Professional Documents
Culture Documents
ELECTRICAL
DESIGN MANUAL
ESD-106
JANUARY 2006
TABLE OF CONTENTS
CHAPTER
1
PAGE
INTRODUCTION...................................................................... 1-1
1.1
1.2
1.3
1.4
2
TITLE
OBJECTIVE................................................................... 1-1
RESPONSIBILITIES OF THE ELECTRICAL
DESIGNER.................................................................... 1-1
DESIGN TASKS ............................................................ 1-2
1.3.1 Study Phase ..................................................... 1-2
1.3.2 Preliminary Design Tasks ................................. 1-2
1.3.3 Final Design Tasks (30%)...................................1-2
1.3.4 Final Design Tasks (60%)...................................1-3
1.3.5 Final Design Tasks (90%)...................................1-3
1.3.6 Final Design Tasks (100%).................................1-4
DOCUMENT CONTROL ............................................... 1-4
2.2
2.3
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TABLE OF CONTENTS
CHAPTER
2.4
2.5
3
TITLE
PAGE
3.2
3.3
3.4
3.5
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ii
TABLE OF CONTENTS
CHAPTER
3.6
3.7
3.8
3.9
3.10
3.11
TITLE
PAGE
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iii
TABLE OF CONTENTS
CHAPTER
3.12
3.13
3.14
3.15
3.16
TITLE
PAGE
3-59
3-59
3-59
3-60
3-61
3-61
3-64
3-64
3-64
3-65
3-67
3-67
3-67
3-67
3-67
3-68
3-68
3-69
3-69
3-70
3-71
3-71
3-71
3-74
3-76
3-76
3-77
3-78
3-80
3-80
3-81
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4-1
4-1
4-1
4-2
4-2
4-3
4-4
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iv
TABLE OF CONTENTS
CHAPTER
4.2
4.3
APPENDIX
A
B
C
D
E
F
G
H
3-3
4-1
4-2
4-3
TITLE
PAGE
PAGE
FIGURE
2-1
2-2
2-3
2-4
2-5
3-1
3-2
TITLE
PAGE
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2-14
2-23
2-29
2-32
2-40
3-25
3-52
3-53
4-17
4-18
4-19
01/06
TABLE OF CONTENTS
CHAPTER
4-4
4-5
4-6
4-7
4-8
F-1
F-2
F-3
F-4
F-5
F-6
F-7
2-4
2-5
3-1
3-2
3-3
4-1
A
TITLE
PAGE
TABLE
2-1
2-2
2-3
TITLE
PAGE
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vi
Chapter 1
INTRODUCTION
1.1
OBJECTIVE
The objective of these electrical design standards is to provide a guide
that can be used for Metropolitan Water District of Southern California's
(Metropolitan) electrical practice. Anticipated users of this manual include
the engineer/designer with limited experience, management staff, and the
more experienced engineer/designer. The senior staff may find the
manual useful as a training tool for subordinates. The information
contained herein has been assembled from a number of sources; a list of
the readily available sources is contained in Appendix A, References.
These electrical design standards shall be used as the basis for all
designs prepared for Metropolitan. Outlined within these standards are
procedures for preparing design instructions, procedures for making most
of the calculations that will be required for a design, a data table that can
be used in making those calculations, drawing presentation formats,
standard legend items and abbreviations, descriptions of materials to be
used, and a number of informative memos. This information, used with
engineering judgment in conjunction with appropriate codes, national
standards, and other reference information, will provide electrical systems
that are safe and electrically suited for the intended application.
1.2
RESPONSIBILITIES OF THE ELECTRICAL DESIGNER
The electrical engineer/designer is responsible for all facets of a project
that are related to:
x Electrical energy for equipment located on the project site;
x Adequate illumination in all areas;
x Special electrical systems;
x Conduits and conductors for power distribution and
instrumentation and control (I&C) systems;
x Protective and safety alarm systems;
x Grounding and lightning protection systems;
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INTRODUCTION
x Communication systems;
1.3
Design Tasks
The following is a partial list of design tasks that the electrical engineer/
designer must assume responsibility for during the course of the design.
1.3.1
Study Phase
x Provide electrical support for preparation of draft study.
x Review electrical elements of project description in draft
study.
1.3.2
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INTRODUCTION
1.3.3
Final Design Tasks (30%)
1.3.4
x
x
x
x
x
1.3.5
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INTRODUCTION
1.4
DOCUMENT CONTROL
This manual is intended to be (1) the primary technical reference resource
for new employees in this discipline, and (2) the only reference guide for
engineering consultants who will augment Metropolitan engineering staff.
It is important that this manual be updated to keep it current and maintain
its usefulness. To propose changes to this manual, follow the change
control system procedure, located in ESD-171, Engineering Administration
Manual.
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Chapter 2
2.1
GENERAL APPROACH
A design project can be broken down into a number of specific elements
that are prepared during several phases of the project. The two project
phases that are being covered by this design manual are the preliminary
design and final design phases. During the preliminary design phase, the
needs of the project must be evaluated, a preliminary one-line diagram
and electrical site plan prepared, the needs of the project outlined in a
brief report, and the design criteria for the project prepared. The electrical
drawings and text specifications are then prepared during final design
using the information prepared during preliminary design as a basis for
that design. All of the major decisions should be made during preliminary
design. Final design is an implementation of those decisions.
2.1.1
Design Criteria
The Electrical Design Criteria is a compilation of general information,
specific requirements that are applicable to the project, and design
instructions that shall be used by all of the design team members to
assure a complete and consistent product. An example Electrical Design
Criteria memo is presented in Appendix C.
2.1.2
Drawings
The purpose of a design is to develop a set of instructions and rules that a
contractor can use to bid the project and, if awarded the contract, build
what the designer had in mind. The drawings are a part of that installation
instruction set and describe the location and quantity of materials and
equipment needed for the project; the text specifications describe the type
and quality of materials and equipment and the quality of workmanship.
See paragraph 2.4, Drawings, for a description of the drawings to be
included in a construction package.
2.1.3
Specifications
The text specifications shall describe the materials to be furnished by the
contractor and the requirements for the products themselves, the
requirements for installing the products, and the quality control measures
that will be used to check the products and the execution of construction.
Moreover, the text specifications provide these descriptions in one place
for the general contractor's comprehension and use. As an electrical
engineer/designer, one may think that the electrical text specifications are
written for the electrical contractor, subcontractor, or equipment supplier,
but this is not the case. The text specifications are addressed to the
general contractor, who decides who shall do the work.
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2.1.3.1
Organization. The electrical text specifications will be
prepared in Construction Specifications Institute (CSI) narrative format in
the indicative mood. The standard electrical text specifications will consist
of sections organized as shown in Metropolitan's ESD-135, Standard
Specifications Sections Catalog.
2.1.3.2
Standard Specifications. The Standard Master Specifications
have been prepared to cover all normal projects that are expected to be
designed for or by Metropolitan. It is intended that the engineer will select
only those text specification sections that are applicable to the project and
then use those sections without changes.
2.1.3.3
Project Specifications. The engineer shall prepare project
specifications in the CSI narrative format for any additional requirements
not covered by the Standard Master Specifications. These specifications
shall also be prepared in the indicative mood. Only three parts will be
provided for in each technical section:
x
x
x
Part 1--General;
Part 2--Products;
Part 3--Execution.
2.2
2.2.1
List of Symbols
E
I
R
X
Z
P
VA
W
Eff
= voltage (volts)
= current (amps)
= resistance (ohms)
= reactance (ohms)
= impedance (ohms)
= power (watts)
= voltampere
= watt
= angle whose cosine is the power factor
= phase
= efficiency
2.2.2
Direct Current (dc) Formulas
Basic formulas for dc current include:
Voltage (E) = Current (I) x Resistance (R)
Power (P) = E2/R = EI
ESD-106
2-2
(Eq. 2-1)
(Eq. 2-2)
01/06
P = I2 x R
2.2.3
(Eq. 2-3)
(Eq. 2-4)
(Eq. 2-5)
(Eq. 2-6)
(Eq. 2-7)
(Eq. 2-8)
(Eq. 2-9)
(Eq. 2-10)
(Eq. 2-11)
where:
Ed
sin
X
2.2.4
Alternating Current (AC), Three Phase
Basic formulas for ac current, three phase, include:
Line Voltage (E) = 31/2 x E (Wye-connected)
Current (I) = 31/2 x I (Delta-connected)
Apparent Power (kVA) = (31/2 x E x I)/1000
Real Power (kW) = kVA x cos
Reactive Power (kvar) = kVA x sin
= arctan (kvar/kW)
Power Factor (PF) = cos = kW/kVA
PF = kW/((E x I x 31/2)/ 1000)
(Eq. 2-12)
(Eq. 2-13)
(Eq. 2-14)
(Eq. 2-15)
(Eq. 2-16)
(Eq. 2-17)
(Eq. 2-18)
(Eq. 2-19)
(Eq. 2-20)
where:
Ed = voltage drop in circuit
sin = load reactive factor
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2.2.5
Motors
Motor (general) formulas include:
1 horsepower (hp) = 746 Watts
Torque (ft-lb) = (hp x 5250)/rpm
Fan hp = (cfm x Pressure)/(33,000 x Eff)
Pump hp = (gpm x Head x
Specific Gravity)/(3960 x Eff)
(Eq. 2-21)
(Eq. 2-22)
(Eq. 2-23)
(Eq. 2-24)
(Eq. 2-25)
(Eq. 2-26)
(Eq. 2-27)
2.2.6
Power Factor Correction
The size of the capacitor needed to increase the power factor from PF1 to
PF2 with the initial kVA given is:
kvar = kVA([1-(PF1)2]1/2 - PF1/PF2[1-(PF2)2]1/2)
2.3
(Eq. 2-28)
DESIGN CALCULATIONS
2.3.1
General
Electrical calculations shall be made for all projects and filed in the project
notebook. They may be made either manually or by computer programs
approved by Metropolitan. As a minimum, the following types of
calculations shall be made where applicable and submitted to Metropolitan
for review:
ESD-106
Load calculations;
Conductor sizing;
Conduit sizing;
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01/06
Voltage drop;
Lighting levels;
Grounding in substations.
Load calculations must include all loads and should be made by summing
all of the loads, using appropriate diversity factors as allowed by NEC
Article 220, that are connected to each panelboard, switchboard, and
motor control center. The loads for each branch of the distribution system
can then be summed back to the service entrance equipment.
2.3.3
Conductor Size, General
Conductor sizes must be determined for general purpose branch circuit
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2-5
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2-6
01/06
ESD-106
2-7
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2.3.3.4
Example No. 4. Conditions: The same load as used in
example No. 3 but the conduit is to be installed in a dry area with an
ambient temperature of 38o C.
Required ampacity calculated above = 281.25 amps.
Ampacity of one 300 kCMIL RHH conductor is 320 in a dry
location.
Correction factor for 90o C conductors in a 38o C ambient =
0.91.
Corrected ampacity = 320 amps x 0.91 = 291.2 amps
The results are the same as for example No. 3, so NEC
Paragraph 240.4(B) must be invoked.
2.3.4
Conduit Size and Fill
Where conductors are installed in conduit, the conduit shall be sized in
accordance with Tables C.1 through C.12(A) in Annex C of the NEC, and
all associated notes. Following are two examples of how conduits can be
sized under different circumstances.
2.3.4.1
Example No. 1. Conditions: Three 4/0 AWG conductors with
RHH/RHW insulation installed in rigid steel conduit (no separate ground
conductor).
See NEC Table 3C.8 for conduit size required for three 4/0
AWG conductors with RHH/RHW insulation.
NEC Table 3C8 would allow three conductors to be installed in a
2-inch conduit.
2.3.4.2
Example No. 2. Conditions: Three No. 4/0 AWG phase
conductors, one No. 1/0 AWG neutral and one No. 2 AWG equipment
ground conductor to be installed in rigid steel conduit. Phase and neutral
conductor insulation will be RHH/RHW and the ground conductor will have
TW insulation.
Because NEC Table C.8 is for situations where all conductors in
a conduit are the same size, they cannot be used for this
example. Table 4 in Chapter 9 of the NEC, using appropriate
conduction areas from Table 5 in Chapter 9 of the NEC, must
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01/06
then be used.
Total conductor area:
Conductor size
4/0 RHH/RHW
1/0 RHH/RHW
# 2 TW
Area
0.4754
0.3039
0.1333
2.3.5
Motor Branch Circuit
NEC Article 430, Motors, Motor Circuits, and Controllers, covers the
provisions for motors, motor circuits, and controllers. NEC Article 430
includes tables for motor full-load currents, which are the minimum values
that can be used in determining sizes of motor branch circuits, motor
feeders, short circuit and overcurrent device sizes and settings, and
miscellaneous load calculations. Actual nameplate currents should be
used if they are known and must be used if they are larger than the
minimum. The full load current to be used for motors with speeds less
than 1,200 rpm should be obtained from the motor manufacturer. NEC
Article 440 contains special provisions that apply to the installation of airconditioning and refrigeration equipment and should be referred to for
these applications.
The following calculations and the accompanying table are based on the
applicable provisions of NEC Article 430 and are provided as a guide for
performing motor branch circuit and feeder calculations and for sizing
components for motor branch circuits as part of a design. The typical
calculations that are required are demonstrated by the following examples.
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2.3.5.1
Example No. 1. Conditions: Induction motor is rated 60 hp,
460 volts, three-phase, 1,800 rpm continuous, and will be powered by a
combination motor starter through a conduit system. All equipment and
the conduit system is located in areas with ambient temperatures of 30o C
or less.
In NEC Table 430.250, the motor full-load current that must be
used in the calculations is 77 amps. Using this value we can
size the motor branch circuit and ground fault protection device,
the branch circuit conductors, and the motor disconnecting
means.
Motor branch circuit and ground fault protection devices are to
be sized as outlined in Part IV of NEC Article 430 with maximum
settings as provided in NEC Table 430.52. Actual settings
should reflect the recommendation of the manufacturer of the
motor control equipment that will be provided.
For example, the following are General Electric's recommendations:
Device type
Magnetic only circuit breaker
Thermal magnetic breaker
Time delay fuses
Rating
100 amp
125 amp
90 amp
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ESD-106
2-11
01/06
NEC Paragraph 430.62 covers the requirements for sizing the motor
feeder short-circuit and ground-vault protection.
NEC Paragraph 430.63 covers the requirements for sizing the feeder
protection when the feeder supplies a motor load and other power and
lighting loads.
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01/06
Table 2-1. Motor Circuit Design Data 480 Volt, Three-Phase Motors
HP
Mcp
Size
Starter
Size
FLA
FLA
*1.50
Conductor Size
Conduit
Size
Max.
Dist.
1/2
3/M
1.25
3#12,1#12G
3/4
5,333
3/4
3/M
1.4
1.75
3#12,1#12G
3/4
3,810
3/M
1.8
2.25
3#12,1#12G
3/4
2,963
1-1/2
7/M
2.6
3.25
3#12,1#12G
3/4
2,051
7/M
3.4
4.25
3#12,1#12G
3/4
1,569
7/M
4.8
6.00
3#12,1#12G
3/4
1,111
15/M
7.6
9.50
3#12,1#12G
3/4
701
7.5
15/M
11
13.75
3#12,1#12G
3/4
485
10
30/M
14
17.50
3#12,1#12G
3/4
381
15
30/M
21
26.25
3#10,1#10G
3/4
403
20
50/M
27
33.75
3#8,1#10G
485
25
50/M
34
42.50
3#6,1#10G
1-1/4
580
30
100/M
40
50.00
3#6,1#10G
1-1/4
493
40
100/M
52
65.00
3#4,1#8G
1-1/4
577
50
100/M
65
81.25
3#3,1#6G
1/1/2
554
60
250/M
77
96.25
3#1,1#6G
719
75
250/M
96
120
3#1,1#6G
577
100
250/M
124
155
3#2/0,1#12G
611
125
250/M
156
195
3#3/0,1#12G
2-1/2
577
150
300
180
225
3#4/0,1#12G
2-1/2
615
200
400
240
300
3#350Kcm,1#3G
600
Notes:1)
2)
3)
4)
5)
6)
ESD-106
2-13
01/06
(Eq. 2-29)
Figure 2-1 is provided to show the relation that exists between apparent
power, real power, and reactive power (kvar). By definition, the power
factor is the cosine of the angle that exists between the real power and
apparent power phasors.
The calculation to determine the amount of capacitance (measured in
kvar) shall be made as follows:
ESD-106
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RESULTANT REACTIVE
POWER (kV AR)
T1
T2
RESULTANT POWER
SUPPLIED BY CAPACITATORS
(kV AR)
APPARENT POWER
(kVA)
REQUIRED
REACTIVE POWER
(kV AR)
ESD-106
2-15
01/06
(Eq. 2-30)
(Eq. 2-31)
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2-16
01/06
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2-17
01/06
ESD-106
2-18
45
75
480
480
480
480
480
480
480
480
480
480
480
480
Volts
90
54
36
18
11
104
78
52
31
21
16
10
Amps
135.00
81.00
54.00
27.00
16.50
156.00
117.00
78.00
46.50
31.50
24.00
15.00
Ckt. Amps
2" C-3#1/0,1#6G
2" C-2#2/0,1#6G
Primary Circuit
150A/3P
90A/3P
60A/3P
30A/3P
20A/3P
175A/2P
125A/2P
80A/2P
50A/2P
30A/2P
25A/2P
20A/2P
Ckt. Breaker
208
208
208
208
208
240
240
240
240
240
240
240
Volts
208
125
83
42
25
208
156
104
63
42
31
21
Amps
260.00
156.25
103.75
52.50
31.25
260.00
175.00
130.00
78.75
52.50
38.75
26.25
Ckt. Amps
26,3#3/0,1#4G
Secondary Circuit
250A/3P
175A/3P
110A/3P
60A/3P
35A/3P
250A/2P
200A/2P
150A/2P
80A/2P
60A/2P
40A/2P
30A/2P
Ckt. Breaker
______________________________________________________________________________________________________________________________________________
Rules Used: 1) Feeder circuit breaker at next size larger than 1.5 times primary amps (NEC 450.3(b) allows up to 250% of primary amps).
2) Panel main breaker sized at next size larger than 1.25 times secondary amps. (NEC 450.3(B) allows up to next larger than 125% of sec. Amps)
3) All conductors No.1 AWG and smaller sized based on 60q C ampacities, larger conductor sizes based on 75q C ampacities. (Conductors sized per
NEC 240-4 including exceptions.
4) Minimum ground conductor sized at #8; Table 250.122 used for other primary side grounds and Table 250.66 used for secondary side grounds.
5) Conduit size based on NEC Chapter 9 Table 3C.
______________________________________________________________________________________________________________________________________________
30
50
15
25
15
37.5
10
Phase
7.5
KVA
Transformer
Conductor sizes for examples No. 1 and No. 2 are based on the use of 60q C wire for sizes Nos.
14 through 1 AWG and 75q C wire for sizes No. 1/0 and larger as required by the General
Information Directory 1988, published by Underwriters Lab, Inc., because many items of
equipment are still not rated with 75q C terminals in these sizes.
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01/06
Voltage Drop
(Eq. 2-33)
where:
V
I
R
X
cos
sin
The voltage drop calculated using this formula must be multiplied by 2 for
single-phase circuits and 1.73 for three-phase circuits.
Calculations using the above formula are not required for most designs
*
Conductor sizes for examples No. 1 and No. 2 are based on the use of 60q C wire for sizes Nos.
