Blue Water Iron ORE Terminal PVT LTD 10

Design basis report - Electrical
S332115-943-DC-03, R2
BLUE WATER IRON ORE TERMINAL PVT LTD
10 MTPA IRON ORE TERMINAL AT PARADIP
DESIGN BASIS REPORT OF ELECTRICAL SYSTEM
Prepared By: 18 August 2010

Ashwini Chavan
Reviewed By: 18 August 2010

Kishor Bhagwat
Approved By: 18 August 2010

Kishor Bhagwat
NOTICE
This document is for the private information and benefit only of the client for whom it was prepared and for the particular purpose
previously advised to Sandwell Engineering Inc. ["Sandwell"]. The contents of this document are not to be relied upon or used, in
whole or in part, by or for the benefit of others without prior adaptation and specific written verification by Sandwell.
Particular financial and other projections and analysis contained herein, to the extent they are based upon assumptions concerning
future events and circumstances over which Sandwell has no control, are by their nature uncertain and are to be treated
accordingly. Sandwell makes no warranties regarding such projections and analysis.
Sandwell and its corporate affiliates and subsidiaries and their respective officers, directors, employees and agents assume no
responsibility for reliance upon this document or any of its contents by any party other than Sandwell's client.
Copyright to this document is wholly reserved to Sandwell.

S332115-943-DC-03, R2
TABLE OF CONTENTS
REVISION SUMMARY .............................................................................................................. 3
1. SCOPE........................................................................................................................... 4
1.1 GENERAL......................................................................................................................... 4
2. INPUT DATA AND DESIGN CRITERIA ......................................................................... 4
2.1 GENERAL......................................................................................................................... 4
2.2 CODES AND STANDARDS .................................................................................................. 5
3. POWER DISTRIBUTION SYSTEM ................................................................................ 5
3.1 LOAD CALCULATION .......................................................................................................... 5
3.2 NORMAL POWER SUPPLY (GRID) ....................................................................................... 5
3.3 EMERGENCY POWER SUPPLY (DG).................................................................................... 5
3.4 DISTRIBUTION VOLTAGE LEVELS ........................................................................................ 6
3.5 POWER FACTOR IMPROVEMENT ......................................................................................... 6
3.6 EQUIPMENT SIZING AND SELECTION ................................................................................... 8
3.7 CONTROL, PROTECTION AND OPERATION PHILOSOPHY ......................................................11
4. SERVICE SYSTEM .......................................................................................................11
4.1 CABLING SYSTEM ............................................................................................................11
4.2 EARTHING SYSTEM (INDOOR AND OUTDOOR) ....................................................................14
4.3 LIGHTNING PROTECTION SYSTEM .....................................................................................15
4.4 LIGHTING SYSTEM ...........................................................................................................16
5. ANNEXURES ................................................................................................................18
5.1 SITE CONDITIONS ............................................................................................................18
5.2 LIST OF STANDARDS ........................................................................................................20
5.3 EARTHING MATERIAL SIZES ..............................................................................................25
5.4 DEGREE OF PROTECTION AND INSULATION .......................................................................26
5.5 ILLUMINATION LEVEL TABLE ..............................................................................................27
5.6 LIST OF APPROVED VENDOR ............................................................................................28
5.7 KEY SINGLE LINE DIAGRAM ...............................................................................................31
5.8 LOAD LIST .......................................................................................................................32
Customer: Blue Water Iron Ore Terminal Pvt Date: 18 Aug 2010
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Project:10 MTPA Iron Ore Terminal (332115)
S332115-943-DC-03, R2
REVISION SUMMARY
Page(s)
Date Rev. Description Rev. By.
Revised
18 Aug 2010 R2 Issued for Approval - -
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1. SCOPE
1.1 General
1.1.1 This design basis report is intended to cover the salient features of the
electrical system envisaged for the minimum 10 MTPA Iron ore terminal at
Paradip, Orissa. This design basis report (DBR) forms the basis for detailed
engineering.
1.1.2 The scope of this document includes design of the electrical distribution
system for the terminal i.e. downstream of 33 kV switchgear up to the
respective load centers through power control centers (PCCs) / distribution
boards. Engineering of electrical system for packages i.e. wagon tippler,
stacker, reclaimer, belt conveyor and ship loader including cabling &
earthing is beyond the scope. The same will be in the scope of respective
package supplier. However the interconnection / hook up of the electrical
system of packages with the main electrical system have been included in
the scope.
1.1.3 The DBR covers design aspects of power distribution system and service
system for the above scope as outlined below.
a. The plant power distribution system:
Normal power supply

Emergency power (DG) supply
Distribution voltage levels
Power factor Improvement
Equipment sizing and selection
Control, protection and operating philosophy
b. The Service system:
Terminal cabling system for areas other than packages mentioned

above
Safety earthing & lightning protection system
Plant lighting system excluding switchyard
2. INPUT DATA AND DESIGN CRITERIA
2.1 General
2.1.1 The following data forms the basis of this design Report:
a. 33KV substation being supplied by others (PPT) will have six outgoing
feeders out of which two feeders are dedicated for iron ore substation.
b. Fault level at 33kV is 1500 MVA for 3 sec.
c. The electrical system shall be designed for the load of packages, their
utilities and other site support facilities. Electrical equipments are sized
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for the existing package loads and utility loads.
d. DG set will be provided as a back-up for feeding the load of either of the
ship loaders, one of its preceding conveyors and emergency lighting in
case of failure of grid power at substation 2. This provision is made to
clear off the material lying on the belt or the ship loader at the time of
power failure.
e. Design ambient temperature for electrical equipment shall be 50°C.

Temperature in substations and central control room shall be maintained
below 30°C.
f. Voltage variation of ±10%, frequency variation of ±5%, combined voltage

and frequency variation of ± 10% is considered.
2.2 Codes and Standards
2.2.1 Refer Annexure 5.2 for the applicable codes and standards. The design
shall conform to the latest editions of the codes and specifications wherever
applicable, unless otherwise indicated.
3. POWER DISTRIBUTION SYSTEM
3.1 Load calculation
3.1.1 The total estimated electrical load of the entire plant is approximately 20000
kVA. Annexure 5.8 gives the preliminary electrical load list.
3.2 Normal power supply (Grid)
3.2.1 Two nos power supply feeders at 33 KV will be made available at the
substation provided by PPT. BWIOTL scope starts from termination of these
two feeders including cable upto main iron ore substation - Substation 1.
3.2.2 Two substations have been envisaged near load centers so as to distribute
the entire plant load evenly on each of the transformers.
3.2.3 Substation 1 located at stockyard shall receive the power at 33KV. It is

stepped down to 6.6kV through 2 nos 12.5 MVA transformers. The
distribution of power to the main loads shall be through 6.6kV switchgear.
Substation 2 shall be fed at 6.6kV from substation 1.
3.2.4 All 415V loads shall be fed through 6.6kV / 433V transformers at respective
substations.
3.2.5 The entire plant shall run on the grid supply in normal conditions.
3.3 Emergency power supply (DG)
3.3.1 DG set at 6.6 kV shall be provided for feeding the load of either of the ship
loaders and its preceding conveyor and emergency lighting in berth area.
3.3.2 Load of the ship loaders, conveyors that are to be fed through DG shall be
managed manually so as to restrict the load on DG.
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3.4 Distribution voltage levels
3.4.1 The plant primary distribution shall be at 6.6kV and secondary distribution
shall be at 415V.
3.4.2 For major packages like wagon tippler, stacker, reclaimer and ship loader,
power shall be fed at 6.6kV.
3.4.3 Belt conveyor motors shall be fed at 6.6kV / 415V through DOL feeder as
applicable.
3.4.4 The scope of work starts at power distribution at 33kV. The primary
distribution voltage shall be at 6.6kV, 3 Ph – 3 wires, 50 Hz, resistance
grounded while the secondary distribution voltage shall be at 415V, 3 Ph – 4
wire, 50 Hz, solidly grounded.
3.4.5 33/6.6 kV transformers which form the primary supply for the plant shall be
located at Substation 1. The detail of the switchgear configuration has been
discussed in subsequent clauses.
3.4.6 6.6kV primary distribution supply shall be stepped down to 415V through
ONAN distribution transformers located at each substation to feed all other
loads.
3.4.7 Further distribution of power up to individual loads shall be carried out

through Power Control Center (PCCs), Motor Control Centers (MCCs) &
Distribution Boards (DBs) located at the respective substations.
3.4.8 415V PCCs which form the secondary distribution shall be located at
respective substations.
3.4.9 The conceptual Single line diagram (SLD) enclosed with this report drg no.
A0-332115-D943-5000 depicts power distribution scheme adopted for the
loads.
3.4.10 Auxiliary supply voltages shall be as follows:
a. Power supply for lighting and receptacles shall be 240V, 1 Ph - 2 wire,

50 Hz, A.C.
b. Power supply for 33kV & 6.6kV breaker control, 415V breaker control
shall be 110V DC.
c. Control power supply for feeders in PMCC and MCC shall be 240V, 1
Ph, AC tapped from the main incomer of PMCC or MCC through
common 415 / 240V control transformer.
3.5 Power factor improvement
3.5.1 The design shall provide for capacitor banks at 415V PCCs for improving
the P.F. to 0.92 at individual 415V PCC.
3.5.2 The power factor correction in the system shall be done by adding suitable
rating capacitor banks to the each main distribution bus supplied from the
transformer. The capacitor banks shall have an automatic power factor
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controller which shall be automatically correcting the power factor with built
in monitoring & protection features.
3.5.3 The capacitors shall be sized to get the envisaged power factor with 10 %
margin.
3.5.4 Capacitors
a. The capacitors shall be of the 3 phase, delta connected with all live parts
totally enclosed and suitable for any random type of mounting i.e.
vertical or horizontal mounting. The capacitor banks shall be mixed
dielectric type or all polypropylene type.
b. The basic unit size shall be of 5 KVAR, 10 KVAR, 20 KVAR or 25 KVAR

as the case may be.
c. Capacitors banks shall be placed in suitable panels or as required.
d. Capacitors shall be provided with permanently connected discharge

resistors.
3.5.5 Automatic power factor controller (APFC)
a. Power factor controller should be mounted on the front of the APFC

panel.
b. The controller shall be capable of sensing incoming power & keep all
capacitor units during normal conditions.
c. Microprocessor based power factor controller shall continuously monitor

all three phases and display various electrical parameters like voltage,
input current, capacitive current, KVA demand, KW, power factor, self
diagnostic error code indication.
d. APFC panel shall be provided with microprocessor based numerical

relay.
e. The APFC shall be provided with over voltage, voltage imbalance, over
temperature, earth leakage protection.
3.5.6 A 3 phase, 6.6 kV capacitor bank of suitable rating shall be connected in

parallel with each 6.6 KV motor and/or 6.6 KV switch board to correct its
power factor to 0.92.
3.5.7 6.6kV capacitors shall be placed next to corresponding 6.6kV switchboard in

respective substations.
3.5.8 0.2% reactors shall be connected in series with each of 6.6kV capacitor for
harmonic suppression.
3.5.9 For packages receiving MV power supply, the respective package vendor
shall provide suitable PF compensation within package system.
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3.6 Equipment sizing and selection
3.6.1 All the electrical equipments such as switchgear, transformer, etc shall be
sized based on the total estimated operating load (i.e. actual load) with a
design margin of 20%.
3.6.2 Criterion for selection of equipment (type and rating) is to standardize as

much as possible for ease of operability, interchangeability and to optimize
on Inventory and spares.
3.6.3 The design ambient temperature for all the electrical equipment shall be
50°C.
3.6.4 The exterior finish paint shade of all electrical equipment shall be Siemens
gray (RAL 7032) as per IS-5 and interior glossy white.
3.6.5 6.6kV Switchgear selection
a. The 6.6kV switchgear at substation 1 shall be indoor VCB single front;

free standing having short circuit rating of 40 kA rms, for 1 sec with Cu
sleeved bus bars with two incomers. The incomer shall be rated to utilize
full transformer capacity.
b. The switchgear shall have minimum IP 54 degree of protection and shall

be designed for ambient temperature. The switchgear shall be epoxy
painted with exterior Siemens grey (RAL 7032) and interior glossy white.
c. The switchgear shall be suitable for bottom cable entry.
d. The switchgear shall have numerical relays, load managers (for

incomers only) and energy meters for all outgoing feeders.
e. Additional contacts for status of the various feeders’ alarms /

annunciation related to abnormal conditions (transformers / trip relay) for
remote monitoring if required shall be provided.
f. All control shall be local & remote from the switchgear panels.
g. CT accuracy limit shall be class 0.5 for metering and 5P20 for the
protection.
h. PT accuracy limit shall be class 0.3 for metering and 3P for protection.
i. The protection for outgoing transformer feeders and incoming (generator

/ grid) feeders shall be provided as mentioned in subsequent clauses.
j. All motor feeders shall be provided with VCB, vacuum contactors, and
motor protection relays compatible for PLC/DCS communication.
3.6.6 415V switchgear selection
a. The Power control center (PCC) shall be rated for 50 kA for 1 sec.
b. All PCCs and Motor control center (MCCs) shall be single / double front
execution based on space requirement, free standing with copper
sleeved bus bars.
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c. All feeders shall be draw out type.
d. The degree of protection of PCC and MCC shall be as per annexure 5.4.
The switchgear shall be epoxy painted with exterior Siemens grey (RAL
7032) and interior glossy white. However for MCC supplied by package
vendor it shall be as specified in the specification.
e. PCCs shall have bottom cable entry with ACBs as Incomers and
outgoing manually operated 3 pole MCCB/ACB feeders with electronic
release. The Incomer ACB shall have electronic trip releases for
overload, time delayed short circuit, earth fault and under voltage
protection as a minimum.
f. For all PCC and MCC the incomer feeder shall be provided with
voltmeter with voltmeter selector switch (VSS), CTs, ammeter with
ammeter selector switch (ASS).
g. The MCCs shall have bottom cable entry. The incoming ACB / MCCB
shall be 3 pole (TPN) manually operated with overload, time delayed
short circuit and earth fault electronic release as minimum.
h. All motors shall be Direct on Line (DOL) start. Motors > 5.5 KW, shall be
provided with 1 no CT and ammeter. Motors less than 5.5 KW shall have
direct connected ammeters in Y phase. If current monitoring is required
in the plant control room, then 4 – 20 mA transducers shall be provided
in the MCC module. All motors including and higher than 30 KW shall be
provided with 240V motor space heaters.
i. The motor feeders up to 55 kW shall be provided with MPCB with inbuilt

short circuit & thermal overload protection. Feeders above 55 kW shall
be provided with MCCB (as main disconnecting switch with only short
circuit protection) & separate thermal overload relay. Suitable size
contactor shall be provided for motor switching. The components shall
be rated for Type–2 Coordination conforming to IS 13947, Part-4 –1993)
j. Motors > 100 kW, shall be ACB / MCCB controlled with electronic motor
protection relay.
k. The 240V control supply for the motor feeders shall be tapped from the
main incomer of the MCC, through a common 415 / 240V control
transformer.
l. Local control stations shall be provided near the motors for start / stop.
Remote starting from MCC is not envisaged. MCC shall have only stop
pushbutton. The Start command shall be sent from plant control system
or from local P.B. station.
3.6.7 Distribution transformer selection
a. 2 nos. distribution transformers for entire plant loads shall be 33kV /

6.6kV, 3 - Ph, 50Hz oil filled, outdoor type, with off load tap changer with
tap ± 5% in step of 2.5% Dyn11, ONAN type located at transformer yard
in substation 1.
b. Secondary of the 33/6.6kV distribution transformers shall be adequately
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resistance grounded.
c. Each substation shall house adequate number 6.6kV / 433V, 3 - Ph,

50Hz oil filled, outdoor type, with off load tap changer with tap ± 5%,
Dyn11, ONAN type distribution transformers for utility loads.
d. Secondary of the distribution transformers shall be solidly grounded.
e. The transformer HV terminals shall be suitable for cable entry while LV

terminals shall be suitable for cable / bus duct entry.
f. The maximum rating of 6.6kV / 433V transformers shall be limited to 2

MVA in view of the fault level and standard switchgear ratings on the LV
side.
g. The transformer ratings mentioned here is tentative. Final size and nos.
shall be decided based on the actual plant load during detailed
engineering.
3.6.8 Motor selection
a. Motors shall be fed at two different voltage levels 6.6kV and 415V.
b. The motors with rating above 160 kW shall be fed at 6.6kV. Others shall
be at 415V.
c. All 415V motors shall conform to energy efficiency class EFF1. EFF2
shall be selected only where EFF1 is not available for the specified
requirement.
d. The motors with ratings of 30 kW and more shall be provided with space
heaters.
e. The motors with ratings of 90 kW and more shall be provided with three
RTDs, one at each phase for temperature detection.
f. The motors with ratings of more than 160 kW shall be provided with
RTDs for measurement of temperature of bearings.
3.6.9 DOL feeder
a. DOL feeder for all belt conveyor drives have been proposed as it is
assumed that the coupling with delayed start feature will be used which
allows motor to accelerate to full speed on no load.
b. It is assumed that the coupling applies load on motor after motor

reaches full speed and also ensures that the maximum torque during
acceleration of load does not exceed acceptable limits.
c. For belt conveyors with two drives, the couplings shall ensure equal
loading of motors during starting.
3.6.10 Battery and battery charger
a. Suitable size of 110V batteries shall be located in each substation. Float

cum boost type battery chargers shall be used.
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3.6.11 Control UPS selection
a. No other UPS is envisaged in the system. UPS for control system

applications is not included in scope of this document.
3.7 Control, protection and operation Philosophy
3.7.1 6.6kV switchgear located at substation 1 shall have two incomers from 2
nos 33/6.6 kV Transformers. The two incomer bus sections shall be
interconnected by means of bus couplers i.e. B/C-1. Suitable interlocking
scheme between I/Cs and B/C shall be provided. In normal operation B/C
will be open circuited.
3.7.2 6.6kV switchgear located at substation 2 shall have one incomer from each
of the bus section of 6.6kV switchgear located at substation 1.
3.7.3 Distribution Transformer protection
a. IDMT and instantaneous over current and earth fault (50, 51 and 50N)
on primary.
b. IDMT over current and earth fault (51 and 51N) on secondary.
c. Standby earth fault on transformer neutral (51G).
d. Buchholz / winding temp / oil temp. – Trip / alarm.
3.7.4 Motor protection
a. MPCB /MCCB and overload relay. (For motors <= 100kW).
b. Micro processor based motor protection relay having comprehensive

motor protection (For motors above 100kW).
4. SERVICE SYSTEM
4.1 Cabling System
4.1.1 Specification of cables (power / control) for utilities shall be as mentioned in

subsequent clauses.
4.1.2 Conductor material, insulation, sheathing material and armouring for the
cables in the plant shall be as follows;
a. Conductor material: Aluminium for all (6 Sq.mm and above) power

cables. Copper for power cables up to 4 sq mm.
b. Insulation material: For 6.6kV power cables XLPE and PVC / XLPE for
415V power and control cables.
c. Armouring: All power and control cables shall be armoured. GI strip /

wire armour shall be provided.
d. Sheathing material: Inner sheath and outer sheath extruded PVC.
4.1.3 Technical specifications of above cables shall be as follows:
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a. Power cables for 6.6KV, non-effectively earthed system : 6.6KV (UE)

grade stranded aluminium conductor, multi core, XLPE insulated,
extruded PVC inner sheathed, galvanized steel wire armoured and PVC
outer sheathed cable, as per IS:7098.
b. Power cables for 415V, solidly earthed system: 1.1KV grade stranded Al
conductor, multi core, PVC / XLPE insulated, extruded PVC inner
sheathed, galvanized steel wire / strip armoured and PVC outer
sheathed cable, as per IS:7098.
c. Control cables: 1.1kV grade stranded copper conductor (of minimum 1.5
sq.mm.), PVC / XLPE insulated, extruded PVC inner sheathed,
galvanized steel wire armoured, PVC outer sheathed as per IS: 1554. If
the cost of XLPE is marginally higher, XLPE may be used.
d. All cables shall be provided with galvanized steel amour.
e. Selection of number of cores: Cables above 300 sq.mm are bulky and
inconvenient for handling and also require more bending radius.
Therefore for applications that require cross sectional area above 300
sq.mm either single core cables or multiple runs of 3 core cables shall
be used.
f. All control cables cores shall be colour coded upto 5 core cables, and
shall be numbered for cables with more than 5 cores.
4.1.4 Sizing of cables: Actual sizing of cables shall be done during detail design
stage. Design parameters of the systems which shall be considered for
arriving at suitable size of cables shall be as follows.
4.1.5 For power cables following factors are considered:-
a. Continuous current carrying capacity: It shall be calculated considering

overall derating factor.
b. Voltage drop: 3 % at motor terminals while running, 15% dip at motor

terminals while starting and 3% for the non motor feeders.
c. Overall derating factor: Overall derating factor shall be calculated

considering derating factors for ambient temperature (ground / air),
depth of laying, method of laying (directly buried / trenches / trays),
grouping factor and thermal resistivity of soil for directly buried cables.
Calculation of derating factor shall be done during detailed engineering
stage.
d. Short time rating: Fault level and duration in sec. considered for breaker
controlled feeders.
4.1.6 For 240V / 110V AC control cables following factors are considered.
a. V. T. circuits: Voltage transformer leads shall be checked for voltage

drop which shall be limited to within 0.2% for commercial metering and
1% for other purposes.
b. C.T. circuits: Voltage drop criteria not applicable. However, suitable
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size should be selected so as to avoid high burden on CT secondary.
c. Control circuits: Voltage drop need not be considered except very

special cases where long lengths are involved.
4.1.7 For lighting cables following factors are considered.
a. Lighting cables shall be designed so that the total voltage drop from
lighting distribution board to lighting panel shall not exceed 3%. For
general / periphery lighting total voltage drop from lighting board to last
fitting shall not exceed 3%.
b. Cable glands: Double compression type cable glands shall be used.

These cable glands shall be brass casting, machine finished and tinned
to avoid corrosion and oxidation.
c. Cable termination: All 6.6kV termination kits shall be of heat shrinkable

type and suitable for XLPE insulation and shall be tested for system
short time ratings. All 1.1kV terminations for power and control cables
shall be crimping type, tinned copper, solder less lugs.
d. Cable joints: Cable joints shall be avoided to the extent possible. If joints
are unavoidable due to circuit length, in excess of permissible maximum
drum length, they shall be heat shrinkable types having a system short
circuit withstand capacity.
e. Cable Trays: Cable trays of ladder and perforated types and associated
accessories such as cable tray covers, coupler plates, tees, elbow etc.
shall be of GI. Cable trays shall be supplied in standard length of 2500
mm and clear inside width of trays shall be as follows:
Perforated type trays : 150, 300, 450 and 600 mm

Ladder type trays : 150, 300, 450, 600 and 750 mm
f. Fire proof Sealing of cable penetration: Cables / cable tray openings in

walls and floors or through pipe sleeves from one area to another or one
elevation to another shall be sealed by a fire-proof sealing compound.
g. Mode of Laying for cables shall be as follows:
Cables in outside areas between various buildings shall be run along

the conveyor gallery.
Cables inside the plant shall be laid either on overhead cable trays or
trenches depending on equipment location. Cables inside the panel
room shall be laid in built-up RCC trenches.
Power cables shall be laid in ladder type trays. Control cables shall
be laid in perforated trays. Cable trays shall be supported from
slabs/walls as found suitable. Power and control cables of various
class of supply shall be laid in separate trays.
Cables of sizes 120 sq.mm and above shall be laid in single layer.
Single core cables used for 3 phase AC power circuits shall be laid in
trefoil form.
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The trays will provided with covers in outdoor areas.
h. Design of cabling system for packages shall be done by package

vendor.
i. Cables laid from substation to admin building, workshops, canteen etc

will be underground or above ground
4.2 Earthing system (Indoor and Outdoor)
4.2.1 Earthing shall be designed as per guidelines of IS: 3043-1987- Code of

