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DOC NO. 1061-SMI-E-DB-1001 PROJECT CLIENT: SAUDI MARJAN INDUSTRIES, JEDDAH ,KSA 1061 NO. SHEET NO. 1
DOC NO.
1061-SMI-E-DB-1001
PROJECT
CLIENT:
SAUDI MARJAN INDUSTRIES, JEDDAH ,KSA
1061
NO.
SHEET NO.
1 of 31
PROJECT
EPC
TITLE
USED LUBE OIL RE-REFINING
AND HYDROGENATION
CONTRACTOR:
CHEMIE - TECH DMCC
LOCATION
JEDDAH, KINGDOM OF SAUDI
ARABIA
ELECTRICAL DESIGN BASIS
REVISION
A
02-04-2016
Issued for Review/Approval
H.N.P
D.P.B
D.P.B
REVISION
PREPARED
CHECKED
APPROVED
DATE
DESCRIPTIONS
NO
BY
BY
BY

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

Table of Contents

1.

INTRODUCTION

4

1.1.

Project

Summary

4

1.2.

Project Objective

4

2.

SCOPE OF WORK

5

2.1.

Definitions /

Abbreviations

5

2.2.

Statutory Requirements, Codes & Standards

7

3.

SITE CONDITION

8

4.

ELECTRICAL SYSTEM DESIGN

9

4.1.

Plant Power Source Details

9

4.2.

Supply System Parameters

10

4.3.

System Earthing Details

10

4.4.

System Voltage and Circuit Parameters

10

4.5.

Permissible Voltage Drops

11

4.6.

Protection Philosophy

12

5.

AREA CLASSIFICATION

13

6.

EQUIPMENT DESIGN PHILOSOPHY

13

6.1.

Transformer

14

6.2.

Emergency Diesel Generator

14

6.3.

MV and LV Switchgear

15

6.4.

Power Factor Improvement System

17

6.5.

LV Motor

17

6.6.

DC System

18

6.7.

Uninterruptible Power Supply System

19

6.8.

Batteries

19

6.9.

Lighting System

20

6.10.

Socket Outlets

22

6.11.

Local Control Station

22

6.12.

Cable Glands

23

6.13.

Earthing and Lightning Protection System

23

6.14.

Cables and cable Tray

25

6.15.

Cathodic Protection System

28

6.16.

Neutral Grounding Resistor

28

6.17.

Low Voltage Bus duct

28

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

Page 2 of 31

THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

6.18.

Overhead Lines (Package Items)

28

7.

ELECTRICAL SUBSTATION/SWITCHGEAR BUILDING

29

8.

INSTALLATION, TESTING AND COMMISSIONING

31

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

Page 3 of 31

THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

1.

INTRODUCTION

Saudi Marjan Industries has planned to setup a Used Lube Oil Re Refining Plant at JEDDAH, K.S.A with Capacity of Distillation Plant to process 200 MT/day USED LUBRICATING OIL Feed. The corresponding Feed Capacity of Hydro-treatment Unit is 170 MT/day.

Chemie-Tech DMCC has been appointed as an EPC contractor for Basic & Detailed Engineering, Procurement & Supply, Installation, Testing and Commissioning of 200 MT/Day Capacity Used Lube Oil Re-refining Plant at JEDDAH, K.S.A

Chemie-Tech DMCC, Dubai (EPC Contractor) has appointed M/s Green Industrial Technologies (GIT-Greece) as a consultant for Basic Engineering of Hydro Treatment (HDT) Plant.

1.1. Project Summary

Project Name

Used Lube Oil Re-Refining Plant

Project Number

1061

Project Location

JEDDAH, K.S.A

Comapany

SAUDI MARJAN INDUSRIES

EPC Contractor

Chemie-Tech DMCC

1.2. Project Objective

This Report describes the Used Lube Oil Re-Refining Plant Electrical Design basis for SAUDI MARJAN INDUSRIES - ULO Re-Refining Plant’ located at JEDDAH, K.S.A. The process is intended to Recover Lube Oil Base Stock (LOBS) as an intermediate product from the used lubricating oil. The recovered LOBS will be sent to Hydro treatment process to produce lube oil base stock of API Gr. II + Grade.

The process comprises of various unit operations for recovery of LOBS & purification in Hydro treating plant.

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

Page 4 of 31

THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

This document shall form the basis for Design & Engineering of Electrical System Used Lube

Oil Re Refining Plant, also for the development of Detailed Engineering specifications.

The objective here is to resourcefully use the collected used lubricating oil for producing

recycled Base oil of API GR-II+ Grade. Through various processes we will be removing

contaminants like free solids, ash content, added additives, water, antifreeze, light ends / fuel

oils in order to reclaim 70-75 % lube oil base stock. A further process of refining (Hydro

treatment & fractionation) and blending is done to produce finished products and apart from

that by-products obtained from the process are asphalt residue and fuel oil which are also

saleable products.

Design Capacity:

The plant is designed to treat 200 MTPD Used Lubricating Oil (ULO) feed rate with stream

efficiency of 8000 hours per year with two planned maintenance of 12 days each & turndown

ratio of 50% of designed capacity.

2. SCOPE OF WORK

The purpose of this document is to set out a Basis of Engineering & Design of electrical

system of the project in respect of:

Design Philosophy

Electrical Parameters

Equipment Requirements

Safety Considerations

This document is intended as a guide for design engineering and to specify the requirements

for this project.

2.1. Definitions / Abbreviations

SHALL

: Indicates a mandatory requirement

SHOULD

: Denotes an action or requirement which is not mandatory but strongly recommended

S/S

: Substation

ANSI

:

American National Standard Institute

BS

:

British Standard Institution

UPS

:

Uninterruptible Power Supply

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

Page 5 of 31

THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

AC

: Alternating Current

DC

: Direct Current

LV

: Low Voltage

MV

: Medium Voltage

Hz

: Hertz

MCC

: Motor Control Centre

MLDB

: Main Lighting Distribution Board

PDB

:

Power Distribution Board

LDB

: Lighting Distribution Board

ACB

: Air Circuit Breaker

VCB

: Vacuum circuit breaker

VFD

: Variable Frequency Drive

APFC

: Automatic Power Factor Correction

CT

: Current Transformer

PT

: Potential Transformer

ATS

: Automatic Transfer Switch

MCCB

: Moulded Case Circuit Breaker

SPN

: Single Phase Neutral

DCDB

: DC Distribution Board

PVC

: Polyvinyl Chloride

XLPE

: Cross (X) Linked Poly Ethylene

FRLS

: Flame Retardant Low Smoke

IP

: Ingress Protection

PLC

: Programmable Logic Controller

SCADA

: Supervisory Control and Data Acquisition System

FAT

: Factory Acceptance Test

SAT

: Site Acceptance Test

JB

: Junction Box

LCS

: Local Control Station

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

2.2. Statutory Requirements, Codes & Standards

The design and the installation shall be in accordance with established codes, good

engineering practices and shall confirm to the statutory regulations applicable in the country.

Latest ANSI standards are to be followed for all electrical equipment/ component design.

The main codes, standards and statutory regulations considered as minimum requirements

are as given below. Latest version of these shall be followed:

American National Standards Institute (ANSI)

American Petroleum Institute (API)

National Electrical Manufacturers Association (NEMA)

Institute of electrical & electronics engineers (IEEE)

National Fire Protection Association (NFPA)

National Association of Corrosion Engineer (NACE)

The design and terminology shall comply as a minimum with the latest editions of the

engineering codes, standards and practices as below. However system/equipment design

shall be in line with latest of all applicable standards-

Codes

Description

ANSI 268

Letter symbols to be used in electrical technology

NEMA

Electrical Motors

ANSI C84.1-2011.

ANSI for Electric Power Systems and Equipment Voltage Ratings (60 Hertz).

ANSI / IEEE

 

C57.13-2008

Instrument transformers: Current transformers

ANSI C57.12

Power Transformers

ANSI 12.13.01-

 

2000

Electrical apparatus for Explosive gas atmospheres

ANSI C37.9

Electrical relays

ANSI C136

Luminaires

ANSI 60502

Power cables with extruded insulation and their accessories for rated voltages from 1 kV up to 30 kV

ANSI 60529

Degree of protection provided by enclosure

ANSI C37.20.1

Low Voltage Switchgear

NEMA PE 1-2012

Uninterruptible Power Systems (UPS)-Specification and Performance Verification

NFPA 780

Installation of Lightning Protection Systems

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

API RP-505

Recommended Practice for the classification of Locations for Electrical Installations at Petroleum facilities classified as Class-I, Zone-0, Zone-1, & Zone-2.

IEEE 80

Grounding Considered for Industrial power system

ANSI C37.55-2002

Medium Voltage Switchgear

The System will be designed and built in accordance with the requirements of the all

applicable local codes and standards.

In case of any conflict / deviation amongst various documents the order of precedence shall

be as follows:

Statutory Regulations

Data Sheet

Technical Specifications

Tender and any other documents forming part of the Contracts

Electrical Design Basis

Referenced Codes & Standards

3. SITE CONDITION

Parameters

 

Description

Altitude from above Sea Level

16.88 Meter

Average Ambient Temperature (Max./Min./ Mean.)

39.4

/18.1 /28.3 °C

Process Design Temperature (Min. / Max.)

7.6

/ 50.4 °C

Design Ambient Temperature (Min. / Max.)

18.1

/ 39.4 °C

Ground Temperature at 1m below ground (Min. / Max.)

(HOLD)

Monthly rainfall (Min. / Max.)

5.1

/ 258.1 mm

Design Wind Velocity

42.2

m/s (HOLD)

Seismic Risk Class

2A as per UBC 97

Minimum Temperature for Battery Sizing

10 °C

Average Soil resistivity for Earthing & CP system

(HOLD)

Relative Humidity (Max./Min./ Mean.)

100 / 3 / 60 %

Environment

(HOLD)

HOLD details shall be confirmed later

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

4. ELECTRICAL SYSTEM DESIGN

4.1. Plant Power Source Details

Grid Supply

Normally the main incoming power supply to the Lube Oil Re Refining Plant is provided by Electricity Company of K.S.A at a voltage and frequency level of 33kV, 3-Phase and 60Hz from the 33kV Overhead Lines. The fault level at 33KV shall be 25kA for 3 second.

The supply will be received subject to agreement with the Grid Supplier on an overhead line termination double pole structure with isolator, protection fuses & metering facility outside the premises of the Lube Oil Re Refining Plant.

Within the premises of the Re Refining Plant site, 33KV Distribution Substation shall be constructed & shall comprise of below listed Equipment:

33KV MV Switchgear with VCB

33KV / 4.16KV Distribution Transformer

33KV / 0.48KV Distribution Transformer

0.48KV Main PCC

0.48KV DG. Set

DG. Set AMF Panel

Remote Tap-changer Control Panel

Battery bank with charger

Heat Tracing Panel

Auxiliary Distribution Boards

A separate Electrical Room within the premises of the Re Refining Plant site shall be

constructed & shall comprise of below listed Equipment:

0.48KV LV MCC with Incomer & Outgoing ACBs suitable for fault current 65kA for 1

second.

VFD panels

AC & DC UPS

PLC / SCADA Panel

Auxiliary Distribution Boards

Normal Operation

In

normal operation, all loads will be powered by the grid Power.

Emergency Operation

In the event of complete power failure from the grid supply, the Diesel Generator will be started

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

automatically and some emergency plant load shall be transferred to D.G. Set through ATS.

Generator breaker will close automatically with time delay after stabilization of DG voltage and frequency to feed power to the emergency load

One number 0.48KV Diesel Generator suitably rated for emergency power generation is envisaged.

4.2. Supply System Parameters

Main Grid Supply

: 33kV, 50Hz, 3-Phase, 3 wire (Provided by Electricity Company of KSA)

Distribution Supply

: 480V, 3-Phase Supply 277V, 1-Phase Supply

Voltage tolerance

: ± 10%

System Frequency

: 60Hz

Frequancy tolerance

: ± 3%

System Power Factor

: 0.8 (Assumed)

Design Fault Level: 33kV System

: 25 kA for 3 Sec. (Max.)

Design Fault Level: 480V System

: 65kA for 1 Sec.

4.3. System Earthing Details

33KV / 4.16KV Transformer (Secondary)

: Neutral Grounded through resistor (NGR)

33KV / 0.48KV Transformer (Secondary)

: Solidly earthed Neutral

480V Diesel Generator

: Solidly earthed Neutral

277V System

: Solidly earthed

DC System

: Unearthed

4.4. System Voltage and Circuit Parameters

Sr.

   

No.

System Description

Voltage Level

1

Grid Incoming Supply

: 33KV ± 10% AC, 60 Hz ± 3%, 3 Phase, 3 Wire

2

Power Factor for the Plant

: 0.92 Lagging (Minimum) as per statutory requirement of Electricity Company of KSA

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

3

Emergency Power Supply

: Diesel Generator 480V, 3Ph, 4 Wire, 60Hz

4

Plant Distribution

: 480 V ± 10% AC, 60 Hz ± 3%, 3 Phase + Neutral + Earth

5

Plant Distribution

: 4.16 KV ± 10% AC, 60 Hz ± 3%, 3 Phase

6

Control Voltage

: 277 V ± 10% AC, 60 Hz ± 3%, 1 Phase, 3 Wire

 

UPS System (for Process Control & Instrumentation system, SCADA/PLC, F&G, ESD, Fire alarm, Communication System, etc)

: 277 V ± 10% AC,1 Ph, 3 Wire, 60 Hz ± 3%, &

6

(24V ± 5% DC supply required for Instrumention packages shall be derived from 277V AC UPS supply)

7

DC System

: 110 V ± 10% DC

8

Welding Receptacles

: 480 V ± 10% AC, 60 Hz ± 3%, 3 Phase + Earth

9

Lighting

: 277 V ± 10% AC, 60 Hz ± 3%, 1 Phase, 3 Wire

10

Motor Power

: 480 V ± 10% AC, 60 Hz ± 3%, 3 Phase

11

Control Supply for Motor feeder

: 277 V ± 10% AC, 60 Hz ± 3%, 3 Phase

12

All Panel space heaters

: 277 V ± 10% AC, 60 Hz ± 3%, 1 Phase, 2 Wire

13

Motor space heater

: 277 V ± 10% AC, 60 Hz ± 3%, 1 Phase, 2 Wire

15

All Panel Indication Lamp

: 277 V ± 10% AC, 60 Hz ± 3%, 1 Phase, 2 Wire

16

Tripping coil Voltage for Breakers

: 110 V ± 10% DC, 2 Wire

 

Spring Charging Motor of MV

 

17

& LV Switchgears Breakers for Incomers

: 110 V ± 10% DC, 2 Wire

18

All LV contactor controlled feeders control and indication

: 277 V ± 10% AC, 60 Hz ± 3%,, 1 Phase, 2 Wire, (via control transformer)

19

All Numerical Relays

: 110 V ± 10% DC, 2 Wire

20

All Panel Sockets & plugs (Industrial type)

: 277 V ± 10% AC, 60 Hz ± 3%,, 3 Wire,

4.5. Permissible Voltage Drops

The maximum voltage drops in various sections of the electrical system under steady state conditions at full load shall be within the limits stated in the following table:

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

   

Maximum

Sr.

No.

System Description

Permissible

Voltage Drops

1

Cable between Grid Supply arrangement and VCB Panel

0.5%

2

Cable between VCB Panel and Transformer primary

0.5%

3

Busduct or cable between Transformer secondary and LV switchgear / PCC

0.5%

4

Cable between MCC (situated near LV switchgear) and LV motor

5%

5

Maximum voltage drop for cables between MCC & LV motor during motor startup

15%

6

Cable between LDB and Lighting panels

1-1.5%

7

Circuit between lighting panels and lighting points

4%

8

DC supply circuit (Electrical controls)

5%

9

UPS outgoing circuit

5%

4.6. Protection Philosophy

The protection system will be designed such that a faulty circuit is identified and disconnected safely and quickly without adversely affecting the stable operation of other healthy circuits and plant.

All the protection relays shall be numerical type (intelligent electronic devices) and shall comply with ANSI Standard.

Typical protection relay applications as minimum are tabulated as follows:

Feeder Description

Type of Feeder

Relay Description

   

IDMT Over current Relay -51

33KV Switchgear with VCB Panel

IDMT Earth fault Relay -51N

Incomer Feeder

Under voltage Relay with Timer -27

Trip circuit supervision Relay -95

 

High speed tripping relay - 86

   

IDMT Over current Relay -51

IDMT Earth fault Relay -51N

Incomer Feeder (From Transformer secondary winding)

Instantaneous Over current Relay -50

LV Switchgear

Instantaneous Earth fault Relay -50N

Under voltage Relay with Timer -27

 

Trip circuit supervision Relay -95

High speed tripping relay 86

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

   

IDMT Over current Relay -51

IDMT Earth fault Relay -51N

LV Switchgear

Outgoing Feeder (LV

MCC)

Under voltage Relay with Timer -27

Motor Protection Relay with (46, 49, 59 Protection Relay)

   

Under voltage Relay with Timer -27

IDMT Over current Relay -51

D.G. Set

Generator Protection

IDMT Earth fault Relay -51N

Generator Protection Relay

   

Reverse Power Relay -Anti motoring protection -32

All numerical protection relays and other communicable meters shall have FO/RS485 port for serial interface, the data of this relays shall be capable of transferring to SCADA/PLC via Modbus communication or Ethernet over ANSI C12.22 protocols.

5. AREA CLASSIFICATION

Hazardous areas shall be defined in accordance with API-RP-505: Recommended Practice for the classification of Locations for Electrical Installations at Petroleum facilities classified as Class-I, Zone-0, Zone-1, & Zone-2.

Electrical equipment installed in the classified area shall be suitable for the area and taken into consideration, during design of the plant equipment, the gases and chemical substances, which shall be handled, processed or stored in the plant. Selection of equipment shall be made in compliance with ANSI/UL Standards.

Electrical apparatuses suitable for use in classified areas with test certificates by an official test laboratory / Notified body such as CESI for Italy, PTB for Germany, BASEEFA for England, LCIE or INERIS for France, FM or UL for US and ATEX etc. will be considered.

The equipment suitable for Zone 1 area will be deemed suitable for zone 2 area.

6. EQUIPMENT DESIGN PHILOSOPHY

General Criteria

All equipment will comply with project specification, data sheets and relevant ANSI code.

All equipment will be suitable for continuous operation at full load and will withstand the thermal and electrodynamics stresses due to the specified abnormal conditions.

All ratings will be continuous at specified maximum ambient temperature.

Unless otherwise specified all components will have at least 20% extra capacity above the expected load.

Insulation levels of the power system will be coordinated in accordance with ANSI standard.

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

Rated short duration power frequency withstand voltage and switching/lightning impulse withstand voltage will take into account of system voltages and type of Earthing.

Design Life

The equipment will be designed for an operational design life of minimum 30 years.

Weather Protection

For Indoor Installations

: IP 42

For Outdoor Installations : IP 55

6.1. Transformer

Transformers shall be hermetically sealed; mineral oil immersed with integral filling type of either pad mount construction and double wound copper winding type suitable for installation outdoor without additional weather protection.

Cooling shall be ONAN using oil. Non-degradable coolants shall not be used. Forced cooling is not envisaged. Windings shall conform to vector group Dyn 11, as defined in ANSI.

The KVA rating (1x100%) shall be decided on the following basis and should be as far as possible a standard value. Sizing shall include 25% margin for future growth in case of Power Transformer and 40% margin for Distribution Transformer.

KVA rating and % impedance of each transformer shall be selected so as to limit the short circuit current to values within the current rating and rupturing capacity of proprietary available switchgear whilst also ensuring that the voltage drop in the system elements stays within permissible limits. The transformer impedances shall comply with the applicable ANSI standards unless otherwise required.

Main Power Transformer shall be provided with On-Load Tap changer on the primary (HV) winding giving voltage variation of +/- 10%.

Distribution Transformer shall be provided with off circuit tap changer (OCTC) on the primary (HV) winding with tap selection for (-) 5% to (+) 5% of rated primary voltage in steps of 2.5%.

6.2. Emergency Diesel Generator

Essential services panel shall be feed from 480V Emergency Diesel Generator for which rating shall be determined on the basis of essential loads.

480V Emergency Diesel Generator driven by battery started diesel engine with AMF panel shall be provided.

The electrical loads of Essential services panel to be fed by emergency generator shall consist of the following as minimum:

20-25% lighting load

Loads critical for process, plant and personnel safety

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

6.3. MV and LV Switchgear

MV Switchgear (33kV VCB Panel)

MV Switchgear shall be air insulated type with VCB and draw out feature. Switchgear

enclosure shall be robust metal construction, vermin & dust proof and shall have minimum degree of protection IP55 suitable for outdoor installation. Each vertical section shall consist of 1 no. of circuit breaker only.

MV Switchgear shall be as per standard ANSI C37.55-2002.

All switchgear shall have integral circuit earthing facilities suitably interlocked with the switching mechanism.

Switchgear mechanisms shall be fully interlocked and provide shutters, door locks etc., to prevent persons contacting live parts.

33kV circuit breakers shall be of the trolley mounted withdrawal type assembled to make up a switchboard. A test position shall be incorporated. The interrupting medium shall be vacuum circuit breaker.

All busbars and jumper connections shall be of electrolytic copper conforming to relevant ANSI standards. They shall be adequately supported on suitable insulators to withstand electrical and mechanical stresses due to specified short circuit currents. Busbar cross section shall be uniforms, throughout the length of switch board.

VCB feeder shall be provided with numerical relays.

All cable connections and entries, including those of the low voltage cables, shall be made from the bottom.

LV Switchgear:

LV Switchgear shall be located in non-hazardous area close to the load Centre in order to

reduce distribution losses, size and length of cables.

Low voltage switchgear will consist of incoming circuit breakers, motor starters, lighting and

power distribution board feeder, APFC units grouped together to form where appropriate a

Motor Control Centre of the cubicle type constructed to ANSI C37.20.1 and internal separation shall be of Form-4. All operating mechanisms shall be between 300 - 1800 mm height from the base of the panel.

LV Switchgear shall be metal enclosed, dead front, floor mounted, free standing type as per

applicable ANSI standards with the following features:

Incomer and bus-tie Circuit Breakers shall be ACB, four poles, spring charged, horizontal draw out electrically operated type single front design.

LV Switchgear / MCC shall be fully draw- out (withdraw-able) double front type. However, Air Circuit Breaker shall be of single front design.

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

Distribution boards (PDB/LDB) shall be fixed type with a single front design.

All the switch boards shall be suitable for future expansion on both sides and all bus bars for all the switch boards shall be electrolytic grade copper and shall be fully insulated unless otherwise specified.

A minimum of 25% spare feeders or one no. of each rating and type on each side of the bus section, whichever is the greater, shall be provided

Circuit breakers / contactors controlling motor feeders shall have a rating of at least 125% of the maximum continuous rating of the connected motors.

Motor starter shall have components listed by UL and applied according to NEC safe for operator and shall provide adequate protection for the components. Motor starter modules shall be fitted with ammeters for motors rated 37 kW and above.

For feeders rated up to and including 630A, MCCBs shall be provided, for the feeders rated above 630A, ACBs shall be provided.

All incomer ACB feeder for LV switchboard shall be provided with numerical relays and outgoing MCCB feeder in LV switchboard shall be with microprocessor based adjustable type release for over current, short circuit, instantaneous and earth fault release. MCCBs shall be provided tripping device with inverse time characteristic for overload protection and instantaneous characteristics for short circuit protection & earth fault protection.

The switch board components like circuit breakers, Main horizontal and vertical bus bars, bus bar joints, bus bar supports etc. shall be designed to withstand the maximum specified short circuit current for a minimum of 1 second, unless otherwise specified.

Provision shall be made for space heater supply of motors rated 30kW and above.

LV switch board shall have metal enclosed horizontal main bus bar compartment running at the top.

Top entry bus duct as incomer for LV MCCs fed from Transformer rated 750kVA and above shall be provided. Incomers for other boards shall be from Bottom entry. All other cables shall be from Bottom entry.

Control transformer of suitable rating shall be provided in each bus section in MCC for control supply. Transformer shall be rated for 100% load requirement of entire panel.

Thermostatically controlled space heater for each panels, maintenance sockets outlets, panel illumination etc. shall be provided.

All switchgear, modules shall be designed to have all safety features, not to have access to live terminals and interlocks to ensure to protect accidental closing while racking in

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

and door opening while in service.

6.4. Power Factor Improvement System

An automatic power factor improvement system shall be considered on Busbar of LV Switchgear. The system shall have capability to improve the overall power factor of the grid supply to above 0.92 lag.

The power factor improvement system shall consist of:

Capacitor banks

Series Reactors

Power cabinets with MCCB, busbars, feeders comprising fuses/breakers and power contactors, control transformers, etc.

Power factor correction relay

6.5. LV Motor

In general, three phase squirrel cage motors shall be totally enclosed, fan cooled type and suitable for continuous outdoor use with protection IP 55. Wherever identified Motors shall be suitable for direct on-line starting.

Motors up to 160KW shall be fed from 480V MCC and Motors above 160KW shall be fed from 4.16KV MV Switchgear.

Motor construction shall be as per NEMA and have premium efficiency class as per NEMA

MG-1.

The type of enclosure for motors (i.e. indoor/outdoor, industrial/non sparking/ flameproof) shall be adequate for the application and area in which it is to be installed.

Hot & Cold Start

Motors shall be designed to allow the minimum number of consecutive starts indicated below:

Condition

Min. no. of consecutive starts

With initial temp. of the motor as ambient temp. (cold)

2

With initial temp. of the motor as full load operating temp. (hot)

1

Minimum locked rotor thermal withstand time at rated voltage shall be 10 seconds under cold conditions and 8 seconds under hot conditions. The hot thermal withstand time at 100% voltage shall be at least 5 seconds more than the starting time at 80% voltage. The starting time of the motor shall be less than the hot thermal withstand time (time te in case of increased safety motors) to facilitate application of conventional bimetal relays or thermal release against locked rotor and overload conditions.

