Electrical Design Criteria

Bechtel France SA

Reliance Petroleum Limited Jamnagar Refinery Complex

Specification 22960-3PS-E80-001 Electrical Design Criteria

1

08/11/96

HJY

RHB

RHB/JJA

16-11-95

Issued for Design Accepted by Client Issued for Approval

0

HJY

RHB

RHB/JJA

A

Aug 95

Issued for Review

HJY

BMW

Rev

Date

Revision

By

Chkd

22960000\/var/www/apps/pdfcoke/pdfcoke/tmp/scratch1/9579163.doc3PS-E80-001 REV. 1

Appr

Client

Page 1 of 25

Reliance Petroleum Limited Jamnagar Refinery Complex

Contents Appendix A

Project Specifications.

22960000\/var/www/apps/pdfcoke/pdfcoke/tmp/scratch1/9579163.doc3PS-E80-001 REV. 1

Page 2 of 25

Reliance Petroleum Limited Jamnagar Refinery Complex

Introduction This specification defines the minimum basis of design of electrical installation for the Reliance Petroleum Ltd, Jamnagar Refinery Complex. This specification shall be read in conjunction with other specifications prepared for this project and the requirements of the applicable codes, standards, and regulations.

Codes, Standards and Regulations Electrical systems design and installation shall be carried out in accordance with Indian Codes and Standards, in particular;

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Indian Electricity Act, 1910

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The Indian Electricity Rules, 1956

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The Petroleum Act, 1934

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The Petroleum Rules, 1976

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The National Electrical Code

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IS5572 - Classification of Hazardous Areas for Electrical Installations : Part I Areas having Flaammable Gases and Vapours

These Codes and Standards will be supplemented by International Electrical Commission (IEC) and British Standards (BS) where no Indian Standard exists or where the IEC or BS offer a design that is safe, modern and more cost effective. Electrical equipment and materials manufacturing standards shall be in accordance with IEC standards, with the option for Indian manufacturers to offer equipment and materials manufactured to equivalent Indian Standards (IS). Wherever Codes and Standards other than those of India are applied the necessary review and approval shall be obtained to ensure that they do not conflict with National and/or local regulations. Certification of equipment and materials for duty, rating, hazardous area use, etc. shall be obtained from recognised National or International testing authorities. Evidence of the appropriate certification shall be obtained prior to commitment to purchase. Equipment of Indian origin selected for installation in hazardous areas shall have a test certificate from the Central Mining Research Station (CMRS) and approval certificates from the Chief Controller of Explosives (CCE).

Reliance Petroleum Limited Jamnagar Refinery Complex

Basic Conditions The selection of electrical equipment shall be governed by fitness for purpose, safety, reliability, maintainability of spares and service, compatibility with specified future expansion, design margins, suitability for environment, economic considerations, and past service history. The SI system of units shall be used. English language shall be used for all drawings, texts and communications.

Equipment and Material Specifications The equipment and material specifications listed in Appendix A shall be utilised in the design and purchase of the electrical power, earthing, lighting, instrument wiring, control and communication systems.

Service Conditions Electrical equipment, materials and installation shall be suitable for operation and their design duty under site conditions as stated in the ‘Basic Engineering Design Data Specification’ document No. 22960-3PS-GA-001. Equipment shall have a design life of at least 20 years.

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Electrical equipment intended for outdoor installation shall have minimum protection toIP54, or IP55 if located in a hazardous area (in accordance with IEC 529). IP54 is acceptable for Exd enclosures and floodlight fittings, and IP43 is acceptable for street lighting fittings. 1

Electrical equipment intended for indoor installation shall have minimum protection to IP31 (in accordance with IEC 529).

Design ambient temperature is: + 40°C for Equipment Located Indoors and lighting fittings located outdoors. 1

+ 435°C for Equipment Located Outdoors

Equipment and materials shall be suitable for operation in service conditions typical of a refinery within a coastal environment in the tropics. The atmosphere is to be considered saliferous, sulphurous and dusty. The possibility of condensation exists, as experienced during large temperature variations in a humid environment. 1

Soil data required for the purpose of grounding calculations (soil electrical resistivity) and cable rating calculations (soil thermal resistivity) will be obtained from the project soil survey. In areas where the soil may become contaminated due to hydrocarbon spillage no electrical cables will be installed underground.

Design Calculations

Reliance Petroleum Limited Jamnagar Refinery Complex Calculations shall be made to substantiate the selection and sizing of electrical facilities, e.g. transformers, bus-duct, switchgear, and cables. The results of the calculations 1 shall be submitted to the Owner for review. Calculations will include: Plant and Unit Electrical Loads Load Flow Fault Calculations Power Factor Voltage Drops Relay Settings Cable Sizing Earthing Lighting Levels

Power Supply Main Power Sources and Systems The refinery will be self sufficient in main power generating capacity to satisfy the maximum refinery load. In addition interconnections with the local utility system shall be provided for export and import of electrical power as and when appropriate.. 1

The necessary onsite electrical power will be generated by the use of gas and steam turbine driven generator sets. The generators shall generate at a voltage of 11kV. The main power generators shall be connected via individual 11/34.53kV step-up transformers to the main 33kV distribution switchboard(s) which shall be located in the Main Receiving Substations 1 & 2 (MRS 1 and MRS 2)Power Plant Substation.

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The local utility interconnection shall be by means of four step down ‘grid’ 220/34.5kV ‘grid’ transformers each rated 53MVA. having a total rating to provide back up supply during main generator downtime. The secondaries of the grid transformers will be connected to the main 33kV switchboards. A 220kV outdoor switchyard shall provide interconnection with the grid and the four grid transformers. Initially the outdoor switchyard will be operated at 132kV to provide a temporary connection to the local 132kV grid system.

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Provision shall be made for integrating the future mega power plant in the overall electrical distribution scheme (refer to one line diagram 22960-E51-RU772001ESK-950-003).

Reliance Petroleum Limited Jamnagar Refinery Complex A Load Management scheme shall be provided to synchronise and control the load sharing between generator sets and also to initiate load shedding that may be necessary in case of any loss of generating set(s) or back up supply capacity. 50Hz alternating current electrical systems shall be provided as follows: Main Power Generators

11kV 3 phase, 3 wire

Neutral high res. earthed

Main Power Distribution

33kV 3 phase, 3 wire

Neutral solidly low res. earthed

Secondary Power Distribution

6.6kV 3 phase, 3 wire

Neutral low res. earthed

Emergency Power Distribution

6.6kV 3 phase, 3 wire

Neutral low res. earthed

LV Power Distribution

415V 3 phase,. & N 4 wire

Neutral solidly earthed

Lighting and Minor Loads

240V 1 phase,. & N 2 wire

Neutral solidly earthed (Derived from 415V system)

Instrumentation

110240V 1 phase., & N 2 wire

1 poleNeutral solidly earthed

Contactor Control

240V 1 phase, 2 wire

Neutral solidly earthed (Derived from 415V system)

Hand Lamps

24V 1 phase, 2 wire

Centre point earthed

1

22110 Volt dc systems shall be provided for the following: Circuit bBreaker cControls Emergency Lighting inside substationsLube system drivers (e.g. for Gas Turbines) Where special equipment has a requirement for power supplies other than those listed above, the equipment shall incorporate the necessary converters. Emergency Power Sources and Systems Emergency power onsite generating capacity shall be provided to satisfy the critical services necessary to permit safe shutdown in the event of main power failure and to enable black starting of a main power generator. 1

The necessary electrical power shall be generated by the use of electrically started diesel engine driven generator sets, generating at a voltage of 6.6kV.

Reliance Petroleum Limited Jamnagar Refinery Complex Main emergency switchboards shall be provided at MRS 1 for the main refinery complex and also at the major substation in the Marine Tank Farm. Emergency diesel engine driven generator sets shall be provided on the main emergency switchboards and arranged to start up and connect to the busbar automatically should the normal supply fail. Retransfer of load from emergency to normal on the main emergency 1 switchboards, shutdown and periodic testing of the emergency generating sets shall be manual operation. From the main emergency switchboards emergency supply shall be distributed to all the substations either directly or indirectly via another substation. For details of emergency distribution system see emergency system overall on line diagram(s).The emergency power generator(s) shall be connected to each section of the main emergency power 6.6kV switchboard and shall be arranged to start up and connect to the board automatically in the event that the normal power feed(s) from the 33kV system fail. Utilisation Utilisation voltage for electric motors will be as follows:

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Rating

Utilisation Voltage

Up to 0.37kW

240V 1 phase

Above 0.37kW up to and including 1650kW

415V 3 phase

Above 1650kW

6.6kV 3 phase

For motors rated above 45000kW, consideration will be given to the use of 33/11.5kV captive transformers connected directly to the 33kV system. Neutral of the 11kV system shall be low resistance earthed. The kW ‘break point’ between utilisation voltages may be varied for individual cases where thisthere will providegive an economical advantage.

1 Lighting and similar loads shall operate at 240V a.c. derived from a connection be connected across phase to neutral connection of a 415V 3 phase 4 wire systemvoltage (240V) from the same LV system. Primary distribution and switching for plant area and street lighting may be by use of three phase four wire circuits. AC Voltage and Frequency Tolerances Steady State Limit 1

Non UPS Voltage +/- 10% Frequency +/- 5% UPPS

1

Voltage +6/- 1% (at equipment) Frequency +/- 1% feed via inverter +/-5% feed via bypass transformer

Reliance Petroleum Limited Jamnagar Refinery Complex Transient Limit 1

Non UPS Voltage +/- 20% Frequency +/- 5%

DC Voltage Tolerances Voltage + 10%, - 15% System Harmonics The limitations of harmonic currents appearing on the system shall comply with the British Electricity Council Engineering Recommendations G5/3. Power Factor Power factor correction will only be applied if electricity supply authority tariffs includes a low power factor penalty or due to system operation requirements such as stability, harmonics etc.. 1

In general, power factor correction equipment shall only be provided on switchboards with power factor below 0.85 lagging under normal design operating conditionsWhere power factor correction is required it shall be applied at process related 415V switchgear/motor control centres only.

Power Distribution General

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The firm capacity of the electrical supply and distribution system (generation, transformers, switchgear and cables), shall be capable of supplying continuously, 125% of the peak load as assessed at the design phase of the project. The above mentioned 125% may be reduced during design development, but on completion of the project a margin of at least 10% spare capacity shall exist. Where secondary selective systems are provided, each incomer shall be rated in accordance with the above. However for transformers, this may be achieved by utilising the ONAF rating, where it is economical to do so. Main Power Distribution

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The main 33kV power distribution switchgear shall be located in Main Receiving Substation Nos 1 & 2 (MRS 1 & MRS 2) .the captive Power Plant Substation. The main 33kV power distribution switchgear will provide power at 33kV to major substations located in process complexes, offsites, utilities, marine terminal and jetty. 33/6.9kV transformers will be located at each major substation. Satellite substations shall generally be fed from major substations by 6.6kV feeders. LV power shall be provided at substations via local 6.6/0.433kV transformers.

Reliance Petroleum Limited Jamnagar Refinery Complex Duplicate power supplies will be provided to switchboards which supply loads which are essential to continuous operation of the facility.

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Primary distributionTransmission of power at 33kV will be by direct buried cables except for feeders to marine terminal and jetty which will be by 33kV overhead lines. Should the marine jetty be deleted and the ship loading berth become a ‘sea island’, power for the loading berths shall be derived from diesel engine driven generators. Emergency Power Distribution Dedicated emergency power distribution feeders from the captive power plant emergency 6.6kV switchboard shall supply LV emergency power switchboards in major substations via local 6.6/0.433kV transformers. Separate autonomous emergency power systems will be provided for the marine terminal and jetty. Process interface buildings and satellite substations shall generally be fed from major substations by dedicated 415V emergency power feeders. Emergency power will be provided to vital loads which are defined as those which when failing in operation or failing if called upon to operate, can cause an unsafe condition or result in damage to the installation. Permissible Voltage Drop In hCables Main Feeders

1%

at full rated current at receiving end terminals

Motor Feeders

5%

at motor terminals for at full load current running condition.

15%

at motor terminals for starting condition.

Secondary Feeders (lighting, small power and other low voltage circuits)

2%

at full rated current at receiving end terminals

Lighting sub-circuits

5%

at the furthestfutherest fitting

1

Where excessively oversized cables would result by applying the above permissible volt drops, each case is to be individually assessed taking the end user requirements into account (e.g. for a main feeder to a transformer which is provided with ‘taps’ the volt drop in that feeder may exceed the above specified 1% provided the increased volt drop can be compensated by the transformer tap(s) and provided the transformer secondary voltage remains within specified tolerances from zero load to full load on the transformer).

Reliance Petroleum Limited Jamnagar Refinery Complex

Substations General 1 1 1 1

All substations shall be located strategically at load centres outside hazardous areas. Substation buildings shall be ventilatedair conditioned and shall generally comprise elevated structures permitting the use of bottom entry switchgear with cable racking and trays below. 33kV Switchgear will be housed in a separate room. Large batteries shall be housed in separate rooms but small batteries when enclosed in ventilated equipment cabinets shall be permitted in the switchroom. An equipment access door shall lead directly to the outside from each switch room. Internal personnel doors may connect adjacent rooms. Power transformers shall be located at grade level in fenced enclosures adjacent to the substations and shall be provided with oil catchment pits pits and sunshades. BlastFire walls will be provided where required by codes and standards. Heat sensitive electronic equipment shall be located in a separate room provided with air conditioning.

Main Receiving(Power Plant) Substations (MRS)

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Two Main Receiving SubstationsA main substation shall be provided adjacent to the captive power generation plant. Each MRSThis substation will accommodate twothe main 33kV power distribution switchboards, 6.6kV station services and emergency power switchboards, LV switchboards and motor control centres. MRS 1 shall also house the main emergency switchboard. The 33kV switchgear shall be accommodated in a separate room. Load management system hardware will also be accommodated in the Captive Power Plant Control Room.same substation. Each main generator package shall be supplied complete with all the auxiliary equipment such asshall incorporate a skid mounted control cabin accommodating the low voltage motor control centre,switchboards and all of the DC equipment and batteries for the auxiliaries associated with the particular generator. Local fFacilities shall be provided for starting the generator, for control of synchronising to the 33kV busbars and for loading the machine. Facilitiesy shall also be provided to transfer control of starting, synchronising and loading of the generating set to a remote location (generator control room within the main substation).

Plant Area Substations

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Plant area substations shall be designated to be either a ‘Major Substation’ supplied with power at 33kV and housing both 6.6kV and LV systems, or as ‘Satellite Substation’ supplied with power at 6.6kV (from one of the Major Substations) and which may house only LV distribution or both 6.6kV and LV systems.

Utility Incoming Switchyard 1

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A switchyard adjacent to the 33kV substation shall be provided for terminating the utility incoming supply and to accommodate the four 220(HOLD)/34.53kV grid transformers. Line isolators, line and transformer earthing switches and metering transformers shall be provided at the high voltage side of the power transformers. Switchyard services equipment together with the tap changer

Reliance Petroleum Limited Jamnagar Refinery Complex control, protection and tariff metering panels will either be located inside MRS auxiliary rooms or inside a kiosk local at the switchyard.

Hazardous Areas Hazardous Area Classification 1

Area shall be classified in accordance with the IS5572 - Classification of Hazardous Areas for Electrical Installations : Part 1 Areas Having Flammable Gases and Vapours.

Equipment Selection Electrical equipment shall meet the requirements of the Institute of Petroleum Model Code of Safe Practice : Part 15. The following equipment shall be selected.

Zone 1 Areas d) Zone 2 Areas

Unclassified Areas

a) Flameproof or explosion proof, Ex(d) equipment b) Pressurised, Ex(p) equipment c) Intrinsically safe, Ex(ia) or Ex(ib) equipment a) Non-sparking, Ex(n) equipment b) Increased safety, Ex(e) equipment c) Equipment complying with the requirements for zone 1 area a) Standard industrial equipment b) Equipment complying with the requirements for zone 1 and 2 areas

Non Indian origin electrical equipment for installation in hazardous areas shall be type certified by CENELEC approved testing authority. Electrical equipment of Indian origin for installation in hazardous areas shall have a test certificate from the Central Mining Research Station (CMRS) and approval certificate from the chief controller of Explosives (CCE).

Equipment Switchgear/Motor Control Centres

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The 220kV switchgear shall be of the outdoor open type design with circuit breakers of the SF6 type and isolators of the open, air break type. Switchgear shall be in accordance with specification 22960-3PS-EZ-001. The main 33kV switchgear shall be of the air insulated, metalclad type with vacuum circuit breaker and in accordance with specification 22960-3PS-ES-001. 6.6kV switchgear/motor control centres shall be of the air insulated, metalclad type with vacuum circuit breaker and in accordance with specifications 22960-3PS-ES002. All motors shall be controlled via circuit breakers. and EC-002. Feeder switches for motor drives up to approximately 4000kW shall be of the fused

Reliance Petroleum Limited Jamnagar Refinery Complex vacuum or SF6 contactor type. Larger motors, transformer and other feeders shall be supplied from circuit breakers.

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415LV switchgear/motor control centres shall be in accordance with specifications 229603PS-ES-003 and EC-003. Motors rated up to and including 90kW shall be controlled by fused contactors. Motors rated above 90kW shall be controlled by air circuit breakers on Power Control Centres (PCC). Fuse switch circuits shall generally be used for outgoing feeders up to and including 63 amps and fused contactors for circuits greater than 63 amps and up to and including 630 amps. Current ratings above 630 amps shall be supplied from air circuit breakers on PCC.. Emergency switchgear complete with automatic changeover facilities shall be provided where appropriate in all the substations. Under normal operating conditions power to the 415V emergency switchboards/MCCs shall be derived from the normal supply network. Oon a loss of normal supply the automatic changeover facilities will changeover the supply from normal to emergency. The retransfer of load back from emergency to normal supply will be an automatic function.Emergency power will be provided by diesel engine driven, 6.6kV generators. The emergency generators will be connected to a 6.6kV emergency switchboard located in the main substation in the captive power plant. Duplicate 6.6kV incoming feeders from the normal power system will be provided. Emergency power will be distributed at 6.6kV throughout the refinery. At each major substation 6.6/0.433kV transformer(s) and 415V emergency switchboard(s) will be provided. Under normal conditions power to the 415V emergency switchboards will be derived from the ‘normal’ 4l5V power supply system. An automatic change over facility will be provided to change over to the emergency supply on loss of normal volts. Separate emergency power systems will be provided in the Marine Terminal and for the Jetty facility. Power will be provided by diesel engine driven, 6.6kV generators and distributed similarly to that for the main refinery.

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Where duplicate feeds are provided to 6.6kV and 415V , switchboards,gea r an automatic transfer scheme will be provided in order to switch to the alternative feeder if a failure occurs in one supply feeder. Protection shall be provided to prevent transfer in the case of a fault downstream of the circuit breaker. The automatic transfer systems shall be independent for each switchboardbusbar section and shall include time delay such that transfer takes place at the 6.6kV level before transfer at LV is effected. The timing shall also be adjusted such that switching to the emergency supply feeder shall only take place if upstream transfers have failed to restore the supply. Return to normal after main power restoration shall be manual. Exceeding of switchgear fault rating during momentary paralleling shall be permitted. Lighting and small power distribution switchboards shall be located in each substation, in other buildings and at strategic locations outdoors around the plant areas. Depending upon their application they shall be supplied either from photocell controlled or manually operated circuits on either the normal or the emergency services LV switchboards. The distribution switchboards shall be in accordance with specification 22960-3PS-EK-001. The distribution switchboards shall be suitable for indoor or outdoor use and the hazardous area classification in which they are to be situated. Distribution boards located in hazardous areas shall be limited to 18 single phase ways.

Reliance Petroleum Limited Jamnagar Refinery Complex Automatic motor reaccelaration/restarting following voltagepower dips will not be provided unless dictated by process requirements.. Power system monitoring, control and protection will be in accordance with specification 22960-3PS-EY-004. Emergency Shut Down (ESD) systems and emergency stops will be hard wired back to the switchgear/MCC. 1

Large motors fed via 33/11.5kV captive transformers will be controlled by 11kV switchgear connected to the secondary side of the captive transformer. Both transformer and 11kV switchgear shall be located in the substation local to the motor controlled. Power Transformers Distribution power transformers shall be in accordance with specification 22960-3PS-ET002. Generator and grid transformers shall be in accordance with specification 22960-3PS-ET001. Cooling arrangement of all transformers shall be ONAN.Where cost effective ONAN/ONAF transformers will be provided (i.e. ONAN rating will match current load requirement with fan cooling (ONAF) fitted in future to provide for future loads). Automatic on-load tap changers shall be provided on the grid transformers and the main distribution transformers located at the Marine Tank Farm major substation..

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Power Factor Correction Power factor correction will be applied only where dictated by para 7.7 above. Where provided Ppower correction equipment shall be in accordance with specification 22960-3PS-EA-002will only be provided should the power supply authority impose a low P.F. penalty within his electricity tariffs. Consideration will be given regarding the alternative of using synchronous machines to improve the overall system power factor of the plant at the point of grid connection. Neutral Earthing Resistors

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Neutral earthing resistors shall be in accordance with specification 22960-3PS-EG-001.will be provided to limit the earth fault current on each of the 33kV, 11kV and 6.6kV network to an appropriate level. Each earthing resistor will be rated to withstand the respective earth fault current for a duration of not less than 10 seconds. For 6.6kV system 250A, and for 11kV system 250A (except generation), see single line diagram(s) for details. DC Supply Units DC supply units shall be in accordance with specification 22960-3PS-ED-001. DC supply Units shall be provided in each substation for:

Reliance Petroleum Limited Jamnagar Refinery Complex • the Sswitchgear protection and tripping supplies

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•

, and Ssubstation alarm annunciators panel(s)

•

Electrical load management system

•

Electrical distribution management system

See single line diagram(s) for DC system configuration. DC supply units will be in accordance with specification 22960-3PS-ED-001. AC Uninterruptible Power Supplies (UPS) Systems AC UPS systems shall be in accordance with specification 22960-3PS-EUP-001. AC UPS systems shall be provided as required in substations, process interface buildings and control rooms to provide no break supplies to the following systems:

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Distributed Control System (DCS)

•

Fire and Gas System

•

ESD System

•

Control panels where deemed appropriate

•

Essential instrumentation

•

Machine/Process Condition Monitoring System (e.g. vibration, analyser and anti-surge).

•

PA/Alarm System

•

Talkback Intercom System

•

Telephone System

•

Radio System

•

CCTV System

See single line diagram(s) for AC UPS system configuration . Busbar Trunkings 1

Busbar trunking shall be in accordance with specification 22960-3PS-EB-001. In general power connections exceeding 1000 amps will be carried out using busbar trunking. Relay Panels and Protective Devices

1

The metering, protection and control equipment associated with the 220kV switchgear shall be housed in dedicated relay panels located in a relay room within located MRS1. Main Substation.

Reliance Petroleum Limited Jamnagar Refinery Complex The bus zone protection equipment associated with the 33kV switchgear shall be housed in dedicated panels located in the relay room within the respective MRS. With the exception of 220kV and 33kV switchgear all other protective devices and meters shall generally be housed within the switchgear cubicles. 1

The metering, protection and control equipment associated with the gassteam and steamgas turbine driven generating sets shall be housed in dedicated panels located inside the auxiliary room within each MRS or Captive Power Plant Control Room respectively.respective local control cabin. All other protective devices and meters shall be housed within the switchgear cubicles. Alarm Annunciators

1

Alarm annunciators shall be in accordance with specification 22960-3PS-EY-003. All fault tripped and equipment malfunction signals occurring within switchgear, MCC’s and other electrical equipment shall be wired into an alarm annunciator panel situated in each substation. A common summary alarm signal from each annunciator shall be fed into the DCS where it shall bring up a substation fault alarm in the Main Control Room.

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Certain alarms shall be fed into the electrical distribution management system which shall bring up an alarm in the CPP Control Room. Interfaces with Process Control Systems Process control interfaces between the DCS and MCC’s shall be by a communications data link. Certain switchgear signals shall be connected into the DCS for remote status monitoring of the electrical system.

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EnergyLoad Management System The Energy Management System shall combine both load management and electrical distribution system management functions. Load management shall be in accordance with specification 22960-3PS-EY-002 and electrical distribution management in accordance with specification 229603PS-EY-004. Load management shall monitor and facilitate control of the main power generation, synchronising and load shedding at the 33kV level. Its functions shall include automatic load sharing, load shedding, grid transformer tap changer control, 33kV breaker control and system parameters/status monitoring.ency genera

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The electrical distribution management shall provide monitoring and control (except emergency system) of the complete electrical power distribution system. This includes breaker control, status monitoring and fault reporting of the distribution circuit breakers and monitoring of system parameters such as voltage and power.

Reliance Petroleum Limited Jamnagar Refinery Complex The communication between the substations and the management system shall either be via optical fibre serial links or hardwired. The system shall have the facility to be monitored from the main Control Room via the DCS serial link communication network. The system shall also have the facility to communicate with the Refinery Information Management System (RIMS).. 1 The main Energy Management System and Electrical Distribution Management System equipment shall be located in the Captive Power Plant Control Room.

Variable Speed Drives 1

Variable speed drives equipment shall be in accordance with specification 22960-3PS-EVP001 . The use of variable speed drives, shall be considered on an economic and technical basis subject to process requirements. Converter equipment shall be located inside the substation, except the associated transformers and reactors, which shall be located outside within a transformer/reactor bay adjacent to the substation..

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Motors and Motor Control Stations Motors generally shall be of the squirrel cage induction type and in accordance with specifications 22960-3PS-EM-001 and 22960-3PS-EM-002. LV motors shall normally be selected to have ratings in accordance with the preferred rated output values of the primary series as listed in IEC 72. Motor enclosures shall be selected to suit the site conditions. As far as is practical, motors shall have totally enclosed fan cooled (TEFC) enclosures. Larger machines will generally have separate internal and external air circuits (CACA or TETC).). 1

All motors above 30kW shall will be fitted with 240V AC rated anti-condensation heaters. Winding heating utilising 24V AC shall be provided for all motors rated 30kW and below. Motors for use in hazardous areas shall be fully certified as follows: Area Zone 1

Certification 6.6kV motors Ex(d) or Ex(p) LV motors

Zone 2

Ex(d)

6.6kV motors Ex(n) or Ex(d) (with Ex(d) or Ex(e) Terminal box) or Ex(p) LV motors

Ex(n) or Ex(d) (with Ex(d) or Ex(e) Terminal box) or Ex(n)

Reliance Petroleum Limited Jamnagar Refinery Complex Each motor shall be provided with a start/stop control station installed on suitable steel support adjacent to the motor. Exception being the critical drives such as 1 emergency D.C. lube oil pumps for the gas turbines. Start/stop control station shall have stay put stop and lock-off stop features (padlocking). Start/stop control stations for motors rated above 30kW and motors driving agitators compressors and blowers shall be provided with ammeters. Ammeter shall have connection to CT (1 amp secondary) located within the motor starter.shalle the control gear. Other motors below 30kW driving agitators, compressors lowers shall also provide

Start/stop control stations for all fin-fan and cooling tower fan motors shall be located at grade. a aA lock-off stop push button shall be located adjacent to each fan motor. 1

Motors having automatic process control shall be provided with control stations incorporating Hand/Off/Auto selector switch (padlockable in Off position). Motors which can be started from more than one location shall be provided with control stations with Local/Off/Remote selector switch (padlockable in Off position). Motor operated valves and electric cranes shall be fully equipped with integral control gear.

Earthing System Earthing systems shall provide low impedance earth paths for earth faults, static discharge and lightning protection. Power system earthing, lightning protection and equipment bonding shall be by a common system. All units shall be bonded together to form a single continuous earthing system.

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The earthing systems in the high voltage switchyard, substation and power plant shall compriseeach consist of a buried grid of galvanised mild steel flat bar bonded together and sized to suit the maximum earth fault current for 1 second plus a 50% corrosion allowance. Earth electrodes providing the requisite value of resistance to the general mass of earth electrodes shall be installed adjacent to transformers and generators and throughout plant areas to ensure that the requisite value of resistance between equipment and the general mass of earth is obtained. The electrodes shall be bonded to the earthing grids through disconnecting links which will permit periodic maintenance testing. Connections from the earthing grid rising above ground to local metalwork and electrical equipment shall be carried out using PVC covered aluminium cablegalvanised steel wire. All large equipment items shall be bonded to earth in at least two places. The design of the earthing grid within the high voltage switchyard shall ensure that ‘step’ and ‘touch’ voltages remain within code requirements.All other units shall have a buried continuous earth ring of mild steel flat bar encompassing the unit area. The mild steel bar shall similarly be designed to carry maximum earth fault current for 1 second plus a 50% margin for corrosion. Connections to local metalwork and equipment shall be carried out as described above.

Reliance Petroleum Limited Jamnagar Refinery Complex A separate earthing system shall be provided for the earthing of instrumentation system inside each area. 1

Earthing and bonding of jetty shall be designed and installed in accordance with relevant standards. Pipe and/or hose connections between ship and the jetty shall be provided with insulation flanges or joints. Gangways shall be insulated from the ship by means of insulated rollers. Electrical equipment on the jetty shall be bonded to the shore earthing system regardless of whether or not the jetty is cathodically protected.

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Earthing and bonding at road and rail loading facilities shall be designed and installed in accordance with the relevant Codes and Standards. Bonding clamps with Ex(d) isolators shall be provided for bonding between tanker and fixed installation. The metallic enclosures of all electrical equipment shall be bonded and earthed to the common earthing grid. In hazardous areas or where the equipment contains a hazardous liquid, the metallic enclosures of non electrical equipment, vessels, tanks, structures, etc., shall be bonded and earthed to the common earthing grid. Maximum values of resistance of equipment earthing systems to the body of earth shall be as follows: • • • •

General Electrical Earthing Earthing for Lightning Protection Instrument ‘Clean’ Earth Intrinsically safe Earth

1 ohm 10 ohms 1 ohm 1 ohm

However, a lower resistance value may be necessary to ensure proper operation of the earth fault protection. Lightning protection shall be provided for all non metallic and all metallic noncontinuously welded structures over 20 metres high. 1

Earthing of lighting and small power systems shall be by means of an earth conductor integral within cable or conduit. Power circuits shall be earthed by separate earth wire connected to the earthing grid.

Lighting General Lighting

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Lighting in industrial plant hazardous and non hazardous areas shall generally be by means of high pressure mercury vapour wellglass twin lamp fluorescent luminairies mounted on the structures, directly beneath beams, or on platform mounted poles. Alternatively, where available to be sourced within India fluorescent luminaires may be provided. Where required, gGeneral lighting for open areas within non hazardous area industrial plants where required shall be by means of 250 or 400 watt high pressure sodium (SON) floodlight luminairies mounted on adjacent structures or on strategically

Reliance Petroleum Limited Jamnagar Refinery Complex located floodlight columns. High mast floodlighting (using 1000W SON) installation shall also be used where appropriate.

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Where required general lighting for open areas within hazardous area industrial plants requiredshall be by means of 400 watt high pressure mercury vapour floodlight luminaires mounted on adjacent structures or on strategically located floodlight columns. High bay type 250 or 400 watt high pressure sodium luminairies shall be used in appropriate non hazardous locations such as compressor houses, warehouses, workshops etc. Lighting in industrial buildings such as substations, workshops, warehouses, canteens, etc. shall be by industrial type ceiling or trunking mounted, twin lamp, fluorescent luminairies.

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Lighting in administration building offices, instrument roomscontrol rooms and similar locations shall be by flush ceiling mounted fluorescent luminairies of a type compatible with the building architectural finishes. Control Room luminaires shall be of the low glare mirror optic type. The following average intensity levels, measured 1m above the floor level in a horizontal plane, shall form the basis for the lighting design: Type of Location

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Control Room - general lighting - rear of instrument panels, aux. and panel rooms. - outside, near entrances Pump and compressor houses, at or near equipment Switchrooms and PIB’s etc. Furnace and boiler areas Outdoor operational areas Outdoor non operational areas Stairways, platforms and walkways Road/Rail loading gantries Rail siding coupling/uncoupling areas Rail storage sidings generally Road truck parking areas Drawing offices Offices First-aid rooms Toilets and locker rooms Workshops - interior generally - exterioroutside Stores - interior between racks - material yards - bulk storage operating areas Refinery Tank FarmsTank farms Marine Area Tank Farms

Lux 400 - 700 250 150 100150 150 510 510 103* 510 50 10 51* 53* 700 400 400 150 250 50 150 5* 50 5*0.5* 5*

Reliance Petroleum Limited Jamnagar Refinery Complex Jetty approaches Roads/main access Roads minor Complex Entrance GatesFence

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105* 5* 53* 50*No specific lighting provided

* At grade Emergency Lighting Emergency lighting shall comprise two categories: 1

Category 1:

No break lights, comprising fluorescent luminaries with integral battery/charger or alternatively central battery fed tungsten luminairies. They shall have 1 hour autonomy

Category 2:

Short break lights, fed from the emergency generators. Luminaires may be of the tungsten or fluorescent type.

The number of emergency luminaries in relation to normal luminaries shall be as follows: Type of location Process area

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10%

Utility area

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20%

5%

25%

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10%

5%

25%

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-

Control and medical rooms

10%

40%

Administration buildings and offices

5%

-

100%

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Machinery rooms (Workshops) Road/Rail loading gantries Switch rooms, equipment rooms and instrument shelters (including process interface building PIBs)

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Category 1 Category 2

Off plot tankage areas and ppump stations

Fire exit doors from buildings Road and Parking area Lighting 1

Road and parking area lig hting shall be provided by means of 250, 400 or 1000 watt high pressure sodium luminaries mounted on 10 metre columns or 20 metre highmast floodlighting columns. This lighting shall be connected to the normal power supply system. Rail Siding Lighting

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High mast floodlig hting shall be utilised in areas where trains are coupled or uncoupled, in switching areas and on the loading/unloading areas and their sidings. Apart from the loading gantries, the rail siding lighting shall be fed from the normal power system only. Tank Farm Light ing

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Reliance Petroleum Limited Jamnagar Refinery Complex High mast floodlighting columns sited in non hazardous locations outside of tank farm bund walls shall be utilised. Local lighting may be provided as necessary in areas of regular plant operational activity. Lighting Control Outdoor lighting circuits shall generally be controlled by photo electric cells. override shall be provided to permit maintenance.

Manual

Indoor lighting shall be controlled locally by suitably located switches.

Power and Convenience Outlets 415 volt, 63 amp, TP&N+E Power outlets shall be provided in workshops and at strategic locations in industrial and plant areas such that all principal equipment locations can be reached by use of 50 metres of extension cable. 240 volt, 16 amp, SP&N+E Convenience outlets shall be provided throughout the industrial areas such that all principal equipment locations can be reached by use of 25 metres of extension cables.

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Convenience outlets for hand lamp supplies with integral transformer, rating - 100VA, 240/24 Volts (centre point earthed), shall be provided near to the manholes of vessels, tanks columns etc. Sufficient 240 volt, 13 amp, SP&N+E Convenience outlets shall be provided in all domestic and administrative buildings, PIBs, switch and equipment rooms, and workshops and offices. All outlets located within hazardous areas shall be certified for such locations.

Cable and Cable Installation Cable Types

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Power cables and control cables may have XLPE or PVC insulation selected on economic considerations, and in accordance with relevant specifications 22960-3PS-EW001. Instrumentation cables shall be selected in accordance with relevant specification 22960-3PS-EW-002s. Conductors 16 sq. mm and greater shall generally be may be either of aluminium or(C copper may be selected on economic orand technical considerations). Conductors smaller than 16 sq. mm shall be copper.. Aluminium and copper conductors shall not both be used on the same circuit.

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All cables used above or below ground in industrial areas shall have non hygroscopic fillers, wire armouring, and PVC overall sheath.. Additionally, cables used underground in hydrocarbon processing or storage areas shall have a lead sheath. Unarmoured cables and wires may be used where proper mechanical protection (e.g. metallic conduit) is provided or where sheathed cables are installed above ceilings or below floors in non industrial locations. Concealed metallic conduits shall be used for buildings where appropriate.

Reliance Petroleum Limited Jamnagar Refinery Complex Cables for critical services shall be of the fire resistant type in accordance with IEC 331. Cables for conduit installation shall be PVC insulated single conductor. 1 1

Earthing of lighting and small power systems shall be by means of an earth conductor integral with the cable or conduit. Cable Installation

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The preferred method of cable installation is for cables to be installed above ground laid on racks and trays within dedicated levels of overhead piperacks and on the sleepers of low level pipeways. In certain instances cables may be routed underground, these include: • high voltage distribution cables and associated control cables • cables entering or leaving buildings • cables in areas where ground contamination is unlikely and economic consideration precludes the erection of special cable supports • cabling within the power generation area • feeder cables to satellite substations. Cables routed underground shall be direct buried within offsite areas and installed in formed concrete trenches within process areas.

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33kV cables shall be laid in a single layer at 300mm centres and at a minimum depth of 900mm below grade. 6.6kV cables shall be laid in one or two layers at 150mm centres and at a minimum depth of 500mm below grade. 415V cables may be laid in up to three layers at 150mm centres and at a minimum depth of 500mm. Control cables and light loaded cables may be grouped together or laid between loaded cables. All cables shall be laid on a sand bed with well compacted sand around and above. Concrete or earthenware tiles shall be laid above the cables in unpaved areas, tiles are not required where cables are laid in formed concrete trenches. Trenches shall be sized to allow for a future 20% increase in cabling.

Where cables leave the main trenches and for road crossings they shall be run in duct banks of concrete encased PVC ducting. Where cables rise above grade to equipment they shall be protected by metallic ‘kick’ sleeve up to 150 mm above grade and from there shall be run on rack or tray or secured by some other suitable means.

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Control and communications signals between the refinery andcables along the pipeline wayleave to the marine area will be carried via fibre optic cables, installed as part

Reliance Petroleum Limited Jamnagar Refinery Complex of the 33kV overhead line system .and jetty shall generally be laid direct buried adjacent to the 33kV overhead lines. Cables shall be installed with spacing to minimise derating but consistent with the total space available. 1

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All underground cables shall be fitted with substantial identification bands at terminations, at 30m intervals over their entire length, at all points where they enter and leave ducts, and at changes in cable direction etc. The identification band shall show the complete cable number. Suitable route markers shall be provided to indicate trench locations and shall be located at 50 m intervals and where the trench changes direction. When the trench is within paved areas, red coloured coversconcrete paving, shall be used to mark cable routes. Cables shall be in one length where practical but underground joints may be installed when necessary. Cable joints shall be recorded and their locations marked accurately on ‘as built’ drawings. When cables pass through a building foundation, ducts or an opening in the foundation shall be used to permit entry. Adequate segregation shall be maintained between different services. In general, power and instrumentation/telecommunication cables shall not be laid in the same trench. A separation of 600mm shall be maintained between parallel runs of instrument and electrical cables.

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Above ground cables shall be supported by cable racks or trays. Power cCables shall generally be laid on racks or trays in a single may be bunched in a maximum of two layers. Control cables may be bunched together. Cables shall be securedcleated at required intervals. Cable racks and trays material shall be fabricated from steel and hot dipped galvanised after fabrication.suitable for the environment in which they are used. Consideration will be given to the use of hot dip galvanised steel, stainless steel and GRP. Cable racks and trays shall be enclosed by removable top covers allowing adequate ventilation in the following situations:

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Mechanical damage of cables is likely to occur during plant maintenance activities.

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Oil or chemical spillage’s on the installation can be expected.

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Covers are required for sun shields

Power (and associated control) HV, LV, and instrumentation/telecommunication cables shall be run in their own racks. HElectricalV cables shall be where practical separated by at least 60750mm from instrumentation and telecommunication cables except at switchgear/MCC an substations.. All cables shall be terminated using an approved compression cable gland which shall be of nickel plated brass except for single core cables where aluminium glands shall be used. All cable entry threads shall be BS conduit (ET) to BS 31.

Reliance Petroleum Limited Jamnagar Refinery Complex Alternative feeders to substations shall follow separate routes as far as is practical. Generally underground cables shall be in separate trenches (e.g. on opposite sides of roads) or if this is impractical shall be separated by at least 1 metre.

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Wiring for lighting, small power and telecommunication systems within non industrial buildings shall be single core pvc insulated copper conductors run in screwed, seamless, metallic conduits. Conduits shall be chased into the blockwork of walls having a plastered finish, elsewhere conduit installations shall be surface run clipped to brickwork, concrete or structural steel. All outlet boxes shall be steel and approved for either surface mounting or flush mounting system. Within plant areas and in all hazardous areas, lighting and small power cables shall be multicore pvc terminated using compression type cable glands.Wiring in buildings for lighting, small power and telecommunication may be installed in conduits. Metallic seamless conduit shall be used in industrial areas but plastic conduits are acceptable in non industrial buildings.

Aircraft Warning Lights and Navigational Aids Aircraft warning lights shall be installed on high chimneys and structures as required by international and local regulations. Navigational aid lighting shall be installed on the Jetty as required by international and local regulations.

Electrical Trace Heating Where necessary electrical trace heating shall be provided for process pipelines. As far as is practical, suitably certified self regulating heating tapes shall be employed. Special types of heating (e.g. skin effect, impedance or induction heating) may be employed in particular applications.

Cathodic Protection Appropriate application shall be made of either impressed current or sacrificial anode methods of cathodic protection for buried or immersed structures, vessels, pipes and tank bases. The responsibility for the design and installation of the ground beds shall be under the scope of the specialist sub contractor. The design of the jetty cathodic protection system, if any, shall take account of the leakage current to the shore earthing system.

Standardisation For ease of maintenance and to limit the spare parts inventory, it is intended that as far as is practical, each class and category of electrical equipment shall be of the same type and supplied by the same manufacturer wherever it is used on the refinery. When similar classes and categories of electrical equipment are included in packages, vendors shall be required to purchase the same standard types.

Reliance Petroleum Limited Jamnagar Refinery Complex

Installation The installation of the electrical and instrument cables and equipment will be carried out under one or more subcontracts. Main equipment, cables and bulk materials will be free issue to the installation subcontractor but minor installation materials including fixings, brackets, steelwork for site fabricated supports, cable tray below 100mm wide, conduit and conduit wiring, sand for cable bedding and cover, cable tiles, trench markers and all consumables will be supplied under the subcontract.

Appendix A Project Specifications

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Specification No.

Description

22960-3PS-E80-002 22960-3PS-E80-003 22960-3PS-E80-004 22960-3PS-E80-005 22960-3PS-E80-006 22960-3PS-EA-002 22960-3PS-EA-003 22960-3PS-EA-004 22960-3PS-EB-001 22960-3PS-EC-001 22960-3PS-EC-003 22960-3PS-ED-001 22960-3PS-EG-001 22960-3PS-EH-001 22960-3PS-EK-001 22960-3PS-EM-001 22960-3PS-EM-002 22960-3PS-EMG-001 22960-3PS-EMG-002 22960-3PS-EQ-001 22960-3PS-ES-001 22960-3PS-ES-002 22960-3PS-ES-003 22960-3PS-ET-001 22960-3PS-ET-002 22960-3PS-ET-003 22960-3PS-EUP-001 22960-3PS-EVP-001 22960-3PS-EW-001 22960-3PS-EW-002 22960-3PS-EY-001 22960-3PS-EY-002 22960-3PS-EY-003 22960-3PS-EY-004 22960-3PS-EY-005 22960-3PS-EZ-001

Electrical Installation And Testing Electrical Requirements For Packaged Equipment Electrical Power System Studies Captive Power Plant Design Criteria Electrical Design and Installation for Electrical Equipment of Buildings Power Factor Correction Equipment Navigational Aids Overhead Line Equipment Busbar Trunkings 415V Outdoor SwitchgearSwitchracks 415V Motor Control Centres DC Power Supply Units Neutral Earthing Resistors Electric Trace Heating Distribution Boards LV Motors HV Motors AC Synchronous Generators Diesel Engine Driven Generators Cathodic Protection 33kV Switchgear 6.6kV Switchgear 415V Switchgear Generator and Grid Transformers Power Distribution Transformers LV Transformers AC UPS Units Variable Speed Drive Systems HV and LV Cables Instrumentation Cables Generator Control Panel Load Management System Substation Alarm Annunciators Panels Electrical Power, Control, Protection and Monitoring Thyristor Control Panels for Electric Heaters HV Open Type Switchgear

22960000\/var/www/apps/pdfcoke/pdfcoke/tmp/scratch1/9579163.doc3PS-E80-001 REV. 1

APP. A Page 1 of 1