33-Chapter 8-Fire Pump Evaluation

CHAPTER 8
FIRE PUMP
This chapter will provide an evaluation and recommendation

to JG Summit Petrochemical Corporations Fire Pump. The first part
will cover the evaluation of existing installation and its conformance
with the provisions of Article 6.95 of Philippine Electrical Code part
1. The second part will provide recommendations as well as sizing
of major equipment and design analysis. The design analysis will
cover voltage drop calculation, short circuit calculation, device
coordination and arc-flash calculation.
8.1 Evaluation of Existing Installation
8.1.1 Fire Pump System Overview

JGSPCs fire-fighting system consist of one (1) electric
driven pump, two (2) diesel driven pumps and a jockey pump as
shown in the piping and instrumentation diagram on Figure 8.1.
This system is protecting JGSPCs critical process equipment such as
vessels, tanks, pumps, compressors, reactors and auxiliary process
equipment. The system is maintaining the water pressure of the fire
water header at 13 bars via the combination of pressure control
valve and the jockey pump. In case of fire, header pressure will
drop in which case the three main fire pumps will automatically run
based on pre-assigned pressure cut-in values for each pump. If the
header pressure falls below 9 bars, the electric-driven pump will
automatically start, if it continues to drop to 5 bars, the first diesel
engine pump will automatically run and lastly if the pressure drops
below 3 bars, the last diesel-driven engine pump will automatically
start. All these start sequence is trigger by pressure sensing device
installed on each pump. Status of the pump condition is monitored
Chapter 8-Fire Pump Page 359
remotely via plant Distributed Control System by the panel Operator
as shown on Figure 8.2.
Figure 8.1 P&ID of Fire Water System of JGSPC
Figure 8.2 DCS Schematic of Fire Water System of JGSPC

8.1.2 Electric Fire Pump Motor Data (GM9900)
The electric driver G9900 is a 600hp, 6.9kV, 3 phase
medium-voltage motor with the complete electrical specification
shown in table 8.1.
Table 8.1 Electrical Specification for G9900 Fire Water Pump

Horsepower 600hp Service factor 1.15
Full load current 47.7A Enclosure TEFC
Voltage 6900V Insulation F
Phase 3 Frame 5810
Locked rotor current 320A Ambient 40oC
Full load RPM 1786 Frequency 60Hz
8.1.3 Fire Pump Controller

Existing fire pump controller is a METRON MV600 UL listed
medium-voltage fire pump controller. This controller is already on
its end-of-life state with several components failing and corroded
panel.
Figure 8.3 Existing Fire Pump Controller Panel

8.1.4 Power Source
Power to the electric-driven fire pump comes from the
6.9kV feeder of TRM. The 3C-25mm2 XLPE cable is routed through
cable trays which traverse the process area and into the fire pump
controller. This process area is a fire hazard zone and has a very
high potential for a fire which may cause damage to the fire pump
cable.
8.1.5 Reliability of Existing Source

Based on the power plant interruption record from January
2012 up to May 2017, there were four (4) power plant trips one
with more than four (4) hours downtime as summarized in Table
8.2 below. According to NFPA 20 Annex A.9.3.2, a reliable power
source has not experienced any shutdowns longer than four (4)
continuous hours. This means that our power plant cannot be
considered as a reliable source. The plant has two (2) diesel-driven
fire pumps and with that condition, NEC 695.3 B 2 exception allows
a single source of reliable power. However, for the last five (5)
years, there were several incident of diesel engine failure during a
scheduled fire pump test run and therefore cannot be considered as
reliable.
Table 8.2 Power Plant Power Interruption Record (from Jan
2013 up to May 2017)
Date and Time Duration Cause
11/30/2014 10:20:48 2hrs Diesel Generator trip
PM (controller issue)
5/22/2016 7:49:07 PM 8hrs Lightning Strikes
10/10/2016 7:54:44 PM 2hrs Diesel generator issue trip
(controller issue)
3/5/2017 8:5:04 AM 2hrs Diesel generator issue
(controller issue)

8.1.6 Design Considerations and Recommendations
1. Since the fire pump motor cable traversed the process area
where fire hazard exists, it is recommended to re-route the
cable outside the process area to minimize the fire hazard.
The cable used is not fire resistant cable so it is also
recommended to replace the cable with fire resistant cable
with 2 hours fire rating. Cable tray shall be used on the entire
length and will serve the required mechanical protection.
2. Existing normal power is not tapped ahead of supply and its
circuit is part of normal loads from a common transformer
serving other utilization equipment. It is recommended to
connect the supply from 13.8kV power plant generator bus
utilizing the spare feeder and 630A SF6 Circuit breaker as well
as a dedicated 13.8kV to 6.9kV step down transformer.
3. The plant has two diesel engine driven fire pumps therefore
no alternative power is required as permitted by NEC 695.3 B
2 exception. However, for the last five (5) years, there were
several incident of diesel engine failure during a scheduled fire
pump test run and these engines are not reliable. On the
other hand, the power plant is deemed not reliable as there
was at least one (1) incident of total power failure of more
than four (4) hours. Moreover, the power plant itself is being
protected by the fire protection system and a fire event within
the power plant area can impaired the normal power supply to
the fire pump. It is therefore recommended to install a
standby generator located within the fire pump area.
4. The step-down transformer 13.8kV-6.9kV shall be located
within the fire pump area. Oil-immersed/sealed type shall be
used.
5. Existing fire pump controller is already on its end-of-life phase
and shall be replaced with a new UL listed DOL fire pump
controller with NEMA 4X IP rating.
8.2 Design Calculations
Based on the recommendations from 8.1.6, the proposed
design of electric fire pump system is shown below in figure 8.3.
G
Power Plant
52FP Dedicated Feeder (from

Spare 630A SF6 CB)
(existing)
Cable (new)
TRFP
Transformer BGENFP
13.8kV-6.9kV Backup
(new) G Generator
(new)
Cable (new)
TSFP
(new)
Fire Pump
Controller
FPC (new)
Cable (new)
Fire Pump
GM9900
(existing)
Figure 8.4 Single Line Drawing for Fire pump

On this proposed design, the normal power will be
connected directly to the power plant bus via a spare breaker. The
new cable will routed outside of the process area via existing cable
tray support structures. The new stepdown transformer will be
installed within the fire pump area along with the new backup
Generator set, new fire pump controller, new transfer switch panel,
switchgear for backup generator breaker.

8.2.1 Generator Load Calculation (power plant)
To verify that the power plant The load required by the fire
pump motor to supply indefinitely its locked-rotor current is
calculated.
Re quired Locked Rotor MVA 3 x ILRC x V

Re quired Locked Rotor MVA (1.732)(320)(6900)
Re quired Locked Rotor MVA 3.824MVA
Each generator has 8.375MVA so at least one generator is

required to successfully start, run and supply the locked-rotor MVA
of the fire pump should there be a fire within the plant.
8.2.2 Standby Generator Sizing (alternative power)

With the consideration of normal starting, running and
locked rotor condition, the size of the standby generator is
approximately
Re quired Locked Rotor MVA 3 x ILRC x V

Re quired Locked Rotor MVA (1.732)(320)(6900)
Re quired Locked Rotor MVA 3.824MVA
Consider 3.824MVA or 4MVA diesel generator set with

3phase 6900kV 60Hz output wye solidly grounded. However,
voltage drop during motor starting will be calculated later in this
chapter and will determine the minimum generator size required to
satisfy the starting and running voltage drop using typical values of
reactance and X/R ratio as shown on Table 8.3.

Table 8.3 Typical Reactance and X/R ratio for Wye-Grounded
Synchronous Generator
Generator Capacity (MVA) X X/R
1.00 0.15 22.8176

1.50 0.15 24.6035
2.00 0.15 25.5712
2.50 0.15 26.2547
3.00 0.15 26.8206
3.50 0.15 27.3333
4.00 0.15 27.8207
Source: SKM Power Tools
8.2.3 Transformer Sizing

Transformer is sized at a minimum of 125% of the FLC of
the fire pump motor.
FLC 47.7A
Transformer 1.25 x 3 x IFLC x V
Transformer (1.25)(1.732)(47.7)(6900)
Transformer 712.6kVA
Say 1MVA but for future expansion consideration where

there is a possibility of adding another fire pump of the same size,
2MVA is selected. Transformer specification will be as follows:
Table 8.3 Transformer Specification

Capacity 2MVA
Voltage(Primary-Secondary) 13.8kV-6.9kV
Connection Delta/Wye resistance
(primary/Secondary) grounded
% Impedance 6
Cooling ONAN

8.2.4 Normal Power Protection Settings Calculation
The fire pump will utilize the spare 630A ABB SF6 Circuit
Breaker since its capacity is more than enough to handle the locked
rotor condition of the fire pump. Only the Time-overcurrent
protection function will be used and will be set at 115% of the
locked-rotor current of the fire pump motor.
Primary CT size:
(transformersize) 2,000,000
IFL / Pr imary 83.67A
3(Pr imaryVoltage) 3(13800)
(150% x 83.67A)=125.5A, CT Ratio= 100:5
25VA (burden designation B-1)
Relaying ANSI 10C100 (class C), BIL rating 95kV
Protection Settings Calculation (Primary Overcurrent protection 51):

51 pickup (I>)
Set at 115% of LRC
LRC 320A
6.9 5
P.U. Current setting (1.15)(320)( )( ) 9.2 In
13.8 100
P.U Current (9.2)(100 / 5) 184A
The circuit breaker size of 630A is enough for the locked-

rotor requirement of 184A. Moreover, the setting is less than 300%
of transformer FLA or 252A which complies with PEC 1 table
4.50.1.3(a) for supervised location and primary protection only.
Time dial setting is set such that the protection curve is 200ms
above the TR-FR inrush point 1004A, 0.1sec.
t 0.1 0.2
TD 1.28
3.922 3.922
0.0982 0.0982
2 2
I 1004
1 1
IP Pump 184
Chapter 8-Fire Page 368
8.2.5 Standby Generator Protection Settings Calculation
Generator Full load current:
(Generatorsize) 3,500,000
IFL 292.85A
3(Pr imaryVoltage) 3(6900)
Circuit Breaker Sizing:

(125% x 292.85)=366A, use 630A, 15kV class, 3pole, 60Hz
Vacuum Circuit breaker, 95kV BIL, Indoor type, calculated from
short circuit calculation from 8.2.7 is 1.953kA with a worst case
adjustment factor of 1.3 from chapter 4.3.5 or 2.53kA, so a 25kAIC
available in the market is sufficient.
Primary CT size:
(150% x 292.85A)=440A, CT Ratio= 500:5
25VA (burden designation B-1)
Relaying ANSI 10C100 (class C), BIL rating 95kV
Phase time overcurrent protection will be set at 115% of

fire pump motor LRC.
LRC 320A and Reference Voltage 6900V

5
P.U. Current setting (1.15)(320)( ) 3.68 In
500
P.U Current (3.6)(500 / 5) 360A
This setting is less than 125% of generator full load

current. Time dial will be set such that the protection curve is above
the knee point of the generator decrement curve. By adjusting the
excel plot, the suitable time dial setting is found at 2.5.
8.2.6 Cable Sizing
The highest fault at 13.8kV bus is 23,360A and with this worst case
fault current, the tripping time of the protective relay is

3.922
t 2
0.0982 2 0.126 second
23360 1
184

Adding a margin to this time

t= 0.2 + 0.126 =0.326s
For an XLPE cable at 13.8kV, the minimum cable size is
A
ISC t

23360 0.326
93.271mm2
143 143
For primary cable (CABLE No.1):
IAmpacityRe q 1.25 x 83.67 104.59A
From Table 8.4 and considering the minimum cable size of

93.271mm2, use 800m 3 x 1C-95mm2 XLPE 12/20kV aluminum
shielded PE (Fire resistant with 3-hour circuit integrity according to
IEC 60331) using trefoil cable formation.
For Transformer Secondary Cable to Transfer Switch (CABLE

No.2):
IAmpacityRe q 1.25(IFLSecTrans)
IAmpacityRe q 1.25 x (83.67)x(13800/6900) 209.175A

From Table 8.4, use 20m 3 x 1C-95mm2 copper XLPE
12/20kV aluminum shielded PE (Fire resistant with 3-hour circuit
integrity according to IEC 60331) using EMT conduit.
For Generator Cable to the Transfer Switch (CABLE No.3):
IAmpacityRe q 1.25(IFLGen)
IAmpacityRe q 1.25 x (292.85) 366.07A/2 183A
From Table 8.4, use 20m 2 sets 3 x 1C-95mm2 copper XLPE

12/20kV aluminum shielded PE (Fire resistant with 3-hour circuit
integrity according to IEC 60331) using EMT conduit.
For Motor Branch Circuit from Transfer Switch (ATS to Fire pump
panel and Fire pump panel to motor) (CABLE No.4):
IAmpacityRe q 1.25(IFLMotor)
IAmpacityRe q 1.25 x (47.7) 59.63A
From Table 8.4,
use 35m 3 x 1C-50mm2 copper XLPE 12/20kV aluminum shielded
PE (Fire resistant with 3-hour circuit integrity according to IEC
60331) using EMT conduit.
Table 8.4 Cable Specification Sheet for LION Cable

Figure 8.5 Cable Specification Sheet
8.2.6 Voltage Drop Calculation

According to article 6.95.1.7 of PEC 1 2009, voltage drop at
controller line terminals shall not drop more than 15% under motor
starting condition and shall not drop below 5% for under running
condition where the motor is operating at 115% of full load current
rating. Using per-unit calculation, the impedances of cables
transformer and motor are calculated below.
Power plant available fault

From Chapter 4 Table 4.3, the Thevenins equivalent impedance at
power plant bus at base 10MVA is
ZPP (0.000739 j0.017982) p u
Cable no. 1 Impedance

For the 800m cable from power plant to transformer, the impedance
is

R Rperkm Dis tan ce 0.224 / km0.8km 0.1792

XL 2f LperkmDis tan ce 260 0.403x103H / km 0.8km 0.1215419
Z 0.1792 j0.1215419
Z 0.1792 j0.1215419
Zcable1 0.00940978 j0.0063821 pu
Zbase 19.0440

Z0 Z0perkm Dis tan ce 0.8291 j0.6850 / km0.8km
0.66328 j0.548
0.66328 j0.548
Z0pu 0.034828 j0.028775 pu
19.044
Transformer Impedance
%IZ=6% at 2MVA base, X/R=6.8
S 10
Z Z2MVAbase BASE 0.06 0.3 pu
S Trans 2
X
R Z x cos tan-1 0.3 cos (tan-1(6.8)) 0.04364 p.u
R
X
X Z x sin tan- 1 0.3 sin (tan- 1(6.8)) 0.2968 p.u
R
ZTrans(1,2,0) 0.04364 j0.2968 pu

20m cable


XL 2f Lperkm Dis tan ce 260 0.403x103H / km 0.02km 0.003038
Z 0.00448 j0.003038

Z 0.00448 j0.003038
Zcable 2 0.000941 j0.000638 pu
Zbase 4.761

0.016582 j0.0137
0.016582 j0.0137
Z0pu 0.0008707 j0.000719 pu
19.044

20m cable

R Rperkm Dis tan ce 0.224 / km0.02km / 2 0.00224

XL 2f L perkm Dis tan ce 260 0.403x10 3 H / km 0.02km / 2 0.001519
Z 0.00224 j0.001519
Z 0.00224 j0.001519
Zcable 2 0.0004705 j0.000319 pu
Zbase 4.761

Z0 Z0perkm Dis tan ce 0.8291 j0.6850 / km0.02km / 2
0.0041455 j0.003425
0.0041455 j0.003425
Z0pu 0.000217 j0.000179 pu
19.044

35m cable


XL 2f Lperkm Dis tan ce 260 0.446x103H / km 0.035km 0.005884
Z 0.01568 j0.005884
Z 0.01568 j0.005884
Zcable 2 0.003293 j0.001235 pu
Zbase 4.761

0.032795 j0.024538
0.032795 j0.024538
Z0pu 0.001722 j0.001288 pu
19.044

Motor Impedance
From chapter 2 equation 2.7, motor sub-transient impedance is
2
" SBASE V
ZM PU x M
3 ILR VM VBASE
2
" 10,000 6900
ZM PU x 2.614811 pu
3 320 6,900 6900
For medium-voltage motors with power per pair poles less than 1
MW,
RM " "
0.15 with XM 0.989 ZM
"
XM
"
XM "
0.989 ZM 0.9892.614811 2.586048 pu
"
R M 0.15XM 0.152.686048 0.387907 pu
ZMotor 0.387907 j 2.586048 pu
Generator Impedance
Typical values for a 4MVA synchronous generator are
X1=0.15 pu, X/R=27.8207
X2=0.15 pu, X/R=27.8207
X0=0.15 pu, X/R=27.8207
At 4MVA base
10
@ 10MVAbase X2 @ 10MVAbase X0 @ 10MVAbase0.15
" " "
X1 0.357 pu
4
0.357
R 0.012832 pu
27.8207
Z4MVAGen 0.012832 j0.357 pu

For 3.5 MVA generator
X1=0.15 pu, X/R=27.333
X2=0.15 pu, X/R=27.333
X0=0.15 pu, X/R=27.333
10
@ 10MVAbase X2 @ 10MVAbase X0 @ 10MVAbase0.15
" " "
X1 0.428 pu
3.5
0.428
R 0.015679 pu
27.333
Z3.5MVAGen 0.015679 j0.428 pu
Starting Voltage Drop for Normal Power
~ 1 pu
Power Plant
Equivalent Fault ZPP (0.000739 j0.017982) p u
Impedance
Cable 1
ZCable1 (0.00940978 j0.0063821) p u
Transformer ZTrans 0.04364 j0.2968 pu
Cable 2+Cable 4
ZCable 2 4 (0.004234 j0.001873) p u
Chapter 8-Fire Pump

Fire Pump Page 377
Motor
ZMotor (0.387907 j2.586048) p u
ZTOTAL 0.445929 j2.909085 p.u
Figure 8.6 Impedance for Normal Power Voltage Drop
Starting-Voltage Drop
1
VDFirePumpMotor 1 ZMotor
Z TOTAL

VDFirePumpMotor 1
1
0.387907 j2.586048
0.445929 j2.909085
VDFirePumpMotor 0.111518pu 11.1518%
Calculation shows that the voltage drop during motor starting is

below 15% and is acceptable.
Running-Voltage Drop for Normal Power
I x1.15
VDFirePumpMotor FL ZCable1 ZTrans ZCable 2 4
IBase
VDFirePumpMotor
47.7x1.15 Z
Cable 1 Z Trans ZCable 2 4
836.73552
VDFirePumpMotor
47.7x1.15 0.310386 0.020348pu
836.73552
%VDFirePumpMotor 2.0348%
Calculation shows that the maximum voltage-drop when

the motor running is below 5% and is acceptable.

Starting Voltage Drop for
Backup Power
~ 1 pu
Gen
ZGen@ 3.5MVA 0.015679 j0.428 pu
Cable 2+Cable4
Chapter 8-Fire Pump

Fire Pump Page 379
Motor
ZCable 2 4 (0.02016 j0.008914) p u
ZMotor (0.387907 j2.586048) p u
ZTOTAL 0.40782 j3.015921 p.u
Figure 8.7 Impedance for Backup Power Voltage Drop
Starting-Voltage Drop
At 3.5MVA, the voltage drop during starting is calcualted below.
1
VDFirePumpMotor 1 ZMotor
Z TOTAL

VDFirePumpMotor 1
1
0.387907 j2.586048
0.40782 j3.015921
VDFirePumpMotor 0.1414pu 14.14%
Calculation shows that the voltage drop during motor

starting is below 15% and is acceptable.
Running-Voltage Drop for Backup Power
I x1.15
VDFirePumpMotor FL ZCable 2 4
IBase
47.7x1.15 Z
VDFirePumpMotor Cable 2 4
836.73552
VDFirePumpMotor
47.7x1.15 0.004629 0.000303pu
836.73552
%VDFirePumpMotor 0.03%

Calculation shows that the maximum voltage-drop when the motor
running is below 5% and is acceptable.
Based on the above results, the minimum generator size

based on the percent voltage drop during motor starting is 3.5MVA.
8.2.6 Short Circuit Calculation

Short circuit calculation shall be performed to verify the
short circuit duties of the protection devices for backup generator
and power plant bus. The result shall also be used for verifying the
protection coordination for both sources.
~ 1 pu
~ 1 pu
Power Plant
0.000739+j0.017982
Equivalent Fault
Impedance
Cable 1
0.009409+j0.006382
Fault Point 1
Transformer
Fault Point 2 0.04364+j0.2968
Cable 2
Fault Point 3
0.004234+j0.001873
Chapter 8-Fire
Cable 4 Pump Page 381
Fault Point 4
0.387907+j2.58604
Fire Pump
Motor
Figure 8.8 Positive Sequence Diagram for Normal Power
Mode
ZGEN EQ,ZERO =0.000555+ J0.017761
BUS1
0.000739+j0.017982
Reference
ZCable1,ZERO=0.034828+j0.028775
0.009409+j0.006382
Z TR,ZERO=0.04364+j0.2968
0.04364+j0.2968
Reference
0.004234+j0.001873
ZCable2,ZERO=0.0008707+j0.000719
0.387907+j2.58604
Figure 8.9 Negative (left) and Zero (right) Sequence

Diagram for Normal Power Mode
Fault Point 1: Fault at primary terminals of transformer

(Normal Power Mode)
Z1=Z2= 0.010148+j0.024364 and Z0=0.035383+j0.046536i
For three-phase fault:
Vfault 1
I3faultpu 37.888 pu
Z1 0.010148 j0.024364
I3faultactual IBase x I3faultpu 418.36976x37.888 15,851 A
Tripping Time at 15,851A


3.922
t 0.0982 1.28 0.126 second
15851 2
1
184
For single-line-to-ground fault:
3Vfault 3
I3faultpu 27.187933 pu
Z0 Z1 Z2 0.05568056 j0.0952642
I3faultactual IBase x I3faultpu 418.3697x27.187933 11,374A
Tripping Time at 11,374 A

3.922
t 0.0982 1.28 0.127 second
2
11374
184 1

Fault Point 2: Fault at secondary terminals of transformer

(Normal Power Mode)
Z1=Z2=0.05378878+j0.3211641 and Z0= 0.04364+j0.2968
V 1
I3faultpu fault 3.0709 pu
Z1 0.05378878 + j0.3211641
I3faultactual IBase x I3faultpu 836.739x3.0709 2,569 A

Tripping Time at 2,569(6900/13800) or 1284.77A

3.922
t 0.0982 1.28 0.23 second
2
1284.77
184 1

3Vfault 3
I3faultpu 3.1538 pu
Z0 Z1 Z2 0.15121756 j0.9391282
I3faultactual IBase x I3faultpu 836.739x3.1538 2,638.93 A
Tripping Time at 2,638.93(0.577) or 1522.66A

3.922
t 0.09821.28 0.2 second
2
1524
184 1

Fault Point 3: Fault at ATS (Normal Power Mode)
Z1=Z2= 0.05472978+j0.321802 and Z0= 0.0445107+j0.297519
Vfault 1
I3faultpu 3.0635 pu
Z1 0.05472978 j0.3218021

I3faultactual IBase x I3faultpu 836.739x3.0635 2,563.4 A Tripping Time at
2,563.4(6900/13800) or 1281.7A

3.922
t 0.0982 1.28 0.231 second
1284.77 2
1
184
3Vfault 3
I3faultpu 3.1458 pu
Z0 Z1 Z2 0.15397026 j0.9411232
Tripping Time at 2,632.2618(0.577) or 1518.815A

3.922
t 0.0982 1.28 0.2 second
1518.815 2
1
184
Fault Point 4: Fault at terminals of Motor (Normal Power

Mode)
Z1=Z2=0.05802278+j0.3230371 and Z0=0.0462327+j0.298807
V 1
Z1 0.05802278 j0.3230371

I3faultactual IBase x I3faultpu 836.739x3.046807 2549.427 A
Tripping Time at 2549.427(6900/13800) or 1274.713A

3.922
t 0.0982 1.28 0.232 second
2
1274.713
184 1

3Vfault 3
I3faultpu 3.1291 pu
Z0 Z1 Z2 0.16227826 j0.9448812
I3faultactual IBase x I3faultpu 836.739x3.1291 2618.313A
Tripping Time at 2618.313(0.577) or 1510.767A

3.922
t 0.0982 1.28 0.201 second
2
1510.767
1
184
~ ~ 1 pu
1 pu
Backup Gen 0.015679+j0.428
Fault Point 5
0.0004705+j0.000319
Cable 3
Fault Point 6
Cable 4
0.003293+j0.001235
Fault Point 7
Fire Pump
Motor
0.387907+j2.58604

Figure 8.10 Positive Sequence Diagram for Backup Power
Mode ZGEN EQ,ZERO =0.015679+ J0.428
BUS1
Reference
0.015679+j0.428
ZCable3,ZERO=0.000217+j0.000179
0.0004705+j0.000319
ZCable4,ZERO=0.001722+j0.001288
0.003293+j0.001235
ZCable4,ZERO=0.387907+j2.586048
0.387907+j2.58604
Figure 8.11 Negative (left) and Zero (right) Sequence

Diagram for Backup power Mode
Fault Point 5: Fault at Backup Generator Breaker Switchgear

(Back Power Mode)
Z1=Z2=Z0= 0.015679+j0.428
Vfault 1
I3faultpu 2.334 pu
Z1 0.015679 + j0.428

Tripping Time at 1,953.687A

3.922
t 0.0982 2.5 0.59 second
1953.687 2
1
360
3Vfault 3
I3faultpu 2.334 pu
Z0 Z1 Z2 0.047037 j1.284
Tripping Time at 1953.687A

3.922
t 0.0982 2.5 0.59 second
1953.687 2
1
360
Fault Point 6: Fault at ATS Panel (Back Power Mode)
Z1=Z2=0.0161495+j0.428319 and Z0=0.015896+j0.428179
V 1
Z1 0.0161495 j0.428319


3.922
t 0.0982 2.5 0.59 second
2
1952.1545
1
360
3Vfault 3
I3faultpu 2.333 pu
Z0 Z1 Z2 0.048195 j1.284817
Tripping Time at 1952.3814

3.922
t 0.0982 2.5 0.59 second
2
1952.3814
1
360
Fault Point 7: Fault at Motor Terminals (Back Power Mode)
Z1=Z2=0.0194425+j0.429554 and Z0=0.017618+j0.429467

V 1
Z1 0.0194425 j0.429554


3.922
t 0.0982 2.5 0.592 second
2
1945.9328
1
360
3Vfault 3
I3faultpu 2.3259 pu
Z0 Z1 Z2 0.056503 j1.288575
I3faultactual IBase x I3faultpu 836.739x2.3259 1,946.1864A
Tripping Time at 1946.186

3.922
t 0.0982 2.5 0.592 second
2
1946.186
1
360
Table 8.5 Summary of Fault Calculation Results

Three Phase Single Line to
Fault Point Location Fault Current Ground Fault
(A) Current (A)
Primary terminals of 15,851 11,374

transformer (Normal Power
Mode)
Secondary terminals of 2,569 1,522.66

transformer (Normal Power
Mode)
ATS (Normal Power Mode) 2,563.4 2,632.2618
Terminals of Motor (Normal 2,549.427 2,618.313
Power Mode)
Backup Generator Breaker 1,953.68 1,953.687
Switchgear (Back Power 7
Mode)
ATS Panel (Back Power 1,952.1545 1,952.3814
Mode)
Motor Terminals (Back Power 1,945.9328 1,946.1864
Mode)

TCC for Phase OC Protection for Fire Pump G9900 on Normal
1000 Power
Transformer
FL=83A
Transformer
G9900
Damage Curve
Motor
100 Running
Curve
IFLA=47.7A Cable Damage
Curve
G9900
Motor
Starting
Curve
ILRC=320A
10
TIME (s)
R1
1 51V
CT 100:5
Pickup=9.2In
Pickup I=184A
ANSI VI
TD=1.28
0.1
Inrush point
1004A @0.1s
0.01
1 10 100 1000 10000 100000
CURRENT (A) AT 13.8kV BASE
Figure 8.12 Time-Current Curve for Normal Power Source of

Fire Pump

TCC for Phase OC Protection for Fire Pump G9900 on Backup
Power (Standby Generator)
1000
Generator 51V
Full load Pickup I=360A
Curve
G9900
100 Motor
Running Generator
Curve Overload
IFLA=47.7A Curve
R2
51V
10 CT 400:5
Pickup=3.68In
Pickup I=360A
TIME (S)
ANSI VI
TD=2.5
Generator
Decrement
Curve
@ 3PU Field
1 Current
Cable Damage
Curve
0.1
0.01
1 10 100 1000 10000 100000
CURRENT (A) AT 6.9kV BASE
Figure 8.13 Time-Current Curve for Backup Power Source of

G9900
Fire Pump Motor
Starting
Curve
ILRC=320A

Generator
Decrement
Curve
@ 3PU Field
8.2.7 Equipment Grounding Conductor
Primary pickup current of 51FP is 184A, according to Table
2.50.6.13 of PEC I 2009, the minimum equipment grounding
conductor size is 14mm2 copper. However, since the full load
current of 2 MVA transformer is 84A and the maximum allowable
setting of the overcurrent protection device at the primary of the
transformer is 252A or 300% of the full load amps, a 22 mm2
equipment grounding conductor is recommended in order to serve
for future expansion of additional fire pumps.
Table 8.6 Summary of Equipment Grounding Conductor Size

Protection EGC
Length
Equipment Size/ Size
(m)
Setting (A) (mm2)
Normal source to power 252 22 820

transformer (Primary)
Power Transformer to ATS 252x2=504 38 22
Generator to ATS 360 30 22
(use 38)
ATS to Fire pump controller Highest of 38 20
panel the two
source (504)
Fire pump control panel to fire 504 38 15
pump motor

Table 8.7 Minimum Size of EGC (PEC I table 2.50.6.13)
8.2.7 Arc-Flash Calculation

Based on the calculated fault currents on various points of the fire
pump circuit, an arc-flash calculation using the same method used
in Chapter 7 is performed and the results are summarized on Table
8.8, 8.9, 8.10.
Table 8.8
100% 80%
Isc Iarc
Location En En
(kA) (kA)
(j/cm2) (j/cm2)
Power Plant 23.25 22.24 9.05 7.59
ATS (Normal) 2.56 2.55 0.87 0.73
ATS (Backup) 1.95 1.95 0.65 0.55
Back up Generator Breaker 1.95 1.95 0.65 0.55
Panel

Table 8.9 Summary of Arc-Flash Incident Energies and
Hazard Level
100% 80%
Location E Hazard E Hazard
(cal/cm2) Level (cal/cm2) Level
Power Plant 9.09 3 7.63 2
ATS (Normal) 2.11 1 1.89 1
ATS (Backup) 5.90 2 6.12 2
Back up Generator 7.86 2 8.15 3
Breaker Panel
Table 8.10 Summary of Arc-Flash Protection boundary

Location AFB (mm) 100% AFB (mm) 85%
Power Plant 4808 4018
ATS (Normal) 1070 955
ATS (Backup) 3082 3199
Back up Generator Breaker Panel 4142 4299
! WARNING
Arc-Flash and Shock Hazard
Appropriate PPE Required
Equipment ID: 52FP
Arc-Flash Protection Shock Protection
Flash Protection Boundary(mm): 4808 13.8kVac Shock Hazard When: Open

Hazard Risk: 3
Incident Energy (cal/cm2): 9.03 Limited Approach Boundary: 1.5 m
PPE:
Cotton Underwear Restricted Approach Boundary: 0.7 m
FR shirt and pants x Prohibited Approach Boundary: 0.2 m
Full arc-flash suit,hood x
Hard Hat
Safety Glasses x
Hearing Protection x
Leather gloves and shoes x Date of Calculation: May 25, 2017
Non-melting shirt & pants x
Figure 8.14 Arc-Flash Label for 52FP Power Plant Circuit

Breaker Panel

! WARNING
Equipment ID: ATSFP/FPC

Hazard Risk: 2
PPE:
Hard Hat
Safety Glasses x
Figure 8.15 Arc-Flash Label for Transfer Switch Panel and

Fire Pump Controller
! WARNING
Equipment ID: BGENFP

Hazard Risk: 3
PPE:
Hard Hat
Safety Glasses x
Figure 8.16 Arc-Flash Label for Backup Generator Panel and

Fire Pump Controller

8.2.8 Bill of Materials
Table 8.4 Bill of Materials

Total Cost
No Description Qty.
(Php)
1 1C-95mm2 copper XLPE 12/20kV aluminum 2520 m 3,293,640.00
shielded PE (Fire resistant with 3-hour circuit
integrity according to IEC 60331)
2 1C-50mm2 copper XLPE 12/20kV aluminum 105 337,235.00

shielded PE (Fire resistant with 3-hour circuit
integrity according to IEC 60331)
3 22mm2 plain annealed copper stranded class 820m 123,000.00
2,450/750V PVC insulation green with yellow
stripes
4 22mm2 plain annealed copper stranded class 80m 40,000.00
2,450/750V PVC insulation green with yellow
stripes
5 Transformer, 2MVA 13.8kV-6.9kV, Oil immersed, 1 set 1,617,083.00
Dyn11
6 Fire Controller Eaton LMR 100-3250hp 6900kV 1 set 450,300.00
DOL
7 Transfer switch 2,100,000.00
8 Generator Switchgear 1,800,000.00
9 Diesel Generator 3.5MVA, 6.9kV 3phase, 60Hz, 1 set 33,250,000.00
1800RPM Turbocharged and after-cooled
complete with Generator Controller, exhaust
muffler, anti-condensation heater, Battery
chargers, PMG, Spring-type vibration isolator,
Fuel tank
10 3M Cold Shrink QT-III Silicone Rubber Indoor 27 sets 1,703,592
Tubular Termination Kits for single core cable.
7624T110 15kV (110kV BIL) including
termination works.
11 Cable tray ladder type-straight section, HDG 225 pcs 2,227,273.75
Steel, 6 rung x12W x 12 L with solid flanged

cover
12 Heavy duty cover clamps HDG steel series 148 625 pcs 490,909
13 Universal splice plates HDG steel series 148 700 pcs 13,420
14 Trefoil Cable cleats 912pcs 15,400
15 Cable tray fittings HDG steel 90deg horizontal 10pcs 25,000
bend series 148, 12
15 Cable tray fittings HDG steel vertical bend inside 10 pcs 25,000
series 148, 12
17 Cable tray fittings HDG steel vertical bend 12 pcs 35,000
outside series 148, 12
18 Bonding jumper 2000A max, 99-1620 700 pcs 54,678
19 Structural and civil works including materials and 1 lot 3,800,000.00
labor for switchgear and generator room
20 Electrical Installation including cable pulling, 2,500,000.00
cable tray installation, panel installation, cable
termination works,
21 Testing and commissioning for Fire pump 1 lot 95,000.00
controller (2 days @ 8hrs per day)
22 Testing and commissioning for diesel generator 1 lot free
(2 days@ 8hrs per day)
23 Testing and commissioning for transfer switch 1 lot 54,000.00
and generator switchgear (2 days @ 8 hrs per
day)
Grand Total (Php) 54,050,530.75
Cable Schedule
Length Size Insulation/Volt/ Raceway
Tag From To 2
(m) (mm ) Sheathing
Cable 52FP TRFP 2400 95 XLPE/12/20kV 6x12 Cable
aluminum tray
1
Shielded/Polyolefin-
Copolymer
Cable TRFP TSFR 60 95 XLPE/12/20kV 65mm-Conduit
aluminum
2
Copolymer
Cable BGEN TSFR 60 95 XLPE/12/20kV 65mm-Conduit
aluminum

3 Shielded/Polyolefin-
Copolymer
Cable TSFR FPC/ 105 50 XLPE/12/20kV 65mm-Conduit
aluminum
4 MOTOR
Copolymer

33-Chapter 8-Fire Pump Evaluation

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33-Chapter 8-Fire Pump Evaluation

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CHAPTER 8

This chapter will provide an evaluation and recommendation

8.1 Evaluation of Existing Installation

8.1.1 Fire Pump System Overview

Figure 8.1 P&ID of Fire Water System of JGSPC

Figure 8.2 DCS Schematic of Fire Water System of JGSPC

Chapter 8-Fire Pump Page 360

Table 8.1 Electrical Specification for G9900 Fire Water Pump

8.1.3 Fire Pump Controller

Figure 8.3 Existing Fire Pump Controller Panel

Chapter 8-Fire Pump Page 361

8.1.5 Reliability of Existing Source

Chapter 8-Fire Pump Page 362

52FP Dedicated Feeder (from

Figure 8.4 Single Line Drawing for Fire pump

Chapter 8-Fire Pump Page 364

Re quired Locked Rotor MVA 3 x ILRC x V

Each generator has 8.375MVA so at least one generator is

8.2.2 Standby Generator Sizing (alternative power)

Re quired Locked Rotor MVA 3 x ILRC x V

Consider 3.824MVA or 4MVA diesel generator set with

Chapter 8-Fire Pump Page 366

1.00 0.15 22.8176

8.2.3 Transformer Sizing

Say 1MVA but for future expansion consideration where

Table 8.3 Transformer Specification

Chapter 8-Fire Pump Page 367

Protection Settings Calculation (Primary Overcurrent protection 51):

The circuit breaker size of 630A is enough for the locked-

Generator Full load current:

Circuit Breaker Sizing:

Phase time overcurrent protection will be set at 115% of

LRC 320A and Reference Voltage 6900V

This setting is less than 125% of generator full load

Adding a margin to this time

For an XLPE cable at 13.8kV, the minimum cable size is

For primary cable (CABLE No.1):

IAmpacityRe q 1.25 x 83.67 104.59A

From Table 8.4 and considering the minimum cable size of

For Transformer Secondary Cable to Transfer Switch (CABLE

Chapter 8-Fire Pump Page 370

For Generator Cable to the Transfer Switch (CABLE No.3):

From Table 8.4, use 20m 2 sets 3 x 1C-95mm2 copper XLPE

Table 8.4 Cable Specification Sheet for LION Cable

Chapter 8-Fire Pump Page 371

8.2.6 Voltage Drop Calculation

Power plant available fault

Cable no. 1 Impedance

Chapter 8-Fire Pump Page 373

Cable no. 2 Impedance

Chapter 8-Fire Pump Page 374

Cable no. 3 Impedance

Cable no. 4 Impedance

Chapter 8-Fire Pump Page 375

ZMotor 0.387907 j 2.586048 pu

Z4MVAGen 0.012832 j0.357 pu

Chapter 8-Fire Pump Page 376

Z3.5MVAGen 0.015679 j0.428 pu

Starting Voltage Drop for Normal Power

Transformer ZTrans 0.04364 j0.2968 pu

Chapter 8-Fire Pump

ZTOTAL 0.445929 j2.909085 p.u

Figure 8.6 Impedance for Normal Power Voltage Drop

VDFirePumpMotor 0.111518pu 11.1518%