Practice for Earthing and Indian Electricity Rules.
4.2.2 Material Selection of earthing conductor depends on resistance to corrosion

in the surrounding medium. Both mild steel (MS) and copper have good
resistance to corrosion. In view of the high cost of Cu, mild steel (MS) is
recommended for the electrical safety earth.
4.2.3 Conductor Size: The required cross sectional area of earthing conductor is
calculated for 1 second duration of fault current of 50 kA.
4.2.4 Earthing system shall be designed to obtain an overall earth resistance of <
1 ohm which shall be achieved by means of main earth grid and earth pits.
4.2.5 Main earth grid conductor around buildings: MS strip of 75x 10 mm cross
section (nominal area) shall be laid at a distance of 1.5 m from the periphery
of the building. The depth of burial shall be 600 mm.
4.2.6 Interconnection of earthing grids: Earthing grid of the various buildings shall
be interconnected by 2 nos of earthing strip of size 75 x 10 mm MS strip
which shall run along the buried cables, wherever available.
4.2.7 Treated Earth Pits: Earth electrodes shall be of GI pipe with 40 mm dia. and
3 metre length. A few earth electrodes with disconnecting facility (test pits)
shall be provided so that the resistance of the earth electrodes may be
measured. These earth pits for test electrodes shall be suitably treated.
4.2.8 Untreated Earth Pits: Earth electrodes shall be of MS rod with 40 mm dia.
and 3 metre length. A few earth electrodes with disconnecting facility (test
pits) shall be provided so that the resistance of the earth electrodes may be
measured.
4.2.9 Earthing connection for the switchgear room: Earthing conductor for the
6.6KV & 415V switchgear shall be formed with GI strip. Typical sizes of the
earth conductors are mentioned in annexure 5.3. Actual sizes shall be
finalized during detail engineering.
4.2.10 Earthing connection inside building: Main earthing loop inside the building
shall be laid on cable trays or in cable trench, based on availability. This
shall be connected to earthing loop of outdoor system at minimum of two
points.
4.2.11 Earthing connection for the cables
a. Armour of three core cables shall be earthed at both ends using double
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compression gland.
b. Earthing strip shall run along the cable tray and shall be connected to
main earthing grid at 25 m interval at minimum two points.
4.2.12 Equipment Earthing
a. Taps from main earthing system shall be connected to earthing

terminals of the equipment / structure. All electrical equipment shall be
connected to the earthing system by two distinct leads.
b. Miscellaneous steel structures, conveyor gallery, all steel structures

accessible to personnel as enclosures, steel stairways etc. shall be
connected to earthing system by one distinct lead.
4.2.13 For sizes of earthing conductor for various equipments refer annexure 5.3.
4.2.14 Design of earthing system for packages shall be done by package vendor.
4.3 Lightning protection system
4.3.1 Lightning Protection system shall be designed as per guidelines of IS:

2309:1989 – Code of Practice for Protection of Buildings and allied
structures against Lightning and Indian Electricity Rules.
4.3.2 Material Selection: Lightning protection of the building structure shall be with
galvanized iron for horizontal roof conductors and down conductors.
4.3.3 IS 2309 recommends the minimum size of roof and down conductor as 20 x
3 mm galvanized iron strip (refer clause 11.1 Table 4 of IS 2309). Higher
conductor size of 25 x 3 mm from considerations of mechanical strength and
resistance to corrosion has been proposed. However actual size shall be
finalized during detailed engineering stage
4.3.4 Vertical air termination: 65 NB (Heavy) 4.0m, long M.S. pipe (assembly hot
dip galvanized).
4.3.5 Air termination system for the buildings: An air termination system
comprising of horizontal roof conductors shall be so laid out that no part of
the roof shall be more than 5 m from the nearest roof conductor and
maximum spacing between the roof conductors shall not be more than 10m
as recommended in IS 2309.
4.3.6 In order to protect the waterproofing from damage while cleating the
horizontal conductors, concrete pedestal of 100mm x 150mm x 150mm shall
be erected and horizontal conductor shall be cleated over the same.
4.3.7 Down conductors: Air termination system shall be connected to the earthing
system by down conductors fixed along the outer surface of building. Each
down comer shall be terminated to a separate untreated test earth
electrode. The number and spacing between the down conductors shall be
as per IS: 2309 (clause 12.2.3). Test link shall be provided in the run of each
down conductor at approximately 1000mm above ground level.
Ltd Page: 15 of 32
S332115-943-DC-03, R2
4.3.8 Termination of lightning down conductor: Down comers of a lightning

protection system shall be connected to earthing electrode via test link
facility located 1 m above ground level.
4.3.9 Metallic pipe, conduit, structures shall be bonded to lightning protection

conductors to prevent the side flashovers. But no metallic pipe, conduit,
structure shall be used as air termination conductor or down conductor.
4.4 Lighting system
4.4.1 Lighting design is considered to provide a general uniform illumination level.
4.4.2 Illumination levels for various areas, rooms shall be chosen in line with IS
recommendations. Illumination lux levels for the main areas and type of
fixtures along with maintenance factor and reflection factor are indicated in
annexure 5.5.
4.4.3 Total lighting load shall be worked out during detailed engineering. The
distribution of lighting fixtures shall be such that each phase shall be equally
loaded. The load current of the protective device (MCB) shall not exceed
80% of the rating of the device.
4.4.4 Lighting distribution: lighting distribution system shall be classified as

follows;
a. Normal lighting (grid supply)
b. Critical lighting (normal supply with battery)
4.4.5 Lighting shall be fed via lighting transformer & main lighting distribution
board (MLDB) at each substation and lighting panels at various locations.
4.4.6 Lighting transformer: 415V/415V, star / star, dry type transformer of

adequate capacity shall feed the MLDB.
4.4.7 MLDB: 415V, TPN main lighting distribution board, shall be fed from lighting
transformer. MLDB shall have incoming and outgoing MCCBs. The outgoing
shall be fed to the lighting panels.
4.4.8 Lighting panel: 415V TPN lighting panel shall have TPN MCB + ELCB
(100mA) as incomer and SPN / TPN MCBs for feeding the lighting fixtures
as outgoing. MCBs rated short circuit capacity shall be 10 kA. ELCB shall be
provided to meet statutory requirements for human safety against shocks
due to earth leakage.
4.4.9 Critical Lighting: Critical lighting shall be fed from lighting panel. Critical
lighting is envisaged in the substation, control room and in staircases /
corridors – basically with the purpose of emergency exit. With normal supply
healthy, these will remain off & shall get ‘ON’ automatically on failure of
normal supply.
4.4.10 Outdoor Lighting: Outdoor lighting is envisaged for stockyard, general area
and street lighting and building periphery lighting. Outdoor lighting shall be
fed from MLDB.
Ltd Page: 16 of 32
S332115-943-DC-03, R2
4.4.11 All lighting panels shall be located indoor and at appropriate places, which
shall be indicated during detailed engineering.
4.4.12 Receptacles
a. All the receptacles shall be fed from DB. The receptacles shall be
5A/15A, 1 phase and 3 phase. Receptacles shall be provided at
appropriate places. For light duty applications it shall be provided with
MCB as incomer. 32A/63A, 3 phase, 5 pin receptacles shall be provided
for welding at appropriate location. All receptacles shall have interlocked
switch and socket along with 300 mA ELCB.
4.4.13 Mode of Wiring
a. Wiring for lighting, receptacles shall be provided in concealed PVC

conduits with insulated copper wires. Wires / cables shall have minimum
size of 2.5 sq.mm for lighting circuits and 4 sq.mm for power receptacles
circuits. The final sizing shall be done during detailed engineering.
b. Armoured cables shall be used for outdoor lighting (Street, flood lighting)
and from lighting distribution board to the lighting panel.
Ltd Page: 17 of 32
S332115-943-DC-03, R2
5. ANNEXURES
5.1 Site conditions
Plant location
Nearest airport Bhubaneswar
Approach road (Highway) NH-5
Nearest railway station Paradip
Nearest seaport Paradip, Orissa
Ambient conditions
Altitude 1.54m below mean sea level (MSL)
Design ambient temperature 50 0C
Maximum humidity 100 %
Primary power supply
Incoming supply 33000 V, 3 Ph, 3Wire, 50Hz, effectively

grounded
Incoming supply system fault level 1500 MVA at 33kV
Distribution voltage for plant 415 V, 3 Ph, 4 Wire, 50 Hz
Envisaged improved power factor 0.92 lagging
Auxiliary Power supply
Lighting fixture, space heater, (1- 240 V, 1 Ph, 50 Hz.

ph- motors, 1-ph receptacle)
Control supply
For HT breakers 110 V, DC supply
For LT breaker 240 V, 1 Ph, 50 Hz. supply
For instrumentation and control 240 V, 1 Ph, 50 Hz.
Supply voltage and frequency variation
Voltage variation 10%
Frequency variation + 5%
Ltd Page: 18 of 32
S332115-943-DC-03, R2
Combined voltage and frequency 10%

variation
Motors
Motors rated < 200W 240 V, 50 Hz, 1 phase supply
Motors rated ≥ 200W 415 V, 50 Hz, 3 phase supply
Ltd Page: 19 of 32
S332115-943-DC-03, R2
5.2 List of standards
MV SWITCHGEAR
IS 3427/IEC 60298 AC metal enclosed switchgear and control gear for
rated voltages above 1KV up to and including 52 KV.
IS 12729 General requirements for switchgear and control gear
for voltages exceeding 1000V.
IS 13118/IEC 60056 General requirements for circuit breakers for voltages
above 1000V.
LV SWITCHGEARS
IS 8623/IEC 60439 Pt. 1, 2, 3 Specifications for low voltage switchgear
IS 4237 General requirements for switchgear and

controlgear for voltages not exceeding 1 000 volts
ac or 1 200 volts dc
IS 10118 Code of practice for selection, installation and
maintenance of switchgear and control gear.
IS 12021 Specification for control transformers for switchgear
and control gear for voltages not exceeding 1000
Volt ac
IS 13947/IEC 60947 Pt. 1 to 5 Low voltage switchgear and control gear
IS 8588 Thermostatic bimetals
INSTRUMENT TRANSFORMERS
IS 2705, Pt 1 to 4 Current transformers
IS 3156, Pt. 1 to 4 Voltage transformers
IS 11322 Method for partial discharge measurement in

instrument transformers
PROTECTIVE AND AUXILIARY RELAYS
IS 3231, Pt. 1, 2, 3 Electrical relays for power system protection
IS: 3842, Pt. 1 to 12 Application guide for electrical relays for AC systems
IS 8686 Static protective relays
IS 8714 Electrical protective relays for use in seismic areas
Ltd Page: 20 of 32
S332115-943-DC-03, R2
ISQC 16000/ IECQC 60255 Electrical relays
IEC 61000 Surge withstand capability of protective relays
IEC 60068 Environmental testing of electrical relays
MEASURING AND INDICATING INSTRUMENTS

IS 1248 Direct acting indicating analogue electrical measuring
instruments
IS 12784 Electrical measuring transducers
IS 14570/IEC 60688 Electrical measuring transducers
IS 13779 AC static watt hour meters
POWER CABLES & ACCESSORIES

IS 7098, Pt 1&2 Cross linked polyethylene insulated PVC sheathed
cables
IS 8130 Conductors for insulated electric cables and flexible
cords
IS 8308 Compression type tubular connectors For copper
conductors of insulated cables
IS 8309 -do-
IS 8438 Moulds for cast resin based straight through joints

and terminations for voltages up to & including 1100V
IS 10810, Pt 0 to 63 Methods of test for cables
IS 10877 Moulds for cast resin based straight joints and

terminations for voltages 3.3KV and above up to and
including 11 KV.
CONTROL CABLES & ACCESSORIES
IS 1554 Pt.1 PVC insulated (Heavy Duty) electric cables for
working voltages up to & including 1100V
IS12943 Brass glands for PVC cables
CABLE INSTALLATION
IS 1255 Code of practice for installation and maintenance of
power cables up to and including 33KV rating
Ltd Page: 21 of 32
S332115-943-DC-03, R2
SP30 National electrical code
IS 732 Code of practice for electrical wiring installations
IS 2667 Fittings for rigid steel conduits for electrical wiring
IS 3480 Flexible conduits for electrical wiring
IS 3837 Accessories for rigid steel conduits for electrical

Wiring
IS 9537 Conduits for electrical installations
IS 14463 -do-
IS 14768 Conduit fittings for electrical installations.
IS 2629 Recommended practice for hot dip galvanizing of iron

& steel
MOTORS
IS 325 Three-phase induction motors – specification
IS 900 Code of practice for installation and maintenance of

induction motors.
IS 996 Single-phase small ac and universal electric motors
IS 1231 Dimensions of three-phase foot-mounted induction

motors.
IS 1885 Electro technical vocabulary
IS 2148 Specification for single phase small AC and universal

electric motors
IS 2223 Dimensions of flange mounted ac induction motors.
IS 2253 Designations for types of construction and mounting

arrangements of rotating electrical machines.
IS 2254 Dimensions of vertical shaft motors for pumps.
IS 2848 Specification for industrial platinum resistance

thermometer sensors
Ltd Page: 22 of 32
S332115-943-DC-03, R2
IS 4029 Guide for testing three-phase induction motors.
IS 4691 Degrees of protection provided by enclosures for

rotating electrical machinery
IS 4722 Rotating electrical machines specification
IS 4728 Terminal marking and direction of rotation for rotating

electrical machinery.
IS 4889 Methods of determination of efficiency of rotating
electrical machines.
IS 6362 Designation of methods of cooling of rotating
electrical machines.
IS 7816 Guide for testing insulation resistance of rotating
machines.
IS 8223 Dimensions and output series for rotating electrical
machines.
IS 8789 Values of performance characteristics for three-phase
induction motors.
IS 2615 Energy efficient induction motors - three phase
squirrel cage
IS 12075 Mechanical vibration of rotating electrical machines
with shaft heights 56 mm and higher - measurement,
evaluation and limits of vibration severity
TRANSFORMER
IS: 2026, BS: 171 and IEC: Power transformers
76
IS: 6600 Guide for loading of oil Immersed transformers
IS: 3639 Fittings and accessories for power transformers
IS: 335 Insulating Oil for transformer and switchgear
IS: 2099 Bushings for alternating voltages above 1000 volts
IS: 3347 Dimensions for porcelain Transformer bushings
IS: 2629 Recommended practice for hot dip galvanizing of iron

and steel
IS: 2633 Methods of testing of coating of zinc coated items
Ltd Page: 23 of 32
S332115-943-DC-03, R2
IS: 11171, IEC: 76 Dry type power transformer
IS – 5 Colour for ready mixed paints and enamels
EARTHING SYSTEM
IS: 3043 Code of practice for earthing
IEEE std. 665 - 1995 IEEE guide for generating station grounding
IEEE std. 80 - 2000 IEEE guide for safety in AC substation grounding
Indian electricity rules 1956
CBIP manual TR 5
IEEE std. 81 – 1983 IEEE guide for measuring earth resistivity, ground
impedance, and earth surface potential of a ground
system.
LIGHTNING PROTECTION SYSTEM
IS: 2309 Code of practice for the protection of building & allied
structures against lightning
LIGHTING SYSTEM
IS : 3646 (Part 1 to 3) Code of practice for interior illumination
IS : 6665 Code of practice for industrial lighting
Ltd Page: 24 of 32
S332115-943-DC-03, R2
5.3 Earthing material sizes
BELOW GRADE
S.
Description Material Size
N.
1 Main Ground Grid MS Flat 75mm X 10mm
2 Risers from ground grid interconnections GI Flat 75mm X 10mm
3 Treated earth electrode ( 3 Mtrs. Long) G.I.Pipe 40 mm dia.
4 Untreated earth electrode (3 Mtrs. Long) M.S.Rod 40 mm dia.
ABOVE GRADE
S.
Description Material Size
N.
1 6.6kV Switchgear room (earth grid) G.I. Flat 50mm X 6mm
2 415V Switchgear room (earth grid) G.I. Flat 50mm X 6mm
6.6kV Switchgear (Interconnection with earth

3 G.I. Flat 50mm X 6mm
bus)
415V Switchgear (PCC) (Interconnection with

earth bus)
415V Switchgear (MCC) (Interconnection with
earth bus)
6 Control panels, Control desk G.I. Flat 25mm X 6mm
Transformer Tank, Radiator, Marshalling Box,

Neutral
8 System Neutral G.I. Flat 25mm X 6mm

2 X 50mm X
9 Transformer Neutral G.I. Flat
6mm
10 Motors (< 37kW) G.I. Flat 25mm X 6mm
11 Motors (>37kW) G.I. Flat 50mm X 6mm
12 Push Button Station G.I. wire 8 SWG
13 Welding Socket G.I. Flat 8 SWG
14 Lighting poles, Fixtures & sockets. G.I. Flat 8 SWG
15 Lightning Protection (horizontal termination) G.I. Flat 25mm X 6mm

Steel Columns / Structures / pipe racks / Rail /
Metal parts
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S332115-943-DC-03, R2
5.4 Degree of Protection and Insulation
System voltage (KV)

Sl. No. Description Unit
0.415 6.6
A. Degree of protection
i Indoor ( enclosed area) IP 54 54
ii Indoor ( controlled atmosphere) IP 42 42
iii Outdoor (covered area) IP 55 55
iv Outdoor(uncovered / polluted area) IPW 65 65
B Insulation
i Circuit breakers Air Vacuum
ii Cables PVC / XLPE XLPE
iii Transformers Oil / Dry Oil
iv Bus bar PVC PVC
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S332115-943-DC-03, R2
5.5 Illumination level table
Area LUX Fixture type

Outdoor stockyard 10 - 20 High mast HPSV
Loading docks 100 HPSV
Belt conveyors 50 HPSV
Transfer tower 70 - 100 HPSV
Utility area and Electrical room
Utility area 150 Industrial FTL / HPMH
MV switchgear room 200 Industrial FTL / HPMH
Substation 200 Industrial FTL / HPMH
Transformer yard 100 HPMH
Cable cellar area 50 Industrial FTL
Control room 300 Decorative FTL / CFL
Site support facility
Office 300 Decorative FTL / CFL
Entrance / Exits office area 100 Decorative FTL / CFL
Corridors / Staircase / Passages 100 Industrial FTL / CFL
Main entrance, Exit roads 20 HPSV Street light
a. Maintenance factor
Air conditioned clean interiors like office rooms, control rooms 0.8
Clean interiors such as office rooms, residence, industrial areas with

0.75
normal interiors such as workshops, stores
Industrial areas with dusty interiors 0.6
Industrial areas with very dusty interiors 0.5
b. Reflection factors
Area Dark colours Semi dark colours Light colours

Ceiling 0.8 0.85 0.9
Wall 0.4 0.5 0.6
Floor 0.2 0.2 0.2
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S332115-943-DC-03, R2
5.6 List of Approved vendor
Sl.
Description Vendor
No.
1 Distribution transformers 1 Crompton
2 Alstom
3 Bharat Bijlee
4 Voltamp
2 MV switchgear 1 ABB
2 Alstom
3 Siemens
4 Crompton
3 LV switchgear 1 L&T
(PCC, MCC,DB.PB) 2 Siemens
3 Alstom
4 Schneider Electric
5 GE Power
4 Cables
a HT cables 1 RPG
2 Industrial cables
3 Universal cables
4 CCI
5 Polycab
6 Fort Gloster
b LT cables 1 Polycab
2 Universal
3 RPG
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S332115-943-DC-03, R2
Sl.
Description Vendor
No.
4 CCI
5 Fort Gloster
6 Lapp
5 Cable trays & accessories 1 Apt Engg
2 Premier
3 Jamuna metals
4 Globe
6 Air circuit breakers 1 Siemens
2 L&T
3 GE-Power
4 ABB
7 Digital meters 1 AE
2 MECO
3 Enercon
8 Motor protection relay 1 ABB
2 Alstom
3 Siemens
9 Transducers 1 ABB
2 AE
3 Siemens
4 L&T
10 APFC 1 Siemens
2 L&T
Ltd Page: 29 of 32
S332115-943-DC-03, R2
Sl.
Description Vendor
No.
3 EPCOS
11 Instrument transformers 1 Kappa
2 Pragati
12 Motor 1 Siemens
2 Bharat Bijlee
3 Crompton
13 Telephone system 1 BOSCH
2 HCL
3 Ericson
4 Siemens
14 Numerical relays 1 ABB
2 Alstom
3 Siemens
15 Electrical EPC 1 ABB
2 Alstom
3 Siemens
Ltd Page: 30 of 32
S332115-943-DC-03, R2
5.7 Key single line diagram
5.7.1 Please refer to the Dwg. No.-A0-332115-D943-5000 R0
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S332115-943-DC-03, R2
5.8 Load list
5.8.1 Please refer to the Doc. No.-332115-943-DC-02, R3
Ltd Page: 32 of 32

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Design basis report - Electrical

BLUE WATER IRON ORE TERMINAL PVT LTD

10 MTPA IRON ORE TERMINAL AT PARADIP

DESIGN BASIS REPORT OF ELECTRICAL SYSTEM

Prepared By: 18 August 2010

Reviewed By: 18 August 2010

Approved By: 18 August 2010

Copyright to this document is wholly reserved to Sandwell.

REVISION SUMMARY .............................................................................................................. 3

2. INPUT DATA AND DESIGN CRITERIA ......................................................................... 4

2.2 CODES AND STANDARDS .................................................................................................. 5

3. POWER DISTRIBUTION SYSTEM ................................................................................ 5

3.1 LOAD CALCULATION .......................................................................................................... 5

3.2 NORMAL POWER SUPPLY (GRID) ....................................................................................... 5

3.3 EMERGENCY POWER SUPPLY (DG).................................................................................... 5

3.4 DISTRIBUTION VOLTAGE LEVELS ........................................................................................ 6

3.5 POWER FACTOR IMPROVEMENT ......................................................................................... 6

3.6 EQUIPMENT SIZING AND SELECTION ................................................................................... 8

3.7 CONTROL, PROTECTION AND OPERATION PHILOSOPHY ......................................................11

4. SERVICE SYSTEM .......................................................................................................11

4.1 CABLING SYSTEM ............................................................................................................11

4.2 EARTHING SYSTEM (INDOOR AND OUTDOOR) ....................................................................14

4.3 LIGHTNING PROTECTION SYSTEM .....................................................................................15

4.4 LIGHTING SYSTEM ...........................................................................................................16

5.1 SITE CONDITIONS ............................................................................................................18

5.2 LIST OF STANDARDS ........................................................................................................20

5.3 EARTHING MATERIAL SIZES ..............................................................................................25

5.4 DEGREE OF PROTECTION AND INSULATION .......................................................................26

5.5 ILLUMINATION LEVEL TABLE ..............................................................................................27

5.6 LIST OF APPROVED VENDOR ............................................................................................28

5.7 KEY SINGLE LINE DIAGRAM ...............................................................................................31

5.8 LOAD LIST .......................................................................................................................32

a. The plant power distribution system:

Normal power supply

b. The Service system:

Terminal cabling system for areas other than packages mentioned

2. INPUT DATA AND DESIGN CRITERIA

b. Fault level at 33kV is 1500 MVA for 3 sec.

for the existing package loads and utility loads.

e. Design ambient temperature for electrical equipment shall be 50°C.

f. Voltage variation of ±10%, frequency variation of ±5%, combined voltage

2.2 Codes and Standards

3. POWER DISTRIBUTION SYSTEM

3.1 Load calculation

3.2 Normal power supply (Grid)

3.2.3 Substation 1 located at stockyard shall receive the power at 33KV. It is

3.3 Emergency power supply (DG)

3.4 Distribution voltage levels

3.4.7 Further distribution of power up to individual loads shall be carried out

3.4.10 Auxiliary supply voltages shall be as follows:

a. Power supply for lighting and receptacles shall be 240V, 1 Ph - 2 wire,

3.5 Power factor improvement

b. The basic unit size shall be of 5 KVAR, 10 KVAR, 20 KVAR or 25 KVAR

c. Capacitors banks shall be placed in suitable panels or as required.

d. Capacitors shall be provided with permanently connected discharge

3.5.5 Automatic power factor controller (APFC)

a. Power factor controller should be mounted on the front of the APFC

c. Microprocessor based power factor controller shall continuously monitor

d. APFC panel shall be provided with microprocessor based numerical

3.5.6 A 3 phase, 6.6 kV capacitor bank of suitable rating shall be connected in

3.5.7 6.6kV capacitors shall be placed next to corresponding 6.6kV switchboard in

3.6 Equipment sizing and selection

3.6.2 Criterion for selection of equipment (type and rating) is to standardize as