14 through 1 AWG and 75q C wire for sizes No. 1/0 and larger as required by the General
Information Directory 1988, published by Underwriters Lab, Inc., because many items of
equipment are still not rated with 75q C terminals in these sizes.
ESD-106
2-20
01/06
ESD-106
2-21
01/06
ESD-106
2-22
0.33
0.50
0.55
0.62
0.66
0.55
0.76
0.82
0.88
0.92
0.51
0.67
0.71
0.76
0.78
0.42
0.64
0.71
0.80
0.83
0.37
0.59
0.66
0.74
0.80
0.70
0.85
0.89
0.92
0.92
0.74
0.94
0.99
1.0
1.1
0.45
0.62
0.68
0.73
0.74
0.50
0.71
0.78
0.85
0.88
500
0.88
1.0
1.1
1.1
1.1
0.91
1.1
1.2
1.2
1.2
0.55
0.71
0.76
0.81
0.83
0.60
0.81
0.88
0.95
0.97
400
1.2
1.3
1.3
1.3
1.3
1.2
1.4
1.4
1.4
1.4
0.73
0.92
0.95
0.97
0.97
0.78
1.0
1.1
1.1
1.1
300
1.4
1.5
1.5
1.5
1.4
1.4
1.6
1.6
1.6
1.6
0.88
1.0
1.1
1.1
1.1
0.92
1.1
1.2
1.2
1.2
250
1.7
1.8
1.8
1.7
1.6
1.7
1.8
1.9
1.8
1.7
1.0
1.1
1.1
1.1
1.1
1.1
1.3
1.3
1.4
1.3
4/0
2.1
2.2
2.2
2.1
1.7
2.1
2.3
2.3
2.2
2.1
1.3
1.5
1.5
1.4
1.4
1.4
1.5
1.6
1.6
1.5
3/0
1.0
1.1
1.2
1.2
1.1
1.0
1.2
1.3
1.3
1.3
0.62
0.80
0.85
0.88
0.88
0.68
0.88
0.95
1.0
1.0
350
3.3
3.4
3.3
3.1
2.8
3.3
3.4
3.4
3.2
2.9
2.1
2.2
2.2
2.1
2.0
2.1
2.3
2.3
2.3
2.1
1/0
Multiply by
1.15
0.577
0.577
2.6
2.7
2.6
2.5
2.3
2.6
2.7
2.7
2.6
2.4
1.6
1.8
1.8
1.7
1.6
1.7
1.9
1.9
1.9
1.8
2/0
4.2
4.2
4.1
3.8
3.4
4.2
4.2
4.1
3.9
3.6
2.6
2.7
2.7
2.5
2.4
2.6
2.8
2.8
2.6
2.5
5.2
5.2
5.0
4.6
4.2
5.2
5.3
5.1
4.7
4.3
3.3
3.4
3.3
3.1
2.8
3.4
3.5
3.4
3.2
3.0
Reproduced from IEEE Std 141-1993, IEEE Recommended Practice for Electric Power
Distribution for Industrial Plants, 1994, by the Institute of Electrical and Electronics
Engineers, Inc., with the permission of the IEEE.
0.59
0.74
0.79
0.83
0.83
0.63
0.83
0.88
0.95
0.98
0.38
0.54
0.59
0.66
0.69
600
700
Load Power
factor
Lagging
1000
900
800
750
Section 1: Copper conductors in magnetic conduit
1.00
0.28
0.31
0.34
0.35
0.95
0.50
0.52
0.55
0.57
0.90
0.57
0.59
0.62
0.64
0.80
0.66
0.68
0.71
0.73
0.70
0.71
0.73
0.76
0.78
8.4
8.2
7.9
7.2
6.4
8.4
8.2
7.9
7.3
6.5
5.3
5.3
5.1
4.7
4.3
5.3
5.3
5.2
4.8
4.4
13
13
12
11
9.9
13
13
12
11
10
8.4
8.2
7.9
7.2
6.4
8.4
8.2
8.0
7.3
6.6
21
20
19
17
15
21
20
19
17
15
13
13
12
11
9.7
13
13
12
11
9.9
8*
Table 2-3. Three-phase line-to-line voltage drop for 600 V single-conductor cable
Per 10 000 A-ft (60q C conductor temperature, 60 Hz)
33
32
30
27
24
33
32
30
27
24
21
20
19
17
15
21
20
19
17
15
10*
52
50
48
42
37
52
50
48
43
37
33
32
30
27
24
33
32
30
27
24
12*
------
------
53
50
48
43
38
53
50
48
43
38
14*
2.3.8.3
Motor Starting. The calculations required to determine the
voltage drop on an electrical system because of motor starting are too
complex to be covered in this design guide. The Industrial Power Systems
Handbook by Beeman and Electrical Systems Analysis and Design for
Industrial Plants by Lazar both have very complete sections on this
subject. These calculations are often done as part of a short circuit
analysis using a computer program such as ETAP, because they are very
complex and are based on much of the same information required to do
the short circuit analysis. These calculations should be made based on
the largest motor at each load center to determine if the voltage drop on
motor starting is of such magnitude that it will cause adverse impacts on
other equipment in the system. For instance, a 20 percent voltage dip
could cause control relays to drop out since many of these are only
designed to operate at voltage levels 10 percent below rated voltage.
2.3.9
Short Circuit
The proper selection of protective devices and coordination of their trip
settings is based on short circuit calculations. The calculations required to
complete a detailed short circuit analysis are very complex and beyond
the scope of this design guide. The Industrial Power Systems Handbook
by Beeman, Electrical Systems Analysis and Design for Industrial Plants
by Lazar, the IEEE Std 141-1993, and many other references contain
detailed procedures for performing short circuit analysis.
In those situations where an approximate value of short circuit current is
needed for preliminary design purposes, the following abbreviated method
can be used to determine a very conservative value. In every situation
where this method is used, a detailed calculation, either made by hand or
using an approved computer program, shall be made during final design.
Calculations to determine an approximate value of symmetrical short
circuit current in a power distribution system are shown in the following
example:
2.3.9.1
Example. Conditions: The load will be served by a 1,500-kVA
transformer at 480 volts three-phase through a single motor control
center. The fault current available from the utility on the source side of the
transformer is unknown, the transformer impedance is assumed to be
5.75 percent (based on published data), and the motor load on the
transformer is approximately 75 percent of the rating of the transformer.
The current flowing during a fault at any point in an electrical
system is limited by the impedance of the circuits and equipment from the source or sources to the point where the fault has
ESD-106
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ESD-106
2-24
(Eq. 2-34)
01/06
ESD-106
2-25
01/06
(Eq. 2-36)
The basic formula for calculating short circuit current when the per-unit
method is used is:
Is.c. rms sym = base kVA y (1.73 x kV x (per-unit Z of the
transformer))
(Eq. 2-37)
Because we have let base kVA = transformer kVA and transformer kVA y
(1.73 x kV) = Transformer load current for three phase transformers, we
can simplify the above formula to:
Is.c. rms sym = Transformer FLA y (%Z y 100)
(Eq. 2-38)
*.Note:
ESD-106
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ESD-106
2-27
01/06
Basic equations:
Footcandles =
Footcandles =
(Eq. 2-40)
where:
CU =
LLF =
LLD =
LDD =
RSD =
coefficient of utilization
light loss factor, which is made up of a number of
factors. The ones to be included in most calculations
are the LLD, LDD, and RSD
lamp lumen depreciation
luminaire dirt depreciation
room surface depreciation
Most CU tables are based on a floor cavity ratio (pfc) of 20, so that figure
will be used for this example (Table 2-4).
If the suspension length of the luminaire below the ceiling is zero, which it
is for this example, the ceiling cavity ratio is equal to the ceiling
reflectance. If the luminaire is suspended, a ceiling cavity ratio must be
calculated before the effective ceiling cavity reflectance can be
determined. Reflectance values for various surfaces are available in the
IES Lighting Handbook. For this example, 70 percent will be used.
The wall reflectance of materials can again be obtained from the IES
ESD-106
2-28
01/06
50
30
50
50
30
74
66
60
54
49
44
39
36
32
29
26
74
64
56
50
44
39
35
31
27
24
21
70
64
58
52
47
42
38
35
31
28
25
70
62
55
49
43
38
34
30
27
24
21
ESD-106
2-29
01/06
Values for LLD, LDD, RSD, and a number of other factors that cause light
loss in the space can be found in the IES Lighting Handbook but for most
calculations dealing with lighting in noncritical areas all of these factors
can be combined into a single factor, which is often referred to as the light
loss factor (LLF). For this calculation, an LLF of 0.75 has been assumed.
Footcandle levels are recommended for a number of applications in the
IES Lighting Handbook. The recommended level for general office work
falls between 50 and 150 footcandles depending on the level of difficulty of
the task. For this calculation, the level required is assumed to be
100 footcandles.
Put all of the numbers into a basic equation (Eq. 2-41) and solve it for the
number of lamps required:
100 = lamps x 3150 x 0.523 x 0.75
15 x 25
No lamps = 30.4
At four lamps/fixture = 7.6 fixtures
Figure 2-3, Zonal Cavity Calculations, provides a form to be used in
making lighting calculation. It, or something similar, shall be used to
document all calculations.
ESD-106
2-30
01/06
B. CAVITY DATA
Room
1. Length
ft
Room
9. Height
dimen.
2. Width
ft
Cavity
10. Ratio
sq ft
Ceiling
11. Height
Cavity
12. Ratio
3. Floor area
4. Ceiling ht.
ft
Surface
5. Ceiling
Reflect.
6. Wall
7. Floor
C. FIXTURE DATA
ft
Floor
14. Height
ft
Cavity
15. Ratio
D. FOOTCANDLES
17. Mft.
(LLF)
Cavity ratio =
footcandles
Length x width
fc
ROOM:
27.
25. Fixtures fc
CEILING:
Option B
26. Fixtures fc
28.
= __
= __
= __
line 1 x line 2
FLOOR:
29.
= __
G. CALCULATING FOOTCANDLES
Footcandles =
no. of fixture x lamps per fixture x lumens per lamp x
32.
Coeff. Of utilization x maintenance factor
33.
34.
Option A
floor area
Line 25 x line 19 x line 21 x line 22
Option B
line 3
Line 26 x line 19 x line 21 x line 22
line 3
___ x __x __ x __
__ x __
___ x __x ___ x ___
__ x __
= __
= __
ESD-106
2-31
01/06
The next task is to lay out the luminaries in the room to determine if they
will fit in a logical arrangement. Since the luminaries are being installed in
a lay-in ceiling, spacing can only be in multiples of 2 feet.
For this example, installation of eight luminaries would require two rows of
four luminaries each.
Spacing across room = 15 y 2 or 8 feet
Between rows and (15 - 8) y 2 or 3.5 feet between wall and
closest luminaire (all dimensions are to centerline)
Spacing length of room = 25 y 4 or 6 feet
Between luminaries in the row and (25 - (3 x 6)) y 2 or 3.5 feet
from the wall to the end luminaries
The footcandle level that results from the number of luminaries to be
installed should then be checked:
Footcandles = (8 x 4) x 3150 x 0.523 x 35 = 105.4
(15) (25)
The maximum spacing of the luminaries shall also be checked against the
mounting height above the work plane (S/MH ratio) to determine if it is
within the ratio of the luminaire being used.
8 ft spacing y 8.5 ft mounting height = 0.94
This is well within the 1.3 S/MH ratio of the luminaire used in the example.
If the luminaries required could not have been fit into the space in a
reasonable layout, or the footcandle levels that resulted from the selected
layout were not acceptable, or the S/MH ratio calculated was not less than
that of the luminaire being used, then the layout would need to be revised
using a luminaire with a different number of lamps or different
characteristics.
The footcandle level calculated tells us the quantity of light that reaches
the work surface. Other factors that affect visual comfort and ability to see
include direct glare, indirect glare, reflected glare, and veiling reflections.
In areas where seeing tasks are critical, these must also be evaluated.
See the IES Lighting Handbook and other lighting design and application
ESD-106
2-32
01/06
45o
End
0
5
15
25
35
45
55
65
75
85
3429
3396
3293
3061
2649
1982
1229
681
314
94
Cross
3429
3401
3328
3133
2814
2051
1110
425
218
90
3429
3460
3401
3245
2906
2188
1247
662
306
78
Basic equations:
Footcandles (horizontal plane) Fc(h) =
candlepower x cos
distance2
(Eq. 2-43)
(Eq. 2-44)
where:
ESD-106
2-33
01/06
Candlepower (CP)
Cos
Sin
Using the above data, calculate the horizontal footcandles on the work
surface 4 feet horizontal from the luminaire. (Figure 2-4)
H
8.5 FT
0
ACTUAL DISTANCE OF
LIGHT SOURCE FROM
TASK POINT
VERTICAL HEIGHT
OF LIGHT SOURCE
FROM WORK SURFACE
WORK SURFACE
R
4 FT
HORIZONTAL DISTANCE
OF LIGHT SOURCE
FROM TASK POINT
ESD-106
2-34
01/06
ESD-106
2-35
01/06
the luminaire.
This method is seldom used within a building except where a single
workstation may exist within a larger space where a lower average level of
illumination is required and a higher level is required at the workstation.
This procedure is often used with outdoor lighting systems to determine
the lighting levels on parking lots and roadways. It is the basis used by
luminaire manufacturers in their computer programs for laying out area
and roadway lighting systems.
As previously shown in Figure 2-3, a form can be used in making these
calculations. This form shall be used with data provided by the
manufacturer of the lighting equipment being specified to determine the
lighting levels, in footcandles, for the spaces being illuminated.
2.3.11
Grounding
Grounding system calculations shall be made for substation and other
areas where step potential will be of concern. The subject is too complex
for presentation in this design guide. Grounding system calculations shall
be in accordance with applicable sections of ANSI/IEEE Standard 80.
2.4
DRAWINGS
2.4.1
General
The purpose of a design is to develop a set of instructions and rules
whereby a contractor can bid the project and, if awarded the contract,
build what the designer had in mind. The drawings are a part of that
instruction set and describe the location and quantity of materials and
equipment needed for the project; the text specifications describe the type
and quality of materials and equipment and the quality of workmanship.
2.4.2
Organization
The drawings are generally divided into the following groups and appear in
the order shown below:
x
x
x
x
x
x
x
x
x
ESD-106
2-36
01/06
Installation Details;
Electrical Schedules.
ESD-106
2-37
01/06
2.4.6
One-Line Diagrams
One-line or single-line diagrams are a symbolic representation of the
major electrical components of the electrical system of the project and
their interconnection. All applicable information shall be included on oneline diagrams as follows.
ESD-106
Instrumentation, including instrument transformers, instrument switches, voltmeter, and ammeter, with appropriate
ratios and ranges;
Motor sizes;
2-38
01/06
ESD-106
2-39
01/06
2.4.8
Grounding Plan
The grounding Plan should be a separate and complete group of
drawings. The set of drawings should show the below-grade grounding
such as the ground grid including locations of all ground rods. If the
grounding plan is for a facility expansion where electrical service will be
provided by the existing facility, show the interconnection of the facility
expansion ground grid with the existing facility ground grid. The abovegrade grounding should be shown in plan form, indicating which steel
columns, fence or specific equipment require bonding. The type of
grounding connection welded type for below-grade and above-grade or
bolted type of above-grade shall be shown using appropriate symbols as
defined in the legend sheet.
2.4.9
Equipment Elevations
Two-dimensional drawings of control pads, switchboards and motor
control centers, secondary unit substations and switchgear shall show the
arrangement of components of the assemblies. The elevation drawings
are usually nonscale drawings. However, their intent is to determine
general space requirements for the assembly so they need to be laid out
using the dimensions of the equipment being specified. The front
elevations typically show main service and feeder circuit protective
devices, metering, branch circuit protective devices and controllers,
terminal board compartments, and future designated space requirements.
Control Schematic Diagrams
2.4. 10
The purpose of the electrical control schematic diagram is to illustrate
schematically for the equipment supplier and contractor how a system is
controlled. The control schematic diagrams contained in the electrical
drawing set are for I&C panels, motor starters, contactors, etc., that are to
be installed as part of the I&C and electrical systems. Each control
schematic diagram shall show all devices that are to be located on the
panel starter or contactor and all field-installed devices. Control logic that
is provided in a remotely located control panel supplied with equipment
shall be shown as a terminal connection. All interfaces with remote
equipment shall be clearly shown using appropriate symbols and clearly
identified so that the contractor can easily make the interconnections in
the field.
2.4.11
Control Panel Drawings. Control panel drawings provide the
following information to the contractor:
x Panel size;
x Major panel components and their layout;
ESD-106
2-40
01/06
x Panel installation.
The following format and content guidelines shall be followed in preparing
control panel drawings:
ESD-106
Show full views of the front of the panel. (Partial views may
be used for details.)
Show location key plans for each panel and include the
sheet number of the mechanical plan where the panel is
located, building and room names where the panel is
located, title (e.g., LP-XXX LOCATION PLAN), scale
(1s=100c or 1s=50c), panel name (e.g., LP-XX), and north
arrow.
2-41
01/06
ESD-106
2-42
01/06
At the completion of the project, each individual shall purge the file of the
project instructions and other memos that were originated by other team
members and submit the purged project files to the project manager for
inclusion in the overall project file. Any memos, instruction sets, and
similar items prepared by the individual shall be left in his or her project file
so that originals of all material prepared or used on the project are
contained within the overall project files.
24
FULL LENGTH
PIANO TYPE
HINGE
2
3
10
30
8
15
18
13
16
19
14
23
11
12
20
17
21
24
22
24
24
27
25
29
30
31
32
33
FRONT
SIDE
SCALE 1 = 1-0
SCALE 1 = 1-0
ESD-106
2-43
01/06
Chapter 3
STANDARD ELECTRICAL
DESIGN PROCEDURES
Note: All references to the National Electrical Code (NEC) are based on
the 2005 Edition of the NEC.
3.1
GENERAL APPROACH
Because no single electrical system is adaptable to all projects, the
specific requirements of each project must be analyzed and the electrical
system designed to meet those needs. Any approach to providing the
required design shall include several considerations that will affect the
overall design. First, safety of personnel and preservation of property are
important factors in the design of electrical systems. Second, reliability
and continuity of service is of utmost importance.
This chapter discusses many of the basic decisions that shall be made
during a design, identifies reference sources that shall be used to help
make those decisions, and outlines the materials that shall be used in
implementing those decisions.
3.1.1
Types of Electrical Systems
Electric power is distributed through a network of conductors and electric
circuit protective and control equipment from its source of supply in the
serving utility to the utilization equipment located on the premises. This
assembly of conductors and equipment is called the electrical distribution
system and is the main subject of this design guide; other subjects
covered include motor controls, lighting, and special systems such as
telephone, paging, and fire alarm.
3.1.2
References
There have been a number of codes, standards, and handbooks prepared
on the basic subjects covered by this design guide. A brief list of some of
the more applicable references, many of which have been used in the
preparation of this design guide are contained in Appendix A. The latest
edition of each of these references shall be used.
ESD-106
3-1
01/06
3.1.3
Plant Distribution Systems
A variety of basic circuit arrangements is available for industrial plant
power distribution. Selection of the best system or combination of systems
will depend upon the needs of the plant process. In general, system costs
increase with system reliability if component quality is equal.
The first step is the analysis of the plant process to determine its reliability
need and potential losses and costs in the event of power interruption.
Some plant processes are minimally affected by interruption. Other plant
processes may sustain long-term damage or experience excessive cost
by even a brief interruption, therefore, a more complex system with an
alternate power source for critical loads may be justified.
ESD-106
3-2
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3.1.3.4
ESD-106
3-3
01/06
BUS DUCT
PANEL
3-4
01/06
ESD-106
3-5
01/06
SECONDARY
UNIT
SUBSTATION
ESD-106
3-6
01/06
SECONDARY
UNIT
SUBSTATION
SECONDARY
UNIT
SUBSTATION
ESD-106
3-7
01/06
The nominal voltage of the systems covered by this design guide will be in
either the low or medium voltage class. Table 3-1, Standard Nominal
System Voltages and Voltage Ranges in Chapter 3 of ANSI/IEEE Std 1411993 lists the standard and nonstandard nominal system voltages within
all three of the voltage classes. The table uses a system voltage
nomenclature that describes how the nominal voltage is supplied.
A single-number, single-phase voltage, such as 120 volts, indicates a twowire single-phase system where the voltage indicated is the nominal
voltage between the two wires.
A single-number, three-phase voltage, such as 480 volts, indicates a
three-wire, three-phase system where the voltage designates the nominal
voltage between any two phase wires.
A two-voltage designation where the smaller number is first, such as
120/240, indicates a single-phase three-wire voltage in which the nominal
voltage between phase conductors is 240 volts and the nominal voltage
between either phase conductor and neutral is 120 volts.
If the two numbers are reversed with a Y between, such as
480Y/277 volts, a three-phase four-wire system supplied by a wye
connected transformer is indicated. The first number indicates the
nominal phase-to-phase voltage and the second number indicates the
nominal phase-to-neutral voltage.
ESD-106
3-8
01/06
3.1.5
Voltage Selection
The preferred utilization voltage for industrial plants is 480Y/277 volts,
three-phase, four-wire. Three-phase loads can then be supplied at 480
volts with single-phase loads such as high bay lights supplied at 277
volts. Small dry-type transformers rated 480-120/240 or 208Y/120 are
then provided to supply 120-volt lighting and convenience receptacles.
The three-phase 208Y/120 volt utilization voltage is preferred except
where only very small loads are involved because it also allows small
three-phase loads to be supplied and it balances the loads on the
480Y/277 volt system. Where double-ended unit substations with tie
breakers are used, loads shall not be connected phase-to-neutral on the
480-volt system to simplify the ground fault protection scheme. Where
individual loads of 500 kVA or more must be supplied, 4,160 volts should
be considered for the utilization voltage for this equipment.
Power distribution voltage within a plant site is often dependent on the
supply voltage available from the serving utility. In a case where the load
on the plant site is small and located in a concentrated area, service from
the utility at 480Y/277 volts shall be specified. Larger sites where the
loads are spread out and a number of unit substations will be required
shall be supplied at a higher voltage. If there are large motors that could
be supplied at a higher voltage, the distribution voltage shall be selected
to supply the large motors without additional transformation. This would
make 4,160 volts three-phase the preferred distribution voltage unless
very large motors are involved.
3.1.6
Voltage Rating
Most electrical utilization equipment has a nameplate voltage that matches
the nominal supply voltage for which the equipment is designed. Motors
are the exception. Motors designed for connection to a 480-volt threephase system are rated 460 volts three-phase. Similar differences are
found in the ratings for motors designed for operation on 120-volt,
208-volt, 240-volt, and 4,160-volt systems. See Table 3-7 in Chapter 3 of
ANSI/IEEE Std 141-1993 for the nameplate voltages of motors as
specified in NEMA MG1. Table 3-8 in Chapter 3 of ANSI/IEEE Std 1411993 also contains information on the effect of voltage variations on the
operation of motors and other equipment.
3.1.7
Protection/Coordination Philosophy
The primary objectives of electrical system protection and coordination are
to prevent injury to personnel, to minimize damage to the system
components, and to limit the duration of outages that result from the
operation of the system protective devices. Protection of personnel and
equipment shall be given first consideration and then coordination of
devices within the system to limit the extent of service interruptions.
ESD-106
3-9
01/06
3.1.7.1
Protection Equipment. The electrical system components
shall be protected against overcurrent, phase to phase faults, and phase
to ground faults. There are two basic types of equipment available to
perform these protection functions: the fuse and the circuit breaker. There
are a variety of devices that fall within these two broad categories, and in
this design guide we will only review a few of them.
A.
B.
2.
Classifications:
a. Low-voltage power circuit breakers
b. Molded-case circuit breakers
Types:
a. Low-voltage power circuit breakers (LVPCBs)
b. Molded-case circuit breakers (MCCBs)
c. Insulated-case circuit breakers (ICCBs)
ESD-106
3-10
01/06
x
3.1.7.2
ESD-106
3-11
01/06
ESD-106
3-12
01/06
C.
3.1.7.3
Coordination. Coordination is the selecting or setting, or both,
of protective devices to minimize the portion of a power distribution system
that is affected by a fault within the system. Although maximum effort
needs to be made to select and set protection equipment to provide
coordination, protection of personnel, and minimization of equipment
damage must be considered first.
Safety of life is always the most important consideration. The system shall
preserve the safety of the general public and be capable of safe operation
by plant personnel. The second consideration should be the preservation
of property. Next, the need for reliability must be balanced against the
cost of providing the electrical system that provides the level of reliability
desired. If the impact of a short outage has little affect on the cost of plant
operation, additional expense to provide a fully coordinated system is
ESD-106
3-13
01/06
Component
Medium voltage switchgear
0.005-0.02
Transformers
0.4-1.90
0.02-0.15
0.13-0.34
0.01-0.40
Cable
1.00-4.00
Motors
x 1-10 hp
14.0-35.0
ESD-106
3-14
01/06
x 10-200 hp
6.00-12.00
x 200-1,500 hp
4.00-7.00
NEMA Type 1;
NEMA Type 3R;
NEMA Types 4 and 4X;
NEMA Type 7, Class I, Group A, B, C, or D;
NEMA Type 12.
ESD-106
3-15
01/06
3.2.2.1
Indoor Locations. Enclosures installed indoors in dry industrial type areas shall be NEMA 12. NEMA 1 enclosures may be used in
electrical rooms, offices, and laboratory areas where flying dust and debris
would not be present. NEMA 4 enclosures shall be installed in indoor
damp and wet areas that do not have corrosive atmospheres. Where
corrosive atmospheres are also anticipated, 316 stainless steel or
reinforced fiberglass NEMA 4X enclosures shall be installed.
3.2.2.2
Outdoor Locations. Enclosures installed outdoors must be
designed to meet a number of conditions. If the atmospheric conditions
are not known, 316 stainless steel or reinforced fiberglass NEMA 4X
enclosures shall be installed. If it is known that no corrosive atmospheric
conditions can be expected, then NEMA 3R or NEMA 4 enclosures could
be used. NEMA 4 enclosures shall be used in process areas where
washdown of the area can be expected, and NEMA 3R can be used for
disconnect switches and similar equipment where it is located away from
process equipment.
3.2.2.3
Hazardous Locations. Equipment enclosures in hazardous
locations shall be classified for use in the hazardous classification that
applies. NEMA 7 enclosures for use in Class I Group A, B, C, and D
locations (gaseous hazards) and NEMA 9 for Class II Groups E, F, and G
locations (explosive amounts of dust) are the two most often needed.
3.3
SWITCHGEAR
Switchgear is a general term covering switching and interrupting devices
alone or in combination with other associated control, metering, protective,
and regulating equipment. A power switchgear assembly consists of a
complete assembly of one or more of the above-noted devices and main
bus conductors, interconnecting wiring, accessories, supporting
structures, and enclosures. Both medium voltage and low voltage
enclosed switchgear will be reviewed in this design guide. See
Chapter 10 of ANSI/IEEE Std 141-1993 and ANSI/IEEE C37.20-1,
C37.20-2, C37.20-3, and C37.100 for additional information on
switchgear.
3.3.1
Low Voltage
Two types of low voltage enclosed switchgear are used in power
distribution systems: the metal-enclosed low voltage power circuit
switchgear, and the power switchboard.
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3.3.1.1
Metal-Enclosed Switchgear. Metal-enclosed low voltage
power circuit switchgear is constructed in accordance with ANSI C37.20-1
and meets the requirements of UL Standard 1558. It features individually
mounted air break power circuit breakers in drawout construction. Power
circuit breakers both with and without current limiting fuses are available.
Circuit breakers are equipped with solid-state tripping systems and offer a
wide range of adjustability. See additional requirements defined in
Metropolitan's Standard Specifications Sections Catalog.
Metal-enclosed low voltage power circuit switchgear shall be used where
the available fault current exceeds 50,000 amps symmetrical at 480 volts
or 65,000 amps symmetrical at 208 or 240 volts.
3.3.1.2
Power Switchboards. Power switchboards are available in
either group-mounted or individually mounted configurations. The groupmounted configuration is normally used for small boards and in
commercial construction. Both types are constructed in accordance with
applicable provisions of UL 891 and NEMA PB-2.
The main circuit protective devices in group-mounted switchboards are
either fixed or drawout-mounted, but the branch devices are all fixedmounted. The main device is either a molded case circuit breaker, a
molded case circuit breaker with solid state trip units, an air break power
circuit breaker, or a bolted pressure switch. The branch devices are either
molded case circuit breakers with or without solid state trip units, or fused
switches. The standard short circuit rating for group mounted
switchboards is 50,000 amps RMS symmetrical, but higher ratings are
available. See Metropolitan's Standard Specifications Sections Catalog
for more detailed requirements of this equipment.
Both the main and feeder circuit protective devices shall be drawout type
in individually mounted configurations. Circuit protective devices shall be
applied in a manner consistent with applicable portions of Section 3.1.6,
Protection and Coordination Philosophy. The standard short circuit rating
for switchboards with individually mounted drawout circuit breakers is
50,000 amps RMS symmetrical, but higher ratings are available. See
Metropolitan's Standard Specifications Sections Catalog for more
complete and detailed requirements for this equipment.
Switchboards with group-mounted circuit protective devices shall be used
where the main bus rating is 800 amps or less, the fault current available
is less than 50,000 amps RMS symmetrical, and the feeder and/or branch
circuit protective devices are all 225 amps or less. Where the main bus
rating must be greater than 800 amps and feeder breakers of 400 amps or
larger are required, switchboards with individually mounted circuit
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3.4.1
Pad-Mounted
Pad-mounted transformers are intended for use with underground power
distribution systems. They offer flexibility and provide a pleasing
installation. Their tamperproof construction allows installation in locations
accessible to the general public without the need for protective fencing or
vaults. They are oil-filled and are not suitable for indoor installation.
Compartmental type pad-mounted transformers are designed for the
underground entrance of primary and secondary conductors. Provisions
are available for live or dead front primary termination on radial or loop
feed systems. Secondary connections are spade terminals mounted to
the tank wall.
Three-phase pad-mounted transformers are available from 45 kVA to
5,000 kVA. They are constructed for a 65o C rise over a 30o C ambient
and have no provisions for increasing overload capability.
3.4.2
Unit Substations
A unit substation consists of a substation type transformer designed for
close coupling to a primary switch or switchgear assembly, and a
secondary switchgear assembly. Each of the three parts need to be
looked at individually because there are several options available for
each. The substation transformer may be installed along or with either the
primary or secondary switchgear assembly where proper bushings and
terminal cabinets are provided and where the switching and protection
functions are provided by remotely located equipment.
3.4.2.1
Primary Switch. Several options are offered for the primary
switch of a unit substation. A metal-clad nonfused interrupter switch shall
be provided where transformer protection is provided elsewhere. Should
transformer protection be required, a metal-clad vacuum circuit breaker
shall be bolted to the high voltage flange of the transformer. Should a
loop feed or primary selective switching be required, a metal-clad
switchgear assembly shall be bolted to the high voltage throat of the
transformer to provide both transformer protection and flexibility in the
distribution system.
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3.4.2.2
Transformer Section. The transformer section shall be either
liquid-filled, dry type, or cast coil type. Selection of the transformer must
be made based on where the transformer is to be installed and the
expected overload requirements.
A.
B.
3.4.2.3
Secondary Switchgear Assembly. Several options are
available for the equipment to be located on the secondary of a unit
substation. They range from an air terminal cabinet for termination of
either a bus duct or cables to a metal-enclosed low-voltage power circuit
switchgear. The circuit protective devices used shall be dependent upon
the needs of the system.
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3.4.3
Equipment Selection
Unit substations are Metropolitan standard. Pad-mounted transformers
shall only be used where transformer requirements are so small that unit
substations are not available.
3.5
MOTOR CONTROL EQUIPMENT
Motor control equipment is a general term that covers a range of voltage
and horsepower ratings and innumerable combinations of equipment
arrangements and operational functions. All such equipment is designed
and produced in accordance with NEMA Standards Publication Industrial
and Control Systems. In addition to ac motor starters, this section
includes discussions of adjustable speed controllers, DC motor controls,
and power factor improvement. Section 10.6 of ANSI/IEEE Std 141-1993
identifies a number of factors that must be kept in mind when selecting the
controller for a motor.
3.5.1
Low Voltage
In ac motor control, contactors are normally used for controlling the power
supply to the motor. The contactor, when applied in conjunction with a
thermal overload heater block, is called a starter. The starter is then
applied in combination with either a magnetic-only circuit breaker or a
thermal magnetic circuit breaker, and is called a combination motor
starter. The thermal overload heater block provides overload protection,
and the circuit breaker provides short circuit protection. The standards for
magnetic controllers rated 115 through 575 volts are summarized in
ANSI/NEMA ICS2. Motor starters for Metropolitan projects shall be sized
as shown in Table 2-1 for 480-volt three-phase motors. Starters for
motors operating at other voltages shall be sized in accordance with
appropriate NEMA standards.
There are several types of low-voltage motor starters available. Following
is a list of the more commonly used types and a brief description of each.
A more complete description can be found in either ANSI/IEEE Std 1411993 or the Switchgear and Control Handbook.
x Manual motor starter. A manual starter is a manually
operated switch that is rated for control of induction loads
and includes thermal overload protection. The manual
starter may not provide undervoltage protection.
x Magnetic, nonreversing motor starter. Provides fullvoltage starting for motors that must be started frequently
and are suitable for use with remote control devices such as
pushbuttons, selector switches, or similar pilot devices. The
magnetic, nonreversing motor starter provides overload
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B)
C)
D)
3.5.3.4
Drive Power Ratings
Drive controls are rated to provide a defined amount of current for
continuous operation at a defined maximum ambient temperature.
Controls re generally identified as one of two basic types.
A)
B)
3.5.3.5
A)
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The AC input line harmonic current magnitudes vary with the design of the
drive. The power distribution system impedance at the installation and the
drive input design determines the actual magnitude of th eline harmonic
currents.
Harmonic distortion levels as stated in IEEE 519 apply at the Point of
Common Coupling (PCC) between the utility system and multiple users.
The harmonic voltage and current distortion values at the PCC may be
reduced through several methods that include:
A)
Design Techniques
x Power System Design - decreasing the drive system load, as
percentage of the total power distribution network load will
improve harmonic voltage distortion conditions.
x DC Link Choke/Inductor - an inherent design feature within
some controls, provides a minimum level of harmonic
reduction by changing the rate of rise of the input current.
B)
Line Impedance
x AC line reactor - based upon the percent of line impedance,
provides lower amplitude of harmonic currents by slowing
down the rate of rise of input current pulses, similar DC link
choke.
x Drive Isolation Transformer - provides similar performance to
an AC line reactor with the additional power quality benefit of
being able to adjust the voltage magnitude.
C)
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Harmonic Filters
x Shunt filters passive filters that are properly designed and
for the 5th, 7th, and 13th harmonics can effectively reduce the
harmonic currents in a power distribution system.
x Series filters these filters consist of a parallel LC circuit
tuned to resonate a specific frequency, similar to a shut filter.
The series reactor acts to de-tune other power distribution
system harmonics form being trapped by the passive filter.
x Harmonic injection adaptive compensators are designed to
constantly monitor the AC line current to the drive by
injecting a current equal in frequency/magnitude and 180
degrees out phase to the distorted current.
x Active Filters designed primarily for multiple non-linear
harmonic loads, monitoring dynamic load conditions and
switching necessary VAR compensation.
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x Locked Rotor Torque. This is the minimum torque developed by the motor at all angular positions of the rotor at the
instant of rated-power application to the motor primary winding circuit. This torque is sometimes referred to as the
breakaway starting torque.
x Full-Load Torque. This is the torque necessary to produce
rated speed with rated-power input.
x Breakdown Torque. This is sometimes referred to as maximum torque and is the maximum torque developed at ratedpower input without an abrupt change in speed.
x Accelerating Torque. This is the torque developed with
rated-power input during the period from standstill to full
rated speed. It is the positive torque available beyond the
requirements of the load.
The torque capabilities of the motor being proposed must be compared
against the torque requirements of the load to verify that the motor is
capable of operating the load. This is typically done by plotting the torque
curve of the motor and the load torque on the same graph from zero
speed to synchronous speed of the motor.
3.6.2.2
Duty Classification. Motors are classified for continuous,
intermittent, or varying duty depending on their ability to drive a load:
x Continuous duty refers to a load that demands operation at a
substantially constant load for an indefinitely long time. Most
motor applications in water treatment and pumping plants
will be continuous duty.
x Intermittent duty refers to a load that demands operation for
alternate intervals of load and rest or load and no-load,
where each interval has a specific duration. Few intermittent
loads occur in water treatment and pumping plants.
x Varying duty refers to a load that demands operation at
loads and for intervals of time both of which may be subject
to wide variations. Most motor applications in water
treatment and pumping plants that are not continuous duty
shall be varying duty.
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3.6.2.3
Motor Speed. Motor speed is designated in terms of revolutions per minute (rpm), and for synchronous and induction motors is
directly related to the frequency of the power source. Following are
several definitions that need to be kept in mind:
x Full-load speed is the rated speed at which rated full-load
torque is delivered with rated-power input.
x Constant speed indicates that the normal operating speed is
constant, or practically constant, for a specified range of
torque.
x Synchronous speed indicates that the motor speed is in
synchronism with the frequency of the power supply. For ac
motors, synchronous speed shall be found by using the
following formula:
Synchronous speed =
(rpm)
(Eq. 3-1)
1,800
1,200
900
720
600
514
450
400
360
327
300
277
257
240
225
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3.6.4
Low-Voltage Three-Phase Induction Motors
Three-phase induction motors shall be specified for most low-voltage
process applications. Apart from the motor controller, three-phase
induction motors do not require any type of auxiliary equipment to facilitate
starting, and therefore they offer the highest reliability available. Lowvoltage three-phase motors are available from 1/4 to 600 hp but shall not
be specified above 200 hp except in special situations. Voltage selection
for motors larger than 200 hp shall be reviewed with Metropolitan.
Low-voltage three-phase induction motors are classified by NEMA in
accordance with five design types (Appendix F). The design types are A,
B, C, D, and F, and the main difference between them is their torque
characteristics. Design B motors shall be specified unless the load being
driven has special torque requirements and a special motor is required.
These motors are capable of being driven as either constant-speed
motors by a full- voltage or reduced-voltage motor controller, or at
adjustable speed by a speed-control system. An adjustable-frequencycontrolled speed drive system can be used to operate a normal induction
motor, whereas a wound-rotor motor is required if a wound-rotor motor
controller is to be used. Except where special circumstances require
otherwise, adjustable-speed motors shall be three-phase induction type
with pulse width modulated (PWM) adjustable-frequency controllers.
Motors specified for operation with adjustable-frequency controllers shall
be sized so that the driven load does not exceed 87 percent of the
nameplate rating of the motor.
3.6.5
Medium-Voltage Induction Motors
Medium-voltage induction motors shall be used for all applications where
the motor size exceeds 200 hp. Medium-voltage motors may be used for
smaller motors if medium-voltage motor control was provided for the
existing motors to be replaced. There are some situations where
synchronous motors should be selected; these applications are covered
under paragraph 3.6.6, Synchronous Motors.
All medium-voltage motors shall include integral overheating protection
provided by resistance temperature devices (RTDs) embedded in the coils
of the motor and in the bearing housings. A multichannel system shall be
provided to monitor the temperature at each RTD location. A contact
operation shall be provided to STOP the motor should the temperature at
any location exceed a preset value.
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3.6.6
Synchronous Motors
Synchronous motors are similar in construction to induction motors and
require similar type controls except that, since they need to be separately
excited, the control equipment is much more complex. Synchronous
motors are available from fractional horsepower to many thousands of
horsepower. They are typically used where large loads are operated
continuously and power factor improvement is required because they can
be a source of VARs when they are overexcited. There are few
applications in a water treatment plant that justify the added expense of a
synchronous motor and its associated controls; each potential application
needs to be reviewed carefully.
The synchronous motor needs to be protected for the same conditions
that apply to a large induction motor. In addition, due to the
characteristics of the synchronous motor, there are a number of additional
types of protection required. These include pull-out protection, loss-offield protection, starting winding protection, and incomplete sequence
protection. The details of these types of protection are covered by several
of the reference texts.
3.6.7
Direct Current Motors
There are a number of applications for dc motors in a water treatment
plant. These motors offer a wide speed range with essentially stepless
variation in speed setting. They are capable of being accelerated and
decelerated quickly and result in very accurate speed control when set.
With their associated controllers, dc motors shall be specified to drive
chemical feed pumps where precise control is required.
Dc motors shall be powered from the low-voltage ac power system using
DC-SCR drive units. Units 5 hp and less shall be supplied power at either
120 or 240 volts single phase.
3.7
RACEWAY SYSTEMS
A raceway system shall be installed to provide protection for conductors
for power, control, and instrumentation circuit conductors. Raceway
systems can take a number of forms, but in a water treatment facility the
forms most likely to be found include conduit systems, wireways, cable
trays, underground trenches, and underground duct systems. The guide
specifications cover the products to be used in each system and the
installation of that material. This section describes when to use the
different systems, the design criteria to be used in sizing the components
of each system, and identifies many of the applicable sections of the NEC.
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3.7.1
Conduit System
The raceway most often used to protect conductors is the conduit.
Conduit is available in a number of materials, but the ones most often
used are Schedule 40 PVC, galvanized rigid steel conduit (GRS), PVCcoated galvanized rigid steel conduit, electrical metallic tubing (EMT), and
liquid-tight flexible metal conduit (flex). Schedule 80 PVC and flexible
metal conduit (not liquid-tight) are also used for some applications.
The conduit type to be used in each situation shall be determined based
on the conditions expected on the project. GRS and PVC-coated GRS
offer superior physical protection and should be selected for those
applications where physical damage can be expected. PVC-coated GRS
and Schedule 40 PVC conduit offer resistance to corrosion and shall be
selected where corrosive conditions can be expected. The properties of
these conduits shall be considered in combination when selecting the
conduit to be used for such applications as turning up out of a corrosive
soil or passing through the interface between concrete and either the soil
or a wet condition exposed to the air. In both of these situations, the
superior properties of PVC-coated GRS make it the preferred choice.
The galvanized coating of EMT resists corrosion well but the walls are so
thin that it does not resist physical damage well. EMT shall be used in dry
areas above ceilings and concealed in walls for lighting, receptacle, and
HVAC circuits.
Schedule 40 PVC shall be used where conduits are to be installed
underground, either direct buried or concrete encased, because of their
superior resistance to corrosion. Schedule 40 PVC shall also be installed
abovegrade where a corrosive environment is anticipated, such as in a
chemical room, and where the conduit can be protected from physical
damage.
Articles 344, 350, 352, 353, and 358 of the NEC contain additional
information pertaining to the installation of conduit systems and shall be
consulted during design.
3.7.2
Conduit Identification
Conduit numbers shall be assigned to conduits. The conduit number shall
be shown on equipment layout drawings, electrical conduit layout
drawings, wiring diagrams, and conduit schedules. The conduit number
shall be composed of the equipment number of the serviced equipment,
plus a sequentially assigned number.
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3.7.3
Wireway
Wireways with conduit nipples shall be used to interconnect electrical
equipment where there will be a number of separate enclosures located
close to each other. The wireway provides an ideal pathway between the
enclosures, it provides space for tapping of conductors, if necessary, and
it makes grouping of conductors from the various enclosures into conduits
leaving the area very easy. Article 376 of the NEC contains additional
information pertaining to the application of wireway and shall be consulted
during design.
3.7.4
Cable Tray System
The cable tray system is an ideal raceway system for use where frequent
changes in the conductor or cable systems are expected. They have
limited use in a water treatment plant where changes occur only
infrequently. There are a number of rules in the NEC which must be kept
in mind should the engineer choose to use a cable tray system.
Article 392 of the NEC covers the installation of cable tray systems and
the installation of conductors and cables in them. Single conductors shall
be No. 1/0 AWG or larger and labeled for installation in a cable tray. All
multiconductor cables shall also be tray cable (TC) rated to be installed in
a cable tray system.
In water treatment plants, cable tray systems shall be used in electrical
rooms to provide convenient routing of feeder conductors between major
equipment items and between the electrical room and the control room to
route control and instrumentation cable.
Ladder or ventilated/trough cable trays without covers permit the
maximum free flow of air across cables and shall be used to route power
and control cables.
Solid bottom steel cable trays with steel covers provide EMI/RFI shielding
protection for sensitive circuits and shall be used to route instrumentation
cables.
3.7.5
Trench System
The trench system offers an alternative to an above ground cable tray
system or a duct bank system in substation and switching station yards
where a large number of conductors and cables must be routed around
the yard. The trench system may be either precast concrete sections or
cast in place. A variety of trench widths and depths are available and the
precast type are available with a broad range of options and accessories.
Barriers shall be provided to separate conductors and cables of different
systems that are routed through the same trenches.
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Trench systems shall be open bottom with a crushed rock fill to provide
drainage and cable and conductor support. The trench shall be covered
by removable fiberglass reinforced concrete panels. Special sections shall
be provided where equipment will be expected to cross the trench system
that are designed to carry traffic loads and meet the requirements of
applicable portions of AASHTO H-20.
3.7.6
Ductbank System
A ductbank system consists of a number of handholes and/or manholes
interconnected by red concrete encased buried conduits. The conduits
are grouped together and routed along a single corridor to minimize the
space required for them.
Ductbanks shall be constructed using Schedule 40 PVC conduit with
appropriate spacers to maintain the NEC required spacing. Separate
ducts shall be installed for low-voltage (600-volt and less), mediumvoltage, control, instrumentation, and communication cables.
Communication duct shall have a separate handhole. High voltage duct
shall have a separate manhole. Low-voltage, power, control, and
instrumentation cables that run in the same manhole or handhole shall be
provided with barrier in accordance with NEC.
The largest ducts shall be installed at the bottom of each ductbank with all
of the spare ducts being provided at the top of the ductbank. Even though
different sizes of ducts may be required by the conductors and cables to
be installed, the number of sizes being installed shall be kept to a
minimum. Each row in the ductbank shall be the same size throughout its
width and the minimum size conduit to be installed shall be 1 inch.
3.8
CONDUCTORS
All conductors, regardless of use, shall be copper and shall be stranded.
This section will cover both low-voltage, including conductors and cables
for instrumentation and control systems, and medium-voltage wiring
systems and their related appurtenances.
3.8.1
Low-Voltage Wiring Systems (600 Volts and Below)
Low-voltage wiring systems shall generally consist of insulated copper
conductors installed in an approved raceway system. The minimum size
conductor to be used for power and lighting systems shall be No. 12
AWG. Conductors used for control circuits shall be No. 14 AWG
minimum, but larger conductors may be used where control circuits are
long.
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3.8.1.1
Power Conductors and Cables. Conductors used for feeders
and branch circuits to process equipment shall be insulated with a crosslinked, thermosetting, polyethylene insulation and shall be UL type RHHRHW-USE. Conductors used for lighting and receptacle branch circuits
shall be PVC insulated, shall have a nylon jacket, and shall be UL Type
XHHW.
Where conductors for power circuits are to be installed in cable trays, they
shall be UL-listed as suitable for that use. The NEC does not allow single
conductors smaller than No. 1/0 AWG to be installed in cable trays.
Smaller feeder and branch circuit conductors to be installed in cable tray
shall be multiconductor power cable rated type TC.
Low-voltage conductors shall be sized in accordance with the requirements of NEC Table 310-16, as described in paragraph 2.3, Design
Calculations. Conductor ampacities used in the calculations shall be
based on the appropriate temperature rating for the conductor and
corrected for the ambient temperature that can be expected and for the
conduit fill conditions. Because many terminals used in equipment for
conductors No. 1 AWG and smaller are not UL-listed for applications
above 60o C, conductors No. 1 and smaller shall be sized using their
60o C ampacities. Where derating factors are used in the calculations for
sizing these conductors, either 75 or 90o C ampacities, whichever is
appropriate for the application, may be used in the calculation as long as
the resulting ampacity calculated is equal to or less than the listed
ampacity at 60o C.
Terminals for larger conductors are rated for use with conductors rated
75o C. The 90o C ampacities of conductors larger than No. 1 can be used
in determining the size of the conductor to be used, if:
x The conductors (conduit) are being installed in a dry area;
x Derating is required due to high ambient temperatures or if
the number of conductors being installed in the conduit
exceeds three;
o
x The resulting ampacity calculated does not exceed the 75 C
rating of the conductor.
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3.8.1.2
Control Conductors and Cables. The minimum size conductor to be used for control circuit shall be No. 14 AWG. No. 12 AWG
conductors shall be used for long circuits where additional physical
strength is required. The conductors shall be PVC insulated, shall have a
nylon jacket, and shall be UL type THWN/THHN/MTW. Where multiple
control conductors are required between two panels or terminal junction
boxes, a multiconductor control cable shall be installed. Multiconductor
control cables shall be constructed using UL type THWN/THHN/MTW
single conductors bound together in a single assembly with a PVC jacket.
The assembly shall be manufactured in accordance with UL 1277 and
shall be UL and NEC Type TC suitable for cable tray installation.
Individual conductors of multiconductor control cable assemblies shall be
color coded in accordance with Method 1, Table K-2 of ICEA 5-66-524.
Control conductors may be installed with motor branch circuit conductors
where control devices are located at or near the motor. Individual
conductors shall be installed with branch circuit conductors No. 4 AWG
and smaller, and multiconductor cables shall be installed where the branch
circuit conductors are No. 2 AWG or larger. Where the branch circuit
conductors are larger than No. 4/0 or parallel conductors are used, control
conductors shall be installed in a separate raceway.
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3.8.2
Medium and High Voltage Conductors (Above 600 Volts)
Two types of insulation must be considered when specifying medium- and
high- voltage conductors. They are the cross-linked polyethylene (XLPE)
and thermosetting ethylene-propylene rubber (EPR) compounds.
Although both insulations have similar properties and ratings, EPR is less
subject to treeing in the presence of water. Therefore, all medium- and
high-voltage conductors shall be shielded, shall have EPR insulation, and
shall have a PVC or neoprene jacket. Conductors with insulation rated
133 percent shall be used on ungrounded and resistance grounded
medium-voltage systems. Conductors with insulation rated 100 percent
may be used on systems that are solidly grounded. See the specifications
for the details of medium-voltage conductor construction.
The ampacity tables of Article 310 of the NEC shall be used in selecting
conductor sizes for medium- and high-voltage circuits but the Engineer
must not forget the effects of short circuit currents on these conductors.
The application of each medium- and high-voltage conductor shall be
reviewed with respect to allowable short circuit current for the conductor
size required and allowable temperature rise of the insulation before the
short circuit protective device trips. Chapter 12, Cable Systems, of IEEE
Standard 141-1993 should be consulted for additional information on this
subject. In addition, several manufacturers have published data and
graphs that are useful in selecting conductors that are properly sized for
applications where fault currents are high.
3.8.3
Splices and Terminations
As a general rule, no conductor, regardless of voltage, shall be spliced,
but there are certain situations where splices and terminations will be
required. This section deals with the splicing and termination of lowvoltage and medium-voltage insulated conductors.
Low-voltage power conductors in lighting and receptacle circuits may be
spliced using UL-listed insulated, twist-on spring connectors (wirenuts).
Splices in conductors to process equipments, control elements, and
instruments shall be made with approved compression type connectors.
Final terminations at motors and similar equipment where removal of the
equipment for maintenance can be expected shall be made with approved
bolted connection. All splices and termination shall be insulated using
heat-shrinkable sleeves that provide an insulation level at least equal to
that of the conductor.
Splices shall not be tolerated in control and instrumentation circuit
conductors. Where splices are required, they shall be made on terminal
strips in a junction box (terminal junction box). Control conductors and
cables shall be terminated at box lug type terminal blocks rated 600 volts
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3.9
JUNCTION BOXES AND PULL BOXES
Junction boxes and pull boxes shall be provided to facilitate the
combination of multiple circuits into a single conduit and the pulling of
conductors and cables. They shall be sized as necessary to
accommodate the conductors and cables being installed and shall be constructed of a material suitable for the environment where they will be
located. Section 16050, Basic Materials and Methods, of Metropolitan's
Standard Specifications Sections Catalog covers the basic materials that
are available for use. Two sizes of boxes are discussed in this section:
device boxes (small boxes) used as junction and pull boxes, and boxes
that must be larger than device boxes. Junction boxes shall be shown on
the drawings as required in the conduit system to group conductors,
terminate cables, etc. Pull boxes may or may not be shown depending on
the needs of the project. Even if pull boxes are not shown, the
specifications require the contractor to install them to limit the number of
bends in a conduit section to not more than three 90o equivalent bends.
3.9.1
Indoor Locations
Indoor locations can have environments that vary anywhere from dry to
wet and can include corrosive as well as hazardous atmospheres.
Corrosive and hazardous atmospheres will be discussed later in this
section.
The boxes used in indoor locations must be able to withstand the physical
abuse they are likely to receive, stand up to the environment, and keep
water out of the raceway system.
Boxes used in dry areas may be manufactured of either sheet steel or cast
metal. Small boxes that may be subject to physical damage shall be
manufactured of cast metal, whereas larger boxes in such locations shall
be manufactured of sheet steel. Small boxes located 4 feet above
finished floor in lighting, and receptacle circuits and concealed boxes in all
raceways, shall be constructed of sheet steel.
Small boxes to be installed in damp or wet locations shall be cast metal.
Larger boxes may be either cast metal, epoxy-coated sheet metal with
stainless steel hardware and neoprene gaskets, stainless steel, or
gasketed reinforced fiber glass with stainless steel hardware rated
NEMA 4.
Cast metal conduit fittings may be used as junction boxes in both dry and
wet areas if the box contains no splices; large device boxes shall be used
wherever splices are necessary.
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3.9.2
Outdoor Locations
Boxes to be installed in outdoor locations that have noncorrosive
atmospheres shall be installed using the same criteria as for indoor wet
areas. Boxes shall be installed in such a way as to protect them from
physical abuse either by locating them out of harm's way or installing them
behind a removable barrier. Concrete pull boxes shall be installed in
underground runs of conduits where the number of conduits passing
through them do not justify installation of a handhole or manhole.
3.9.3
Corrosive Locations
Boxes to be installed in corrosive locations shall be rated NEMA 4X and
shall be manufactured of a material suitable for the corrosive
environment. These boxes should be located away from corrosive
materials as much as possible. Acceptable materials include 316 SST,
reinforced fiberglass, and PVC. PVC may only be used in the smaller
sizes.
3.9.4
Hazardous Locations
Boxes to be installed in hazardous locations shall be UL-listed for use in
an area with the hazard classification that exists if a standard exists.
Where a standard does not exist, the boxes shall be designed to meet the
requirements of NEMA 7 as a minimum.
3.9.5
Terminal Junction Boxes
The term "terminal junction box" (TJB) shall be a term applied to junction
boxes that contain terminal strips for the termination of either control
conductors, small power conductors, or instrumentation cables. They
shall be constructed using a junction or pullbox that is suitable for the area
where it is to be installed and contains terminal strips that are suitable for
the conductors to be terminated. See Section 16050, Basic Materials and
Methods, of Metropolitan's Standard Specifications Sections Catalog for
additional requirements for TJBs.
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3.10
MANHOLES AND HANDHOLES
Manholes and handholes are similar in construction except for their size,
but are used for different purposes. Handholes are smaller and are used
as pull points and locations to redirect circuits in low-voltage and
communication ductbank systems where it is reasonable to work with the
conductors from above ground. Manholes are much larger and are used
as pull points and places to redirect circuits in medium- voltage ductbanks
and in low-voltage ductbanks where the conductors are too large to work
from above the ground. Manholes are constructed with enough depth to
allow a worker to climb down into it. Since a worker must be able to move
within the manhole without contacting the low- and medium-voltage
conductors that pass through it, the horizontal dimensions of the manhole
must also be larger than that of a handhole.
3.10.1
Handholes
Handholes shall be precast concrete, shall contain blockouts or knockouts
on all four sides, and shall have a square or rectangular opening in the
cover. The opening in the cover shall be equipped with a hinged cover
that is suitable for the location where the handhole is to be installed.
Handholes that will be installed in driveways, parking areas, or other areas
where vehicle travel can be expected shall be equipped with covers that
are rated for AASHTO H-20 loading. Handholes in other areas may have
covers with a lower loading class.
Handholes that are smaller than 4 feet by 4 feet by 4 feet need not be
equipped with cable racks and insulators, but the contractor shall be
required to provide adequate support for all conductors and cable to keep
them from laying on the floor of the handhole.
Handholes to be installed in areas with high groundwater shall be
equipped with a single drain opening that can be either plugged or
plumbed to a drain. When trying to keep the inside of the handhole dry,
remember the buoyant effect that can result. It is often better to leave the
opening open and allow the water level in the handhole to rise and fall with
the groundwater level. In areas where groundwater is not a problem,
similar handholes can be used, or handholes with no bottom are also
acceptable.
Handholes shall be installed in low voltage and communication system
ductbank at all 90o bends, adjacent to every building and/or structure
where large numbers of ducts enter the ductbank system, and as
necessary to limit pulling tension required for installation of conductors
and cable to within safe limits.
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3.10.2
Manholes
Manholes shall be precast concrete, shall contain blockouts or knockouts
on all four sides, and shall have a round opening in the top. The opening
in the top shall be equipped with a cast metal cover that is suitable for
AASHTO H-20 loading. The manhole shall be a minimum height of
6-1/2 feet clear inside so that a person can stand full erect within the
manhole.
Manholes shall be equipped with heavy duty inserts and cable racks to
provide support for conductors and cables that pass through them. All
conductors and cables shall be trained around the perimeter of the
manhole and shall be tied into place with suitable wire ties or similar
banding material.
Manholes shall be equipped with a depressed area for installation of a
portable sump pump. Remember, in high groundwater areas the
buoyancy of the manhole may be sufficient to lift it out of the ground;
therefore, it may be necessary to provide a drain in the bottom of the
manhole to allow the level of the water in the manhole to rise and fall with
the groundwater level.
Manholes shall be used in all medium-voltage ductbank systems and in
low-voltage ductbank systems where the size of the conductors makes it
impossible to work with them from above the ground. They shall be
installed at all 90o bends and as necessary to limit the pulling tension
required for conductor or cable installation to within safe limits. Should
handhole or manhole spacings greater than 300 feet be desired or 90o
bends be necessary, pulling tension calculations shall be performed.
3.11
LIGHTING SYSTEMS
In this section, three different lighting systems are discussed. The first
provides general illumination for visual tasks that are necessary in and
around a facility, the second is an emergency/standby system to provide
minimum illumination of means of egress so that safe exit from an area is
possible should normal power fail, and the third is exit signing. All three
lighting systems are not always necessary; building codes and common
sense dictate when the second and third types of systems are necessary.
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3.11.1
General Illumination
Lighting for general illumination can be provided by a variety of sources
depending on the visual tasks that are anticipated, the lighting levels
required, the mounting height of the luminaires, and the frequency of use
of the lighting system. Illumination should be provided by the source that
provides the highest light output (lumens) per watt of input power
(efficacy) that can be used, providing reasonable color rendition for the
visual tasks in the area. Fluorescent lamps shall be the preferred source
in indoor locations, and high-pressure sodium (HPS) lamps shall be the
preferred source in outdoor and high bay indoor locations.
Fluorescent lamps are available in several types and each has very
specific characteristics. Because of their long life expectancy, the
fluorescent lamps most often used are the 48-inch, 40-watt (34-watt
energy saver) preheat rapid start; the 96-inch, 75-watt (60-watt energy
saver) slim line; and the 96-inch, 110-watt (95-watt energy saver) high
output lamps. They are available in several color classifications, but the
only ones that will be considered here are the cool white and warm white
classifications.
Although warm white lamps produce a higher light output, cool white
lamps are recommended for most applications because they provide truer
color rendition and thus better visibility. Warm white may be selected for
industrial type applications where color rendition is not important.
HPS lamps are available in a number wattages and are suitable for
burning in any position. Even though their color rendition is not equivalent
to that of fluorescents, their increased efficacy (lumens per watt) and their
longer life make them the best choice for outdoor and hard to relamp
indoor areas. One characteristic of all high- intensity discharge lamps
(mercury vapor, HPS, and metal halide) is that they require a warm-up
and restrike time, they are not immediately on as is a fluorescent or
incandescent lamp. The warm-up time for a HPS can be as much as 3 to
4 minutes, during which time the light output is greatly reduced. The
restrike time for a HPS is usually 1 minute or less. Where immediate light
output is necessary on re-energization, an auxiliary quartz lamp can be
provided by some luminaire manufacturers.
Other lamps that may be used include the incandescent, the mercury
vapor, and the metal halide or multivapor lamps. The incandescent has
very low efficacy and short life, but it is on immediately when energized
and is very low cost. It has applications in out-of-the-way places that are
not visited frequently, and where low temperatures or hazardous
environments make the selection of other sources difficult. Mercury vapor
and metal halide could be applied in the same areas where HPSs have
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Footcandles
Office/Lab Areas
General
Close Work
50
100
Control Room
50
Process Areas
30
Storage Areas/Active
20
Storage Areas/Inactive
10
Outdoor Areas
Filters
Pump Stations
Storage Areas
Walkways
Roadways
5
10
5
2
1
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3.11.6
Exit Signs
The Life Safety Code, NFPA 101, that defines the need for exit signing
and lighting contains no requirement that would require exit signs in most
buildings of a water treatment plant. There are some locations, however,
where exit signs should be provided.
Exit signs and lighting shall be provided in the administration building
where the public and persons unfamiliar with the building may have
access. Exit signs shall provide adequate direction to the exits. Rooms
that have a single door that does exit to the outdoors need not be
equipped with an exit sign. In addition, process buildings that contain
multiple rooms so that the means of egress is not obvious shall be
equipped with exit signs to direct a person to the nearest exit. All exit
signs shall be electrically powered and shall contain an integral battery
and low-voltage lamps to provide uninterrupted illumination should the
normal power supply fail.
3.11.7
Controls
Controls for lighting systems shall be designed to meet the needs of the
space where the lighting system equipment is to be installed. Areas that
will require illumination 24 hours per day shall be provided with switching
duty circuit breakers and no local switches. In all office and process areas
where illumination is not required continuously, provide a separate switch
for each room. Where large rooms are encountered, at least one switch
shall be provided for each two 20-amp lighting circuits.
In office areas where lighting requirements will vary depending on the task
at hand, dimmers, two-level switching, or occupancy lighting control
sensors shall be provided to maximize energy savings.
All outdoor lighting circuits shall be routed through a photocell or photocell
controlled contactor to assure that they will be OFF when not required.
Where outdoor lights are controlled by photocell controlled contactor, a
three-position switch shall be provided so that they can be turned on for
testing. In some pole-mounted lighting applications, an individual ON/OFF
switch shall be installed on each pole of the lighting fixtures.
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3.12.1
Voltage Selection
Low-voltage power for lighting, receptacles, and miscellaneous power
needs shall be distributed at 208Y/120 volts unless some other power
need dictates a different voltage. Low-voltage power shall be supplied by
installation of 480-208Y/120-volt, three-phase dry-type transformers
located at each load center. Instruments shall be powered from a
separate supply transformer and panelboard unless their number is very
limited and the low-voltage power panel is connected to no loads that can
be expected to generate harmonics back onto the bus. The instrument
power supply transformer may be a 480-120/240-volt, single-phase
transformer.
3.12.2
Panelboards
Panelboards shall be installed as necessary to provide power to the
120-volt, single- phase and 208-volt, single- and three-phase loads shown
on the drawing. Branch circuit breakers shall be thermal-magnetic type
and sized in accordance with applicable paragraphs of Articles 210, 220,
225, and 430 of the NEC. Where Article 220 allows the use of demand
factors, they shall be used with caution. Demand factors may be used for
feeder and transformer sizing calculations but not branch circuit
calculations.
Where more circuits are required than can be provided by a single
panelboard, provide a subfeed breaker in the panelboard supplied by the
transformer to supply a second panelboard. The second panelboard may
be located remote from the first panelboard. All panelboards supplied
from a transformer shall have a main circuit breaker (transformer
secondary breaker) that has been sized in accordance with the National
Electrical Code (see paragraph 2.3.7 in this manual for sample
calculations).
The load on 20-amp branch circuits that supply lighting and receptacles
must be limited to 80 percent of the rating of the branch circuit protective
device, a 20-amp molded case circuit breaker per Article 210 of the NEC,
because lighting and receptacle loads must be considered "continuous." It
is recommended that the load on these circuits be limited further to
1,800 VA to limit voltage drop on these circuits.
Branch circuit breakers for instruments, instrumentation panels, and so on
where the exact load is unknown but is small in magnitude shall be sized
at 15 amps to allow installation of multiple conductors in the same
conduit. (Number of conductors limited by derating required by Article
310.15(B)(2) of the NEC.) In addition, these circuits often pass through an
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3.13.1
General
Electrical circuits, equipment, and equipment enclosures shall be bonded
and grounded as required by Article 250 of the NEC. All process
equipment and structures subject to potential and current flow due to
lightning, static accumulation, or other abnormal conditions shall be
grounded by two ground connections.
References to be used in designing grounding systems shall include the
following:
x NFPA 70--The National Electrical Code;
x ANSI/IEEE Standard 80--IEEE Guide for Safety in AC
Substation Grounding;
x IEEE Standard 142--IEEE Recommended Practice for
Grounding of Industrial and Commercial Power Systems.
Three types of grounding are discussed in IEEE Standard 142: system
grounding, equipment grounding, and static and lightning protection
grounding. The following sections will cover grounding of both plant
electrical systems and substation grounding.
3.13.2
System Grounding
Electrical distribution systems can be either ungrounded (no intentional
ground) or grounded (intentionally grounded). For the purposes of this
manual, a grounded system shall be a system of conductors in which at
least one conductor or point is intentionally grounded, either solidly or
through an impedance. The basic reasons for system grounding are the
following.
x To limit the difference of electric potential between all
uninsulated conducting objects in a local area;
x To provide for isolation of faulted equipment and circuits
when a fault occurs;
x To limit overvoltages appearing on the system under various
conditions.
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However, because of galvanic action between buried steel pipes and other
nearby dissimilar metals, Metropolitan does not use buried large diameter
steel pipes in its distribution system as grounding electrodes.
3.13.3.1 Service Entrance Grounding. Each power supply system shall
be connected to a grounding electrode system meeting all requirements of
Article 250 of the NEC. Each item within the system shall be bonded
together by a bonding conductor sized in accordance with the
requirements of the NEC. Where made electrodes are included in the
grounding electrode system, they shall be 5/8-inch by 10-foot (minimum)
copper-plated steel rod (copperweld or equal).
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3.13.4
Equipment Grounding
The NEC requirements for equipment grounding are covered in Article 250. In Metropolitan-owned premises, all noncurrent carrying metal
parts of fixed equipment likely to become energized shall be grounded.
The equipment grounding connection shall be provided by an equipment
grounding conductor sized in accordance with Table 250-122 of the NEC
routed with the phase conductors. Use of the raceway system for
grounding is not acceptable, but all metallic segments of the raceway
system shall be bonded to the equipment grounding conductor installed in
it.
3.13.5
Instrumentation and Computer Grounding
Each piece of equipment shall be connected to the equipment ground
point at the electric service equipment by an equipment ground conductor
run with the branch circuit conductors to provide the equipment ground
required by the NEC. Where isolated grounding type receptacles are
used, the requirements of NEC Section 250.146(D) shall be applied. A
dedicated grounding conductor connected directly to the equipment
grounding conductor terminal of the applicable derived system or service
may be required in some instrumentation and computer grounding
applications.
3.13.6
Lightning Protection System Grounding
Even though southern California is in an area of relatively low thunderstorm activity, grounding for lightning protection is still a subject that
should be dealt with. NFPA 78 The Lightning Protection Code and IEEE
Standard 142 both deal with the grounding requirements of a lightning
protection system. The need for a lightning protection system is a
separate subject and will not be addressed here.
Where a lightning protection system is installed on a building or structure,
its grounding system shall be installed separate from the electrical system
ground, but the two shall be interconnected to provide a common ground
potential.
3.14
3.14.1
General
Because emergency and standby power systems both use the same
equipment and often serve the same purpose, they are both discussed in
this section. For the purposes of this manual, the following definitions of
emergency power and standby power systems will be used:
x Emergency power system. An independent reserve source
of electric energy that, upon failure or outage of the normal
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3.14.4
Optional Standby Systems
Standby power supply equipment shall be installed to provide an alternate
source of power for critical control and monitoring functions, and
processes that, when stopped during any power outage, could cause
discomfort, serious interruption of the process, damage to the product or
process, or the like. Optional standby systems shall meet all applicable
requirements of Article 702 of the NEC.
Lighting requirements shall be provided by unit type equipment as defined
in Article 700 of the NEDC.
An interruptible power supply system shall be provided for all computerbased control and monitoring equipment that may not have integral battery
backup capability.
3.14.5
Engine Generators
Engine generators are the most often used source of onsite emergency or
standby power. They can be diesel, natural gas, gasoline, or even
propane powered. To be used as an emergency or legally required
standby power supply, the NEC requires onsite storage of sufficient fuel
for 2 hours of full load operation; therefore, natural gas engines are not
often used. In addition, due to fuel volatility nature, gasoline engines are
seldom used except in very small sizes. Synchronous generators shall be
used for all applications.
3.14.5.1 Diesel Engine Driven Generator. The diesel engine driven
generator is the preferred source of emergency and legally required
standby power because of its low first cost. For optional standby power,
the natural gas engine driven generator should be given first consideration
due to its cleaner burning and longer run time between maintenance.
Gasoline engine driven and propane engine driven generators should not
be used unless other sources of fuel are not available.
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3.14.7
Computer Power Systems
Power shall be supplied through uninterruptible power supplies (UPS) to
computer systems and microprocessor-based equipment such as remote
terminal units (RTUs) and programmable logic controllers (PLCs) that
have volatile memories. The UPS provides conditioned power to the
equipment during normal operation and provides uninterrupted standby
power should the normal source fail. Where multiple units are located in
close proximity to each other, a single large UPS system shall be
specified. Where the equipment is dispersed, multiple smaller UPSs shall
be specified.
Batteries supplied with UPS systems shall be of the low-maintenance type
specifically designed for use with UPS modules.
3.15
SPECIAL SYSTEMS
3.15.1
Plant Communication System
A complete plant communication system consists of a telephone system
and a paging system. The objective of the plant communication system is
to locate people within the plant and to communicate with the world
outside the plant. The operation of the plant will be simpler and the design
easier if these systems work together. It is important to get the users'
early input to the communication system design.
The objective of this section is to point out the steps to be followed to
design a communication system for a medium to large water treatment
plant. For smaller plants, which may not require paging systems, it is
usually advisable to have the telephone system supplied by the local
telephone company.
3.15.1.1 Telephone System. The engineer/designer should give detailed
attention to how the telephone system should work; as noted below, this
does not mean that a detailed design is necessary.
The first option to consider in getting the users their preferred type of
telephone system is to exclude it from the design package or include it as
an allowance. The reasons for this are:
x Leaving the telephone system selection to installation time
will get a more up-to-date system. Telephone systems are
changing rapidly. The telephone systems available at design
time may have all been replaced with significantly changed
models by the time the contractor places an order.
x Putting the telephone system selection in the competitive
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Initiation
Industrial occupancy
Notification
Manual or automatic
Business occupancy
Underground structure
or sprinkler
Manual or automatic
Windowless structure
Manual or automatic
Laboratory
(not specified)
In addition to an audible alarm, a visual alarm may be required by the governing authorities in some cities and
counties.
ELECTRICAL TESTING
3.16.1
General Requirements
The electrical testing and equipment checkout process cannot be
designed into a project. Thus, it is necessary that the required testing and
checkout procedures be established in the project specifications.
Electrical testing of the power system and its associated equipment is an
absolute requirement that will provide a safe and reliable electrical system,
as well as prevent damage to equipment and possible injury to operating
personnel. The testing and checkout process must be started during the
period the equipment is being manufactured, and should be continued by
the electrical contractor during, and upon completion of, the plant
construction. It is the designer's responsibility to be familiar with the
testing and checkout procedures in order to be able to specify what is
required of the contractor.
In general, the electrical testing and system checkout should include the
following:
x The power supply as furnished by the serving electric utility
company;
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3.16.2.1 Utility Service Tests. The utility company's incoming threephase service voltages should be continuously recorded for a period of
24 hours at the point of termination after the installation is essentially
complete and the plant is in operation. Voltage amplitude and balance
between phases for loaded and unloaded conditions should be recorded
and reviewed. If an unbalance, as defined by NEMA, exceeds 1 percent,
the cause of the unbalance should be located and corrections should be
made. Should the voltage vary by more than plus or minus 4 percent
throughout the day from loaded to unloaded conditions, a request should
be made to the utility company to have the condition corrected.
3.16.2.2 Equipment Line Current. The line current in each phase
conductor for all three-phase equipment and/or for each substation,
switchgear, switchboard, and panelboard should be measured and
recorded after the utility company has made final adjustments to the
incoming service voltage.
3.16.2.3 Equipment Operations. Require the contractors and/or
equipment suppliers to check out each item of equipment and demonstrate that it operates in accordance with the requirements of the project
specifications. The contractor must demonstrate that protective functions
are operating properly and are properly incorporated into the electrical
system protection and control schemes and into the plant control system.
3.16.2.4 Plant Illumination. The plant illumination system should be
visually checked after the fixture installation has been completed. The
initial lighting levels should be checked against the design criteria and for
compliance with Title 24 of the State Administrative Code requirements.
Exterior lighting should also be checked for proper fixture aiming.
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Applied potential;
Induced potential;
No load losses;
Voltage ratio;
Polarity;
Continuity.
The manufacturer will also perform the following additional tests on units
identical to the design type being supplied:
x
x
x
x
x
Sound level;
Temperature rise;
Full-load losses;
Regulation;
Impedance.
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After a transformer has been energized, the contractor should make the
following checks and/or tests:
x
x
x
x
x
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Conductors
Emergency/Standby Generators
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Grounding
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Chapter 4
CONTROL SYSTEM
DESIGN PROCEDURES
4.1
CONTROL PANELS
Control panels shall concentrate local process control and monitoring
functions from within a given area. Control panels shall provide manual
control of process equipment. Control panels shall be designed to permit
interfacing with the field equipment and the remote terminal units.
Control panels shall provide the means for the operator to take over
control from remote terminal units (RTU). The panels shall only be used
in case of RTU unavailability. The panel design shall consolidate
functions wherever possible.
This section contains design standards for panel layouts, construction,
and some representative control and monitoring devices mounted on or in
the panels.
4.1.1
NEMA Standards
Panel types shall be compatible with and suitable for the environment of
their installed location, and shall protect instruments and equipment
enclosed. The choice of location for panels shall minimize exposure to
ambient temperature extremes, moisture, dirt, and gaseous contaminants. Panels shall be designed, manufactured, and tested in accordance
with the latest applicable standards of NEMA, IEEE, and ANSI. See
Appendix D for the complete list of NEMA enclosure types that shall be
used to select an enclosure.
4.1.2
Panel Design
Panels and cabinets shall be designed to accommodate all necessary
accessories such as instrument air, power supplies, mounting hardware,
terminal blocks, and signal conditioning or conversion equipment
required. Panel layout and equipment spacing shall allow for device
removal, calibration, and maintenance without disassembly or adjacent
devices.
Removable eye bolts shall be provided for sling handling of enclosures.
Eye bolt mounting shall be a part of the structural support bracing to
distribute stresses and enclosure weight.
Sufficient structural reinforcements shall be provided to ensure a plane
surface, to limit vibration, and to provide rigidity during shipment,
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Function
AmberOverload
Red
Equipment running, valve fully open, circuit
breaker closed, or high speed
Green
Equipment stopped (safe), valve closed, circuit
breaker open, or low speed
White
Valve intermediate position or alarm and
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4.1.5
Annunciators
Indication of alarms shall be displayed on a panel-mounted, internally
illuminated, solid-state annunciator.
Annunciator power rating shall be 120 volts ac, 60 Hz.
Lamps shall have a nominal 20,000 hours minimum life at rated voltage.
All positions in the annunciator cabinet shall contain one solid state alarm
plug-in module. Each annunciator alarm point shall have one alarm
module. The alarm module shall be capable of accepting a normally open
field contacts that close on alarm or normally closed contacts that open on
alarm, selectable by a slide switch.
The annunciator sequence shown in Table 4-1 is an example of the many
sequences available. For other annunciator sequences refer to
ANSI/ISA-518.1.
The annunciator cabinet shall be suitable for front-panel mounting.
Terminals for field connections shall be accessible from the rear. The
design of the unit shall permit front-of-panel relamping.
Annunciators shall provide auxiliary signals for remote annunciation of
each and every point.
The annunciator shall be provided with horn and pushbuttons for reset,
silence (acknowledge), and lamp test functions.