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

Insulation

All motors shall have class F insulation with temperature rise limit to class B on a maximum ambient temperature measured by resistance, in accordance with NEMA Standards, for all parts of the machine windings.

Motors identified to be driven and controlled by a VFD shall be suitable for the required variable speed range at a temperature rise within the permissible limits. All motors driven by VFDs shall be suitable for inverter duty application and shall have embedded PTC thermistors in the windings operating a thermistor trip relay in the VFD should the temperature of the winding exceed the permissible limits.

VFD shall be interface with SCADA/PLC through serial link by either Modbus or Profibus protocol.

Provision shall be made for space heater supply of motors rated 30kW and above.

6.6. DC System

DC Power supply system comprises the converters, battery banks and the Main DC

Distribution Boards (Main DCDBs).

System shall supply continuous 110V DC power to MV and LV switchgear and relays. The dc power supply system shall be a fully redundant system consisting of two units operating in parallel.

The DC UPS system shall comply with NEC. The DC UPS rectifier shall be IGBT/Thyristor

based three phase full wave rectification.

Each unit shall consist of one 100% Float-cum-boost charger with 100% loading capability but operating at 50% load. Batteries shall be one common 100% sealed maintenance free Nickel Cadmium battery bank placed in a separate well ventilated room on racks.

In case of normal power failure to the float-cum-boost chargers, each battery unit shall have sufficient capacity to supply the total 110V DC system loads for 60 Minutes (1Hours.).

Under normal condition the Float-cum-boost charger will take care of all DC load connected to its Main DCDB and keep the battery under charged condition. In case of failure of normal supply, battery will feed the DC load requirement. Retransfer of load on resumption of normal supply will be done without interruption of supply to loads.

AC input to the DC system shall be 480V ± 10%, 3 phase, and 60Hz ± 3% from the plant LV Switchgear.

Each battery charger and DCDB shall be sized to cater to selected battery capacity.

Each DCDB shall have at least 10% spare for future loads. All the DB’s shall have cable entry at the bottom.

The battery chargers shall have intelligent monitoring / metering system and shall display the

capacity of the battery, battery voltage, rectifier voltage and current and events and alarms

and communicable for remote monitoring.

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

6.7. Uninterruptible Power Supply System

Uninterruptible Power Supply system comprises the converters, static inverters, static automatic transfer switch, battery banks, and Isolation transformer with voltage stabilizer in bypass along with maintenance by pass switch along with AC & DC distribution Board.

One complete Uninterruptible Power Supply System consisting of two parallel units (for redundancy) shall be provided for powering the plant Process PLC, FGS, instrument package equipment system, and local control panels.

The inverter shall be transistorized (IGBT) type or with the latest proven technology. All components shall be of a high quality and reliability that satisfy the requirements of a secure AC power to vital equipment with respect to performance.

Rectifier shall be Thyristor base three phase full wave rectification.

The system input shall be 3 phase, 480V ± 10%, 60Hz ± 3%, Output shall be 277V ± 10% AC,1 Phase, 60Hz ± 3% & 24V ± 5% DC. Harmonic filters shall be considered at input side, if required. System total harmonic distortion (THD) content shall be not exceeding 5%, conforming to IEEE-519.

UPS system shall consist of two parallel units (each including a 100 % converter, a 100 % solid state inverter,) with one common 100% sealed maintenance free Nickel Cadmium battery bank, static automatic transfer switch, and a constant voltage by-pass transformer with maintenance by pass switch. Batteries to be placed in a separate well ventilated room on racks.

Both units shall operate in parallel, each shall provide 50% load but each shall have 100% loading capability. Battery backup time shall be 60 Minutes (1 Hours).for the complete system.

Under normal condition, the converter will feed the inverter load requirement through static switch and keep the battery under charged condition. On failure of supply to converter, the battery will start feeding the inverter load requirements automatically without interruption. Reverse transfer on resumption of normal power will also be automatic.

Usually, the two UPS units will operate in parallel and share total load requirement equally. On failure of inverter of one of the UPS the other UPS will start feeding 100 % of the load automatically without any interruption. In case of failure of both the inverters, the bypass mains will take care of 100 % of the load through static bypass switch automatically without interruption. Forward and reverse transfer of load will be done automatically and without any interruption of supply to loads.

Each UPS shall have at least 10 % spare feeders and the UPS shall be designed to cater additional 10 % for future loads.

6.8. Batteries

Sealed maintenance free Nickel Cadmium Batteries shall be of adequate capacity to meet the backup requirements as envisaged in the duty cycle. While sizing the battery, temperature

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

correction factor, and ageing factor shall be considered in addition to the maintenance factor. Battery backup time shall be 60 Minutes (1 Hours).for the complete system.

6.9. Lighting System

Plant lighting will be broadly classified into 2 categories:

Normal lighting

Emergency Lighting

Power for normal and emergency lighting shall be drawn from the LV Light Distribution Boards (LDB). The LDB protected with MCCB in incomer and outgoing with MCBs with ELCB protection

Generally 20-25% of the total lighting fixture shall be fed from AC emergency lighting via 480V Emergency Diesel Generator.

During normal operation normal and emergency lighting shall be fed from normal power source. On failure of normal power supply, emergency lighting shall be transferred to emergency power supply source.

The lighting design and installation will be in accordance to ANSI Standard

Lighting installation will be designed to provide an average sustained illumination level not less than the values tabulated below.

Location

 

Lux (average)

Process & Utilities areas

 

Pumps, collectors, separators areas

70

to 85 at grade

Ladders and stairs

45

at floor level

Instruments, Local boards

150

at 1 m level

Storage area

 

Tanks (ladder, gauge area)

15

at grade

Manifold area

10

at grade

Loading area

 

General area

70

to 85 at grade

Tank loading point

250

at 1 m level

Street & fence lighting

 

Main road

15

at grade

Secondary road

10

at grade

Fences

10

at grade

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

Buildings

 

Administrative buildings Office

300

Control rooms

500

Electrical rooms

300

Instrumentation rooms

400

First aid room

500

Lockers rooms showers - toilets

150

Laboratories

500

Workshops

300

Fire station

150

Gate house

250

Stairs

150

Exits

100

Pantry

400

Car park

12 at grade

Fittings to be installed in hazardous area shall be suitable for the Zone specified and certified by a notified body.

Indoor Lighting System

Lighting system will consist of fluorescents lighting fixtures for indoor lighting of non-process buildings, and control room. Battery room shall be provided with chemical resistant fixtures. HPMV lamp shall be used for bay lighting in Process building/Shop floor. A maintenance factor of 0.8 shall be considered for illumination level calculation for indoor areas.

Outdoor Lighting System

External area lighting will consist of Flood light High-Pressure sodium Vapour (HPSV) lamps rapid re-strike type. Telescopic tubular hot dip galvanized high masts shall be provided for illumination of tank farm/general areas. Where feasible street lighting poles may be avoided where lighting high masts provide adequate illumination, Street lighting will be standard luminaries, 277V±10%, on galvanized steel pole. For High mast & street lighting HPSV luminaries shall be used.

All fittings to be installed outdoors shall have ingress protection of IP65 and shall be weatherproof and have a guard. All Light Fittings, JBs shall be so located to have easy maintenance approach. A maintenance factor of 0.65 shall be considered for illumination level calculation for outdoor areas.

External lighting will be automatically controlled by Photoelectric cell or timer.

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

Wiring Type

Process plant/Shed & Outdoor area

Armoured cable

Non plant building with/without false Ceiling / Control room

Surface conduit wiring above false ceiling & Canceled conduit wiring on wall below false ceiling

Substation (Switchgear Room)

Surface conduit / Armoured cable in G.I perforated trays

Wiring for lighting in outdoor area shall be done with armoured cable run along the columns/ Platform & structures.

6.10.Socket Outlets

Enclosure of the convenience receptacle shall be suitable for site conditions such as weather proof, dust proof, flame proof, corrosion resistant etc. Necessary interlocks and earthing facilities shall be provided as per safety requirements. These receptacles shall be provided at selected locations in the plant.

For office buildings, 277V, 13A/15A twin socket outlet will be provided for PC, monitors and printer from UPS supply. 277V, 13A/15A, socket outlets will be provided in each room from normal supply for general purpose. In halls, one socket for each 10m of the hall periphery will be provided.

Apart from the above power outlets will also be provided for Pantry appliances, water coolers, refrigerators and Lab.

Welding outlets (480V-3ph-63A-4P+E) will be provided at suitable location near major equipment like Pump house, Process area etc. to provide power for portable equipment at inspection and maintenance point.

Substation will have industrial type receptacle while Control Room and Office rooms will have decorative type receptacles, with ELCB (sensitivity range 30mA-300mA) controlled socket, 277V, 1 phase, Neutral & Earthing,13A/15A,3Pin.

All receptacles shall have looping facility & shall have cable entry at the bottom.

6.11.Local Control Station

All motors will be provided with local control stations each having START (Green)/STOP (Red) pushbuttons. The stop position is stay put type with pad lock facility.

The local control stations shall be of aluminium alloy (LM6) construction, Enclosure of the control station shall be suitable for site conditions such as weather proof, dust proof, fla me proof (Ex-d), corrosion resistant etc. LCS located outside shall have minimum IP-65.

Local/Remote (Hand - Auto) selector switch shall be provided in LCS.

LCS cable gland shall be provided by the vendor properly coordinated with the cable size and

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

shall be of high quality. Cable glands shall be brass compression type with isometric threads.

6.12.Cable Glands

All cable glands shall be made of nickel chromium plated brass and shall have ISO metric entry threads with 1.5mm pitch. The same type and make of cable glands shall be used throughout the installation.

Cable glands shall be dual certified for EEx de for installing in hazardous area and industrial type weatherproof for installing in safe area. Glands shall be provided with an integral permanent sealing device to prevent water ingress at the armour clamp. Each gland shall be supplied complete with an IP66 entry thread seal and a brass locknut. Cable shrouds shall not be required. Cable glands shall be double compression type.

6.13.Earthing and Lightning Protection System

Entire electrical system envisaged for the terminal, shall follow earthing installation practice in accordance with the provisions of the relevant NFPA-70. For the Earthing calculation purpose IEEE 80 shall be followed.

The earthing system will protect the electric network and assure personal safety in case of an electric failure and against static charges.

Earthing system in general cover the various earthing system listed below.

Cable armoring (multi-core power cables)

Generator and Transformer neutral points.

Substation building ground busbars.

MV and LV Switchboard/MCC/PDB ground buses.

Main Lighting DBs (MLDB), High Mast, Security tower

Motor / generator machine frames.

Metallic structure of building and metallic reinforcement of concrete building Pipe rack steel.

Frames of skids.

Tanks, vessels, towers, stack

Lorry tanks during loading, if necessary

Base plate of rotating machinery

All non-current carrying metallic structures

Metal fences, gates, side rails

Separate clean earth system for Instrumentation. I.e. SCADA / PLC Panel as per specified requirements.

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

Main earth grid will be provided around substation and main plant area. It will consist of buried copper conductor connected to rods driven earth pits at several points.

Size of copper conductor shall be calculated based on the system fault level. Copper conductor shall be laid at a depth of not less than 500 mm below ground level. Earth pit will consist of 16 mm dia., 3m long copper clad steel rod. The main earthing ring shall be extended to earth bus to connect parts of all electrical equipment and machinery at two separate and distinct earth connectors.

All product and water tanks shall be adequately protected against lightning strokes, by connecting them to the earth grid with adequate size of Cu earth continuity conductors.

Depending on the tank diameter following number of cleats shall be welded on the tank body with application of bituminous paint at welded joint-

Tank Diameter (D) in meters

Earthing Connection

 

≤ 20

2 Nos. at 180°

20

≤ D ≤ 30

3 Nos. at 120°

30

≤ D ≤ 40

4 Nos. at 90°

40

≤ D ≤ 50

5 Nos. at 72°

50

≤ D ≤ 60

6 Nos. at 60°

In addition to tank earthing at base, Internal floating roof tanks will provided with earthing on floating roofs. This is to ensure that the floating roof is of the same potential as the tank shell and thus reduce the chance of potential spark and to allow a path to earth in the event of lightning strike.

Earthing resistance of the grid shall be measured after connecting all the earth electrodes to the grid. Value of resistance of earth grid to the general mass of earth shall be as follows:

For electrical system and equipment, a value that ensures operation of the protective device in the electrical circuit but not in excess of 5 ohms.

For lightning protection, value of resistance of 5 ohms as earth resistance shall be desirable, but in no case it shall be more than 10 ohm.

Overall grid resistance shall be less than 5 ohm.

Below ground earthing is carried out by Thermit welding and above ground earthing through compression type lugs. Cadmium coated nuts and bolts are to be used at tapping points where welding is not envisaged. Lighting fixtures and receptacles shall be earthed through the extra core provided in the lighting circuit / cable for this purpose.

Recommended earthing Conductor sizes are indicated in the table below:

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

Equipment

Size of Earthing copper cable

Metallic enclosure of electrical equipment having a supply cable with cross section more than 35 sq.mm

Half of the phase conductor

Metallic enclosure of electrical equipment having a supply cable with cross section more than 16 sq.mm and up to 35 sq.mm

16 Sq.mm Multi-stranded Cu green/yellow flexible PVC insulated cables

Metallic enclosure of electrical equipment having a supply cable with cross section more than 6 sq.mm and up to 16 sq.mm

same as phase conductor

Metallic enclosure of electrical equipment having a supply cable with cross section 6 sq.mm and less

6

Sq.mm Multi-stranded

Cu green/yellow flexible PVC insulated cables

 

70

Sq.mm Multi-stranded

Storage tanks (vertical & horizontal)

Cu green/yellow flexible PVC insulated cables

 

25

Sq.mm Multi-stranded

Pipe racks, vessels & heat exchangers

Cu green/yellow flexible PVC insulated cables

 

6

Sq.mm Multi-stranded

Small equipment & instruments

Cu green/yellow flexible

PVC insulated cables

 

6

Sq.mm Multi-stranded

Push button station

Cu green/yellow flexible PVC insulated cables

 

25

Sq.mm Multi-stranded

Lighting Poles

Cu green/yellow flexible PVC insulated cables

Lightning Protection

Lightning protection will be provided to equipment, structure and buildings which are higher than 20 meters or as per the risk index analysis worked as per NFPA 780.

Lightning protection system shall consist of air rods, down conductors and ground Copper rods. Air rods shall be of fully stainless steel Early Streamer Emission (ESE) type tested in a high voltage laboratory in accordance with NFC-17-102.

6.14. Cables and cable Tray

Electrical Cables:

The cables shall be sized based on the maximum continuous load current, the voltage drop, system voltage, system earthing and short circuit withstand criteria as applicable. The Laying condition de rating due to ambient air temperature, ground temperature, grouping and proximity of cables with each other, thermal resistivity of soil etc., shall be taken in to account.

MV cables shall be dry cured XLPE insulated, extruded PVC sheathed, steel wire armoured type with copper conductors. All cables rated for 1 kV and above shall be provided with both conductor screening and insulation screening. Outer PVC sheath of all cables used shall be

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

flame retardant type conforming to ANSI.

All LV power & Lighting cables shall be with stranded copper conductor with XLPE insulation, PVC inner sheathed, steel round wire armoured, PVC outer flame retardant (FRLS) sheath and construction as per ANSI.

The control cables shall be PVC insulated, extruded PVC sheathed, steel round armored type, outer FRLS sheathed with copper conductors. Special cables like twisted or shielded control cables etc. shall be used as applicable for numerical relays, VFD etc. to suit selected equipment as per equipment supplier’s recommendation

All earthing cables shall be Multi-stranded Copper conductor, flexible PVC insulated, colored Yellow/Green, for above/underground use.

All power and control cables shall be in continuous lengths without any joints subject to availability of drum length. The cables used for lighting and wires in conduits shall have appropriate junction boxes with adequately sized terminals. Cable joints in hazardous areas shall not be permitted.

In case of difficulty in connecting the cables to instrument or relay terminals, minimum cross section may be reduced to 1.5 Sq.mm copper. For lighting inside the building, minimum 2.5 Sq.mm copper conductor, PVC insulated wire shall be used in conduit system (for circuit and point wiring), with proper color coding.

Cable Tray and Cable laying philosophy:

General:

Cables will be in general laid above ground on cable trays and or directly buried as per the convenience at each location.

Cable trays will be hot dip galvanized steel ladder type. Covers will be provided for protection against direct sunlight, rain water and mechanical damage.

Electrical cables will not be laid in the same trench, tray or conduit with the instrument and communication cables.

Cable trenches, Trays and PVC duct banks will have 20% of spare space for future cables.

Multi-core HV cables will be arranged in a single layer with one cable diameter spacing between them. Single core HV cables shall be arranged in trefoil formation in single layer, with one trefoil cable diameter spacing between them.

Buildings:

In the plant buildings, sub stations, control rooms, etc. cables will generally be laid on cable trays supported on overhead metal structures, trenches, cable cellars, basement or along building structures, walls, ceilings, etc.

In other non-plant buildings, power cables shall be laid in FRP cable trays/UPVC conduits. In the false ceiling area, cables shall be laid above false ceiling and vertical dropper below the false ceiling shall be concealed in wall. In the non-false ceiling area vertical trays shall be

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

provided with cover.

Outdoor Underground Area:

In unpaved areas cables will be in general directly buried on a layer of sand and covered by

sand.

In paved areas cables will be laid in concrete trenches filled with sand and covered with concrete slab or will be laid in PVC pipe/conduits in concrete duct bank.

For road crossing cables will be laid in PVC sleeves in concrete duct bank.

Cables will be identified with corrosion resistant cable strips, showing the cable numbers, every 10m and at both side of road crossing, where ever transition from underground to above ground and vice versa. A warning system of plastic strips will be provided above the top level of all cables run in trenches. For unpaved areas cable trench markers will be provided at grade over the cable trenches to show clearly the extent and the run of the cables.

Outdoor Aboveground Area:

Cables will be laid on hot-dip galvanized cable trays (ladder type) or in heavy PVC conduits.

Cable trays will be bolted to steel structures and walls or to adequately sized tray supports and shall be routed on dedicated tiers of the pipe racks and on sleepers to equipment.

Cable Tray:

The trays shall not show deflection / bend / deformation after laying of cables.

For terminal area, all cable trays and accessories shall be prefabricated, 2 mm thick hot dipped Galvanized Iron ladder trays with rungs at 300 mm interval. Maximum width of trays will be 600mm.Collar height will be 75 mm. The maximum length of single cable tray shall be 3000 mm.

For tray system design, in addition to self-load and wind forces, following guidelines for de- sign shall be considered.

Support span - 2000 mm for horizontal & 1500 mm for vertical tray supports. Nuts, bolts and any other hardware to be used in cable trays shall be stainless steel/cadmium coated. Fastening of cables in cable ways shall be done with UV resistant (Black) PVC cable ties.

Cable trays used in the outdoor areas shall be provided with covers on top layer, for protection from rain water & mechanical damage.

A horizontal clearance of 300 mm shall be maintained between instrumentation, signal cable

and electrical power/control cables.

For all cable trays stacked vertically, there shall be a minimum vertical working clearance of 300 mm from the top of the lower tray to the bottom of the tray above.

The trays shall be supported at appropriate intervals both vertically and horizontally, as

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

required by the cable tray manufacturer’s design criteria.

6.15.Cathodic Protection System

Cathodic protection will be provided for tank external bottom plates and Buries pipe line with impressed current cathodic protection.

A

CP specialist shall be engaged during the detailed engineering stage to confirm the extent

of

the cathodic protection required. It shall be designed and implemented by the CP

specialist. Responsibly of engaging the services of the CP specialist shall be included in the

scope of the EPC contractor.

6.16.Neutral Grounding Resistor

The Neutral Grounding Resistor (NGR) shall be rated to withstand the fault current and shall

be out door type with IP 55 enclosure. The NGR element shall be stainless steel / ni-chrome.

6.17.Low Voltage Bus duct

LV bus ducts will be provided for interconnection of the 33/0.48kV transformer rated 750KVA

& above from the transformer secondary to the 480V LV Switchgear.

Non-phase segregated, self-cooled type, 3 phase, 4 wires with copper bus bars with heat shrinkable PVC Sleeves.

Enclosure will be fabricated from 3 mm thick aluminum sheets for ratings above 3000A and 2

mm

thick sheet steel otherwise. The Indoor portion of the bus duct shall be minimum IP42

and

the outdoor portion of the bus duct shall be minimum IP55. The adopter box with flexible

bus

bars on both ends of the bus duct shall be designed as part of the bus duct.

Bus

bar supporting insulator shall be made of SMC (Sheet molding compound). Bus bar shall

be supported at regular intervals on insulator made of high dielectric strength. Non hygroscopic, non-inflammable material with tracking index equal to or more than that defined

in standard.

Both Bus bar and supports shall be adequately sized and braced to withstand dynamic and thermal stress expected due to the specified short time rating. Seal-off bushings with wall frame assembly wherever the Busduct crosses wall from outdoor to indoor.

The Rating of the bus ducts connected to breakers shall have same continuous and short

circuit rating as that of breakers.

Neoprene rubber bellows for enclosure wherever expansion joints, transformer end, panels

end are provided.

6.18.Overhead Lines (Package Items)

In general the main components of an overhead line like conductor, supports, insulators, cross arms and all related equipment shall be designed to provide adequate protection against the adverse effects of all prevailing site conditions.

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

The design of an overhead line should take into account local utility practice in determining the type of construction and the selection of materials.

Conductors :

Phase and earth conductors shall be aluminium alloy, although ACSR (Aluminium Conductor Steel Reinforced) may be considered & shall be complying with ANSI H35.1. Galvanised steel may also be considered for earth conductors.

Supports :

The support may either be wooden poles, steel pole or lattice steel tower as determined on economic basis after satisfying the technical design parameters. Wooden poles shall comply with ANSI standard. Steel poles & tower shall comply with relevant national standard.

Insulators :

Post insulators and pin insulators shall be glazed porcelain, complying with ANSI/NEMA C29. They shall be used in suspension insulation strings at higher voltages and in tension insulator string at all voltages.

The insulators profile and insulator creep age length shall be selected to suit the site conditions.

Steel Components :

All steel components, including fasteners shall comply with the relevant international standard and shall be hot dip Galvanised.

Lightning Arresters:

Lighting Arrester shall be complying with NFPA-780 applies to non-linear metal-oxide resistor type surge arresters without spark gaps designed to limit voltage surges on AC power circuits. Lighting Arrester shall be installed as every cable termination.

7. ELECTRICAL SUBSTATION/SWITCHGEAR BUILDING

The substation building will consist of switchgear room and transformer bay. The switchgear room will house LV Switchboard, MCC, auxiliary switchboards, UPS & battery bank and Distribution Boards.

The sub-station shall be located in a safe area close to the load center. Proper access shall be provided/ ensured for operation/ maintenance of indoor and outdoor equipment. Layout of the substation shall comply with the requirements of the latest versions of relevant standards

The Substation shall have a minimum two access points, one entry suitably sized to accommodate equipment / normal entry and the second for emergency exit. Both exits shall be fitted with a proprietary panic bar. The doors will be equipped with anti-panic handles and will open outward.

The switchgear room floor will be elevated such that the floor level of the building will be 1.8

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

meter above the site FGL (ground level) to allow trenches below switchboards for cabling.

The Substation shall be sized to accommodate all electrical loads identified and to give adequate clearances between items of equipment for ease of maintenance. Space for two adjacent panels for future extension on each side of each switchboard shall be provided.

The Substation shall be designed for mounting on raised columns to provide access for the installation of cables to the equipment. All switchgear panels shall be arranged to permit all cables to enter from below.

Transformer bay & neutral grounding resistor (if any) will be outdoor type separated from substation building with firewalls Fence & gate.

Sub-station wall adjacent to the transformer bays shall be 355 mm thick (inclusive of plastering) in case of brick construction or 230 mm thick in case of RCC construction.

Batteries of UPS and DC Power Supply System shall be located separately in well ventilated room provided with an exhaust fan and heat detectors.

The substation building shall be sized to maintain adequate clearances between equipment for ease of maintenance. The following minimum clearances around various equipment shall be maintained:

Sr. No.

Location

Clearance

1

Front clearance for HV switchboard

2500

mm

2

Rear clearance for HV switchboard

1500

mm

3

All around clearance for transformer

1000

mm

4

All around clearance for NGR

1000 mm on two sides, 200 mm on the other

5

Diesel generator set to wall

1500

mm

6

Clear height of bus-duct from FFL

3000

mm

7

Rear clearance for LV switchboard which require Maintenance from rear

1000

mm

8

Rear clearance for panels having maintenance access from front only

Less 200 mm Or more than 750 mm

9

Front-Front of 2 switchboards facing each other

2000

mm

10

Side clearance between switch boards or from nearest obstruction

1000 mm after considering space for future panels

11

Minimum substation building free height

3500

mm

The substation shall be provided with portable fire extinguishers, safety signs, First-aid box etc. in accordance with international safety requirements.

ELECTRICAL DESIGN BASIS (1061-SMI-E-DB-1001_Rev_A Dt. 02/04/2016)

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA

ELECTRICAL DESIGN BASIS

SAUDI MARJAN INDUSTRIES, JEDDAH, KSA ELECTRICAL DESIGN BASIS

Project No.: 1061

1061-SMI-E-DB-1001

8. INSTALLATION, TESTING AND COMMISSIONING

Installation of all electrical equipment shall be carried out with high standard or workmanship, neat routing/layouts, and clearances/access as per recommendations by the manufacturers, standards and good engineering practices.

After installation the system equipment shall be tested for pre-commissioning test as recommended by the manufacturers & established practices. Further, commissioning tests shall be conducted to prove agreed performance within specified tolerance, temperature rise, noise and vibration.

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THIS DOCUMENT, DATA OR ANY INFORMATION CONTAINED HEREIN IS CONFIDENTIAL BEING THE PROPERTY OF CHEMIE TECH DMCC . NO CONTENTS OF THIS DOCUMENT DATA OR INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DICLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE TECH DMCC.THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED.