HINDUSTAN PETROLEUM CORPORATION LIMITED MUMBAI REFINERY DHT PROJECT ENGINEERING DESIGN BASIS ELECTRICAL

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1 Sheet 1 of 40 HINDUSTAN PETROLEUM CORPORATION LIMITED MUMBAI REFINERY DHT PROJECT ENGINEERING DESIGN BASIS ELECTRICAL DOCUMENT NO: 44LK /E.02/0001/A4 Rev No. Issue Date Pages Rev Description Prepared By Checked By Approved By A Issued for Approval MSJ VDV RBD B Issued for Engineering MSJ VDV VDV C Revised after incorporating HPCL comments & Issued for FEED Approved by HPCL & Issued for Implementation MSJ VDV VDV MSJ VDV VDV

2 CONTENTS LIST LIST OF ENCLOSURES NO. OF SHEETS ENCLOSED (YES / NO) A EXISTING DATA 2 YES B GENERAL INFORMATION 4 YES C RECEIVING SWITCHYARD 3 YES D STANDBY / CAPTIVE POWER GENERATION 1 YES E H. T. SWITCHGEAR 1 YES F MAIN / DISTRIBUTION TRANSFORMER 1 YES G POWER CONTROL CENTRE (PCC) 2 YES H MOTOR CONTROL CENTRE (MCC/PMCC) 2 YES I H.T. MOTORS 1 YES J L.T. MOTORS 1 YES K CABLES & ACCESSORIES 1 YES L DISTRIBUTION BOARDS (MLDB, MPDB, LDB, SLDB, PDB) 1 YES M CONTROL STATIONS 1 YES N LIGHT FITTINGS 1 YES O BATTERY & BATTERY CHARGER 1 YES P CAPACITORS 1 YES Q PUBLIC ADDRESS SYSTEM 1 YES R TELEPHONE SYSTEM 1 YES S ELECTRICAL INSTALLATION 1 YES T EARTHING 1 YES U UPS 1 YES V FIRE ALARM SYSTEM 1 YES W VARIABLE SPEED DRIVES 1 YES ANNEXURE I (SCHEME FOR VSDs UP TO 75 KW RATING) 1 YES DesignBasis_44LK5100_Rev0.doc Page 2 of 40

3 EXISTING DATA 1.0 HOOK UP WITH EXISTING SWITCHGEAR IS REQUIRED? REQUIRED 2.0 DETAILS OF EXISTING HV / MV SWITCHGEAR 2.1 VOLTAGE LEVEL & FREQUENCY 22 KV / 6.6 KV, 50HZ 2.2 FAULT LEVEL & BUSBAR RATING OF EXISTING HV/MV SWITCHGEAR PANELS. 2.3 SPARE HV/MV BREAKER PANELS AVAILABLE FOR USE. 2.4 SPARE BREAKER PANEL CONTAINS REQUIRED BREAKER, CT S, PT S, RELAYS, METERING ETC MVA for 3 sec. FOR 22 KV 350 MVA for 3 sec. FOR 6.6 KV * * 2.5 SPACE AVAILABILITY FOR EXPANSION. * 3.0 DETAILS OF EXISTING LV SWITCHGEAR 3.1 FAULT LEVEL & BUSBAR RATING OF EXISTING LV SWITCHGEAR PANELS. 50 KA FOR 1 SEC FOR 415V 3.2 SPARE LV BREAKER PANELS AVAILABLE FOR USE. * 3.3 SPARE BREAKER PANEL CONTAINS REQUIRED BREAKER, CT S, PT S, RELAYS, METERING ETC. * 3.4 SPACE AVAILABILITY FOR EXPANSION. * 4.0 DETAILS OF EXISTING FIRE ALARM SYSTEM * 4.1 HOOK UP WITH EXISTING FIRE ALARM PANEL REQUIRED? 4.2 MAKE & MODEL OF EXISTING FIRE ALARM PANEL. 4.3 TYPE OF EXISTING FIRE ALARM PANEL. 4.4 SPARE CARD AVAILABLE IN EXISTING FIRE ALARM PANEL FOR HOOK UP OF NEW DETECTORS? 5.0 DETAILS OF EXISTING TELEPHONE SYSTEM * 5.1 NEW TELEPHONES TO BE CONNECTED TO EXISTING EPABX? 5.2 MAKE & MODEL OF EXISTING EPABX. 6.0 CABLE LAYING ** 6.1 NEW CABLE TRAYS TO BE LAID ON EXISTING PIPE RACK? DesignBasis_44LK5100_Rev0.doc Page 3 of 40

4 6.2 MAXIMUM LOAD, WHICH THE EXISTING PIPE RACK CAN TAKE? 6.3 EXISTING CABLE TRAYS TO BE USED FOR LAYING OF NEW CABLES? 6.4 SPACE AVAILABLE ON EXISTING CABLE TRAYS IN CASE EXISTING CABLE TRAYS ARE TO BE USED. NOTE: * - INFORMATION TO BE FURNISHED BY CLIENT. ** - SHALL BE DECIDED DURING DETAIL ENGINEERING. DesignBasis_44LK5100_Rev0.doc Page 4 of 40

5 GENERAL NFORMATION 1.0 SITE CONDITIONS 1.1 ALTITUDE: Above MSL 6.71 Meters 1.2 AMBIENT TEMP MAXIMUM: 40 o C MINIMUM: 12 o C 1.3 RECOMMENDED DESIGN TEMP. FOR ELECTRICAL EQUIPMENT S (IS 9676) 45 o C 1.4 SOIL RESISTIVITY Later (After Soil Resistivity test). 1.5 SESIMIC ZONE (IS-1893 Part-1) Zone-III 1.6 RELATIVE HUMIDITY 95% 1.7 SITE ENVIRONMENT Tropicalized, Marine, with presence of corrosive fumes. 2.0 ELECTRICAL DETAILS OF INCOMING SUPPLY 2.1 VOLTAGE & FREQUENCY AT POINT OF SUPPLY 110 KV 2.2 FAULT LEVEL (Sym) AT POINT OF SUPPLY (DESIGNED & ACTUAL) DESIGNED - ** / * ACTUAL - ** / * 2.3 NEUTRAL EARTHING AT SUPPLY END SOLIDLY EARTHED 2.4 FLUCTUATION VOLTAGE ± 10% FREQUENCY ± 5% COMBINED ± 10% 2.5 MINIMUM LOAD POWER FACTOR STIPULATED BY SUPPLY AUTHORITY PARALLEL OPERATION OF INCOMERS Momentary Paralleling At 6.6 kv and 415 V. 3.0 DETAILS OF ELECTRICAL DISTRIBUTION SYSTEM 3.1 PRIMARY DISTRIBUTION VOLTAGE LEVEL: VOLTAGE: 6.6 kv FREQUENCY: 50 Hz PRIMARY DISTRIBUTION SYSTEM NEUTRAL EARTHING: Resistance Earthing (Thru NGR) 3.2 INTERMEDIATE DISTRIBUTION VOLTAGE LEVEL VOLTAGE 6.6 kv DesignBasis_44LK5100_Rev0.doc Page 5 of 40

6 GENERAL NFORMATION INTERMEDIATE DISTRIBUTION SYSTEM NEUTRAL EARTHING Resistance Earthing (Thru NGR) EARTH FAULT CURRENT LIMITED TO: 100 A 4.0 LT. POWER DISTRIBUTION SYSTEM 4.1 VOLTAGE 415 V A.C 3 Phase. 4.2 NEUTRAL EARTHING Solidly Earthed 4.3 VOLTAGE AND FREQUENCY VARIATION: A.C SYSTEM a) VOLTAGE: ± 10 % b) FREQUENCY: ± 5 % c) COMBINED VOLTAGE AND FREQUENCY ± 10 % D.C SYSTEM (At system output terminals) a) Electrical control, lighting etc. ± 1 % at Charger terminals ± 10 % at Battery terminals (Limits during charging/discharging cycle) b) Instrumentation power supplies: ± 1 % at Charger terminals ± 10 % at Battery terminals (Limits during charging/discharging cycle) 5.0 VOLTAGE FOR LIGHTING DISTRIBUTION 5.1 NORMAL LIGHTING a) VOLTAGE b) FREQUENCY c) SOURCE 5.2 EMERGENCY LIGHTING a) VOLTAGE b) SOURCE c) APPROX. % 5.3 CRITICAL LIGHTING a) VOLTAGE b) SOURCE c) LOCATIONS 240 V A.C 1 Phase 50 Hz Existing power supply available from TEC 240 V A.C 1 Phase Emergency PCC. 15% 220 V D.C Battery Back-Up Light fittings / Battery Charger (SEE NOTE 1) Escape Routes, Substations, Control rooms, Near Incomers of 6.6 kv Swgr & 415V PCC 5.4 LIGHTING TRANSFORMER /S TO BE PROVIDED Yes / No (415 V / 415 V) DesignBasis_44LK5100_Rev0.doc Page 6 of 40

7 GENERAL NFORMATION 6.0 CONTROL SUPPLY FOR ELECTRICAL SYSTEM 6.1 HIGH TENSION CIRCUIT BREAKERS a) SPRING CHARGING MOTORS 110 V DC b) CLOSING CIRCUITS 110 V DC c) TRIP CIRCUITS 110 V DC d) ALARM 110 V DC e) INDICATION 110 V DC f) RELAY AUX. SUPPLY 110 V DC g) HEATERS IN PANELS 240 V A.C 1 Phase h) CONTROL CIRCUIT 110 V DC 6.2 LOW TENSION CIRCUIT BREAKERS (PCC / PMCC) a) SPRING CHARGING MOTORS 110 V DC b) CLOSING CIRCUIT 110 V DC c) TRIP CIRCUIT 110 V DC d) ALARM 110 V DC e) INDICATION 110 V DC f) RELAY AUX. SUPPLY 110 V DC g) HEATERS IN PANEL 240 V A.C 1 Phase h) CONTROL CIRCUIT 110 V DC DesignBasis_44LK5100_Rev0.doc Page 7 of 40

8 GENERAL NFORMATION 6.3 LOW TENSION MOTORS CONTROLLED BY CONTACTORS (MCC) a) COIL CIRCUIT VOLTAGE 240 V A.C 1 Phase (Refer Note 2) b) INDICATIONS 240 V A.C 1 Phase c) ALARM 240 V A.C 1 Phase d) SPACE HEATER CIRCUIT 240 V A.C 1 Phase 7.0 POWER SUPPLY TO LOCAL CONTROL PANELS FOR PACKAGE UNITS 415 V A.C, 50 Hz, 3 Phase. (Any other power supply required shall be derived within the panel by package vendor) 8.0 SOURCE OF SUPPLY FOR CRITICAL LOADS UPS 9.0 PAINTING FOR ELECTRICAL EQUIPMENT S & STRUCTURES 9.1 OUTDOOR EQUIPMENT EPOXY BASED POWDER COATED 9.2 INDOOR EQUIPMENT EPOXY BASED POWDER COATED 9.3 CABLE TRAY & STRUCTURAL STEEL-MATERIAL OF CONSTRUCTION CABLE TRAY SUPPORTS SHALL BE EPOXY PAINTED, PREFABRICATED FRP/GI TRAYS (SEE NOTE 3) 9.4 SHADE 632 OF IS: GENERAL 10.1 CORPORATE STANDARD TO BE FOLLOWED 10.2 STANDARDS OTHER THAN 'IS' IF TO BE FOLLOWED Jacobs Standards to be followed alongwith IS, OISD, NFPA. IEC, (IEEE wherever IEC does not deal) TIE UP WITH EXISTING SYSTEM IF APPLICABLE YES 11.0 TYPE OF ELECTRICAL EQUIPMENT S TO BE USED IN HAZARDOUS AREAS DesignBasis_44LK5100_Rev0.doc Page 8 of 40

9 GENERAL NFORMATION a) ZONE 0 As defined in Engineering Design Guidelines Doc. No. 44LK /E.02/0002/A4 b) ZONE 1 c) ZONE ACCURACY CLASS OF METERS a) REVENUE METERS CL. 0.5 b) kw METER CL. 0.5 c) AMMETER CL. 1 d) FIELD AMMETERS CL MOTORS Up to & including 160 kw 415 V A.C, 50 Hz, 3 Phase 14.0 CABLE-COLOUR CODES POWER RESPECTIVE PHASE NEUTRAL POWER CONTROL, METERING SAFETY SWITCHES / EMERGENCY EARTH Above 160 kw & 6 MW 6.6 kv A.C, 50Hz, 3 Phase. ** RED / YELLOW / BLUE BLACK GREY ORANGE GREEN / YELLOW WITH GREEN STRIPES 15.0 INDICATION LAMP- LED TYPE OFF ON FAULT STATUS PHASE 16.0 PUSH BUTTON START STOP RESET INCREASE / DECREASE GREEN RED AMBER / YELLOW WHITE RED,YELLOW, BLUE GREEN RED YELLOW / WHITE BLACK NOTES : 1) SEPARATE BATTERY & CHARGER SHALL BE PROVIDED FOR CRITICAL LIGHTING. 2) FOR MOTORS <= 55 KW (WHICH ARE HAVING DOL STARTER) THE CONTROL SUPPLY FOR MOTOR FEEDERS SHALL BE 110V DC WHEREVER THE LENGTH OF CABLES IS MORE THAN 500 MTRS. 3) CABLE TRAYS INSIDE SUBSTATION BUILDINGS SHALL BE PREFABRICATED GI AND CABLE TRAYS OUTSIDE SUBSTATION BUILDINGS SHALL BE PREFABRICATED FRP. DesignBasis_44LK5100_Rev0.doc Page 9 of 40

10 GENERAL NFORMATION 4) PAINTING FOR OUTDOOR EQUIPMENTS SHALL BE WITH SHADE NO 632 AS PER IS:5 AND FOR INDOOR EQUIPMENTS SHALL BE SHADE NO 631 AS PER IS:5. 5) IN CASE OF 4 CORE LIGHTING CABLES THE COLOUR CODE SHALL BE RED & YELLOW FOR PHASE, BLACK FOR NEUTRAL AND GREEN FOR EARTHING. ONE NO CORE SHALL BE SPARE. * - INFORMATION TO BE FURNISHED BY CLIENT. ** - SHALL BE DECIDED DURING DETAIL ENGINEERING. DesignBasis_44LK5100_Rev0.doc Page 10 of 40

11 RECEIVING GIS 1.0 EQUIPMENT S TO BE INSTALLED BY ELECTRIC AUTHORITY 1.1 LIST OF EQUIPMENT S TO BE SUPPLIED BY ELECTRIC AUTHORITY CT / PT/ TVM 1.2 INSTALLATION (OUTDOOR / INDOOR) INDOOR 1.3 REQUIREMENT OF ROOM FOR INSTALLING CIRCUIT BREAKER / RELAY PANEL / METERING PANEL 1.4 AREA REQUIRED FOR RECEIVING YARD TO ACCOMMODATE EQUIPMENT S SUPPLIED BY ELECTRIC AUTHORITY 1.5 INCASE METERING EQUIPMENT TO BE SUPPLIED BY CLIENT, DETAILS OF THE SAME ** / * ** / * NA 2.0 INCOMING LINE 1. WITH CABLES 2. OVERHEAD LINES SINGLE CIRCUIT DOUBLE CIRCUIT 2.1 IN CASE OF DOUBLE CIRCUIT a) OPERATION b) BUS COUPLER c) NO. OF OUTGOING BAYS IN GIS d) PROVISION FOR FUTURE IN GIS 3.0 GIS DESIGN PARTICULARS * * INDEPENDENT / PARALLEL ISOLATOR / CIRCUIT BREAKER ** ** ** New GIS shall be identical in all respects to the existing one. Additionally pressure gauges along with pressure switches should be available. 1. NOMINAL SYSTEM VOLTAGE 110 KV 2. HIGHEST SYSTEM VOLTAGE 123 KV 3. SYM. FAULT LEVEL AT NOMINAL VOLTAGE ** / * MVA 4. BASIC INSULATION LEVEL 650 KVP 5. AUXILIARY POWER CONTROL LIGHTING 6. CREEPAGE DISTANCE 6.1 FOR ENCLOSED INSULATORS 6.2 FOR EXPOSED INSULATORS 415 V AC 110 V DC 240 V AC 12 mm / kv 31 mm / kv DesignBasis_44LK5100_Rev0.doc Page 11 of 40

12 RECEIVING GIS 7. MINIMUM CLEARANCES i) PHASE TO PHASE ii) MINIMUM CLEARANCES BETWEEN POLES TO EARTH ** 8. BUS BAR ARRANGEMENT DOUBLE BUS ARRANGEMENT 9. BUS BAR TYPE NA 10. MATERIAL COPPER 11. ENCLOSURE CONFIGURATION 1-PHASE / 3-PHASE ** / * 12. TYPE OF MATERIAL FOR ENCLOSURE NON CORROSIVE ALUMINIUM 13. DEGREE OF PROTECTION FOR GIS IP 4X 14. MAXIMUM DESIGN PRESSURE OF ENCLOSURE ** 15. INTERNAL FAULT AND PRESSURE LIMITING DEVICES 16. OPERATING MECHANISM 16.1 DISCONNECT AND GROUNDING SWITCHES 16.2 CIRCUIT BREAKER 16.3 OFF CIRCUIT ISOLATOR 17. SEALING END BOX FOR UNDERGROUND CABLE TERMINATION REQUIRED COMMON / SEPARATE MOTORISED MOTORISED MOTORISED REQUIRED 18. TYPE OF CABLE (XLPE) XLPE 19. SF6-TO-OIL TRANSFORMER TERMINATION REQUIRED 20. GAS INSULATED SURGE ARRESTERS REQUIRED 21. TIE UP WITH EXISTING GIS REQUIRED 4.0 GROUNDING SYSTEM IEEE 80 & IEEE GROUNDING MATERIAL COPPER 4.2 ALLOWABLE GROUND INSULATION ** 4.3 MAGNITUDE OF FAULT CURRENT 40 KA 4.4 DURATION 1.0 sec. for grounding material size & 0.6 sec for step / touch potential calculations 4.5 CONNECTION WITH EXISTING GROUNDING SYSTEM OF GIS REQUIRED 5.0 LIGHTING IN GIS SUBSTATION 5.1 ILLUMINATION LEVEL REQUIRED 200 LUX DesignBasis_44LK5100_Rev0.doc Page 12 of 40

13 RECEIVING GIS 5.2 TYPE OF LIGHTING FITTING Medium Bay / ** 5.3 TYPE OF LAMPS HPMV 6.0 CABLE TRENCHES TYPE COVER RCC RCC 7.0 CABLE TRAYS WITHIN TRENCH TYPE REQUIRED / NOT REQUIRED GI LADDER TYPE NOTES : 1) PROTECTION RELAY PANELS FOR GIS SHALL BE KEPT TOUCHING WITH WALL AND BACK ACCESS SHALL NOT BE AVAILABLE FOR MAINTENANCE PURPOSE. VENDOR TO ENSURE THAT MAINTENANCE SHALL BE POSSIBLE FROM FRONT SIDE OF THE PANEL. * - INFORMATION TO BE FURNISHED BY CLIENT. ** - SHALL BE DECIDED DURING DETAIL ENGINEERING DesignBasis_44LK5100_Rev0.doc Page 13 of 40

14 STANDBY / CAPTIVE POWER GENERATION 1.0 GENERATION VOLTAGE 415V 2.0 PRIME MOVER TYPE EMERGENCY DG SET 3.0 TYPE OF STARTING AMF 4.0 NO. OF SETS 1 NO. 5.0 MODE OF OPERATION 5.1 INDEPENDENT REQUIRED 5.2 SYNCHRONIZED NA 6.0 PARALLELING WITH GRID NA 7.0 NEUTRAL EARTHING SOLID 8.0 SERVICE 8.1 UNDER MAINS FAILURE ONLY CHANGE OVER SCHEME REQUIRED 8.2 POWER CUT NA 8.3 CONTINUOUS NA NOTES : 1) COMMON EMERGENCY DG SET SHALL BE PROVIDED FOR PROVIDING EMERGENCY LIGHTING IN MAIN SUBSTATION, CONTROL ROOM, DHT, HGU, SULPHUR RECOVERY BLOCK AND OSBL AREAS. EEMERGENCY DG SHALL SUPPLY POWER TO EMERGENCY PCC. SWITCH FUSE FEEDERS SHALL BE PROVIDED IN EMERGENCY PCC FOR GIVING SUPPLY TO EMERGENCY BUS OF MAIN LIGHTING DISTRIBUTION BOARDS. 2) * - INFORMATION TO BE FURNISHED BY CLIENT. DesignBasis_44LK5100_Rev0.doc Page 14 of 40

15 HT SWITCHGEAR (INDOOR) 1.0 TYPE OF CIRCUIT BREAKER BASED ON QUENCHING MEDIUM (VACUUM, SF6, OIL, AIR) kv NOT APPLICABLE kv Vacuum 2.0 BUS BAR 6.6 KV, 50 HZ, TP (SINGLE BUSBAR SYSTEM) 2.1 MATERIAL/NOS. Copper (6.6 kv, TP, Single Busbar System) 2.2 INSULATION SUCH AS CAST RESIN Raychem sleeving required with shrouds at joints. 2.3 FAULT LEVEL AND DURATION kv NOT APPLICABLE kv 450 MVA for 3 sec. 3.0 PROTECTIVE RELAYS 3.1 INCOMING FEEDER 3.2 BUS COUPLER 3.3 OUTGOING FEEDERS As defined in Engineering TRANSFORMER FEEDER Design Guidelines Document No TIE FEEDER 44LK /E.02/0002/A MOTOR FEEDERS CAPACITOR FEEDER 4.0 METERING 4.1 INCOMING FEEDER 4.2 BUS COUPLER 4.3 OUTGOING FEEDERS As defined in Engineering TRANSFORMER FEEDER Design Guidelines Document No TIE FEEDER 44LK /E.02/0002/A MOTOR FEEDERS CAPACITOR FEEDER 5.0 TYPE OF CABLE TERMINATION Heat Shrinkable (Raychem make) 6.0 PROVISION FOR EXTENSION Required / Not Required DesignBasis_44LK5100_Rev0.doc Page 15 of 40

16 HT SWITCHGEAR (INDOOR) 7.0 EXECUTION Draw out 8.0 SWITCHGEARS FOR MOTOR CONTROL FEEDERS Circuit breaker 9.0 AUTO CHANGEOVER SCHEME Required / Not Required 10.0 PROVISION OF REMOTE ALARM / ANNUNCIATOR PANEL FOR HT SWITCHGEAR 11.0 RELAYS SHALL BE COMMUNICABLE TYPE AND SHALL COMMUNICATE WITH DCS / ECS / MMI. Required / Not Required YES / NO (USING IEC PROTOCOL) NOTE: 1) * - INFORMATION TO BE FURNISHED BY CLIENT. DesignBasis_44LK5100_Rev0.doc Page 16 of 40

17 MAIN / DISTRIBUTION TRANSFORMER 1.0 SELECTION OF TRANSFORMERS 1.1 SPARE CAPACITY TO BE CONSIDERED 20% 1.2 STANDBY TRANSFORMERS 100% 1.3 NORMAL LOADING OF EACH TRANSFORMER 40% of the capacity 1.4 TYPE OF COOLING ONAN / ONAF 2.0 VOLTAGE RATIO AT NO LOAD 110 / 6.9 kv, 6.6 / kv 3.0 TAP CHANGER MAIN TRAFO DISTRIB: TRAFO 3.1 OFF CIRCUIT For Distribution transformer (6.6 / kv) 3.2 ON LOAD For Power transformer (110 / 6.9 kv) 4.0 RANGE OF TAP CHANGING +/- 7.5 % in steps of 2.5% For Distribution transformer +/- 10% in steps of 1.25% For Power transformer 5.0 PRIMARY AND SECONDARY TERMINAL ARRANGEMENT 5.1 OVERHEAD CONDUCTOR Not Applicable 5.2 CABLE PRIMARY: GIS Duct on Primary side of 110 / 6.9 kv & Cables on Primary side of 6.6 / kv transformers SECONDARY: Cable for 110 / 6.9 kv transformers & 6.6 / kv transformers rated below 1.6 MVA 5.3 BUS DUCT For secondary of 6.6 / kv transformers (1.6MVA and above) 6.0 NEUTRAL EARTH ARRANGEMENT For 110 / 6.9 kv transformer through NGR For 6.6 / kv transformer Solidly Grounded. 7.0 VECTOR GROUP Dyn TAP CHANGER-INCREASE/DECREASE CONTROL MAIN TRAFO Local tap changer control panel / RTCC DISTRIB: TRAFO Local tap changer wheel NOTES : 1) DISTRIBUTION TRANSFORMERS SHALL BE EITHER OIL FILLED OR DRY TYPE TRANSFORMERS. 2) DISTRIBUTION TRANSFORMERS SHALL BE OF MINIMUM 2.5 MVA RATING. DesignBasis_44LK5100_Rev0.doc Page 17 of 40

18 POWER CONTROL CENTRE (PCC & PMCC) 1.0 TYPE OF CIRCUIT BREAKER 1.1 DRAWOUT / NON DRAWOUT Draw Out. 1.2 TPN / 4 POLE TPN 2.0 BUS BAR 415 V, TPN, 50 HZ, 50 KA FOR 1 SEC 2.1 MATERIAL. Copper 2.2 PVC SLEEVING Required / Not Required 2.3 BUS BAR SUPPORT Epoxy Resin / SMC / FRP 3.0 CONSTRUCTION FORM 3 B Construction 3.1 COMPARTMETALISED / NON COMPARMENTALISED Compartmentalized 3.2 OUTGOING FEEDERS Draw out / Non Draw out 3.3 BUS BAR LOCATION Top (Including Neutral Busbar) See Note PAD LOCKING FOR OUTGOING FEEDERS Required / Not Required 3.5 SIZE OF INSTRUMENTS Minimum 96 x 96 Sq. mm for analogue instruments 3.6 ENCLOSURE a) MATERIAL (SHEET STEEL, CAST IRON) CRCA Sheet Steel b) PROTECTION CLASS Min. IP EQUIPMENT SELECTION 4.1 RATING UPTO WHICH SWITCH DISCONNECTOR FUSE TO BE USED 4.2 RATINGS ABOVE WHICH ACB TO BE USED As specified in Engineering Design Guidelines Doc. No. 44LK /E.02/0002/A4. For feeders rated above 400 A and for motors rated above 55 kw. 5.0 PROTECTIVE RELAYS 5.1 INCOMING FEEDERS 5.2 BUS COUPLER 5.3 POWER FEEDERS As specified in Engineering Design 5.4 FEEDER TO MCC Guidelines Doc. No.: 5.5 FEEDER TO MLDB 44LK /E.02/0002/A4 5.6 FEEDER TO CAPACITOR BOARD (Discreet Numerical relays shall be 5.7 FEEDER TO MOTORS provided instead of releases for all 5.8 THERMISTOR RELAY/ COMPREHENSIVE MPR FOR MOTORS 75KW & ABOVE ACBs) DesignBasis_44LK5100_Rev0.doc Page 18 of 40

19 POWER CONTROL CENTRE (PCC & PMCC) 6.0 METERING 6.1 INCOMING FEEDERS 6.2 BUS COUPLER 6.3 POWER FEEDERS As specified in Engineering Design 6.4 FEEDER TO MCC Guidelines Doc. No.: 6.5 FEEDER TO MPDB 44LK /E.02/0002/A4 6.6 FEEDER TO CAPACITOR BOARD 6.7 FEEDER TO MOTOR 7.0 INDICATING LAMPS 7.1 INCOMERS As specified in Engineering Design 7.2 POWER FEEDERS Guidelines Doc. No.: 7.3 MOTOR FEEDERS 44LK /E.02/0002/A4 8.0 CURRENT TRANSFORMER SECONDARY 8.1 PROTECTION 1 A 8.2 METERING 1 A 9.0 POTENTIAL TRANSFORMER SECONDARY 110 V / 3 A.C 1 Phase 10.0 NO. OF FRONTS Single front for PCCs & PMCCs V MOTORS RATED ABOVE 55 KW & UPTO 160 KW 12.0 AUTOCHANGEOVER FACILITY AND SYNCHRO CHECK FACILITY SHALL BE PROVIDED. To be controlled from PCC / PMCC through ACB (Refer in Doc. No. 44LK /E.02/0002/A4). YES / NO 13.0 RELAYS SHALL BE COMMUNICABLE TYPE. YES 14.0 PROTOCOL OF COMMUNICATION FOR THE RELAYS. IEC NOTES : 1) FOR MOTOR FEEDERS ABOVE 55 KW NUMERICAL MOTOR PROTECTION RELAY WITH INBUILT CARD FOR ACCEPTING THERMISTOR INPUT SHALL BE PROVIDED. 2) IN CASE OF PCC / PMCC ALL OUTGOING FEEDERS SHALL BE MINIMUM 800A ACBS. 3) ANALOG AMMETERS ARE NOT REQUIRED FOR ALL PCC OUTGOING FEEDERS. 4) EARTH FAULT PROTECTION SHALL BE PROVIDED FOR ALL MOTOR FEEDERS. 5) THE VERTICAL NEUTRAL DROPPERS SHOULD BE AVAILABLE FOR ALL THE VERTICAL SECTIONS. DesignBasis_44LK5100_Rev0.doc Page 19 of 40

20 MOTOR CONTROL CENTRE (MCC) 1.0 TYPE Double Front 2.0 EXECUTION Draw out / Fixed 3.0 BUSBARS 415 V, TPN, 50 HZ, 50 KA FOR 1 SEC 3.1 MATERIAL Copper 3.2 PVC SLEEVING. Required / Not Required 3.3 BUS BAR SUPPORT Cast Resin / SMC / FRP 4.0 SEPARATE MARSHALLING CABINET Required / Not Required 5.0 LOCATION OF MAIN BUS BARS (TOP / BOTTOM) TOP (Including Neutral Busbar) See Note TYPE OF MOTOR STARTER a) DOL STARTER As specified in Engineering Design b) STAR / DELTA STARTER Guidelines Doc. No. 44LK /E.02/0002/A4 (Star Delta Starter not required) c) ANY OTHER TYPE Soft Starter. 7.0 MAXIMUM NO. OF FEEDERS PER PANEL TYPE OF ASSISTED STARTERS FOR MOTORS As specified in Engineering Design Guidelines Doc. No. 44LK /E.02/0002/A4 9.0 INCOMING FEEDERS 9.1 CIRCUIT BREAKER / SWITCH / SWITCHFUSE As specified in Engineering Design Guidelines Doc. No. 44LK /E.02/0002/A4 9.2 METERS (AMMETER, VOLTMETER, KWH, PF). 9.3 NOS. AND AMMETERS, SIZE 9.4 PROTECTION 10.0 OUTGOING FEEDERS 10.1 MOTOR FEEDERS CONTROL DEVICES ON COMPARTMENT DOOR Stop Push Button, BMR RESET PB, Ammeter, L/R Selector Switch INDICATION ON COMPARTMENT DOOR (ON / OFF / TRIP). ON / OFF / TRIP AMMETER ON MOTOR FEEDERS Required on all motor feeders DesignBasis_44LK5100_Rev0.doc Page 20 of 40

21 MOTOR CONTROL CENTRE (MCC) NO. & AMMETER SIZE ON MOTOR FEEDERS 1 No. / 72 X 72 Sq. mm Ammeter Selector Switch (ASS) for motors rated 37 kw and above CURRENT TRANSFORMER SECONDARY FOR METER & RELAYS CONTROL SUPPLY For Meter: 1 A For Relays: 1 A 240 V A.C 1 Phase SPARE FEEDERS 25% Spare feeders with min. one No. of each rating and type in each switchboard PAD LOCKING FOR ISOLATOR/MCCB/MPCB IN OFF POSITION. Required 10.2 SWITCHFUSE FEEDERS METERS NA 10.3 CONTROL TRANSFORMER FEEDER a) COMMON CONTROL TRANSFORMER FOR ENTIRE MCC b) WORKING & STANDBY CONTROL TRANSFORMER WITH CHANGE OVER SWITCH. c) CONTROL TRANSFORMER FOR EACH MOTOR FEEDER. No YES No FOUR POLE SWITCH / AUX. SWITCH IN ALL MOTOR FEEDERS FOR ISOLATING CONTROL SUPPLY Auxiliary switch with fuse and link 11.0 ELCB FOR EACH FEEDER Required 12.0 OTHER ACCESSORIES 12.1 CONTROL SUPPLY BUS BARS Wire Bus / Solid Bus 12.2 SPACE HEATER SUPPLY BUS BARS. Wire bus / Solid Bus 12.3 SPACE HEATER FOR MCC REQUIRED / NOT REQUIRED 13.0 ENCLOSURE: a) MATERIAL CRCA Sheet Steel / Cast Iron b) PROTECTION CLASS Minimum IP AUTOCHANGEOVER FACILITY AND SYNCHRO CHECK FACILITY SHALL BE PROVIDED. NOT REQUIRED IN MCC 15.0 RELAYS SHALL BE COMMUNICABLE TYPE YES DesignBasis_44LK5100_Rev0.doc Page 21 of 40

22 MOTOR CONTROL CENTRE (MCC) 16.0 PROTOCOL OF COMMUNICATION FOR THE RELAYS IEC MOTOR FEEDERS SHALL BE COMMUNICABLE TYPE NO 18.0 PROTOCOL OF COMMUNICATION FOR THE MOTOR FEEDERS NOT APPLICABLE NOTE : 1) SELECTOR SWITCH SHALL BE PROVIDED FOR TRIPPING & CLOSING OF BREAKERS DURING LOAD TRANSFER IN CASE OF MCCs. 2) FOR MOTORS <= 55 KW (WHICH ARE HAVING DOL STARTER) THE CONTROL SUPPLY FOR MOTOR FEEDERS SHALL BE 110V DC, WHEREVER THE LENGTH OF CABLES ARE MORE THAN 500 MTRS. 3) IN CASE OF MCC SWITCH FUSE UNITS SHALL BE USED FOR RATINGS UP TO 400A AND ACBS SHALL BE USED FOR RATING ABOVE 400A. 4) THE VERTICAL NEUTRAL DROPPERS SHOULD BE AVAILABLE FOR ALL THE VERTICAL SECTIONS. * - INFORMATION TO BE FURNISHED BY CLIENT. ** - SHALL BE DECIDED DURING DETAIL ENGINEERING. DesignBasis_44LK5100_Rev0.doc Page 22 of 40

23 H.T MOTORS 1.0 RATED VOLTAGE 6.6. KV 2.0 VOLTAGE AND FREQUENCY VARIATION ± 10 %V, ± 5 %Hz 3.0 COMBINED VOLTAGE AND FREQUENCY VARIATION ± 10 % 4.0 CLASS OF INSULATION & TEMP. RISE Class F with Temp. Rise limited to Class B 5.0 ENCLOSURE PROTECTION CLASS IPW TYPE OF ENCLOSURE As per Area Classification 7.0 TYPE OF COOLING (TEFC / CACA / CACW / TETV) TEFC / CACA As per Manufacturers Standard 8.0 TEMPERATURE DETECTORS FOR WINDING (RTD) Simplex / Duplex (2 nos per phase) 9.0 a) TEMPERATURE DETECTORS FOR BEARING b) DIAL TYPE LOCAL TEMP. INDICATOR FOR BEARINGS FAULT WITHSTAND CAPACITY FOR MAIN TERMINAL BOX Simplex / Duplex (1 each for DE & NDE bearing) Required 0.25 sec NEUTRAL TERMINAL BOX Required / Not Required 12.0 TYPE OF CABLE TERMINATION AT MOTOR END Heat Shrinkable (Phase Segregated) 13.0 NO. OF COLD STARTS PER HOUR 3 Nos. (min) / hour, Equally Spaced 14.0 NO. OF HOT STARTS PER HOUR 2 Nos. (min) / hour, Equally Spaced 15.0 SPECIAL WINDING TREATMENT Suitable for corrosive atmosphere with Epoxy Gel treatment on winding overhang 16.0 SEPARATE TERMINAL BOX FOR a) SPACE HEATER Required / Not Required b) RTD Required / Not Required 17.0 AUXILIARY NAME PLATE Required (SS) NOTES : 1) SAFE STALLING TIME OF MOTOR SHALL BE MINIMUM 2.5 SECS MORE THAN THE STARTING TIME OF MOTOR AT 80% VOLTAGE. 2) HT MOTORS IN HAZARDOUS AREAS SHALL BE EITHER WITH Ex d OR Ex p ENCLOSURE ONLY, IRRESPECTIVE OF ZONE CLASSIFICATION OF ZONE 1 OR ZONE 2. DesignBasis_44LK5100_Rev0.doc Page 23 of 40

24 LT MOTORS 1.0 RATED VOLTAGE 415 V 2.0 VOLTAGE AND FREQUENCY VARIATION ± 10 % V, ± 5 % Hz 3.0 COMBINED VOLTAGE AND FREQUENCY VARIATION ± 10 % 4.0 CLASS OF INSULATION & TEMP. RISE Class F with Temperature Rise Limited to Class B. 5.0 ENCLOSURE PROTECTION CLASS IPW 55 (Minimum) 6.0 TYPE OF ENCLOSURE As per Area Classification 7.0 TYPE OF COOLING (TEFC / SPDP) TEFC 8.0 TEMPERATURE DETECTORS FOR WINDING Thermistors for motors rated 75 kw and above and For all VSD driven motors. 9.0 TEMPERATURE DETECTORS FOR BEARING Not Required 10.0 NO. OF COLD STARTS PER HOUR 4 (Minimum) 11.0 NO. OF HOT STARTS PER HOUR 3 (Minimum) 12.0 WHETHER ENERGY EFFICIENT MOTORS REQUIRED? 13.0 ENERGY EFFICIENCY CLASS AS PER IS (2004) YES / NO EFF SPECIAL WINDING TREATMENT Suitable for corrosive atmosphere with epoxy gel treatment on winding overhang. NOTES : 1) MOTORS OF RATING 55 KW AND ABOVE SHALL BE PROVIDED WITH SPACE HEATERS. 2) SAFE STALLING TIME OF MOTOR SHALL BE MINIMUM 2.5 SEC MORE THAN THE STARTING TIME OF MOTOR AT 80% VOLTAGE. 3) MOTORS DRIVEN BY VSD SHALL BE INVERTER GRADE AND SHALL BE SUITABLY DERATED TO TAKE CARE OF REDUCED COOLING AT LOWER SPEEDS. 4) MOTOR TERMINAL BOX SHALL BE SUITABLE FOR TERMINATING THE ACTUAL NO. OF CABLES. 5) FOR PACKAGE UNIT MOTORS THE TERMINAL BOX SHALL BE FREELY ACCESSIBLE. * - INFORMATION TO BE FURNISHED BY CLIENT. DesignBasis_44LK5100_Rev0.doc Page 24 of 40

25 CABLES & ACCESSORIES 1.0 HIGH TENSION 1.1 VOLTAGE GRADE 6.6 kv (UE) 1.2 EARTHED / UNEARTHED SYSTEM As per clause no. 1.1 above. 1.3 ARMOURED / UNARMOURED Armoured 1.4 CONDUCTOR MATERIAL Aluminum / Copper (Based on Fault Withstand Capacity) 1.5 CONDUCTOR SCREENING Semi conducting compound 1.6 TYPE OF OUTER SHEATHING Extruded FRLS PVC Outer sheath. 1.7 FAULT LEVEL WITHSTAND TIME a) FEEDER WITHOUT INST. TRIPPING DEVICE. 1 sec. b) FEEDER WITH INST. TRIPPING DEVICE sec. 1.8 INSULATING MATERIAL XLPE 1.9 INSULATION SCREENING With semi conducting compound and with non-magnetic material (Cu foil) for multicore cables TYPE OF CABLE TERMINATION (RAYCHEM / M- SEAL / PUSH ON / BITUMEN COMPOUND) Raychem heat shrinkable type 1.11 ANY SPECIAL REQUIREMENT None 1.12 TYPE & MATERIAL OF CABLE LUGS Tinned Copper / Aluminium 1.13 MAXIMUM / MINIMUM SIZE TO BE USED As specified in Engineering Design Guidelines Doc. No. 44LK /E.02/0002/A4 2.0 LOW TENSION 2.1 VOLTAGE GRADE. 650 / 1100 V 2.2 CONDUCTOR MATERIAL Up to 16 Sq.mm Cu. Above 16 Sq.mm Al /CU - See Note 1 below 2.2 INSULATING MATERIAL XLPE 2.3 TYPE OF INNER SHEATH (EXTRUDED / TAPE) EXTRUDED 2.4 ARMOURED / UNARMOURED ARMOURED 2.5 TYPE OF OUTER SHEATH (PVC / HRPVC / FRLS) FRLS 2.6 TYPE AND MATERIAL OF CABLE LUGS Tinned cu for cu cables / Al for Al cables 2.7 TYPE OF CABLE GLANDS a) MATERIAL Nickel Plated Brass b) INDOOR PANEL Double compression type c) MOTORS IN FIELD Double compression type d) PUSH BUTTON & CONTROL PANELS IN FIELD Double compression type DesignBasis_44LK5100_Rev0.doc Page 25 of 40

26 CABLES & ACCESSORIES e) EQUIPMENT IN ZONE - 2 AREAS Ex (e)-double compression type f) EQUIPMENT IN ZONE - 1 AREAS Ex (d)-double compression type 2.8 MAXIMUM/MINIMUM SIZE TO BE USED As specified in Engineering Design Guidelines Doc. No. 44LK /E.02/0002/A ANY SPECIAL REQUIREMENT ---- NOTES : 1)If the length of the cable involved is high and if the number & size of the cable with Al conductor needed to limit voltage drop is high and is difficult to be terminated in the motor terminal box, then copper conductor cables which will result in lesser number/size of cable shall be provided. Providing junction box (JB) near to the motor end to terminate multiple cable from switchgear and providing lesser number/size of cable from JB to motor is not acceptable for motors <110 kw. Ex d Junction boxes may be provided for LT motors >= 110 kw 2) Bimetallic washers to be used for Copper Aluminium connections DesignBasis_44LK5100_Rev0.doc Page 26 of 40

27 DISTRIBUTION BOARDS (MLDB, ASB, LP, SLP, PP) A) MAIN DISTRIBUTION BOARD (MLDB, ASB) 1.0 DESIGN (COMPARTMENTALISED/FLOOR MOUNTING/DRAWOUT/FIXED TYPE) Project Title : DHT Compartmentalized / Floor mounting / Wall mounting / Fixed type 2.0 BUS BAR 415 V, TPN, 50 HZ, 50 KA FOR 1 SEC 2.1 MATERIAL Copper 2.2 INSULATING SLEEVING (HEAT SHRINKABLE PVC Required SLEEVING) 2.3 LOCATION Top (including Neutral busbar) 3.0 INCOMING FEEDERS 3.1 TYPE OF COMPONENT (FUSE SWITCH / MCCB) Switch fuse unit up to 400A rating and ACB above 400A rating MLDB, ASB 3.2 METERING Digital Enercon kwh Meter and Analogue voltmeter 4.0 OUTGOING FEEDERS 4.1 TYPE OF COMPONENT (FUSE SWITCH /MCCB/MCB) Switch Fuse Unit - MLDB, ASB 4.2 ENCLOSURE a) MATERIAL CRCA sheet steel b) TYPE & PROTECTION CLASS FOR INDOOR INSTALLATION FOR OUTDOOR INSTALLATION IP 52 Minimum Cast Al for outdoor duty IP 55 Minimum B) SUB-DISTRIBUTION BOARD (LP, SLP, PP) 1.0 BUS BAR 415 V, 50 HZ, TPN 1.1 MATERIAL Copper 2.0 INCOMING FEEDER 2.1 TYPE OF COMPONENT (FUSE SWITCH /MCCB/MCB) MCB (10kA) LP, SLP, PP 3.0 OUTGOING FEEDER 3.1 COMPONENT (FUSE SWITCH /MCB/ELMCB) SPN MCB with ELCB - LP, PP DesignBasis_44LK5100_Rev0.doc Page 27 of 40

28 DISTRIBUTION BOARDS (MLDB, ASB, LP, SLP, PP) Project Title : DHT 4.0 ELCB REQUIREMENT For outgoing feeders NOTES : 1) SWITCH FUSE UNITS SHALL BE PROVIDED IN AUXILIARY SWITCH BOARD (ASB) FOR GIVING SUPPLY TO WELDING RECEPTACLES. 2) IN CASE OF ASB / MLDB SWITCH FUSE UNITS SHALL BE USED FOR RATINGS UP TO 400A AND ACBS SHALL BE USED FOR RATING ABOVE 400A. * - INFORMATION TO BE FURNISHED BY CLIENT. DesignBasis_44LK5100_Rev0.doc Page 28 of 40

29 CONTROL STATIONS 1.0 MATERIAL OF ENCLOSURE Sheet steel / Cast iron / Cast Al. / FRP 2.0 PROTECTION CLASS OF ENCLOSURE IP PROVISION OF AMMETERS FOR DRIVES Required for all motors rated 15 kw and above and all Emergency & Critical Drives 4.0 REQUIREMENT OF SEPARATE / INTEGRAL CANOPY CANOPY OF FRP 5.0 STOP PUSH BUTTON TYPE MUSHROOM HEAD WITH STAYPUT FEATURE (PRESS TO LOCK AND TURN TO UNLOCK), LOCKABLE PROTECTIVE COVER TO PREVENT ACCIDENTAL ACTIVATION OF PB. 6.0 START PUSH BUTTON TYPE SHROUDED TYPE 7.0 LOCAL/ REMOTE SS (WITH MAKE BEFORE BREAK CONTACTS) REQUIRED 8.0 PAD LOCKING REQUIREMENT REQUIRED FOR STOP PB NOTES: * - INFORMATION TO BE FURNISHED BY CLIENT. DesignBasis_44LK5100_Rev0.doc Page 29 of 40

30 LIGHT FITTINGS 1.0 TYPES OF LAMP (GLS / FLUORESCENT / HPMV / HPSV) a) FOR PROCESS AREAS HPMV b) FOR OUTDOOR AREAS HPMV (For Safe Areas) c) FOR ROAD & SECURITY HPMV HPMV (For Hazardous Area) d) FOR GODOWN / WAREHOUSE ETC Not Applicable e) SUBSTATION / CONTROL ROOM Fluorescent f) ADMINISTRATION & OTHER NON PLANT BUILDINGS Fluorescent 2.0 PERCENTAGE OF LIGHT FITTINGS ON EMERGENCY SUPPLY. 3.0 LIGHT FITTINGS ON DC / UPS SUPPLY FOR CRITICAL AREAS 4.0 TYPE OF AUTOMATIC CONTROL OF LIGHTING- OUTDOOR LIGHTING 15% As specified in Engineering Design Guidelines Doc. No. 44LK /E.02/0002/A4 Control is through existing Centralized Lighting scheme / Photocell / Timer 5.0 TYPE OF FITTINGS IN HAZARDOUS AREA ZONE - I ZONE -II Ex (d) Ex (d) 6.0 PROVISION FOR LOOPING Junction box in Light fitting for looping 7.0 WIRING OF LIGHT FITTING, CONDUIT / CABLE (SPECIFY AREA WISE) Outdoor Areas with Armoured Copper cable stranded Cu Buildings with false ceiling: - Concealed conduit wiring below false ceiling PVC Conduits - Surface conduit wiring above false ceiling. PVC Conduits 8.0 ILLUMINATION LEVEL As specified in Engineering Design Guidelines Doc.No. 44LK /E.02/0002/A4 NOTES: * - INFORMATION TO BE FURNISHED BY CLIENT. DesignBasis_44LK5100_Rev0.doc Page 30 of 40

31 BATTERY & BATTERY CHARGER 1.0 BATTERY 1.1 TYPE Ni-Cd 1.2 VOLTAGE 110 V DC for Switchgear DC Control Supply & 220 V DC for Critical DC Lighting Supply 1.3 BACK UP TIME OF BATTERY 2 Hours (for Switchgear DC Control Supply) 1 Hour (Critical DC Lighting Supply) 2.0 BATTERY CHARGER 2.1 TYPE (DIODE WITH AUTO TRANSFORMER / THYRISTOR) 2.2 FLOAT CHARGING CUM BOOST CHARGER / FLOAT & BOOST CHARGER SEPARATELY Thyristor Float cum Boost Charger 2.3 REDUNDANCY OF BATTERY & CHARGER Charger : 100% redundant (for Switchgear DC Control Supply) : Single (for Critical DC Ltg Supply) Battery : One (1) Battery Bank for Switchgear DC Control Supply and One (1) Battery Bank for Critical DC Lighting Supply NOTES: * - INFORMATION TO BE FURNISHED BY CLIENT DesignBasis_44LK5100_Rev0.doc Page 31 of 40

32 CAPACITOR 1.0 FINAL POWER FACTOR REQUIRED 0.95 (*) 2.0 TYPE OF PF CONTROL a) GROUP CONTROL AT HT b) GROUP CONTROL AT LT (PCC / MCC) c) INDIVIDUAL CONTROL WITH MOTOR 6.6 kv Switchgear NA NA 3.0 TYPE OF CONTROL MANUAL 4.0 TYPE OF DI - ELECTRIC APP **. NOTE : 1) DELETED. * - INFORMATION TO BE FURNISHED BY CLIENT ** - SHALL BE DECIDED DURING DETAIL ENGINEERING. DesignBasis_44LK5100_Rev0.doc Page 32 of 40

33 PUBLIC ADDRESS SYSTEM 1.0 REQUIREMENTS (GENERAL PAGING / CONFERENCE BETWEEN VARIOUS STATIONS / POINT TO POINT COMMUNICATION) Refer Doc. No. 44LK /E.02/0002/A4 2.0 NO. OF STATIONS REQUIRED FOR ** 2.1 FOR OPERATION OF THE PLANT SECURITY Yes 2.2 INTEGRATION WITH TELEPHONE SYSTEM Required 2.3 INTEGRATION WITH FIRE ALARM SYSTEM Required 3.0 HOOK UP WITH EXISTING PA SYSTEM NOT REQUIRED NOTES : 1) PA SYSTEM SWITCHING PANEL SHALL BE LOCATED IN NEW CONTROL ROOM. * - INFORMATION TO BE FURNISHED BY CLIENT. ** - SHALL BE DECIDED DURING DETAIL ENGINEERING. DesignBasis_44LK5100_Rev0.doc Page 33 of 40

34 TELEPHONE SYSTEM 1.0 FUNCTIONAL REQUIREMENTS (BRIEF DESCRIPTION OF PLANT REQUIRED) 2.0 NO. OF HAND SETS Refer Doc. No. 44LK /E.02/0002/A4 As per scope requirement 3.0 FURTHER EXPANSION TO BE CONSIDERED YES 4.0 NO. OF P& T LINES TO BE INTERCONNECTED As per scope requirement 5.0 HOOK UP WITH PA & FA SYSTEM REQUIRED 6.0 HOOK UP WITH EXISTING TELEPHONE SYSTEM REQUIRED NOTES : 1) NEW EPABX (IF PROVIDED) SHALL BE INTEGRATED WITH EXISTING EPABX. NEW EPABX (IF PROVIDED) SHALL BE LOCATED IN NEW CONTROL ROOM. * - INFORMATION TO BE FURNISHED BY CLIENT. ** - SHALL BE DECIDED DURING DETAIL ENGINEERING. DesignBasis_44LK5100_Rev0.doc Page 34 of 40

35 ELECTRICAL INSTALLATION 1.0 MODE OF CABLE LAYING (TRENCH / BURIED / OVER HEAD TRAYS) 2.0 TYPE OF CABLE TRAY AND ACCESSORIES (PRE- FABRICATED / FABRICATED AT SITE WITH STRUCTURAL STEEL) Sand filled cable trench / Buried / Overhead tray Pre-fabricated ladder type. 3.0 MATERIAL OF PRE-FABRICATED TRAYS FRP / GI (Refer Note 1) 4.0 CABLE CLAMPING ARRANGEMENT (CLAMPS MADE OF STEEL / AL / NYLON ROPES) Clamps made of Aluminum 5.0 CABLE TAG (ALUMINIUM / S.S) SS 6.0 CABLE MARKER FOR UNDERGROUND CABLE / MATERIAL Wherever Applicable. (Shall be provided 15 Mtrs apart) SS 7.0 SECURITY LIGHTING WITH STRUCTURAL TOWERS Shall be provided Wherever Applicable. 8.0 TYPE OF STREET LIGHT POLE REQUIRED 12 / 10 meters high swaged tubular as per IS 2713 Aluminium Poles 9.0 SOCKET OUTLETS - INDUSTRIAL / FLP TYPE FLP socket outlets in DHT, HGU & Sulphur recovery block areas. IND / FLP socket outlets in OSBL areas. a) FOR WELDING (RATINGS & AREAS TO BE COVERED) 63 A, 415 V TPN + E As per area classification. b) FOR PORTABLE ELECTRICAL EQUIPMENT S 20 A, 240 V, SPN + E c) FOR FANS & OTHER EQUIPMENT S IN NON- PLANT AREAS d) FOR HAZARDOUS AREAS A, 240 V, SPN + E 20 A, 240 V, DP + E, Ex (d) type 20 A, 240 V, DP + E, Ex (e) type (As Applicable) NOTES : 1) CABLE TRAYS INSIDE SUBSTATION BUILDINGS SHALL BE PREFABRICATED GI AND CABLE TRAYS OUTSIDE SUBSTATION BUILDINGS SHALL BE PREFABRICATED FRP. 2) 200A, 415V, TPN+E SOCKET OUTLETS SHALL BE PROVIDED FOR MAINTENANCE ACTIVITIES DURING SHUTDOWN. 3) 24V AC SOCKET OUTLETS SHALL BE PROVIDED AT EACH ELEVATION OF PROCESS BLDG. * - INFORMATION TO BE FURNISHED BY CLIENT. DesignBasis_44LK5100_Rev0.doc Page 35 of 40

36 EARTHING 1.0 EARTH PIT TYPE & MATERIAL 100 mm Dia G.I Pipe for Neutral & Body Earthing of Transformer & Generators. Plate Electrode for GIS 2.0 EARTHING MATERIAL G.I Pipe: for other plant areas 3.0 TYPE OF EARTHING CONDUCTOR FOR EQUIPMENT S 3.1 EARTHING MAIN GRID 3.2 SWITCH YARD EQUIPMENT G.I Strip a) TRANSFORMER NEUTRAL Not Applicable b) EQUIPMENT Not Applicable c) LIGHTNING ARRESTOR Not Applicable d) STRUCTURE Not Applicable 3.3 SUBSTATION EQUIPMENT a) EQUIPMENT (PCC / MCC / HT SWGR. ETC.) G.I Strip b) TRANSFORMER NEUTRAL G.I Strip 3.4 PLANT EQUIPMENT a) MOTORS & LCS Unarmoured insulated aluminium cables of appropriate sizes (For cable sizes Refer Dwg.No. 44LK /E.01/0054/A3). Cables shall be Green in colour. b) STATIC EARTHING G.I Strip c) LIGHTING FITTINGS By 3 rd core of 3C x 4 YWY Lighting 4.0 LIGHTNING PROTECTION 4.1 AIR TERMINAL MATERIAL Copper Cable. & G.I of standard wire gauge 4.2 DOWN CONDUCTOR G.I Strip (32 X 6 mm) 4.3 EARTH PIT 1 No. per down conductor 4.4 LIGHTNING PROTECTION FOR TANK FARM AREA (Refer Dwg.No. 44LK /E.01/0054/A3) DesignBasis_44LK5100_Rev0.doc Page 36 of 40

37 STATIC UNINTERRUPTABLE POWER SUPPLY UNITS (UPS) 1.0 TYPE IGBT / Transistorized 2.0 REDUNDANCY / TYPE OF REDUNDANCY 100 % Dual Static parallel redundant 3.0 BACKUP TIME REQUIRED 30 Minutes 4.0 INPUT SUPPLY VOLTAGE 415 V, TPN, 50Hz 5.0 OUTPUT SUPPLY VOLTAGE 110 V SPN for Instrumentation loads 6.0 TYPE OF BATTERIES Ni-Cd 415 V TPN for Critical Load (If any) 7.0 BATTERY EXECUTION Single bank up to 600 Ah / Parallel bank above 600 Ah (2 nos Battery banks for Parallel Redundant UPS) 8.0 STABILISER IN BYPASS LINE Static Voltage Regulator 9.0 BYPASS TRANSFER CONTROL Auto / Manual through Static Switch (Manual for maintenance Bypass) 10.0 VDU WITH PC/PRINTER ETC. Required / Not Required 11.0 COMMUNICATION PORT Required NOTES: * - INFORMATION TO BE FURNISHED BY CLIENT. ** - SHALL BE DECIDED DURING DETAIL ENGINEERING. DesignBasis_44LK5100_Rev0.doc Page 37 of 40

38 FIRE ALARM SYSTEM 1.0 TYPE OF FIRE ALARM SYSTEM Digital addressable 2.0 FIRE ALARM PANEL Microprocessor based digital addressable 3.0 TYPE OF DETECTORS Beam detectors, Smoke detectors, Heat detectors as per application (Multi detection) 4.0 PROVISION OF MANUAL CALL POINTS Required 5.0 HOOK UP WITH PA & TELEPHONE SYSTEM REQUIRED 6.0 HOOK UP WITH EXISTING FA SYSTEM NA 7.0 HOOK UP WITH HVAC SYSTEM REQUIRED NOTES : 1) MAIN FIRE ALARM PANEL SHALL BE KEPT IN NEW CONTROL ROOM WHICH SHALL BE HOOKED UP WITH EXISTING FIRE ALARM PANEL IN FIRE STATION. 2) MAIN FIRE ALARM PANEL SHALL BE COMMON FOR MAIN SUBSTATION, DHT, HGU, SULPHUR RECOVERY, NEW CONTROL ROOM & OSBL AREAS. 3) LCD DISPLAY SHALL BE PROVIDED IN FIRE STATION. * - INFORMATION TO BE FURNISHED BY CLIENT. ** - SHALL BE DECIDED DURING DETAIL ENGINEERING. DesignBasis_44LK5100_Rev0.doc Page 38 of 40

39 VARIABLE SPEED DRIVE 1.0 VOLTAGE RATING OF VFD & MOTORS HAVING RATING ABOVE 160kW 1.1 REDUNDANCY IN TRANSFORMER FOR 415V / 660V VFD 415V NOT REQUIRED 2.0 RECTIFIER CONFIGURATION MINIMUM 12 PULSE 3.0 LOCATION OF VSD SEPARATE PANEL 4.0 INPUT ISOLATION TRANSFORMER REQUIRED 4.0 OUTPUT CHOKE REQUIRED / NOT REQUIRED 5.0 PROTOCOL COMMNUNICATION NOT REQUIRED 5.1 IF REQUIRED 6.0 VSD BYPASS BYPASS REQUIRED FOR MOTORS UP TO 55 KW. 7.0 REQUIREMENTS FOR CONTROL & MONITORING ON 7.1 VSD 7.2 LOP REFER NOTE 1 & 2 BELOW. 7.3 DCS / SCADA ON / OFF CONTROL FROM DCS AND RUNNING INDICATION TO DCS. 8.0 PROVISION OF SEPARATE THERMISTOR RELAY REQUIRED 9.0 CLIENT SPECIFIC REQUIREMENTS NOTES : 1) DOL BYPASS SHALL BE PROVIDED FOR VSDs OF RATING UP TO 55 KW. IN THESE VSDs VSD/DOL SELECTOR SWITCH SHALL BE PROVIDED ON THE VSD PANEL ITSELF. THE SCHEME OF THESE VSDs IS AS GIVEN IN ATTACHED ANNEXURE-I. LOCAL CONTROL STATION IN ABOVE MENTIONED VSDs SHALL INCLUDE START AND STOP PB, SPEED RAISE / LOWER PB, DIGITAL AMMETER AND DIGITAL SPEED INDICATOR. SOFTWARE LOCAL/REMOTE SELECTOR SWITCH SHALL BE PROVIDED IN DCS. 2) VSDs WITHOUT BYPASS LCS SHALL BE PROVIDED WITH START AND STOP PB, SPEED RAISE / LOWER PB, DIGITAL AMMETER AND DIGITAL SPEED INDICATOR. SOFTWARE LOCAL/REMOTE SELECTOR SWITCH SHALL BE PROVIDED IN DCS. 3) DELETED 4) IN CASE OF VSDs WITHOUT BYPASS ACB (ACB WITHOUT RELEASES) / SWITCH SHALL BE PROVIDED ON THE INCOMING SIDE. 5) FOR CRITICAL MOTORS (LIKE ID/FD FAN MOTORS) SOFT STARTER SHALL BE PROVIDED ON BYPASS SIDE TO VSD. DesignBasis_44LK5100_Rev0.doc Page 39 of 40

40 ANNEXURE-I (SCHEME FOR VSDs UP TO 55 KW RATING) From MCC SWITCH VFD PANEL I/P Contactor VSD DOL Bypass Contactor + Overload Relay O/P Contactor To Motor DesignBasis_44LK5100_Rev0.doc Page 40 of 40