Annunciator pushbutton colors shall be:
Color
Function
Green
Blue
Yellow
Reset
Test
Acknowledge
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Visual
Annunciator
Audible
Annunciator
Off
Off
Intermittent
Fast flash
Fast flash
On
Operator Acknowledgement
1st alarm
2nd alarm
Slow flash
Steady on
Off
Off
Operator Reset
1st alarm
2nd alarm
Steady on
Steady on
Off
Off
Off
Off
Normal
Off Normal
1st alarm
2nd alarm steady
Return to Normal
On
4.1.6
Relays and Timers
Control logic relays shall be heavy-duty, machine tool industrial-type with
contacts rated not less than 10 amperes at 600 volts ac. Relay coils shall
be molded construction and operate on 120 volts ac 60 Hz, 10 percent.
Auxiliary interposing relays shall be supplied by the same manufacturer to
assure similar appearance and uniform operating characteristics. Relays
shall have a clear polycarbonate dust cover. Relays shall be UL
recognized.
Operating temperature range shall be compatible with the environment in
which the relay will be installed. Contact material shall be gold or gold
flashing over silver and rated 0.5 amperes at 125 volts ac in instances
where low-level signal currents are being switched.
Relay shall be an octal or 11-pin base plug-in type furnished with
appropriate sockets.
Electrical timing relays shall be supplied by the same manufacturer to
assure similar appearance and time setting procedures.
Operating voltage shall be 120 volts ac 60 Hz 1 percent. Contact rating
shall be 10 amperes at 120 volts ac and have a minimum mechanical life
of 1 million operations. Operating temperature range shall be compatible
with the environment in which the timer will be installed.
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01/06
ESD-106
4-5
01/06
MWD
CONTROL SYSTEM DESIGN PROCEDURES
Indicators, 36 to 60 inches from the floor
ESD-106
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01/06
ESD-106
4-7
01/06
ESD-106
4-8
01/06
FIELD WIRING
4.2.1
4.2.1.1
General. Field signal wiring includes monitoring and control
signal wiring between field equipment (sensors, valves, and motor control
centers), control panels and remote terminal units (RTU).
4.2.1.2
Sizing. Single pair wires shall be 18 AWG or larger. Multipair
conductors shall be 22 AWG or larger. Thermocouple extension wires
shall be solid conductors of the same material as the associated
thermocouple.
4.2.1.3
Insulation. Signal wiring insulation shall have a minimum
dielectric strength of 600 volts. Insulation temperature range shall extend
to at least 75o C in dry locations and 90o C in wet locations. Multipair
cable overall jacket material shall be moisture-resistant, abrasionresistant, flame-retardant, and compatible with the environment in which it
is installed and shall be type TC tray cable.
4.2.1.4
Color Code Identification. Each wire shall have a color code
identification to facilitate wiring and troubleshooting.
The colors of individual conductors shall be in accordance with NEMA
WC-70 as follows:
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4-9
01/06
1-Black
7-Red/Black
13-Blue/Red
2-Red
8-Blue/Black
14-Orange/Red
3-Blue
9-Orange/Black
15-Yellow/Red
4-Orange
10-Yellow/Black
16-Brown/Red
5-Yellow
11-Brown/Black
17-Black/Blue
6-Brown
12-Black/Red
18-Red/Blue
19-Orange/Blue
The following abbreviations shall be used for identification of multiconductor cables and colored wires when developing wire lists or
documentation:
Color
Abbreviation
Color
Abbreviation
Black
Brown
BR
White
Red
Green
Orange
Gray
GY
Blue
BL
Yellow
4.2.1.5
Twisting. Signal wires shall be uniformly twisted with a
minimum of six twists per foot (2-inch lay). Cable lays and pairs shall be
twisted in the same direction.
4.2.1.6
Shielding. Where shielding is required, shields shall be
continuous foil or conductive metalized plastic providing 100 percent
coverage. A drain wire in continuous contact with the shield shall be
included.
4.2.1.7
ESD-106
Description
I
II
4-10
01/06
x Analog Signals
Analog signals are isolated 4-20 mA inputs received from
remote instruments and isolated 4-20 mA outputs transmitted to remote control elements.
Type II and IV wiring shall be used for individual and
multipair runs, respectively.
x Contact Inputs
Contact inputs originating from isolated contact closures
and conducting less than 10 mA at 48 volts dc.
Type I and III wiring shall be used for individual and multipair runs, respectively.
4.2.1.8
Instrument Power and Control Wiring. Wire and cable
insulation shall be 600-volt type THHN or THWN. Conductors shall be
stranded copper.
As a general rule, no wire smaller than No. 12 AWG shall be used for
power wiring.
Contact outputs are isolated contacts from interposing relays actuated by
the RTU for controlling 120-volt devices.
No wire smaller than No. 14 AWG shall be used for control wiring.
4.2.1.9
Shield Grounding. Signal shields shall have one ground point
located at the source of the signal (e.g., analog transmitter or contact
closure) unless otherwise recommended by the instrument or equipment
manufacturer. Shields shall be continuous through cabinets, panels, and
junction boxes.
4.2.1.10 Splicing. A minimum distance of 1,000 feet between splices
shall be maintained. Splicing shall only occur at a junction or pull box.
Continuity of conductors and shields shall be maintained at each splice.
Connections shall be made gas tight by compressing the two wires to be
joined with an isolated compression device or bolted connection.
Thermocouple, RTDs, and other low-level signal lines shall be continuous
ESD-106
4-11
01/06
0 to 100 mV;
100 mV to 5 V;
5 V to 75 V.
ESD-106
4-12
01/06
Conduit
4.2.2.1
Construction. Conduit construction must be in accordance
with the latest revision of the National Electrical Code. The conduit shall
be of galvanized rigid steel with a flexible section for connection to
devices. Conduit that has been crushed or deformed in any way shall not
be used.
4.2.2.2
Number of Bends. Bends of rigid conduit shall be made such
that the conduit will not be injured and that the internal diameter of the
conduit will not be effectively reduced. The radius of the curve shall not
be less than that recommended by either the National Electrical Code or
manufacturer of the wires or cables to be contained within the conduit.
The maximum angle of bends between pulls shall not total more than
180 degrees including entrance and exit to pull boxes or access fittings.
4.2.2.3
Distance Between Pull Points. The maximum allowable
distance between pull points shall be 300 feet or the distance based on
allowable maximum cable pulling tension, whichever is less. When the
distance between the two pull points contains the maximum angle of
bends, as stated above, the maximum allowable distance shall be 75 feet.
A lubricating agent compatible with the wire insulation shall be used. The
pull boxes shall be sized to allow adequate bending radius for the wire or
cable being pulled.
4.2.2.4
Conduit Fill. The combined cross-sectional area of conductors
and cables in a conduit shall not exceed the fill percentages specified by
the National Electrical Code.
4.2.2.5
Conduit Support. Conduit shall be firmly supported within
3 feet of each pull box, junction box, or termination point. The conduit
shall be sufficiently supported elsewhere in accordance with the National
Electrical Code requirements.
ESD-106
4-13
01/06
4.2.2.6
Continuity. Conduit runs shall be solidly connected to assure
the ground continuity of the entire run. Ground jumpers shall be installed
where the possibility of losing continuity exists.
4.2.2.7
Condensation Drains. Conduit runs shall be provided with
condensation drains at low points.
4.2.2.8
Installation. Exposed conduit runs shall be parallel or
perpendicular to building walls.
4.2.3
Spare Conductors
Spare conductors in each conduit equal to 25 percent of the number
required for both present and (defined) future conditions, but in no case
less than two spare wires, shall be installed. Each cable shall have
10 percent spare conductors but not less than two conductors.
4.3
CONTROL DEVICE INTERFACING
This section covers the design requirements for the interface between
remote terminal units and field control devices. Included are the types of
input and output hardware at the RTU, interlocks and manual control
equipment at field control panels, stations and alarm monitoring at the field
control devices, and control hardware at the field devices.
Control circuit diagrams for various types of field devices are shown on
Figures 4-1 through 4-10 (located at the back of this chapter).
The following are the types of field devices specifically covered in this
section. Design requirements for other field devices shall follow the
general requirements established in this section.
x Modulating control valves:
Electric motor operator;
Hydraulic actuator.
x Open/close control valves:
Electric motor operator;
Hydraulic actuator.
x Electric motors:
Constant speed;
Multiple speed;
Variable speed.
ESD-106
4-14
01/06
4.3.1.1
RTU Termination Cabinet
Remote terminal units (RTU) shall have a termination cabinet. The size of
the termination cabinet is slelected based on the number of I/O
terminations in the RTU. Termination cabinets shall be 36 or 48 or 60
wide, 24 deep and 72 or 76 high for Metropolitans small or standard
RTU, and 20 wide x 20 high x 8 deep for wall-mounted RTU.
Separate terminal blocks shall be provided for analog discrete signals.
Analog signals shall have three terminal blocks, one each for signal (+),
signal(-) and shield. Each discrete input and output shall have two terminal
blocks. The terminal blocks for analog and discrete signals shall be switch
type terminal block to permit isolating and testing of the signal loop.
Termination cabinets shall be supplied with non-UPS 120V AC power for
enclosure lights and outlets, and a copper grounding bar with M5 and M6
tapped holes and insulating mounting brackets.
It is Metropolitans practice to terminate all conductors between TRU and
the corresponding termination cabinet for the construction contractor to
terminate field wiring between termination cabinet and field mounted
devices.
4.3.1.2
Contact Outputs. Contact outputs to field control devices
shall be momentary contact closures using interposing relays, with the
duration of the closure controlled by RTU hardware. Two contacts shall
be provided for each control device; one to initiate control action, the other
to stop or reverse control action. The time between initiating and stopping
or reversing control action shall be controlled by RTU software. Seal-in
circuits shall be provided in either the field control panel or the motor
starter.
4.3.1.3
Modulating Outputs. Modulating devices such as variablespeed pumps and automatic control valves shall be controlled by isolated
4-20 mA outputs. Contact closure-type outputs shall be used for constant
speed motor-operated valves and gates. For contact closure-type
outputs, two separate contacts are required for each device. Closing one
of the contacts shall cause the motor to operate, the other shall cause the
motor to reverse.
When neither contact is closed, the motor is stopped. The position of the
device shall not change during loss of remote control. In addition,
transfers between remote and local control are made without changing
position.
ESD-106
4-15
01/06
Control Panels
4.3.2.1
Control Transfer Switch. Control transfer switches shall be
provided at control panels to select either remote (from RTU) or local (at
the control panel) control. Auxiliary contacts shall be available for
reporting to the RTU. Field devices may be grouped or be individually
controlled by one control transfer switch. The control transfer switch shall
be maintained in each position.
4.3.2.2
Panel Controls. Pushbutton controls on the control panels
shall be momentary to match the RTU outputs. Pushbuttons shall not
operate unless the control transfer switch is in the local position. (See
Figure 4-1.)
Indicating lights, of the colors shown on the figures, shall be provided on
the control panel adjacent to pushbuttons to show control device status.
Indicating lights may be incorporated into the pushbuttons if desired.
4.3.3
Status Monitoring
4.3.3.1
Valve Monitoring. Limit switches shall be furnished to monitor
the fully closed and open position of flow routing valves and gates. Full
open-close type valves that are remotely controlled shall have limit
switches for both the open and closed positions. Manual valves and gates
used solely for maintenance (e.g., pump suction and discharge isolation
valves) shall have limit switches as required.
Throttling valves shall have limit switches for fully opened and closed
position monitoring and a 4-20 mA output signal for monitoring valve
position.
Limit switches and the position signal shall be furnished by the valve
manufacturer as an integral part of the valve assembly. Whenever
possible, a 4-20 mA position signal is preferred instead of a potentiometer.
4.3.3.2
Motor Monitoring. Motor starter auxiliary contacts shall be
provided for remote monitoring of the running status of motors that are
controlled by the RTU.
Large motors, generally over 100 horsepower, that are critical to the
process, plant, or system shall be monitored for alarm conditions such as
high bearing temperature, high motor winding temperature, and motor
vibration.
Equipment and personnel safety interlocks shall be locally hardwired to
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ESD-106
4-17
01/06
ESD-106
4-18
01/06
ESD-106
4-19
01/06
ESD-106
4-20
01/06
ESD-106
4-21
01/06
ESD-106
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01/06
ESD-106
4-23
01/06
ESD-106
4-24
01/06
ESD-106
4-25
01/06
Appendix A
REFERENCES
Note: The most current edition of referenced publications applies, unless otherwise
specified.
American National Standards Institute
ANSI C2, National Electrical Safety Code
California Code of Regulations
CCR Title 8, Division 1, Chapter 4, Subchapter 5, Electrical Safety Orders
CCR Title 24. California Building Standards Code
Institute of Electrical and Electronics Engineers
Note: Many IEEE documents are adopted by ANSI and have an ANSI/IEEE document
number similar to the IEEE document number.
IEEE Std 80, IEEE Guide for Safety in AC Substation Grounding
IEEE Std 141, IEEE Recommended Practice for Electric Power Distribution for Industrial
Plants
IEEE Std 142, IEEE Recommended Practice for Grounding of Industrial and
Commercial Power Systems
IEEE Std. 242, IEEE Recommended Practice for Protection and Coordination of
Industrial and commercial power systems
IEEE Std 399, IEEE Recommended Practice for Industrial and Commercial Power
Systems Analysis
IEEE Std 422, IEEE Guide for the Design and Installation of Cable Systems in Power
Generating Stations
IEEE Std 433, IEEE Recommended Practice for the Design of Reliable Industrial and
Commercial Power Systems
IEEE Std 446, IEEE Recommended Practice for Emergency and Standby Power
Systems for Industrial and Commercial Applications
IEEE Std 484, IEEE Recommended Practice for Installation Design and Installation of
Large Lead Storage Batteries for Generating Stations and Substations
IEEE Std 493, IEEE Recommended Practice for the Design of Reliable Industrial and
Commercial Power Systems
IEEE Std 519, Recommended Practice and Requirements for Harmonic Control in
Electrical Power Systems
ESD-106
A-1
01/06
Appendix A
REFERENCES
IEEE Std 525, IEEE Guide for the Design and Installation of Cable Systetms in
Substations
IEEE Std 605, IEEE Guide for Design of Substation Rigid-Bus Structures
IEEE Std 739, IEEE Recommended Practice for Energy Management in Industrial and
Commercial Facilities
IEEE Std 979, IEEE Guide for Substation Fire Protection
IEEE Std 980, IEEE Guide for Containment and Control of Oil Spills in Substations
IEEE Std 1050, IEEE Guide for Instrumentation and Control Equipment Grounding in
Generating Stations
IEEE Std 1100, IEEE Recommended Practice for Powering and Grounding Electronic
Equipment
IEEE Std 1187, IEEE Recommended Practice for Installation Design and Installation of
Valve Regulated Lead-Acid Storage Batteries for Stationary Applications
IEEE Std C37.2, IEEE Standard Electrical Power System Device Function Numbers
IEEE Std C37.20-1, IEEE Standard for Metal-Enclosed Low-Voltage Power CircuitBreaker Switchgear
IEEE Std C37.20-2, IEEE Standard for Metal-Clad and Station-Type Cubicle Switchgear
IEEE Std C37.20-3, IEEE Standard for Metal-Enclosed Interrupter Switchgear
IEEE Std C37.96, IEEE Guide for AC Motor Protection
IEEE Std C37.100, IEEE Standard Definitions for Power Switchgear
IEEE Std C37.101, IEEE Guide for Generator Ground Protection
IEEE Std C37.102, IEEE Guide for AC Generator Protection
Illuminating Engineering Society
IES Lighting Handbook
National Electrical Manufacturers Association
NEMA MG 1, Motors and Generators
NEMA 250, Enclosures for Electrical Equipment (1000 Volts Maximum)
NEMA WC 70/ICEA S-95-658, Nonshielded Power Cables Rated 2000 Volts or less for
the Distribution of Electrical Energy
NEMA WC 71/ICEA S-96-659, Standard for Nonshielded Cables Rated 2001-5000
Volts for Use in the Distribution of Electric Energy
ESD-106
A-2
01/06
Appendix A
REFERENCES
NEMA WC 74/ICEA S-93-639, 5-46 kV Shielded Power Cable for Use in the
Transmission and Distribution of Electric Energy.
National Fire Protection Association
NFPA 45, Fire Protection for Laboratories Using Chemicals
NFPA 70, National Electrical Code (2005 Edition)
NFPA 70E, Standard for Electrical Safety in the Workplace
NFPA 72, National Fire Alarm Code
NFPA 75, Protection of Information Technology Equipment
NFPA 76, Fire Protection of Telecommunications Facilities
NFPA 79, Electrical Standard for Industrial Machinery
NFPA 101, Life Safety Code
NFPA 110, Emergency and Standby Power Systems
NFPA 780, Installation of Lightning Protection Systems
NFPA 820, Protection in Wastewater Treatment and Collection Facilities
NFPA 851, Fire Protection for Hydroelectric Generating Plants
Underwriters Laboratory
UL 845, Motor Control Centers
UL 891, Switchboards
UL 1008, Transfer Switch Equipment
Miscellaneous Documents
Electrical Installations in Hazardous Locations, Peter J. Schram and Mark W. Earley,
editors, National Fire Protection Association
Electric Service Requirements, City of Los Angeles Department of Water and Power
Electrical Service Requirements Manual, Southern California Edison
Electrical Engineers Portable Handbook, Bob Hickey, editor, McGraw-Hill
Electrical Systems Analysis and Design for Industrial Plants, Irwin Lazar, editor,
McGraw Hill
Handbook of Electric Power Calculations, H. Wayne Beaty, editor, McGraw-Hill
Industrial Power Systems Handbook, Donald Beeman, editor, McGraw-Hill
ESD-106
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01/06
Appendix A
REFERENCES
ESD-106
A-4
01/06
Appendix B
ABBREVIATIONS
A
A or AMP
A/C
AC
AF
AFF
AFG
AG
ASD
AT
ATS
AUX
AWG
Ampere
Air Conditioner (Conditioning)
Alternating Current
Ampere Frame
Above Finished Floor
Above Finished Grave
Above Ground
Adjustable Speed Drive
Ampere Trip
Automatic Transfer Switch
Auxiliary
American Wire Gauge
B
BAT
BC
BET
BOT
BLDG
BKR
BTU
BTU/H
Battery
Bare Copper
Between
Bottom
Building
Breaker
British Thermal Unit
British Thermal Unit Per Hour
C
C
CAB
CAT
CB
CHLOR
CONC
CKT
CMIL
CNTL or CONT
CONTD
ESD-106
Conduit
Cabinet
Catalog
Circuit Breaker
Chlorine
Concrete
Circuit
Circular Mil
Control
Continued
B-1
01/06
Appendix B
ABBREVIATIONS
D
D
DC
DIA or
DN
DISC
DIST
DPDT
Depth
Direct Current
Diameter
Down
Disconnect
Distribution
Double Pole Double Throw
E
EL or ELEV
EXIST
EM
EPR
Elevation
Existing
Emergency
Ethylene Propylene Rubber
F
F
FDR
FL
FLEX
FS
FVR
FVNR
Frequency
Feeder
Floor
Flexible
Flow Switch
Full Voltage Reversing
Full Voltage Non-Reversing
G
G
GFI
GFCI
GND or GRD
Ground
Ground Fault Interrupter
Ground Fault Circuit Interrupter
Ground
H
H or HGT
HDAF
HH
HOA
HP
ESD-106
Height
Hot Dipped After Fabrication
Handhole
Hand-Off-Automatic
Horsepower
B-2
01/06
Appendix B
ABBREVIATIONS
HPF
HPU
HTR
HV
HZ
I
IEEE
INST
INSTR
I/O
ITC
J
J
JB
Junction
Junction Box
K
K
KAIC
KCMIL
KW
KV
KVA
KVAR
L
LP
LS
LT
LTG
LV
Lighting Panel
Level or Limit Switch
Liquidtight
Lighting
Low Voltage
M
M
ESD-106
Motor
B-3
01/06
Appendix B
ABBREVIATIONS
mA
MAX
MCC
MCP
MFE
MFR
MIN
MH
MOD
MV
MVA
MWD
Milliamp
Maximum
Motor Control Center
Motor Circuit Protector
Metropolitan Furnished Equipment
Manufacturer
Minimum
Manhole
Module
Medium Voltage
Megavoltampere
Metropolitan Water District
N
NC
NEC
NEMA
NFPA
NIC
NO
NO. or #
NTS
Normally Closed
National Electric Code
National Electrical Manufacturers Association
National Fire Protection Association
Not In Contract
Normally Open
Number
Not To Scale
P
P
PB
PDR
PF
PH or
PLC
PNL
PS
PVC
PWR
ESD-106
Pole
Pullbox or Pushbutton
Preliminary Design Report
Power Factor
Phase
Programmable Logic Controller
Panel
Pressure Switch
Polyvinyl Chloride
Power
B-4
01/06
Appendix B
ABBREVIATIONS
R
R
RECPT or RCPT
RGS
RTU
Resistor
Receptacle
Rigid Galvanized Steel
Remote Terminal Unit
S
SCE
SHLD
SHT or SH
SN
SP
SPDT
STD
STR
SV
SW
SWGR
T
TB
TC
TD
TEL
TERM
THRU
TM
TS
TSP
TST
TYP
ESD-106
Terminal Box
Terminal Cabinet
Timer Delay
Telephone
Terminal
Through
Thermal Magnetic
Temperature or Time Switch
Twisted Shield Pair
Twisted Shield Triad
Typical
B-5
01/06
Appendix B
ABBREVIATIONS
U
UG or U/G
UPS
UL
USA
Underground
Uninterruptible Power System
Underwriters Laboratories
Underground Service Alert
V
V
VA
VFD
Volt
Voltampere
Variable Frequency Drive
W
W
W/
WP
Watt
With
Weatherproof
X
XDCR
XFMR
ESD-106
Transducer
Transformer
B-6
01/06
Appendix C
The (title of facility) is a new facility. This document is intended to provide guidance
for the electrical system design. If there is a better way to meet the design
objectives, submit a recommendation to the project lead electrical engineer for
processing.
See the preliminary design report (PDR) for a description of the electrical system to
be provided for this project.
OBJECTIVES
The design objectives on this particular project are clarity, simplicity, and
standardization. In addition, the usual standards of the profession will apply such as
constructibility, completeness, and reasonable accuracy.
Clarity
The design and presentation must be clear. Show how you arrived at significant
decisions. If you want a specific result, show the contractor what shall be done for
the particular situation.
Simplicity
The design itself, of course, shall not be more complex than necessary to produce a
good electrical system. In addition, the presentation shall be as simple as clarity
permits. Simplicity shall not go so far as to shift tasks normally accomplished during
design into the construction phase.
Standardization
The design must show uniformity throughout so that similar problems are solved in
similar ways. If several people work on areas that can share solutions, they shall
only produce one solution and reference it elsewhere. Where possible,
manufacturers' standard assemblies shall be used.
SCHEDULING
An electrical work plan will be provided separately. This section tells what
information must be available before beginning the design for each part. The object
of having this information available before the design begins is to minimize changes
in the electrical design. If the information listed below is not available at the time the
design for a particular portion is scheduled to begin, do not begin that portion of the
design. Problems that you encounter in obtaining the necessary information will
either be immediately resolved or referred to the Design Manager and/or Project
Manager.
ESD-106
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01/06
Appendix C
Single-Line Diagram
A single-line diagram for the plant electrical distribution system is included in the
PDR. I will modify this single line as necessary to accommodate changes that have
been made since the PDR was completed. Single-line diagrams for motor control
centers (MCC) will not be started until a reasonably complete motor list has been
developed for the area where the MCC is to be located. The P&IDs shall be used to
check the equipment lists given to us by the process leads. Each motor and
equipment number shall be checked against the current P&ID set before the
equipment list is considered complete.
Facility and Process Plans
The process electrical design for any area will be started only after the following
things have been accomplished for that area:
x Equipment data sheets are complete and reviewed by the lead
engineer in charge of the process;
x Equipment selection calculations have been reviewed;
x P&IDs completed.
Facility electrical design, lights, and outlets, for any area will be started only after the
process design is completed and building plans and sections are prepared and
drafted by the architects (changes in process design may still take place).
REFERENCE MATERIALS
Besides the usual codes and standards, the following documents are available as
information.
x The PDR and single-line diagrams
STANDARDS AND CODES
Electrical design shall conform to the latest editions of the following applicable
standards and codes:
x National Electrical Code (NEC);
x National Electrical Safety Code (NESC);
x California State Electrical Code;
x State of California Code, Title 8, CAL/OSHA Standards Board,
ESD-106
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Appendix C
Local codes and standards shall be applied as appropriate. Where the requirements
of more than one code or standard are applicable, the more restrictive shall govern.
Requirements of applicable codes and standards are not repeated in this section.
Applicable state and local codes and UL listing requirements shall be followed for
electrical inspection. Exit signs, emergency egress lighting, and emergency lighting
power supply shall conform to requirements of the building inspector.
VOLTAGES
The primary distribution voltage within the plant shall be 4,160-volt, three-phase.
The secondary distribution voltage shall be 480-volt, three-phase, wye, highresistance grounded.
Under normal circumstances, the voltage for fluorescent, high pressure sodium, and
incandescent lighting shall be 120-volt, single-phase. This voltage also shall be
supplied to heaters up to 1,500 watts, convenience outlets, motor controls, and
motors of less than 1/2 horsepower (hp). Heaters above 1,500 watts and motors
from 1/2 to 200 hp shall be 480 volts, three-phase. Motors above 200 hp shall be
4,160 volts, three-phase.
The code allowable total voltage drop from the 480-volt source bus (excluding site
distribution) to the point of use (including feeder, branch circuit, and transformation)
shall not be exceeded.
ESD-106
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01/06
Appendix C
In addition, due to the complexity and expense of providing ground fault protection
for three-phase 4-wire double ended substations with multiple grounds, no phase to
neutral loads shall be supplied directly from the 480-volt transformer secondaries.
DRAWINGS
Legend Sheet
In general, the standard Metropolitan symbols shall be used. The legend sheet shall
contain only the symbols and final abbreviations actually used in the drawing set.
The development of this sheet is my responsibility, with input from the project team.
A preliminary legend sheet is included in the PDR.
Site And Area Plans
The site plan shall show the location of all facilities and major equipment, duct bank
routes, handholes, and manholes. Area plans shall show all of the above items and
facility designs where the facility does not require a separate drawing such as
clarifiers, thickeners, etc. Site and area plans shall be overlayed on civil
backgrounds (base sheets).
Single-Line Diagram
The single-line diagram shall show the entire electrical distribution system from the
elec trical service down to 460-volt utilization devices and 208Y/120-volt
panelboards. Circuiting of 208Y/120-volt panelboards shall be shown on the panel
schedules. Circuiting of 480Y/277-volt panelboards shall be shown on the panel
schedules where possible, but where motors are powered from panelboards, the
branch circuit, including all combination motor starters and disconnect switches,
shall be shown on the single-line diagram.
Information on single-line diagrams shall include bus capacity, short circuit ratings,
overcurrent device types and ratings, C.T. and P.T. ratios, protective relay types and
ratings, metering and load ratings (horsepower or kilowatt), and circuit breaker and
switch ratings.
Conduit and conductor sizes shall be indicated on the single-line as well.
ESD-106
C-4
01/06
Appendix C
Elevations
Front elevations shall be shown for all medium-voltage switchgear, low-voltage
switchboards, unit substations, and motor control centers. Elevations shall be drawn
to scale and shall show the locations of MCC units, overcurrent devices, metering,
and conductor entrances. MCC units with extra height shall be shown where
required for relays. Switchboard and switchgear elevations shall be informally
reviewed by the first-named manufacturer for placement of units and overall
dimensional accuracy. Where important, note depths of assemblies on elevations.
Elevations of the equipment shall be developed by the designer of the facility that
the equipment is located in and reviewed by me.
Remember that even one control relay in a motor starter will usually require an
additional 3 inches of compartment height. Assume that this will be the case when
you need to have relays. Two will fit in the added 3 inches; if you need 3, add
another 3 inches, etc.
Motor Elementary Control Diagrams
Motor elementary control diagrams (ECDs) shall be done in the style shown on the
attached example. The ECDs shall show control circuit devices, which are not
mounted in I&C panels. Single controls in an I&C panel (on/off selector switch,
start/stop pushbuttons) may be shown. More complex control in an I&C panel shall
be shown as two terminals in a dashed rectangle with a reference to the signals as
they are labeled at the I&C panel, such as "RUN M-1-1 @ FP-2." Except as noted
below, all control devices shall be shown on the P&IDs. Talk to the I&C engineer
before adding control devices. The following control devices, not shown on the
P&IDs, shall be shown on the ECDs where we feel that they are necessary:
x ON/OFF/REMOTE switch (where required and not shown)
x Elapsed time meters (will be provided if the motor falls into the criteria
described hereinafter)
x Ground fault relays
x Metering
x Motor heaters
x Motor thermal devices
x ON/OFF status lights
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Appendix C
ECDs shalll be developed by each facility designer for the equipment located in that
facility.
Schedules
Luminaire and panel schedules shall be put on the drawings. The luminaire
schedule shall be prepared in a format similar to the lighting fixture schedule shown
on attached example. A preliminary list of luminaires shall be developed before
design is started and the same luminaire shall be used for all similar applications
throughout the plant. Addition of a new luminaire to the schedule shall require
review with the project lead electrical engineer. A preliminary list of luminaires
shown in the format to be used is enclosed hereinafter.
Panel schedules shall be prepared similar to the panel schedule shown on attached
example. The lead design engineer for each facility shall be responsible for the
preparation (and review) of all panel schedules related to that facility. A separate
panel shall be provided within each facility for the power supply to process related
instruments and equipment. In smaller facilities, this panel may be subfed from the
lighting panel, but in larger facilities it shall be fed from a transformer and transfer
switch that is separated from the building facilities power supply.
The panel schedules shall be included on the drawings with the buildings or facilities
where they are located or with the single-line diagrams or equipment elevation of the
related equipment. The panel schedule format is available upon request.
Details
Details shall be numbered as noted in the project instructions. The project lead
electrical engineer will act as, or appoint a detail coordinator. A preliminary set of
design details will be selected and a copy of each will be provided to each design
team member. Details will generally be Metropolitan standard details. When you
need to use a detail that has already been used, find out the number from the detail
coordinator. If it has not been used, obtain a new number from the detail coordinator
and tell the coordinator the standard detail number, whether you are modifying the
detail or whether you are creating a detail from scratch. Every 1 to 2 weeks, the
detail coordinator shall send a copy of details being added to the project to each
electrical designer on the project.
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Appendix C
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Appendix C
DIVISION 16 SPECIFICATIONS
Refer to Metropolitan's ESD-135, Standard Specifications Sections Catalog for a list
of specifications necessary for this job. These specifications shall be developed by
the project lead electrical engineer with input from each electrical design engineer
where a specification affects an area they are designing. When developed, these
specifications shall be compatible in requirements to Metropolitan Standard
Specifications Sections Catalog.
CIRCUIT AND RACEWAY SCHEDULES
A computer-developed circuit and raceway schedule shall be used for all circuits that
are routed through the duct bank system, with the exception of those shown on the
area plans (1"=20' scale site plans) where the ultimate destination of the circuit is
also shown on the same plan. To coordinate the efforts of all staff having input to
the schedules, each electrical designengineer shall be responsible for all circuits that
leave their facility and enter the duct bank system. They shall verify that each of their
circuits is completely routed through the duct system to its final destination.
For cable and circuit identification, refer to AppendixG.
Information to be presented in circuit and raceway schedules shall show the
following information:
x Circuit number;
x Circuit end points;
x Circuit type (power, control, instrumentation, etc.);
x Conductor size, count and type - identify neutral and grounds;
x Routinglist raceways in the order that the circuit passes through
them.
The raceway schedule shall show the following information:
x
x
x
x
Raceway number;
Raceway end points;
Number, size, and type of conduits, e.g., 2-4 inch PVC;
Circuits carried in the raceway.
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Appendix C
x Cable number;
x Circuits carried in the cable.
Each multiconductor cable shall also appear in the circuit schedule.
What to include in circuit and raceway schedules. The following circuits and the
raceways containing them shall be identified and entered into the circuit and
raceway schedule:
x Circuits which leave a sheet (exception: circuits which leave one floor
plan to a second floor of the same building but do not leave the
building).
x Circuits which leave a facility, unless they do not leave the sheet, and
the routing between facilities is clear.
x Circuits which are part of a control cable. An interconnection diagram
similar to that shown in Figure 5 shall be prepared for all terminal
junction boxes (TJBs) from which a control cable originates. These
diagrams may or may not be on the drawings depending on the
complexity of the diagram.
If a circuit is identified anywhere on its route, it shall be identified for its entire route.
All raceways containing that circuit shall also be identified unless the raceway
remains entirely within one facility. In such a case, that portion of the circuit may be
identified in the circuit schedule and the circuit will be identified as part of the
raceway fill on the drawings.
Information shall not be duplicated on the drawings and circuit and raceway
schedules. For anything appearing in the schedules, just give enough information
on the drawings to locate it in the schedules. This means that once the need to
identify a circuit has been established, the only information that needs to be put on
the drawings about that circuit is the circuit number and the raceways that contain it.
FAULT STUDIES
A preliminary fault study shall be completed for the entire plant as part of the PDR
but no later than the start of final design. The following assumptions shall be made:
x An infinite source is available on the high side of each utility service
transformer.
x The utility service transformers shall not be operated in parallel.
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Appendix C
x The standby engine generators shall not operate in parallel with the
utility source but the gas utilization generator shall.
x The maximum load operating on each 480-volt bus at each load center
shall be equal to 100 percent of the installed transformer capacity at
that load center.
The study shall show the load and fault duty on each bus and feeder overcurrent
device rated 460 volts or higher.
The final fault study shall be an update of the preliminary fault study.
The final load study shall show the load at each distribution assembly in the following
categories:
x
x
x
x
x
HVAC;
Process;
Lighting;
Other facility loads;
Total.
Other categories may be added to the above, if required by the electric utility.
PROCESS CONSIDERATIONS
Hazardous Areas
The project lead electrical engineer shall review the various areas of the plant that
may contain hazardous concentrations of hazardous gases. Based on the
requirements of NFPA 820, a drawing shall be developed to deal with each area.
The areas that will be affected include enclosed areas, scum pits, and similar areas.
These are areas open to raw sewage or secondary influent (i.e., up to the aeration
basin), which shall be considered Hazardous Class I, Division I due to the presence
of methane and gasoline unless adequate ventilation is provided. In addition, the
digester gas compressor rooms shall also be classified as Class I, Division I areas.
Other areas may be classified hazardous as required by NFPA 820. Devices that
contain contacts located in hazardous areas shall generally be wired intrinsically
safe, except in Class I, Division II areas where hermetically sealed contacts may be
installed.
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Appendix C
Reliability
This plant requires EPA Class I reliability. One utility source is available at the plant
and a standby generator shall also be provided. The plant shall be designed with
double-ended unit substations and MCCs in all facilities. Power for duplicate
equipment shall be put into different conduits so as to maintain the Class I reliability.
Redundancy of supply criteria shall comply with EPA Bulletin EPA 430-99-74-001
definitions for a Class I plant.
UTILIZATION EQUIPMENT CONSIDERATIONS
Utilization Equipment Identification
Permanent. Utilization equipment shall be identified by I&C tag numbers as those
numbers become available. Utilization equipment that does not appear on the
P&IDs will be identified in the same manner as electrical distribution equipment (see
below) using an appropriate equipment type; for example, UH for unit heater.
Interim. Until I&C tag numbers become available, utilization equipment will be
identified by the following format:
x FF-SS
x Where FF is the facility number in or near which the equip ment is
located and SS is a sequence number. Sequence numbers shall be
assigned in order by the facility designer. Sequence numbers for
deleted equipment shall not be reused.
Miscellaneous
Provide disconnects where required at process equipment, especially at
motor-operated valves. Work with the equipment specified to see if integral
disconnects are a standard option. Do not ask that they be specified unless they are
a standard option. Provide disconnect switches for all HVAC equipment that has
any integral controls (i.e., unit heaters, compressors, duct heaters, air handlers,
etc.).
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Appendix C
208Y/120 Volts
Lighting, Receptacles,
and Miscellaneous Power
CMS
JB
MCC
MSR
=
=
=
=
x
x
x
x
x
x
x
PNL =
DPNL =
SB
=
SWG =
TJB
=
TX
=
USB =
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Appendix C
Sequence numbers are required even if only one of a particular type of equipment is
in a particular facility. For TJBs only, the sequence number will be followed by "A"
for analog, "D" for discrete, or "P" for power.
The following equipment will be identified:
x
x
x
x
x
x
x
x
Other equipment may be identified if identification is required for other purposes; for
example, junction boxes may need to be identified in order to homerun to them.
Major electrical equipment, i.e., MCCs, SWBDs, etc., shall be located on the site
plan and the 1"=20' scale area plans in addition to the facility and process electrical
plans.
Distribution System Protection
The following types of protective devices shall be used for the medium- and
low-voltage distribution systems:
x 4.16-kV main switchgear assembly: Draw-out vacuum type power
circuit breakers in NEMA Type 1 enclosure for indoor or NEMA Type
3R enclosure for outdoor.
x 4,160-volt motor control: Draw-out type vacuum contactors with
current limiting fuses in NEMA Type 1 gasketed enclosure.
x 480-volt switchboard: 100 percent rated insulated case circuit breaker
with solid-state trip for mains and feeders 600 amperes and larger.
Smaller feeder breakers shall be molded case with solid state trips.
x 480-volt motor control center main circuit breaker: 100 percent rated
molded case with solid state trips.
x 480-volt motor control center branch circuit breaker (other than combination motor starters): molded case thermal magnetic.
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Appendix C
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Appendix C
Panelboards
A separate circuit breaker shall be provided for instruments that perform the same
function on parallel flow streams, such as DO meters, flow meters, etc. Instruments
of different types that are all associated with the same flow stream may be
connected to the same branch circuit to simplify the design. Where multiple
instruments are connected to a single-branch circuit, a toggle switch shall be
provided at each tap to allow each individual instrument to be disconnected from the
branch circuit.
A common branch circuit shall be provided for all valve and gate operators that are
associated with a single-flow stream.
Examples:
x One circuit per bar screen channel
Branch circuits or feeders shall be identified on the drawings with the panelboard
and device protecting the individual circuit or feeder.
Lighting panelboards shall be surface-mounted, 208Y/120-volt, three-phase,
four-wire type with the main circuit breaker sized to match the lighting transformer
capacity. Separate panelboards shall be provided to supply power to instruments
and control panels where the equipment to be supplied requires a conditioned power
supply. Where two 480-volt power supplies are available, an automatic transfer
switch shall be provided to supply power to the lighting panelboard transformers
from either 480-volt source.
Each panelboard shall be equipped with a minimum of 20 percent spare breakers
with spaces, bus work, and terminations to complete the standard size panelboard.
Panelboard schedules shall show the circuit description, protective device trip rating,
number of poles, rating of main lugs or main circuit breaker, neutral bus size, ground
bus size, and interrupting rating of breakers. Computer-generated panelboard
schedules shall be included in the drawings.
Panelboard schedules shall be prepared indicating circuit description, protective
device trip rating, number of poles, load in volt-amps by phase, rating of main lugs or
main circuit breaker, neutral bus size, ground bus size, and interrupting rating of
breakers.
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Appendix C
Convenience Receptacles
Duplex receptacles for general service shall be spaced not more than 40 feet apart
inside all process buildings and 75 feet apart in outside process areas and shall be
located on the surface of walls or columns. Receptacles in outdoor locations and
areas subject to washdown shall be weatherproof. Receptacles shall be located as
needed in commercial areas.
Ground Fault
Ground fault systems shall be zero sequence type. Coordination shall be obtained
by hard-wired trip restraints (about 2ms restraint). Facilities shall be provided for
testing the ground fault circuit by secondary current injection, with or without tripping
and for indicating the occurrence of a ground fault. Current and time trip levels shall
be adjustable. Ground fault shall be supplied external to the circuit breaker. Motor
ground fault shall be an instantaneous trip.
Power Factor
Power factor correction capacitors shall be applied to all motor starters for motors of
40 hp and larger. Capacitor banks shall generally be located on top of motor control
centers.
Raceways
Specific types of raceway shall be chosen for use in various locations in the facility
based on moisture, temperature, exposure to damage, corrosion, voltage, and cost.
Separate, concrete-encased, polyvinyl chloride (PVC) conduit, underground duct
bank shall be provided for the following systems:
x Power wiring above 600 volts;
x Power and discrete control wiring below 600 volts;
x Process instrumentation analog and communication wiring.
Underground raceways that are not installed in a duct bank shall be direct-buried,
schedule 40 PVC conduit.
The following general guidelines shall be used for raceway sizing, selection, and
installation:
x Conduit size shall be based on THWN insulation for sizes below No. 6
AWG, and THW insulation for all other wiring 600 volts and below.
x The minimum diameter of conduit in all areas shall be 3/4 inch.
x Exposed raceways shall be installed in process areas.
x Raceways in walls and ceilings in control rooms, offices, and all areas
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Appendix C
x
x
x
ESD-106
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Appendix C
ESD-106
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Appendix C
Foot-Candle
Office
70
Process, inside
50
Process, outside
Storage, inside
10
Walkway
General site
The following general types of light service shall be used to provide the proposed
foot-candle levels:
AreaLight Service
Office
Fluorescent
Process, inside to
12 feet mounting
height
Fluorescent
Process, above
12 feet mounting
height
Storage, inside
Fluorescent
Walkway, inside
Fluorescent
Walkway, outside
General site
Transformers
Transformers to supply 208Y/120 volt requirements shall be dry type and suitable for
the area in which they are to be located. Transformers that include a small
panelboard in the same enclosure shall not be used, A small transformer with a
separate panelboard shall be used in every case.
Transformers to supply 480 volt 3-phase and 4160 volt 3-phase shall be of the pad
mount type where located outdoors and of the dry type where located indoors.
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Appendix C
Miscellaneous Systems
Fire alarm systems shall be included in buildings as required by applicable codes.
INTERFACES
Facility
Each facility shall have designated interface points for connection with conductors
that leave the facility. For each facility, make a list showing where the interfaces are.
x Power Interfaces. Power interfaces shall be done at an assembly or
device and shall not require a junction box.
x Discrete Instrument and Control Interfaces. Where all discrete I&C
circuits that leave a facility are in a single assembly, that assembly
shall be used as the interface. Where discrete I&C circuits that leave a
facility come from several assemblies, a TJB shall be installed for the
interface (see Figure ___).
x Analog Instrument and Control Interfaces. Where all analog I&C
circuits that leave a facility are in a single assembly, that assembly
shall be used as the interface. Where analog I&C circuits that leave a
facility come from several assemblies, a JB or TJB (if conversion to a
multiconductor cable is required) shall be installed for the interface.
CALCULATIONS REQUIRED
Calculations shall be done in an orderly manner either on a desktop PC computer or
on computation paper. Each sheet shall have the date on which the computations
were made, the project number, and the designers name. All information used in the
preparation of the design shall be kept in a notebook with tabs to properly divide the
different items such as telco memos, comps, letters, equipment data sheets, etc.
Each computation shall clearly identify the facility for which the calculations are
being made and the type of computation that is being performed. Copies of all
calculations shall be sent to project lead electrical engineer as they are completed
for his review and filing. At the completion of the project, all pertinent information
shall be assembled in a single set of notebooks for inclusion in the project files.
The computations listed below are the minimum that need to be documented. All
calculations shall be reviewed before the related drawings are drafted.
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Appendix C
Wire Sizing
Take into account wet/dry areas and ambient temperaturessee attached form for a
guide. Show wiring sizing for all services, feeders, and large branch circuits.
Calculations shall include a summary of all loads to be served where there is more
than one load. Calculations for feeders to panelboards shall reference the specific
panelboard being supplied and a copy of the panel schedule with all loads indicated
shall be included with the calculations.
Primary and secondary feeders to/from dry type transformers shall be sized in
accordance with the attached transformer table and the proper sized main breaker
shall be shown in the panelboard that is served from the transformer.
Dry Type Transformers
Include a list of all branch circuit panelboards to be supplied and the connected load
on each panel. Demand and diversity factors that are allowed by the NEC may be
used for sizing transformers that supply loads in areas that are not process related,
but transformers in other areas shall be adequately sized to supply the total
connected load connected to the process.
Pad Mounted and Unit Substation Transformers
All power supply transformers shall be sized to supply the total load that is normally
connected to the transformer's secondary bus without exceeding the air-cooled
rating of the transformer. Where there are three MCC buses, it shall be assumed
that the third MCC bus can be "normally connected" to either transformer. Each
transformer shall also be able to carry the total load of the load center that would be
expected to be operating during peak flow conditions without exceeding the
transformer's overload rating, assuming that one transformer has failed.
Voltage Drop
Prepare steady-state voltage drop calculations for all heavily loaded and/or long
branch circuits and feeders using the attached "Voltage Drop Calculation Data."
Base calculations for motor circuits on an 80 percent power factor. Motor starting
voltage drop calculations shall be shown for all motors that exceed 20 percent of the
rating of the serving transformer.
Steady state voltage drop shall be limited to the values listed in the Design Criteria
with not more than 2 percent drop on feeder. Motor starting voltage drop shall be
limited to 20 percent.
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Appendix C
Branch Circuits
Connected load and NEC requirements shall be used for sizing branch circuit
breakers and conductors.
A minimum wire size of No. 12 AWG copper shall be used for lighting and receptacle
branch circuits. No. 10 AWG shall be used where the first convenience receptacle is
more than 75 feet from the panelboard.
In general, 120 volt lighting branch circuit load shall be used for up to 1800
voltamps.
120 volt lighting loads shall be connected to circuits separate from receptacles
except in storage rooms where the lights may be connected to receptacle circuits or
vice versa.
Branch circuit shall be limited to five duplex receptacles in process areas and six
duplex receptacles in office areas. Special areas may require further reduction in
number of receptacles per circuit.
Conduit Size
Calculations shall be included for sizing of all conduits that are not covered by the
table of conduit sizes included hereinafter. Conduit fill shall not exceed that allowed
by the NEC when all conductors, including the ground conductor, are included in the
calculation assuming that ground conductors have TW insulation and phase
conductors have THW insulation.
Power Factor Correction
Calculations shall be made for the sizing of all power correction capacitors. The
calculations shall include a statement showing all assumptions that are made to
make the calculation. If tables are used, a copy of the table used with appropriate
values marked, shall be included in the calculation section of the notebook.
Lighting
Calculations may be in any form. For small areas, a statement that "so many" lights
of "such" a size will do the job, and is all that is required. For larger areas, use the
"Zonal Cavity Calculations" form attached. The foot-candle level resulting from the
actual fixtures to be installed shall be documented.
Fault Study and Coordination
This should take into account future loads and changed conditions. Presume the
utility is an infinite bus unless better information can be obtained.
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Appendix D
ENCLOSURE TYPES
NEMA Type 1, General Purpose. Enclosures intended for indoor use primarily to
provide a degree of protection against limited amounts of falling dirt.
NEMA Type 2, Dripproof. Enclosures intended for indoor use primarily to provide a
degree of protection against limited amounts of failing water and dirt. Enclosures have
provisions for drainage. If provision is made for the entrance of conduit at the top, it
consists of a conduit hub or equivalent.
NEMA Type 3, Dusttight, Raintight, and Sleet- (Ice-) Resistant. Enclosures intended for
outdoor use primarily to provide a degree of protection against rain, sleet, windblown
dust and damage from external ice formation. Enclosures have conduit hubs or
equivalent provision for watertight connection at the conduit entrance.
NEMA Type 3R, Rainproof and Sleet- (Ice-) Resistant. Enclosures intended for outdoor
use primarily to provide a degree of protection against rain, sleet, and damage from
external ice formation.
NEMA Type 3S, Dusttight, Raintight, and Sleetproof (Iceproof) Enclosures intended for
outdoor use primarily to provide a degree of protection against rain, sleet, windblown
dust and to provide for operation of external mechanisms when ice laden. Enclosures
have conduit hubs or equivalent provision for watertight connection at the conduit
entrance, mounting means external to the equipment cavity, and provision for locking.
NEMA Type 4, Watertight, Dusttight, and Sleet-Resistant. Enclosures intended for
indoor or outdoor use primarily to provide a degree of protection against windblown dust
and rain, splashing water, hose-directed water and damage from external ice formation.
Enclosures have conduit hubs or equivalent provision for watertight connection at the
conduit entrance and mounting means external to the equipment cavity.
NEMA Type 4X, Watertight, Dusttight, Sleet- and Corrosion Resistant: Same provisions
as Type 4 enclosure, and in addition, are corrosion-resistant.
NEMA Type 6, Submersible, Watertight, Dusttight, and Sleet- (Ice-) Resistant.
Enclosures intended for indoor or outdoor use primarily to provide a degree of
protection against hose-directed water, and the entry of water during occasional
temporary submersion at a limited depth and damage from external ice formation.
Enclosures have conduit hubs or equivalent provision for watertight connection at the
conduit entrance and mounting means external to the equipment cavity.
NEMA Type 6P, Submersible, Watertight, Dusttight, and Sleet- (Ice-) Resistant. Same
provisions as Type 6 enclosure except for protection against entry of water during
prolonged submersion at a limited depth.
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Appendix D
ENCLOSURE TYPES
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Appendix E
OPEN MACHINE: ventilation openings permit passage of external cooling air over and
around the winding of the machine
DRIP-PROOF MACHINE: ventilation openings are so constructed that successful
operation is not interfered with when drops of liquid or solid particles strike or
enter the enclosure at any angle from 0 to 15 degrees downward from the
vertical.
SPLASH-PROOF MACHINE: ventilation openings are constructed so that successful
operation is not interfered with when drops of liquid or solid particles strike or
enter the enclosure at any angle not greater than 100 degrees downward from
the vertical.
SEMIGUARDED MACHINE: ventilation openings in the machine, usually in the top
half, are guarded as in the case of a "guarded machine," but the others are left
open.
GUARDED MACHINE: all openings giving direct access to live metal or rotating parts
are limited in size by structural parts or by screens, baffles, grilles, expanded
metal, or other means to prevent accidental contact with hazardous parts.
DRIP-PROOF GUARDED MACHINES: a drip-proof machine with guarded ventilation
openings.
OPEN EXTERNALLY VENTILATED MACHINE: ventilated by means of a separate
motor-driven blower mounted on the machine enclosure.
OPEN PIPE VENTILATED MACHINE: openings for the admission of the ventilation are
so arranged that inlet ducts or pipes can be connected to them. Machine shall
be self-ventilated or force-ventilated, external from and not a part of the
machine.
WEATHER PROTECTED MACHINE TYPE I: ventilation passages constructed so as to
minimize the entrance of rain, snow, and airborne particles.
WEATHER PROTECTED MACHINE TYPE II: ventilation passages at both intake and
discharge are arranged so that high velocity air and airborne particles blown
into the machine by storms or high winds can be discharged without entering
the internal ventilating passages.
TOTALLY ENCLOSED MACHINE: enclosed to prevent the free exchange of air
between the inside and outside of the enclosure but not sufficiently enclosed
to be termed airtight.
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Appendix E
ESD-106
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Appendix E
ESD-106
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Appendix F
The polyphase induction motor shall be of either the squirrel-cage or the wound-rotor
type. The squirrel-cage induction motor has been classified by National Electrical
Manufacturers Association (NEMA) Tests and Performance-AC (MG1-1987) according
to the following designs.
Design A. A Design A motor is a squirrel-cage motor designed to withstand full-voltage
starting and to develop locked-rotor torque. It has a breakdown torque as shown in
Table MG1-12-39. It has a locked-rotor current higher than the value shown in Table
MG1-12-35 and a slip at rated load of less than 5 percent.
Design A motors are usually used for applications where extremely high efficiency and
extremely high full-load speed are required. Therefore, Design A motors tend to be
special motors.
Design B. A Design B motor is a squirrel-cage induction motor designed to withstand
full-voltage starting, developing locked-rotor and breakdown torques adequate for
general application as specified in Tables MG1-12-38.1 and MG1-12-39, drawing
locked-rotor current not to exceed the values shown in Table MG1-12-35, and having a
slip at rated load of less than 5 percent. Motors with 10 and more poles may have a slip
slightly greater than 5 percent.
Design B motors are the standard general-purpose motors used where low locked-rotor
current and moderate locked-rotor torque are required along with high full-load speed
and efficiency.
Design C. A Design C motor is a squirrel-cage motor designed to withstand full-voltage
starting, developing locked-rotor torque for special high-torque applications up to the
values shown in Table MG1-12-38.2, breakdown torque up to the values shown in Table
MG1-12-39.2, with locked-rotor current not to exceed the values shown in Table
MG1-12-35, and having a slip at rated load of less than 5 percent.
Design D. A Design D motor is a squirrel-cage motor designed to withstand full-voltage
starting, developing high locked-rotor torque as shown in Table MG1-12-38.2, with
locked-rotor current not greater than that shown in Table MG1-12-35, and having a slip
at rated load of 5 percent or more.
Design F. A Design F motor is a squirrel-cage motor designed to withstand full-voltage
starting, developing low locked-rotor torque as shown in Table MG1-12-38.1 with
breakdown torque as shown in Table MG1-12-38.2, with locked-rotor current not to
exceed the values shown in Table MG1-12-35, and having a slip at rated load of less
than 5 percent.
ESD-106
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Appendix F
The following figure shows typical speed-torque curves of NEMA design-class squirrel
cage motors.
ESD-106
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Appendix G
ESD-106
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Appendix H
1.
b. IP-1 A
2.
b. 1P1-1 A
3.
ESD-106
H-1
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Appendix H
4.
b. 1C1-1 A
5.
b. PS500 C A
ESD-106
c. LI302C-1
d. LI302C-1 A
H-2
01/06
Appendix H
6.
b. I-PS500 A
c. I-LI302-1
d. I-LI302-1 A
ESD-106
H-3
01/06
Appendix H
Figure H-1.
ESD-106
H-4
01/06
Appendix H
Figure H-2.
ESD-106
H-5
01/06
Appendix H
ELECTRICAL BRANCH
HYDRO PLANT DESIGN SECTION
STANDARD SPECIFICATION
FOR THE IDENTIFICATION OF
ELECTRICAL CURRENT
1.0
2.00
DEFINITIONS:
Cable: A current carrying conductor/ conductors enclosed in an insulating
sheath and bound by an outer jacket of insulating material.
Conductor:
A single current carrying material enclosed by an insulating jacket.
3.0.
INSTALLATION REQUIREMENTS:
3.10
3.20
ESD-106
SCOPE:
This standard provides the means of identifying electrical current
Carrying conductors on single line diagrams, wiring diagrams, wire lists.
Instrument loop diagrams, and internal/external panel diagrams. Also
provided is the installation requirements for cable identification tags.
3.21
EXCEPTIONS:
I. where taping or shielding is required the tag shall be placed as close
to the termination point as physically possible.
3.30
3.31
3.32
BACKGROUND
COLOR
TABLE - A
CHARACTER
COLOR
RED
ORANGE
BLUE
BLACK
BROWN
GREEN
WHITE
BLACK
WHITE
WHITE
WHITE
WHITE
H-6
VOLTAGE LEVEL
12KV AND UP
4.16KV
480V
240V
120V
SIGNAL
01/06
Appendix H
4.0.0
IDENTIFICATION REQUIREMENTS:
4.1.0
4.1.1
4.2.0
4.2.1
4.2.2
EQUIPMENT NUMBER
The equipment number or letter identifies a particular piece of
equipment that is related to the associated plant system.
4.2.3
X XX X X X
CABLE TAG NUMBER 00 THROUGH 99
EQUIPMENT NUMBER
ASSOCIATED PLANT SYSTEM
UNIT OR EXPANSION NUMBER
Figure H-2.
ESD-106
Cable Identification
H-7
01/06
Appendix H
ESD-106
Figure H-3.
Figure H-4.
H-8
01/06
Appendix H
ELECTRICAL SYSTEMS
AD
ALUM DISTRIBUTION
SS
STATION SERVICE
BD
BASIN DEWATERING
US
UNIT SUBSTATION
BP
BACKWASH POLYMER
MC
CI
CHEMICAL INJECTION
ST
STATION TRANSFER
CD
CHLORINE DISTRIBUTION
UT
UNIT SUB-STATION
DP
DRY POLYMER
MT
MCC TRANSFORMER
EQ
L1
LIGHTING PANEL 1
FA
D1
DISTRIBUTION PANEL 1
FB
FLOCCULATION BASINS
FD
FLOOR DRAINS
FI
FILTER OPERATION
FO
FOAM ABATEMENT
FL
FLOCCULENT AID
DISTRIBUTION
FW
GW
GRAY WATER
IW
INDUSTRIAL WATER
IQ
PA
PLANT AIR
PI
PLANT INFLUENT
SD
SUBDRAINS
SP
SPARGER PUMPS
SW
SURFACE WASHWATER
TB
TRAVELING BRIDGE
WP
WS
WATER SAMPLING
WW
WASHWATER
ESD-106
H-9
01/06
Appendix H
XXXXXX
1MH123
TYPICAL MANHOLE IDENTIFICATION
1MHH123
TYPICAL PULLBOX IDENTIFICATION
1PB123
TYPICAL JUNCTION BOX IDENTIFICATION
1JB123
TYPICAL TERMINATION BOX IDENTIFICATION
1TB123
Figure H-5.
ESD-106
H-10
01/06
Appendix H
X X X X X X
COLUMNS 01 TO 99
01
02
03
04
05
1
1A1101
2
1A1201
ROWS
1 TO 9
3
1A1301
4
1A1401
5
1A1501 1A1502 1A1503 1A1504
1A1505
H-11
01/06