilization voltage of
the emergency loads and incase if MV (IE) 3.3kV OR 6.6kV is
considered, the LV loads shall be fed through step down transformer.
EDG SIZING

• STARTING OF LARGEST MOTOR WITH BASE LOAD

The EDG sizing shall be checked with respect to allowable voltage dip at the
terminal of the largest motor being started and shall generally be within 20% of
rated voltage

• SIZING BASED ON MAXIMUM ACTIVE POWER REQUIRED DURING

STARTING OF LARGEST MOTOR

• BASED ON MAXIMUM ALLOWABLE SHORT TIME OVERLOAD IN DG SET

DURING STARTING OF LARGEST MOTOR

• KW AND LOAD LIST POWER FACTOR ( STANDARD DG RATING IN KVA

AT .8 PF)
EDG RATING

•KVA – 1000kVA

• Voltage – 415 V

• Power factor – 0.8

•Frequency – 50 Hz ( no of poles 4 & Engine RPM 1500 )

•Duty ( Emergency / continuous )

( ISO 8528-01)
•Over Load
ALTERNATOR RATING
•KVA – 1000kVA

• Voltage – 415 V

• Power factor – 0.8

•Frequency – 50 Hz

•Insulation class – H

•Ambient temp.

•Duty

•Excitation system

•Short circuit withstand rating

ASSIGNMENT

DG KVA / KW / PF / CURRENT
IMPORTANCE OF PF AND KW IN
GENERATOR SELECTION
•KW load is derived from Engine
• KVAR is derived from Alternator
1)Alternator – 415 V,1000kVA, P.F. 0.8, 800kW, Amp – 1374 A

2) If P.F. is increased to 0.9 with no change in KW:

800 KW, 900 KVA, 1252 A.
Correct selection ?
3) Now KW is increased to 900 KW:
900 KW, P.F. 0.9, 1000 KVA, Amp -1374 A
Correct selection ?
4) If P.F. becomes 0.7 with no change in KW:
800 KW, 1142 KVA, 1589 A.
Correct selection ?
IMPORTANCE OF PF AND KW IN
GENERATOR SELECTION
•KW load is derived from Engine
• KVAR is derived from Alternator
1)Alternator – 415 V,1000kVA, P.F. 0.8, 800kW, Amp – 1400 A

2) If P.F. is increased to 0.9 with no change in KW:

800 KW, 888 KVA, 1250A.

3) Now KW is increased to 900 KW:

900 KW, P.F. 0.9, 1000 KVA, Amp -1400 A

4) If P.F. becomes 0.7 with no change in KW:

800 KW, 1142 KVA, 1590A.