November 2002

Process Industry Practices

Electrical
PIP ELCGL01D
Data Sheet for Electrical Design Criteria
PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES
In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these
technical requirements into a single set of Practices, administrative, application, and
engineering costs to both the purchaser and the manufacturer should be reduced. While
this Practice is expected to incorporate the majority of requirements of most users,
individual applications may involve requirements that will be appended to and take
precedence over this Practice. Determinations concerning fitness for purpose and
particular matters or application of the Practice to particular project or engineering
situations should not be made solely on information contained in these materials. The
use of trade names from time to time should not be viewed as an expression of
preference but rather recognized as normal usage in the trade. Other brands having the
same specifications are equally correct and may be substituted for those named. All
Practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these Practices or guidelines
should conflict with OSHA or other applicable laws or regulations, such laws or
regulations must be followed. Consult an appropriate professional before applying or
acting on any material contained in or suggested by the Practice.
This Practice is subject to revision at any time by the responsible Function Team and
will be reviewed every 5 years. This Practice will be revised, reaffirmed, or withdrawn.
Information on whether this Practice has been revised may be found at www.pip.org.
Process Industry Practices (PIP), Construction Industry Institute, The
University of Texas at Austin, 3925 West Braker Lane (R4500), Austin,
Texas 78759. PIP member companies and subscribers may copy this Practice
for their internal use. Changes, overlays, addenda, or modifications of any
kind are not permitted within any PIP Practice without the express written
authorization of PIP.
PIP will not consider requests for interpretations (inquiries) for this Practice.
Not printed with State funds
ASSOC. PIP:
ELCGL01
DATA SHEET FOR ELECTRICAL
DESIGN CRITERIA
ELCGLO1D
PAGE 1 OF 8
November 2002
Client: Engineering Org.: Specification No.:
Project Title: Location: Date:
Project Location: Contract No.: Equipment No.:
Project No.: Specifier Name: Telephone No.:
Purchaser Order No.:
Refer to PIP ELCGL01 for General Requirements.
3. System Design Criteria
3.2 Other Applicable Codes:
3.3 System Studies
! Load Flow ! Short Circuit ! Motor Starting ! Harmonic ! Transient Stability ! Underground Cable Thermal
! Ground Grid ! Load Summary ! Device Coordination
Software: ___________________________________________________________________________________
3.4 Utility Interface Parameters
Max. Voltage: _________________ Min. Voltage: _________________ Frequency: _________________
Max. Short Circuit MVA 3-Phase: ________ Min. Short Circuit MVA 3-Phase: ________ X/R: ______
Max Short Circuit MVA L-G: ________ Min. Short Circuit MVA L-G: ________ X/R: ______
3.5 Three-Phase System Voltage Parameters
Bus Voltage Transformer Secondary Connection Grounding Method Motor Horsepower Range
! 13800 ! Wye
! Delta
! Solid
! Low Resistance
! High Resistance
_________ through _________
! 12470 ! Wye
! Delta
! Solid
! Low Resistance
! High Resistance
_________ through _________
! 7200 ! Wye
! Delta
! Solid
! Low Resistance
! High Resistance
_________ through _________
! 4160 ! Wye
! Delta
! Solid
! Low Resistance
! High Resistance
_________ through _________
! 2400 ! Wye
! Delta
! Solid
! Low Resistance
! High Resistance
_________ through _________
! 480 ! Wye
! Delta
! Solid
! High Resistance
! Ungrounded
_________ through _________
! 120/208 ! Wye Solid
! 120/240 1-Phase Solid Less than ___________ hp
Other
Voltages
! ________
! 1-Phase
! 3-Phase
! Wye
! Delta
! Solid
! Low Resistance
! High Resistance
! Ungrounded
_______ through _________
ASSOC. PIP:
ELCGL01
DATA SHEET FOR ELECTRICAL
DESIGN CRITERIA
ELCGLO1D
PAGE 2 OF 8
November 2002
3.7 Motor-Starting Voltage Drop
3.7.2 Acceleration Study ! Required ! Not Required ! >600 Volts and 5000 Volts ! >5000 Volts
Motor-Rated Voltage Required System Starting Voltage at Bus:
3.7.3 600 Volts ! 90% ! ________%
3.7.6 >600 Volts and 5000 Volts ! 85% ! ________%
>5000 Volts ! 85% ! ________%
Motor-Rated Voltage Required System-Starting Voltage at Motor Terminals:
3.7.7 >600 Volts and 5000 Volts ! 80% ! ________%
>5000 Volts ! 80% ! ________%
3.7.5 600-Volt Reduced Voltage Starting Method ! Soft Start ! Other ______
3.7.8 >600-Volt Reduced Voltage Starting Method ! Captive Xfmr ! Soft Start ! Auto-Transformer ! Other ___________
3.8 Design Allowance
3.8.1 Spare Capacity Feeder Cable Ampacity ! 20% ! _______%
Above NEC
Requirements
Transformer Capacity ! 20% ! _______%
Switchgear Bus Ampacity ! 20% ! _______%
MCC Bus Ampacity ! 20% ! _______%
3.8.2 Spare Devices MV Starters _______ ! 2 Per Line-up ! 2 Per Sub ! 2 Total Project
MV Switchgear Circuit Breaker
or Fused Switches
_______ ! 2 Per Line-up ! 2 Per Sub ! 2 Total Project
Low-Voltage Switchgear
Circuit Breakers
_______ ! 2 Per Line-up ! 2 Per Sub ! 2 Total Project
Low-Voltage Starters (per
MCC)
Size 1 ________
Size 4 ________
Size 2 ________
Size 5 ________
Size 3 _________
Size 6 __________
Feeder Breakers: _________ Fused Switches: _________
3.8.3 Equipped
Spaces
MV Starters (per Line-up) ______ ! 2 Per Line-up ! 2 Per Bldg ! 2 Total Project
Low-Voltage Switchgear
Circuit Breakers
______ ! 2 Per Line-up ! 2 Per Bldg ! 2 Total Project
MV Switchgear Circuit
Breakers
______ ! 2 Per Line-up ! 2 Per Bldg ! 2 Total Project
Unequipped Spaces MV Starters (per Line-up) ______ ! 2 Per Line-up ! 2 Per Bldg ! 2 Total Project
Low-Voltage Switchgear
Circuit Breakers
______ ! 2 Per Line-up ! 2 Per Bldg ! 2 Total Project
MV Switchgear Circuit
Breakers or Fused Switches
______ ! 2 Per Line-up ! 2 Per Bldg ! 2 Total Project
3.8.4 Future Unit
Spaces
Low-Voltage Starters (per
MCC)
Size 1 _________
Size 4 _________
Size 2 _________
Size 5 _________
Size 3 ___________
Size 6 _____________
Feeder Breakers _________ Fused Switches _________
3.9 Power Factor
Power Factor Correction Required: ! No ! Yes
Minimum System Power Factor ______% ! At Utility Interface or ! Other _______________
Method(s) of Power Factor Correction:
! Capacitors ! On Major Power Bus ! On MCC Bus ! At Motor ! Fixed ! Switched
! Other_________________________________________________________
3.11 Electrical Equipment Rooms
3.11.1 ! 2 or more doors ! 1 Door if Allowable per NEC ! Other ______
3.11.3 ! No Locks ! Locks with Night Latch Feature ! Other ______
4. Area Classification
4.1 " Per PIP ELEHA01 " Other_______________
4.2 " Division Method " Zone Method
ASSOC. PIP:
ELCGL01
DATA SHEET FOR ELECTRICAL
DESIGN CRITERIA
ELCGLO1D
PAGE 3 OF 8
November 2002
5. Power Distribution
5.1 System Configuration
System
Configuration
Arrangements
! Simple Radial
System
! Expanded
Radial System
! Primary
Selective
System
! Primary Loop
System
! Secondary
Selective
System
! One Line Attached Document Number ________________________________
5.2 Utility Interface and Unit Substations
5.2.3 Primary or Utility Interface Substation
! Outdoor ! Open Bus ! NEMA 3R Walk-in ! NEMA 3R Non-Walk-in
! Indoor ! Prefabricated Power
Center
! Fabricated in Place Building Pressurization Required
! Yes ! No
HVAC Required ! Yes ! No Internal Temperature Range _______________
Elevation ! At Grade ! Elevated ________ Feet
Unit Substations ! Outdoor ! NEMA 3R Walk-in ! NEMA 3R Non-Walk-in
! Indoor ! Prefabricated Power
Center
! Fabricated
Building
! NEMA 3R
Walk-in
! NEMA 3R Non-Walk-in
HVAC Required ! Yes ! No Internal Temperature Range _______________
Pressurized ! Yes ! No
Elevation ! At Grade ! Elevated ________ Feet
5.2.4 Single-Ended Substation Expansion
! One Direction ! Two Directions Number of Sections ______ ! None Required
5.2.5 Future Conversion of Single-Ended to Double-Ended Substation
! Required ! Not Required
5.2.6 Double-Ended Substation Expansion
! One Direction ! Two Directions Number of Sections ______ ! None Required
5.3 Transformers
5.3.1 Power Transformers
! Liquid Filled ! Indoor ! Outdoor
! Dry Type ! Indoor ! Outdoor
! Cast Coil ! Indoor ! Outdoor
5.3.2 Transformer Size Based On
! 65
0
C Rise ! 55
0
C Rise ! Other _________
5.3.4 ! Liquid Type: _________
5.3.5 Power Transformer Location ! Outdoor ! Other _________
5.3.5 Outdoor Transformer Spec ! PIP ELSTR01 ! PIP ELSTR04 ! Other __________
5.3.5 Indoor Transformer Spec ! PIP ELSTR03 ! Other _________
5.3.6 Control Power and Lighting Transformers ! 80
0
C / 220
0
C ! Other __________
5.3.7 Outdoor Control Power and Lighting Transformers ! Epoxy-Encapsulated ! Other __________
5.4 Metering, Monitoring, and Relaying
5.4.1 Metering
" Voltmeter " Ammeter " Power Factor Meter " Watt-Hour Meter " kW Demand Meter
" Microprocessor-Based
Multifunction Metering
" Other _____________ " Analog Meters with
Selector Switches
" Individual Phase Analog Meters
5.4.2
Communications Type: " None " RS232 " RS422 " RS485 " Other_____
Devices Monitored: " Circuit Breaker Protective Relays " Circuit Breaker
Trip Units
" Multifunction Metering
Devices
" Other_____
5.4.3 Relay Selection
" Microprocessor-Based Relay(s) " Solid State Relays " Electro-Mechanical Relays
ASSOC. PIP:
ELCGL01
DATA SHEET FOR ELECTRICAL
DESIGN CRITERIA
ELCGLO1D
PAGE 4 OF 8
November 2002
5.5 Switchgear
5.5.1 Low-Voltage Switchgear " Metal-Enclosed Drawout (PIP ELSSG01) " MCCB Panelboard
5.5.2 Medium-Voltage Switchgear " Metal-Clad
(PIP ELSSG02)
" Metal-Enclosed
(PIP ELSSG03)
" Metal-Enclosed (PIP ELSSG03) for
Transformer Main Only
5.5.3 Control Voltage LV Metal-Enclosed " 125 VDC Trip
" 125 VDC Close
" Captrip Trip
" AC Close
MV Metal-Clad " 125 VDC Trip
" 125 VDC Close
" Captrip Trip
" AC Close
MV Metal-Enclosed " 125 VDC Trip
" 125 VDC Close
" Captrip Trip
" AC Close
5.6 Switchgear / Substation Batteries " Flooded-Cell Lead-Acid per PIP ELSAP11 ! Other _______________
5.7 Switchgear Rooms
" Power Center per PIP ELSSG11 " NEMA 3R Walk-in per PIP ELSSG12 " Built-in-Place Metal Walls
" Built-in-Place Block Walls " Other ______________
6. Motors " Installed per PIP ELIMT000 " Other _______________
7. Motor Control
7.2 480-Volt Motor Control
7.2.1 MCC Type " Fused Disconnect Switch
(PIP ELSMC12)
" Molded-Case Circuit
Breaker (PIP ELSMC13)
" Motor Circuit Protector
(PIP ELSMC13)
" Other _______
7.2.2 MCC Indoor Enclosure Type " NEMA 1 Gasketed " NEMA 12
7.2.4 MCC Outdoor Enclosure Type " NEMA 3R " NEMA 4X " Other _________________
7.2.5 MCC Enclosure Arrangement " Front Only " Back-to-Back
7.2.6 Indoor MCC Floor Space " 20% Growth " Other _________________
7.2.8 Outdoor Starters (Non-Classified) " NEMA 4X " NEMA 3R " Other _________________
7.2.9 Explosion-Proof Starter Enclosures " Bolted " Threaded " Other _________________
7.2.11 Minimum Starter Size " Size 1 " Other _________________
7.2.12 Overload Protection " Electronic
" Eutectic Alloy " Class 10 " Class 20 " Class 30
" Bi-Metallic " Class 10 " Class 20 " Class 30
7.3 Low-Voltage Adjustable Speed Drives " Per PIP ELSMC20 " Other_____________________________
7.4 Medium-Voltage Motor Control
7.4.1
For 2.3-kV Motors: Circuit Breaker Used as Motor Starter at _______ hp and above
For 4-kV Motors: Circuit Breaker Used as Motor Starter at _______ hp and above
7.4.2 " Drawout (Roll-out) Contactor " Stationary (Bolt-in) Contactor
7.4.4 " Medium-Voltage Starters per PIP ELSMC11 " Other _____________________
7.4.5 " Medium-Voltage Adjustable Speed Drive per PIP ELSMC21 " Other _____________________
7.4.6 Microprocessor-Based Motor Protection Relay Type _________________
7.4.7 " Differential Protection 1500 hp " Differential Protection _____ hp
ASSOC. PIP:
ELCGL01
DATA SHEET FOR ELECTRICAL
DESIGN CRITERIA
ELCGLO1D
PAGE 5 OF 8
November 2002
8. Grounding
8.1 Ground Grid Conductor " Bare " Covered
8.2 System Grounding (Also See 3.5)
8.2.2 " 480-Volt Wye per PIP ELSGS01 " 480-Volt Delta per PIP ELSGS02 " Other _______________
8.2.3 " Low Resistance - XFMR Wye Neutral Resistor per PIP ELSGS11 " Low Resistance Other ______________
High Resistance per the Following:
" 2400-Volt Wye per PIP ELSGS03 " 2400-Volt Delta per PIP ELSGS04
" 4160-Volt Wye per PIP ELSGS05 " 4160-Volt Delta per PIP ELSGS06
8.2.4 Distribution System Grounding
Method
" XFMR Wye Neutral Resistor per
PIP ELSGS11
" Zig-Zag Transformer
" Other___________________
8.3 Equipment Grounding
8.3.1 Equipment Grounding
Primary:
! Equipment Grounding Conductor Run with Power Wiring
! Use Raceways and Cable Tray
! Any Method Permitted by NEC
Secondary:
! Visible Ground Conductor to Ground Grid or Grounded Steel
Structure
! Use Raceways and Cable Tray
! None
8.3.2 Medium-Voltage Motor Supplemental Grounding
" Adjacent Building or Structure Steel
" Reinforcing Mesh or Bars in the Concrete Foundation
! Bare Copper Conductor
! Uninsulated Tin-Coated Copper Conductor
" Adequately Sized Bare or Green-Colored, Covered Copper
Conductor around the Equipment Foundation and Connected
to at Least Two Ground Rods or Ground Grid
! Covered Copper Conductor
8.3.3 460-Volt Motor Supplemental Grounding ! Not Required ! Required
" Adjacent Building or Structure Steel
" Reinforcing Mesh or Bars in the Concrete Foundation
! Bare Copper Conductor
! Uninsulated Tin-Coated Copper Conductor
" Adequately Sized Bare or Green-Colored, Covered Copper
Conductor around the Equipment Foundation and Connected
to at Least Two Ground Rods or Ground Grid
! Covered Copper Conductor
8.4 Plant Grounding
8.4.1 Plant Grounding System
" Effectively Grounded Metal Structure " Driven Electrode System " Concrete-Encased Electrode System
" Ground Loop
8.4.5 Ground Loop Conductor
" No. 2/0 " No. 4/0 " Other _______________
" Bare
" Insulated " XHHW " THW " Other _______________
Ground Electrodes " Driven Rods " Rebar " Buried Plate " Other _______________
Connections to Ground Loop " Compression " Exothermic
Ground Conductor Minimum Depth (below Surface) _____________ Inches
8.4.7 " Bare Underground Cables Shall Be Tin-Coated.
ASSOC. PIP:
ELCGL01
DATA SHEET FOR ELECTRICAL
DESIGN CRITERIA
ELCGLO1D
PAGE 6 OF 8
November 2002
9. Lighting
9.1 Illumination Level ! Per API RP540 ! Other __________
9.2 Luminaires and Circuits
9.2.1 Areas Luminaire Type Voltage Rating
General Building / Office ! Fluorescent
! Incandescent
! Metal Halide
! 120
! 208
! 277
Shops, Warehouse, etc. ! Fluorescent
! Metal Halide
! High-Pressure Sodium
! 120
! 208
! 277
! 480
Floodlights, Roadway
Lighting, Parking Lots,
etc.
! Metal Halide
! High-Pressure Sodium
! 120
! 208
! 277
! 480
Outdoor Process ! Metal Halide
! High-Pressure Sodium
! 120
! 208
! 277
! 480
Indoor Process ! Fluorescent
! Metal Halide
! High-Pressure Sodium
! 120
! 208
! 277
! 480
Control Room ! Fluorescent
! Incandescent
! Other __________________
! 120
! 208
! 277
9.2.2 Photoelectric Cell
Control
! Dedicated Photoelectric
Cells
! Photoelectric Cell
Controlled Panels
! Astronomical Clock
! Other ____________________
9.2.3 Standby ! Incandescent
! Fluorescent
! High-Pressure Sodium
! Instant Restrike
! Battery
! 120
! 208
! 277
! 480
9.2.4 Emergency Lighting
Locations
! Per 9.2.4 ! Per 9.2.4 and Other __________
10. Power Receptacles and Convenience Outlets
10.1 Receptacles ! No Receptacles Allowed in Div. 1 Areas
10.1.1 Max. Receptacle Distance from Equipment ! 50 feet ! Other ________
10.1.4 GFCI Protected Receptacle Locations ! Per NEC and ! Other Locations:_____________________________
Type Voltage Phase Current Rating
10.1.3
10.2.1
Convenience
Power
120
480
1
3
! 15A (5-15R)
! Not Allowed
! 20A (5-20R)
! 30A
! 30A (5-30R)
! 60A
! ______ A
! ______ A
10.2.4 480-Volt Plug Type _______________________
11. Wiring Methods
11.1 Cable Tray
! Aluminum ! Hot-Dipped Galvanized Steel ! Stainless Steel ! Fiberglass (Polyester)
! Fiberglass (Vinyl-Ester)
Spare Space in Tray ! 20% ! 40% ! ____%
Cable Tray Class " 12C " 16C " 20C " _________________
Cable Tray Type " Ladder " Trough " _________________
Cable Tray Rung Spacing " 6 " 9 " 12 " _________________
11.1.6 Cable Tray Covers " Required " Not Required " Comments _______________________________
11.1.7 ! Separate Trays for Each Voltage Class ! Other_____________
ASSOC. PIP:
ELCGL01
DATA SHEET FOR ELECTRICAL
DESIGN CRITERIA
ELCGLO1D
PAGE 7 OF 8
November 2002
11.2 Aboveground Conduit and Fittings
11.2.1 Acceptable Types of Conduit " Rigid Galvanized Steel (RGS) " Rigid Aluminum " EMT (See Section 11.2.2)
11.2.1 Acceptable Conduit Sizes " 1/2 " 3/4 " 1 " 1-1/4 " 1-1/2 " 2 " 2-1/2 " 3 " 4 " 5 " 6
11.2.9 Aboveground Corrosive Areas " RGS " Rigid Aluminum " PVC-Coated Steel " PVC " Fiberglass
11.3 Underground Conduit and Duct Banks
11.3.1 Duct Bank " Rigid Galvanized Steel Conduit " Schedule 40 PVC Conduit
11.3.3 Acceptable Underground Conduit Sizes " 1 " 1-1/4 " 1-1/2 " 2 " 2-1/2 " 3 " 4 " 5 " 6
11.3.6 Minimum Depth (Below Surface) ____________________________
11.3.9 Spare " 20% " Other __________________
11.4 Direct Burial " Not Allowed " Armored Cable " Non-Armored Cable
11.5 Overhead Pole Lines " Not Allowed " Open Wire " Messenger
11.6 Messenger Cable Support Method __________________
12. Power and Control Wiring
12.3 Cable Construction
Low-Voltage ! TC " THWN/PVC " THWN/CPE " THWN/CSPE " _______________
Cable " XHHW/PVC " XHHW/CPE " XHHW/CSPE Ground Wires " Reqd " Not Reqd
Composite Cable " Acceptable Max Conductor " No. 4 " No. 2 " ______________
" Not Acceptable
! MC " THWN/PVC " THWN/CPE " THWN/CSPE " _______________
" XHHW/PVC " XHHW/CPE " XHHW/CSPE Ground Wires " Reqd " Not Reqd
" Continuous Corrugated Aluminum " Interlocked Aluminum " Interlocked Galvanized Steel
Composite Cable " Acceptable Max Conductor " No. 4 " No. 2 " ______________
" Not Acceptable
ASD Motor Feeder Cable ! MC Required ! MC Not Required
! 1/C " THWN " XHHW " RHW " _______________
Medium-Voltage " Copper Conductors " Aluminum Conductors
Power Cable
3/C " XLPE/PVC " XLPE/CPE " XLPE/CSPE " Other _______________
" EPR/PVC " EPR/CPE " EPR/CSPE Ground Wires: " Reqd " Not Reqd
" Armored " Galvanized Steel " Aluminum
1/C " XLPE/PVC " XLPE/CPE " XLPE/CSPE " Other _______________
" EPR/PVC " EPR/CPE " EPR/CSPE
12.5 Multiconductor Minimum Size " No. 14 " No. 16 " Other _______________
12.6 Composite Power/Control Cable " Allowed " Not Allowed
12.8 Power Cable Termination Methods
600-V Cable " Not Specified " Tape " Reusable Boot " Other _______________
5-kV Cable " Tape " Cold Shrink " Heat Shrink " Other _______________
15-kV Cable " Tape " Cold Shrink " Heat Shrink " Other _______________
ASSOC. PIP:
ELCGL01
DATA SHEET FOR ELECTRICAL
DESIGN CRITERIA
ELCGLO1D
PAGE 8 OF 8
November 2002
14. Freeze Protection and Process Heat-Tracing Systems
Process Heaters 1.8 kW
> 1.8 kW
120 V
480 V
! 1-Phase
! 1-Phase ! 3-Phase
Electric Heat Tracing Types Allowed Voltage Sheath Required Outer Jacket Required
Self-Limiting Cable ! 120 V
! 208 V
! 240 V
! Tinned Copper
! Stainless Steel
! _________
! Fluoropolymer
! Thermoplastic Rubber
! None
! _____________
Constant Wattage
Cable
! 120 V
! 208 V
! 240 V
! Tinned Copper
! Stainless Steel
! _________
! Fluoropolymer
! Thermoplastic Rubber
! None
! _____________
Mineral Insulated
Cable
! 120 V
! 208 V
! 240 V
! 277 V
! 480 V
! Copper
! Stainless Steel
! Inconel
! Other _________
Impedance Heating ! 480 V
! ________
Control Types Allowed ! Mechanical Thermostats ! Electronic Controllers ! Microprocessor-Based System
! Upper Temperature Limit Required
Continuity Monitoring ! None
! End Lights
! Third-Wire Monitor Circuit
! Current Indication
! Current Flow Detection
! Other ___________________
Ground Fault Protection ! EPD Breaker ! Integral in Controller ! ____________________
16. Uninterruptible / Standby Power
16.1 Critical Power Supply Requirements: ________________________________________________________________________
16.2 UPS Required ! No
! Yes ! PWM ! Ferroresonant ! Other _________________________
Battery-Operating Time @ 25
o
C (77
o
F) _________ Minutes
Battery Type: ! Flooded Cell per PIP ELSAP15 ! Valve Regulated per PIP ELSAP16
16.3 Generator Required ! Yes ! No
Alternate Utility/Plant Feeder: ! Yes ! No
17. Skid-Mounted or Packaged Equipment
! Per PIP ELSPS01 ! Other ___________________
Other Requirements: