Professional Documents
Culture Documents
OISD - RP - 149
First Edition
February, 1996
Amended Edition, September
2001
FOR RESTRICTED
CIRCULATION ONLY
Prepared by:
COMMITTEE ON “DESIGN ASPECTS FOR ELECTRICAL SAFETY”
Though every effort has been made to assure the accuracy and
reliability of the data contained in these documents, OISD hereby
expressly disclaims any liability or responsibility for loss or damage
resulting from their use.
Oil Industry in India is nearly 100 years old. Due to various collaboration
agreements a variety of international codes, standards and practices are in vogue,
Standardisation in design philosophies, operating and maintenance practices at a national
level was hardly in existence. This lack of uniformity coupled with feedback from some
serious accidents that occurred in the recent past in India and abroad, emphasised the
need for the industry to review the existing state of art in designing, operating and
maintaining oil and gas installations.
With this in view, the Ministry of Petroleum and Natural Gas in 1986 constituted a
Safety Council assisted by the Oil Industry Safety Directorate (OISD) staffed from within
the industry in formulating and implementing a series of self-regulatory measures aimed
at removing obsolescence, standardising and upgrading the existing standards to ensure
safer operations. Accordingly OISD constituted a number of functional committees
comprising of experts nominated from the industry to draw up standards and guidelines
on various subjects.
The present document on “Design Aspects for Safety in Electrical System” was
prepared by the Functional committee on “Design Aspects for Electrical Safety”. This
document is based on the accumulated knowledge and experience of industry members
and the various national and international codes and practices.
Suggestions are invited from the users after it is put into practice to improve the
document further. Suggestions for amendments, if any, to this standard should be
addressed to :
The Co-ordinator
Committee on “Design Aspects for Electrical Safety”
OIL INDUSTRY SAFETY DIRECTORATE
th
7 Floor, ‘New Delhi House’
27, Barakhamba Road
New Delhi – 110 001
MEMBERS
MEMBER CO-ORDINATORS
CONTENTS
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SECTION DESCRIPTION PAGE NO.
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1.0 INTRODUCTION
2.0 SCOPE
3.0 DEFINITIONS
7.1 Characteristics
7.2.1 Transformers
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SECTION DESCRIPTION PAGE NO.
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7.2.9 Cables
12.6 Vehicles
13.0 REFERENCES
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DESIGN ASPECTS FOR SAFETY IN ELECTRICAL SYSTEM
Following the guidelines and adhering to The final conductor by which the
the safe practices given in this standard, connection to the earth electrode is made.
would ensure adequate levels of safety in
the electrical facilities of Oil Industry. v) Voltage, Low - (LV)
xxxix) Sand-filled apparatus (Ex-q) (Ref : IS : The certificate will normally describe
7724)- the techniques and conditions of use.
ii) The neutral earthing system employs one 4.3 Short Circuit Capacities
of the following methods:
i) Each short-circuit interrupting device shall
a) Solid earthing for low, medium voltage have fault duty higher than the maximum
system (upto 650V) and for high value of short circuit current calculated at its
voltage above 11 K.V. location. The related switchgear and bus
ducts shall withstand the above maximum
b) Resistance earthing for 3.3 KV to 11KV fault current (mechanical and thermal
system. stresses) for a minimum duration of one
second.)
iii) The values of neutral earthing resistors
normally applied in industrial power system ii) The sizing of high voltage cables shall be
are selected to meet the governing criteria based on the short circuit withstand
for limiting transient over-voltages, i.e. capacity for a minimum time period as
earth fault current should not be less than dictated by the protection system in addition
the system charging current. Besides, the to the maximum anticipated load current
value of neutral earthing resistor selected carrying capacity.
shall limit the earth fault current to a value,
which shall be sufficient for selective and iii) It is to be noted that in the case of
reliable operation of earth fault protection generators, whose excitation power is
system. terminal dependent, short circuit in the
system will result in drop of the terminal
However, where an earthing transformer is voltage and consequently the over-current
used for obtaining the system neutral, the protective devices may not get adequate
zero sequence reactance limit (i.e. RO > 2 current for operation. To avoid such a
X0) should also be considered. (R0 - zero situation, necessary excitation support shall
sequence resistance of the circuit be provided unless & otherwise required.
including neutral resistor and X0 zero
sequence inductive reactance of the iv) While sizing, the system necessary
circuit). consideration shall be given to restrict the
system voltage drop within permissible
iv) The neutral earthing resistor shall be able to limits during starting of large rated motor
carry at least 10% of its rated current or group of motors. At the same time, the
continuously, unless otherwise required, short circuit current shall be kept within
and full rated current (100%) for a minimum limits keeping in view of the market
duration of 10 seconds. availability of switchgears. Reduced
voltage starting (soft start feature) for
4.2.2 Unearthed System motors may be considered as per system
requirements.
i) It is recommended that use of unearthed
system may be avoided since arcing ground 4.4 Insulation coordination
faults can result in severe over voltages.
i) The insulation of electrical facilities shall
ii) Where unavoidable (such as expansion be designed considering the system
projects where existing systems have voltage, the system neutral earthing, and
unearthed system) unearthed system shall the over-voltages resulting due to system
have provision for detecting earth fault and fault, switching or lightning surges. The
for isolation of faulty section through the insulation co-ordination between the
use of core balance current transformers. electrical equipment and the protective
The current transformers (CTS) shall be devices shall be done in line with IS: 3716
sized in relation to the system capacitive and IS: 2165.
earthed, restricted earth fault protection
ii) Insulation coordination is a correlation of may be provided for transformer
insulation of equipment and circuit with the secondary.
characteristic of protective devices such
that the insulation is protected from over iv) Particular care should be taken in the
voltages. selection of protective devices for
machines and equipment operating in
iii) The rated insulation level of Switchgears hazardous areas, so as to isolate the faulty
shall refer to the power frequency section in the shortest time possible. For
withstand voltage and impulse voltage high voltage system, protective relays shall
withstand values which characterise the be used. For medium voltage systems,
insulation. In respect of systems with direct acting releases and/or protective
nominal voltage of 132 KV and above, full relays may be employed.
insulation values shall be considered for
non-effectively earthed system, and In general, quick acting relays (with time
reduced insulation values may be used for delays if necessary) shall be used and all
effectively earthed system. fault tripping shall be done through high
speed tripping relays.
4.5 Protection and Metering
v) The supply of Energy to every electrical
i) The protective system shall be selected installation other than low voltage
and coordinated to ensure the following: installations below 5 KW and those low
voltage installations which do not attract
a. Protection of equipment against damage provisions of Section 30 of the Indian
which can occur due to internal or Electricity Act, 1910, shall be controlled by
external short circuits, overloading, an earth leakage protective device so as to
abnormal operating conditions, disconnect the supply instantly on the
switching, lightning surges, etc. occurrence of earth fault or leakage of
current (IE Rule 61A).
b. The continuity of operation of those parts
of the system not affected by the fault, is Provided that the above shall not apply to
maintained. overhead supply lines having protective
devices which are effectively bonded to the
c. Personnel and plant safety. neutral of supply transformers and
conforming to Rule 91 of I.E. Rules, 1956.
ii) Accordingly, relays and protective devices
shall be suitably selected and coordinated. vi) Metering instruments shall be provided on
As a minimum, differential protection shall plant Main Switch Board to monitor the
be provided for the following: power consumption and supervision of all
concerned parameters like current,
a. Transformers rated 5 MVA and above, voltage, power, frequency, power factor
etc. Ammeters in the field for monitoring
b. Induction and synchronous motors motor current may be provided as per
rated 1500 KW and above, process requirements. Metering and
protection current transformers shall be
c. Generators rated 2 MVA and above. preferably kept separate. In the case of
contactor controlled feeders having long
d. Bus differential shall be provided for all length of control cables (more than 800
H.T. switchgear having direct Mts. or so) due consideration shall be
connection with the inplant generators given to the effect of capacitance on
and other vital H.T. switchgear. ON/OFF operations of contactor.
iii) Longitudinal differential protection shall be vii) Recommended relay protections for
provided for important plant feeders in Transformers, motors and feeders which
general, and plant feeders connected to a are generally encountered in distributing
captive power plant bus in particular. network are given below :
Wherever the system is resistance
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RELAY TRANSFORMER MOTOR OUTGOING INCOMER
REF :ANSI/IEEE POWER DIST HV HV MVPCCC HV MVPCC
(IEEC 37.2)
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A. 51 IDMTL O.C. YES YES - YES YES YES YES
(4) (4)
- Unbalanced loading protection (46) vi) Each element of basic capacitor unit
may have its own built in fuse, which
(Negative sequence current protection) shall isolate the faulty capacitor.
- Stator winding temperature protection The capacitor bank feeders shall generally
(49 T) be tripped on bus under/over voltage
conditions and necessary interlock shall be
- Under frequency protection (81) provided for re-switching to take care of
capacitor residual voltage.
When generator with unit transformers
is employed besides individual M.V capacitors of smaller ratings may be
equipment protection, the following controlled with switch fuse units.
additional protections are
recommended: The continuous current rating of fuses and
switching devices for capacitors should be
i) Transformer over fluxing protection 30% higher than the normal full load
current.
4.6 Emergency Power Supply continuity of supply to critical loads (e.g.
process control, communication, fire alarm
i) This is an independent back-up source of systems etc.) in the event of
electric energy that upon failure or outage normal/emergency supply failure.
of normal source, automatically provides
reliable electric power within specified time 4.7.1 Un-interrupted Power Supply (UPS)
to critical devices and equipment whose
failure to operate satisfactorily may i) An un-interrupted power supply shall be
jeopardise the health and safety of provided, as required for meeting critical
personnel or result in damage to property. loads that cannot withstand a momentary
interruption/other A.C. mains disturbance
ii) The emergency power supply system shall in supply voltage. A separate battery shall
feed the following loads to enable be provided for UPS system.
continuity of supply in the event of failure
of MAIN SUPPLY. ii) Following loads shall be connected to the
UPS system:
- Electrical loads essential for the
safe shutdown of the plant. - Critical instrumentation and process
control,
- Emergency lighting, security
lighting, obstruction lights. - Critical communication equipment,
- D.C. Supply system, UPS system iii) In case of total power failure, un-
interrupted power supply shall be available
- Auxiliaries of emergency set as for at least 30 minutes or as determined by
applicable the process considerations.
- Fire fighting equipment excluding iv) Each branch circuit of the UPS distribution
main fire water pumps system shall have a fused disconnect
switch. The fuse shall be fast clearing type
- Essential ventilation loads, and and the fuse rating shall be coordinated
with the rating of the UPS system.
- Loads critical for process, plant and
personnel safety. 4.7.2 DC Power Supply
iv) It is recommended that D.C. supply for a) Area classification, i.e. Zone 0, 1 or 2
electrical controls, instrumentation, UPS
etc. shall have separate independent b) Gas group classification, i.e. the gas
battery banks. group.
If these parts are moving elements, ii) Transformers connected to Grid supply
then these shall be greased. may have ON LOAD TAP CHANGERS for
inplant control of secondary voltage. Plant
vii) Prevention of Harmful effects distribution transformers may have OFF
CIRCUIT TAP changers.
trucks of the same rating shall be
iii) In addition to standard accessories, the interchangeable.
transformer shall be provided with auxiliary
devices/protective devices such as vi) Suitable interlocks shall be provided to
Buchholz relay, oil level and oil temp. prevent faulty operation such as:
indicator with alarm trip output contacts
and current transformers for the secondary - ‘Pluging in’ or ‘drawing out’ of a closed
side neutral for Protection. Transformers breaker.
of rating above 2000 KVA may be
preferably have winding temperature - ‘Pluging in’ a breaker with earthing
indicators with Alarm/Trip provisions. isolator closed.
7.2.2 High Voltage (H.V)/Medium Voltage - ‘Closing’ of earthing isolator with the
(M.V) Switchboards breaker ‘Plugged in’.
i) These shall be designed to ensure - Pulling out of auxiliary circuit plug with
maximum safety during operation, breaker in service position.
inspection, connection of cables and
maintenance with Switchboards energised. - Pushing in breaker to service position
with auxiliary circuit plug not in
ii) The switchboard shall be totally enclosed, position.
dust and vermin proof.
- Opening of compartment door with
iii) Each unit of the switchgear shall have isolating switch in ON position and
necessary internal sheet metal barrier to vice-versa for Motor Control Centres.
form separate compartments for buses
instruments/relays/cable connections etc. The maximum height of operating
Compartment for cable connection shall handle/switches shall not exceed 1800
allow cable pulling, termination and mm and the minimum height not below
connection work with switchgear 300 mm.
energised. Suitable arc propagation
barriers shall also be provided. - It shall not be possible to operate the
Independent pressure release flaps shall circuit-breaker unless it is fully in
preferably be provided for each different service or Test or isolated position.
compartment of H.V. Switchboards.
Terminal strip for outgoing control cable vii) Suitable eye bolts for lifting of panels shall
connections should be accessible to be provided. On removing the eye bolts,
facilitate working and testing with breaker no holes offering access to panel shall be
in test/service condition and while the permitted.
switchboard is energised.
viii) Different sections, viz. busbar,
iv) Barriers shall be provided to permit switchgear, cable, relays and meters etc.
personnel to work safely within an empty shall be compartmentalised. Busbars and
compartment with the bus bars energised. supports shall withstand specified short
The minimum clearance and creepage circuit level without permanent
distance of bus bars shall conform to IS deformation. Busbars shall be preferably
4237. sleeved and joints shall be
taped/shrouded. Minimum clearances
v) The drawout carriage on the switchboard between live parts, between live parts to
shall have three positions viz., ‘Service’, Earth and Neutral shall conform to
‘Test’ and ‘drawn out’. Automatic safety applicable IS code (IS 4237)
shutters shall be provided to ensure the Switchboards shall have additional safety
inaccessibility of all live parts after the features such as falling tool shrouds for
breaker is drawn out. It shall not be trapping of free fall of maintenance tools
possible to drawout the carriage or rack it on live parts. Busbar supports shall be of
in with circuit breaker closed. The synthetic material with high tracking
breaker/contractor feeder trolley shall index. The switchboard shall have earth
remain inside the cubicle even in the test busbar of adequate size. The switchgear
position. There shall be distinct overall drawout trolley (in case of drawout
door for the breaker compartment and it design) shall have suitable scraping earth
should be lockable. All circuit breaker connection. Feeder tag plates shall be
provided at both front and rear side of suitable for starting under specified load
panels. Where required, busbar routing conditions with 75% of the rated voltage at
shall be clearly marked on the back side the terminals.
of the H.V. Switch board panels for easy
identification during maintenance. iv) The permissible noise level shall not
exceed the stipulations laid down in IEC 34-
ix) All non-current carry metallic parts of 9.
mounted equipment/components shall be
bonded to the earth bus. v) Motor vibrations shall be within the limits of
IS-4729 unless otherwise specified for the
x) Surge absorbers to limit the switching driven equipment. Motors with sleeve
surges shall be provided as dictated by bearings may require proximity probes to
the type of arc quenching media and measure shaft vibration adjacent & relative
switching device. to the bearings.
xi) Starting of motors from substation shall i) Motors shall be required for continuous,
not be allowed and switch boards shall satisfactory operation at rated output under
not have close push button at the following conditions :
switchboard for motor starting.
a) The terminal voltage differing from its
xii) In specific cases, motors requiring rated value by not more than ± 6%.
frequent start/stop, (e.g. product, loading
pumps etc.) shall be controlled by b) The frequency differing from its rated
contractor feeder appropriate to its rating. value by not more than ± 3%
xiii) Switch Boards shall have anti c) Any combination of (a) and (b).
condensation heaters.
vii) Motor ratings and torque characteristics
7.2.3 MOTORS HIGH VOLTAGE (H.V.) shall be adequate to accelerate the load
from zero to rated speed under starting
& MEDIUM VOLTAGE (M.V)
requirements as stipulated by process
operating conditions. Normally, the starting
7.2.3.1 General
time shall be less than the hot withstand
time of the motor.
(1) Motors shall be totally enclosed,
fan cooled type as far as
viii) M.V. Motors in general and H.V. Motors
practicable. As a minimum, all
where required shall be suitable for
H.V. motors shall have anti
restarting under full load after a
condensation heaters. The
momentary loss of voltage with the
minimum degree of enclosure
possibility of application of 100 percent of
protection for motor shall be
the rated voltage, when the residual
preferably IP 44 for indoor use and
voltage has dropped down to 50 percent
IP 55 for outdoor duty motors.
and is in phase opposition to the applied
voltage.
ii) Generally Motors upto and including 160
KW shall be rated for medium voltage and
ix) Motor bearings shall be selected to give a
motors of rating above 160 kw shall be
minimum L-10 life rating of 5 years (40,000
rated for high voltage. If required, the rating
hours) at rated operating condition (the L-
of medium voltage motors may be extended
10 rating life is the number of hours at
upto and including 200 KW. Sleeve or anti
constant speed that 90% of a group of
friction type bearings shall be used. Vertical
identical bearings will complete or exceed
motors shall have thrust bearings suitable
before the first evidence of failure). The
for the load imposed by the driven
bearings shall be adequate to absorb axial
machinery. Unless otherwise specified, all
thrust in either direction produced by the
motors shall be designed for ‘Direct ON
motor itself or due to shaft expansion. On
line’ starting.
line greasing facility should be provided on
motor for all grease lubricated bearings
iii) High voltage motors shall be suitable for
(anti friction bearings). Wherever
starting under specified load conditions with
spaceheaters are provided for motors, a
80% of the rated voltage at the terminals
separate terminal box should be provided
and medium voltage motors shall be
for termination of spaceheater cables, as
far as practicable. Polarisation index of H.V. stator winding
shall have a value of at least 2. If the
7.2.3.2 H. V. Motors insulation value of the motor exceeds a
value of 120 (Un+1) (where Un is rated line
i) Winding insulation shall be class F and - line voltage (KV) mega ohm, a minimum
temperature rise limited to that specified in polarisation index of 1.5 is acceptable.
the applicable IS for class B insulation.
7.2.3.3 M. V. Motors
ii) Motors shall be designed to allow minimum
number of consecutive hot starts as i) Motors shall be designed to allow three
dictated by process operating requirements. consecutive starts from cold condition, two
Number of uniformly spaced startups in an consecutive starts from hot condition and
hour shall be a minimum of three. four uniformly distributed starts in one hour.
iii) The main power Terminal Box shall be ii) Motors shall be provided with minimum
phase segregated and suitable to withstand class ‘B’ insulation or class ‘F’ insulation
the specified fault level for a minimum may be considered for special applications
duration of 0.2 sec. (Commensurate with and permissible temperature rise above the
instantaneous short circuit protection). specified ambient temperature shall be
Winding ends shall be preferably brought limited to the values applicable for class ‘B’
out and star point made in a separate insulation. The windings shall be
terminal box. Neutral terminal box shall tropicalised and adequately braced. The
have necessary space provision to mount ends of the windings shall be brought out in
differential CTs for motors of rating 1500 a terminal box with six terminals with
KW & above. suitable links to connect them in Delta.
However, motors rated upto 2.2 KW may be
iv) Motors of rating above 1000 kw shall be connected in star with three terminals.
provided with RTDs, BTDs. Separate
terminal boxes shall be provided for space iii) The terminal box of motor controlled by air
heater and RTDs, BTDs. circuit breaker shall be capable of
withstanding the full internal short circuit
v) Induced voltage at the shaft of the motor conditions, with the specified system fault
having uninsulated bearing system shall not level for a minimum duration of 0.2 second
exceed 250 mV r.m.s. for roller and ball (Commensurate with instantaneous short
bearings and 400 mV r.m.s. for sleeve circuit protection). Where motor control is
bearings with the motor running at no load. through contactor and MCCB, or back up
Alternatively, the non driving end bearing fuse, the terminal box shall be able to
shall be insulated from the motor frame to withstand the let-through energy of
avoid circulating current. protective devices corresponding to
maximum system fault level.
vi) The insulated bearing end shield or
pedestal shall bear a prominent warning iv) The terminal box shall be of sturdy
and manufacturer shall provide detailed construction and large enough to facilitate
drawing showing insulation arrangement. easy connection of required number of
cable runs and size. (specifically Aluminium
vii) Motors shall be designed to withstand Conductor Cables). Additional trifurcating
impulse voltage of at least (4Un+5) KV with boxes may be considered for motors
a wave front raise time of 1.2 microsecond requiring termination of two or more parallel
and decay time of 50 microsecond to half runs of power cables.
the peak voltage.
7.2.4 Battery Charger and D.C.
viii)The interturn insulation of H.V. motors shall Distribution Board
be able to withstand a peak voltage of at
least 0.5 (4Un+5) KV with a wave front rise Charger and D.B. shall be floor mounted,
time between 0.5 & 1.5 microsecond and a free standing, metal enclosed and vermin
decay time to half the peak voltage of proof type having front access hinged door
between 3 & 10 (microsecond). and suitable for indoor use.
Un = rated line to line voltage.
This shall consist of battery
ix) Polarisation index charger/rectifier, which shall feed the load
and keep the batteries under fully charged be instantaneously transferred to the by-
condition. Provision shall also be made for pass line through the static switch. Normally
necessary boost charging/initial charging of the inverter shall be operated in
battery. synchronised mode with the by-pass line,
and manual forward transfer or manual
7.2.5 Batteries and Battery Accessories reverse transfer shall be effected without
any break.
i) This shall be indoor stationary type (lead
acid/Ni-Cd etc.) with adequate capacity to Automatic forward transfer, in case of
meet the backup requirements as inverter malfunction, shall be effected with a
envisaged in the duty cycle. Accessories break not exceeding 5 ms.
shall generally be as follows :
7.2.7 Capacitor Banks
- Battery stand made of treated first
class teakwood assembled without the i) The capacitor shall conform to IS 2834
use of any metal fastenings.
- specifications for shunt capacitor for power
- Intercell, inter ro and inter bank system.
connectors and end take offs.
ii) H. V. capacitor shall comprise appropriate
- Porcelain cell insulators, stand nos. of basic single phase units (minimum 4
insulators. nos. basic units in parallel per phase) which
shall be connected in star formation.
- Hydrometers suitable for specific
gravity readings. iii) Capacitor banks shall be with necessary
ii) Under normal conditions, the rectifier-cum- v) Necessary series reactor to limit in rush
charger shall feed the inverter and charge current and suppress harmonics (where
the battery set. In case of mains failure, the required)
battery shall supply the necessary power to
the inverter. The inverter in turn feeds the vi) The impregnant in the capacitors shall be
load through the static switch. If the inverter non-toxic.
malfunctions or is overloaded, the load shall
7.2.8 Emergency Generator
i) In order to avoid spread of fire due to
i) The emergency generating sets shall form cables, it is recommended that the outer
a complete package and shall be designed PVC sheath of all cables used in industry
to start automatically on power failure and shall be flame retardant type conforming to
feed the selected loads. It shall be capable category AF as per IS: 10810. The cable
of taking care of the load variations (e.g. the shall have a low smoke property. The
Note 3
starting of largest rated motors on a minimum Oxygen Index shall be 29 .
preloaded system). The unit shall be
complete with necessary starting ii) High voltage cables may be
equipment, associated control panel and Aluminium/Copper Conductor XLPE
shall be suitable for remote starting. insulated PVC sheathed, armored type.
ii) The regulation of generator voltage shall be The conductor screen, XLPE insulation
automatic and necessary instruments for screen shall all be extruded in one
metering viz. Ammeter, Voltmeter, operation by ‘Triple Extrusion’ process.
Frequency meter, KWH meter, Power
Factor, Hour run counter etc. shall be iii) 1.1 K.V. grade cables may be
included in control panel. Aluminium/Copper Conductor PVC
insulated, PVC sheathed, armored type.
iii) Warning of abnormal conditions shall be
incorporated prior to automatic trip to iv) All power and control cables shall preferably
prevent unnecessary shutdown. have extruded inner and outer sheaths.
All the six stator winding ends shall be v) Where single core cables are armored and
brought out to an externally mounted are meant for use on A.C circuits,
terminal box and shall be connected in star. armouring with non-magnetic material (e.g.
Necessary temperature detectors shall be Aluminium) shall be given.
provided for the stator winding. The terminal
box shall have sufficient space to receive The communication cables shall conform to
the cables of specified size. ITD specification. For fire alarm systems,
PVC insulated, armoured and overall PVC
iv) Emergency D.G. set shall have Auto sheathed cable with 1.5 mm2 copper
starting arrangement but only with manual conductors may be used.
switching off features. The rating (Ampere
Hours) of battery, for cranking the engine vi) The power and control cables shall have
shall be adequate to make three attempts the following minimum cross sectional
with an interval of 5 to 10 seconds, if areas :
required. In case the engine fails to start
2
‘FAIL TO START’ annunciation shall be a) Medium voltage 4mm
provided in substation or in control room. powercable Aluminium or
2
2.5 mm Copper
v) The generator set shall be provided with
2
complete protection against overloads, b) Control cables 2.5 mm (Copper)
short circuits, ground faults, excitation (See Note 1 below)
failure, prime mover failure and shall
include other connected instrumentation c) Lighting 2.5 mm2 (Copper)/
interlocks. 4mm2 (Aluminium)
(See Note 2 below).
vi) The load shall be switched on to the
generator only after the requisite voltage Note 1 In case of difficulty in connecting the
build-up. cables to instrument relay Annuciation
terminals, the minimum cross section
vii) Diesel Engine installation, do not call for may be reduced to 1.5 mm2 copper.
Area Classification, provided the D.G. room
is properly ventilated. Normally the Note 2 For lighting inside the building copper
ventilation provided to remove heat from the conductor cables shall be used.
radiator is adequate to take care of hazard Where conduit wiring is adopted,
aspect. minimum 1.5 mm2 copper conductor
PVC insulated wire may be used.
7.2.9 Cables
Note 3 Conductor size for wiring inside the - Start/stop push button/close, neutral,
panel for electronic Trip Switch
circuits/components shall be as per
manufacturer’s standard. - Ammeter,
ii) The control station enclosure shall have 7.2.12 Actuators for Motor Operated
suitable protection for site conditions such Valves
as flameproof, weather-proof, dust-proof,
corrosion resistant, etc.). i) Valves with electrical actuators shall
generally be provided with integral starters.
iii) The control station shall include the
following equipment as per individual ii) The necessary local/remote selector
requirements : switch, start/stop control switches or push
button, torque limit switches etc. shall be
provided on actuator for local/remote
control depending on mode of selection. In High voltage, medium voltage and other
case of failure of torque limit switches, the control cables shall be separated from each
mechanical design shall be adequate to other by required spacing or running
stall and trip the motor without damage. through independant pipes, trenches or
cable trays as applicable. Cable trenches
iii) The control circuits shall AC operated for inside substations shall be filled with sand,
short distance or DC operated for pebbles or similar non-flammable materials
extended distance. The actuator shall be or covered with incombustible slabs. If a
provided with an anti condensation heater. significant number of cables are taken on
racks/supports provided on the side wall of
8.0 Plant Cabling trench.
i) Cables below ground may be laid in iv) RCC covers of trenches shall be effectively
concrete trench/tunnel or directly buried. sealed to avoid ingress of chemicals and
Cables above ground shall be laid in cable oils.
trays/cable racks.
v) In unpaved areas, cables may be directly
However cabling for fire water system shall buried in ground. Where underground
as far as possible be taken in exclusive cables cross roadways or pipe sleepers at
route through underground trench. grade etc., they shall be protected by being
drawn through sleeves/ducts to provide a
ii) While designing layout with single core permanent crossing. Sleeves/ducts ends
cable installations following factors shall be shall be effectively sealed thereafter.
considered :
vi) Concrete lined trenches shall have suitable
a) Cables are laid as a general practice in drainage arrangement to avoid water
trefoil formation touching each other. collection. Concrete lined cable trenches
shall be sealed against ingress of liquid and
or gases wherever the trenches leave a
hazardous area or enter control room or
b) flat formation with spacing as per substation. Pipes laid for mechanical
requirement. protection shall be sealed at both ends.
- When cables are laid in a flat vii) Above ground cables shall be well
formation, the individual cable fixing supported suitably at every 2 to 2.5 metres
clamps, and spacers shall be of non interval and protected against mechanical
magnetic material. damage. Routing shall be decided to avoid
proximity to hot sources, place subject to
- As a general practice, the sheath of undue fire risk, gas, water, steam oil drains,
single core cables shall earthed to piping, air conditioning duct etc. Cable
keep sheath at earth potential. trays, racks and trenches shall sized to
However depending on the current allow for 10 to 20% future cables reserve.
the cable has to carry, the feeder Each cable tray tier shall accommodate the
length and permissible sheath cables preferably in single layer.
potential, various methods of sheath
bonding are employed, viz. single Instrument and communication cables shall
point bonding, bonding at middle, not be laid in the same trench/tray along
sectionalised bonding etc., for which with electrical cables. The overall cable
cable manufacturers layouts shall be designed for minimum
recommendations shall be followed. interference between signal and power
cables.
- It should be noted here that the
current rating of cables will vary viii) Cable cellars and important cable
depending upon laying formation, tunnels shall be provided with fire detection
method of sheath bonding etc., apart and monitoring devices.
from other derating factors normally
considered. (Ambient temp., depth ix) Trailing cables for equipment such as
of laying etc.) cranes and excavators shall have one
additional core for earthing and the cable
iii) All trenches shall be sized depending upon shall be well protected against mechanical
the number of cables, and its voltage grade. damage.
critical lighting will be either on 220V or
x) Cable straight through joints in power & 110V DC.
control cables shall be avoided as far as
possible. ii) Sufficient lighting shall be provided so as to
enable plant operators to move safely within
xi) Only type tested and approved make the accessible areas of plant and to perform
termination kits shall be used. While routine operations. In the event of normal
selecting the type of cable kit, necessary power failure, emergency lighting may be
consideration may be given to the additional provided.
safety measures needed for carrying out
termination with kits of type such as heat iii) Lighting requirements provided during the
shrinkable type (particularly in hazardous failure of power supply for Normal lighting
areas). are intended broadly,
xii) Cable route markers shall be installed at a. to facilitate carrying out of specified
every 30 metres intervals all along the cable operations, for safe shutdown of the
routes and also at cable joints and locations plant.
where the direction of cable trench
changes. Cable route markers shall extend b. to gain access and permit ready
600 mm above ground. identification of fire fighting facilities such
as fire water pumps, fire alarm stations
xiii) Cable installations shall provide for etc.
minimum cable bending redii as
recommended by manufacturer. c. Escape route for safe evacuation of
operating personnel.
xiv) Cable trenches in hazardous area
shall be filled with sand and covered with iv) The recommended areas for critical
RCC slabs to prevent accumulation of lighting (D.C.) include :
flammable gas/vapour inside the trench.
- Control rooms (Process & utility)
xv)Cables shall be identified close to their
termination point by cable tag numbers as - Main substations
per cable schedule. Cable tag numbers
shall be punched on aluminium strap 2mm - D. G. Shed
thick flat or circular, securely fastened to
the cable. - Central Fire Station
xvi) Besides each underground cable shall - Fire water pump house (for startup
be provided with identify tags of lead of Diesel driven F.W. pump)
securely fastened at every 30 metres of
underground length with at least one tag at - First Aid Centre
each end before the cable enters the
ground. - Emergency escape route
For further details, on installation practices v) The recommended areas for A.C.
and requirements refer OISD Standard 147 emergency lighting includes :
on ‘Inspection and Safe Practices during
Electrical Installations’. - Control rooms (Process & utility)
I) Near to areas where Spot ii) The earthing system envisages an earthing
specific safety operations lighting network with designed number of earth
(visual tasks are to be to be electrodes attached to it. The following shall
carried out (e.g. control provided be earthed :
room)
- System neutral,
ii) Escape Lighting
- Current and potential transformer
a. Escape way (interior) - 5 Lux secondary neutral
xii) The lighting fixtures on various circuits shall - Cable trays and racks, lighting mast and
be suitably interlaced so that failure of any poles.
one circuit do not result in complete
darkness. - Storage tanks, spheres, vessels, columns
and all other process equipments.
xiii)Taller structures shall have aviation
obstruction lighting as per statutory - Electrical equipment fencing (e.g.
regulations (D.G.C.A.). transformer, yard etc.)
xiv)Battery room shall have fixtures mounted - Cable shields and armour
on wall in order to facilitate easy
replacement of fused lamps. Switches - Flexible earth provision for Wagon,
controlling the lighting fixtures and exhaust Truck
fan shall be installed outside the battery
room. iii) Plant earthing design shall generally be
carried out in accordance with the
xv)Switches of lighting panels installed in requirements of Indian Electricity Rules and
hazardous area, shall have a pole to break code of practice for earthing IS 3043.
the neutral in addition to the poles for
phases. - As far as possible, all earth
connections shall be visible for inspection.
When the means of isolation is located in a
non-hazardous area, the switch shall break iv) All connections shall be carefully made and
all poles including neutral or alternatively adequately locked against loosening.
Normally earthing system shall comprise of
GI strip as main earth grid alongwith - For lightning protection, the value of
suitably located GI disconnecting plates to 5 ohms as earth resistance shall be
provide multiple earth connections between desirable, but in no case it shall be
earth grid and equipment and for more than 10 ohms.
connections between main earth grid and
electrodes. Alternatively, mild steel strip can xi) The main earthing network shall be used for
also be used for earth grid after providing earthing of equipment to protect against
corrosion allowance. static electricity.
viii) Equipment located remote from main Storage Tank (Vertical 40 X 5 Strip
earth network may be earthed by means of & Horizontal)
individual earth conductors and earth
electrodes. Loading Racks 40 X 5 Strip
ix) Lighting protection shall be provided for the Pipe racks, Vessels 10 mm (3/8") &
equipment, structures and buildings which Heat Exchanvers Wire Rope
are higher than 20 metres or as per the risk
index analysis worked out as per IS 2309. Small Equipment & No. 8 SWG Solid
Self-conducting structures do not require Instruments
lightning protection with aerial rod and down
conductors. They shall be connected to the Lighting, Power & 10 mm (3/8")
earthing system at two points of the base. Instrument Panels Wire Rope
An independent earthing network shall be
provided for lighting protection and this shall Main Earth Bus/LT & As
be bonded with the main earthing network HT SW. Gear Intercon- Calculated
below ground, minimum at two points. nections/Power Trans-
former
x) The resistance value of an earthing system
to the general mass of earth shall be as EHV & HV Sub-Stations As Calculated
follows :
Push Button Stations No. 8 SWG Solid
- For the electrical system and equipment, a Wire
value that ensures the operation of
the protective device in the electrical Street Light Poles 10 mm (3/8")
circuit but not in excess of 5 ohms. Wire Rope
However, for generating stations and
large sub-stations this value shall Lighting Transformer 16 mm (5/8")
not be more than 1 ohm. Wire Rope
----------------------------------------------------------- unmistakable way and indicate the
Note : Lighting fixtures shall be earthed location of fire and initiate operation of
through the extra core provided in the ancillary service such as fire extinguishing
lighting cable. system, etc;
xii) Earth rods and conductors shall be d) remain insensitive to phenomena other
designed to cope with the conditions than those which its function is to detect;
imposed. The earth conductor shall be and
adequately sized to carry the applicable
maximum earth fault current without e) signal immediately and clearly any
undue temperature rise. All joints shall supervised fault that might jeopardies the
be protected against corrosion. correct performance of the system. The
system shall also include a FIRE SIREN
xiii) All the electrical equipment operating of distinguished tone having a range of
above 250 volts shall have two separate about 8 kms. Audio/visual fire alarm may
and distinct connections to earth grid. be required at the following locations in a
large plant:
11.0 Plant Safety and Security systems
- Control room
This shall include the following systems: - Fire station
- First aid centre
11.1 Plant Fire Detection and Alarm System - Security office
- Fire water pump house
i) The purpose of a fire detection and alarm
system is to detect fire at the earliest and iv) Detailed design, selection and installation
to give an alarm so that appropriate of fire detection and alarm system shall
action can be taken (e.g. evacuation of be as per IS-2189.
personnel summoning the fire fighting
organisation, triggering of extinguishing 11.2 Communication system
process etc.). An alarm system may be
activated by automatic detection devices The plant communication system shall
viz. smoke detectors, heat detectors etc. include some or all of the following
or by manual operation of manual call facilities as per individual plant
points i.e. break glass units. requirements:
iii) A fire detection and alarm system shall: i) A private automatic branch exchange
(PABX) system shall be provided. Trunk
a) operate quickly enough to fulfil its lines connecting with the external telephone
intended functions; network shall be provided and number of
trunk lines shall be decided based on plant
b) reliably transmit the detection signal; size and requirement.
c) Translate this signal into a clear alarm ii) Selective telephone service control shall be
indication that will attract the attention of arranged for all the extensions of the PABX
the user in an immediate and
to have one or more of the following service ambient level for effective recognition of
functions: speaker’s voice signals.
- All phones shall have direct inter- Also the field stations shall be capable of
communication between all the extensions operating in areas of high noise levels
of this exchange and all the extensions without any interference.
shall be able to accept any external calls
handled by the exchange operators. 11.2.3 Emergency Communication System
- Non executive phones shall operate with i) The ‘Hot line system’ shall be designed to
operator assistance for connection to provide a dependable communication link
external lines for both local and long between predesignated points of operation.
distance telephone service. This system shall be completely isolated
from the telephone system.
- Executive phone service shall include direct
unassisted (operator bypass) ii) The emergency communication system
communication to external lines for both shall include a ‘Direct phone to phone hot
local and long distance telephone service. line (H.L.) system’ and a ‘Dedicated hot line
(D.H.L.) system’.
iii) In areas with high ambient noise levels,
intensified bell signals may be provided to iii) H. L. System
produce an effective recognition noise level
of 6db above anticipated ambient noise By removing phone from cradle switch, the
levels. corresponding phone at opposite end will
ring till answered or until the phone is
11.2.2 Public Address System returned back to cradle disengaging the
circuit switch.
i) A public address system shall be provided
for communication within the plant area and iv) D.H.L. System
it shall comprise master stations, central
cabinet/exchange equipment (field station A simplified selective dial scheme shall be
modules, amplifiers etc.), field stations, provided to give selective contact between
paging loudspeakers etc. The public all the extensions of this system. All the
address system shall provide, as a telephones used for the emergency
minimum, the following facilities: communication system shall be red in
colour and shall have ringing indication
a) Paging within the plant area over lights.
loudspeaker from the master station
located in process control room. 11.2.4. Radio Communication System
b) Call back from any of the field stations to Portable Walkie - Talkie system.
the master control station.
i) A walkie-talkie system shall be provided for
c) Communication or call from Master Control radio communication within the plant area.
Station to any of the field stations and The system shall operate in the simplex
communication between field stations at the mode on U.H.F. and the exact frequency
discretion of Master Station. shall be decided in consultation with P & T
authorities.
d) Communication between pre-designated
field stations as per process operating ii) The system shall consist of base station,
requirements without interference of the monitoring receivers, portable stations,
operator manning the master station. antennas and associated accessories.
Adequate number of hand stations shall be
e) Operating an alarm call from master control provided.
station over all the loud speakers during an
emergency. iii) The system shall enable communication
between portable station and the base
ii) Paging speakers provided in areas having station or between any of the two portable
high ambient noise levels shall produce a 6 stations. The system shall have a range of
dB paging noise level above anticipated approximately 6 km.
iv) The system shall provide excellent installed diesel engines in Zone-2 area
penetration in all operating areas of the should be avoided wherever possible.
plant with no marginal locations and extend
beyond the boundaries of the plant. The ii) In the event of use of a permanently
system shall operate above the man-made installed diesel engine, being necessary in
noise spectrum to provide clear noise free Zone-2 it is recommended that it should
communication in all areas of high electrical have the following minimum protection to
noise. ensure safety :
i) Hand lamps for use in hazardous area shall e) In order to contain discharge of sparks or
be flameproof with an operating voltage of flames from the exhaust system, a gas
24 V. The hand lamp shall be connected to conditioner box and a flame trap shall be
the source of supply by a flexible 3x1.5 sq. installed. Alternatively, the exhaust should
mm copper conductor PVC insulated metal be designed to discharge to a location
braided cable. within a safe area.
ii) The source of supply shall be located as g) The surface temperature of the engine and
near as possible to the points to be exhaust system shall not exceed 250°C
illuminated. Automatic protection employing when tested under full load conditions. In
earth leakage detection scheme (e.g. using some situations cooling of the exhaust
ELCB with current sensitivity of 30 mA) manifold and piping may be necessary,
shall be provided to disconnect supply on using water jacketing or finned coolers
occurrence of an earth fault. Hand lamps and/or high temperature cut/outs or alarms
with self contained batteries shall have type should be provided.
of protection appropriate to the applicable
hazardous zone. h) However when either the free movement of
air is restricted by thermal or acoustic
12.2 DIESEL ENGINES shielding or the ignition temperature of the
surrounding flammable atmosphere is
i) The use of permanently installed diesel below 200°C, no engine exposed surface
engines in Zone-0 and zone-1 areas is temperature shall exceed the minimum
unacceptable and the use of permanently ignition temperature of the gases involved.
i) To prevent overspeeding of the engine due 12.3 STORAGE BATTERIES
to induction of flammable gases or vapours,
means shall be provided to stop the engine. i) Storage batteries shall not be installed in
It can be either : Zone 1 locations, except those used in
portable lamps where the enclosure
i) a valve to close the air intake, or housing bulb, switch and battery shall be
ii) a system to inject carbon dioxide into flameproof type.
the air intake.
ii) As far as practicable use of storage
j) Alarms of automatic shutdown devices shall batteries in Zone 2 areas shall be avoided.
be provided, actioned by excessive water However where unavoidable, storage
temperature and low lube oil pressure. batteries for use in Zone 2 areas shall be
“Increased Safety” type. These shall meet
k) A system using an alarm or trip device to the following requirements :
protect the engine from excessive vibration
should be considered. a) Celluloid and similar combustibles shall not
be used as constructional materials.
l) An engine having a crank case volume of
over 0.5 m3 shall be provided with relief b) Battery containers as well as fittings and
devices. Relief valves or breathers on insulating parts outside the enclosed cells
engines shall be fitted with flame traps or shall not consist of porous materials e.g.
discharge into the induction system wood or other flammable materials and
downstream of the flame trap, if fitted and shall be resistant to flame and the action of
upstream of the shut-off valve, if fitted. electrolytes.
Dipsticks and/or filler caps should be
screwed or effectively secured by other c) Openings of cells necessary for the escape
means. of the gases given off shall be so
constructed as to prevent splashing of the
m) Intake and exhaust system design shall electrolyte.
meet the following minimum requirements:
d) The exterior of the cells shall be so
i) The length of the flame path through or constructed as to resist impact, and the cell
across any joint shall be not less than 13 cases shall be firmly fixed.
mm.
e) The cells shall be so built into the
ii) Suitable metal-clad or other acceptable containers that connection of the cells
jointing material shall be interposed getting loose in operation is improbable and
between all joint faces to ensure that normally, the discharge voltage exceeding
leakage does not occur. 24 volts should not appear between
adjacent rows of cells.
iii) Where valve spindles pass through the
walls of any component of the induction f) The creepage distance between two poles
system, the diametrical clearance shall not of adjacent cells shall not be less than 35
exceed 0.13 mm, unless end caps are mm. Where the discharge voltage exceeds
fitted. 24 volts, the creepage distance shall be
correspondingly increased by 1mm per 2
iv) No screw, stud or bolt-hole shall pass volts.
through the wall of any component of the
system. g) Where voltage of batteries is not less than
50 volts, either the battery case shall be
n) Decompression systems should not subdivided by partitions or the batteries
normally be provided. However, if they are shall be grouped into containers such that
essential, then the decompression parts in no grouping does a voltage exceeding 50
should be provided with flame traps and volts occur. In these cases, the partitions or
ducted away to safe area. the containers shall have heights of at least
half that of the battery case.
o) The fuel injection pump and governor
where fitted should be so designed that h) The battery case shall be so constructed as
reverse running of the engine is not to ensure sufficient ventilation in order to
possible. prevent accumulation of gases given off
from the battery, and the free space within f) All electrical circuits shall be cut off
the case shall be as small as possible. automatically in the event of :
i) The metallic cover of the battery case shall i) The current in any circuit exceeding
be lined with materials resistant to more than the rated value in any circuit.
electrolyte.
ii) A leakage current to earth/earth fault.
j) The cover of the battery case shall have
special fastenings. 12.6 VEHICLES
k) Exposed live parts of battery contained in a Commercial vehicles such as jeeps, trucks,
case shall be protected with rubber or cars etc. shall not be allowed inside
equivalent insulated materials. However, hazardous area unless these are
the openings for checking voltage may be specifically certified by competent authority
provided. for use hazardous areas.
c) Terminals shall be provided with rubber a) OISD - 147 “Inspection, and safe
covers. practices during Electrical Installation”.
d) Enclosure and other constructional features b) OISD - 116 - Fire Protection facilities
shall be suitable as per the area for petroleum refineries and oil/gas
requirement. processing plants.
a) The electrical equipment and the system as d) OISD - 118 Layout for Oil and Gas
a part of mobile equipment shall be of Installations
intrinsically safe/flame proof design, if
required to be taken in classified hazardous e) OISD - 113 ‘Electrical Area
areas. Classification’.
b) The mobile apparatus shall be used for f) OISD - 137 “Inspection of Electrical
temporary purpose only under competent Equipment”
supervision.
iii) Indian Electricity Act & Rules 1956 (Ministry
c) No uninsulated current carrying part shall of Irrigation & Power, Govt. of India)
be exposed.
iv) The Petroleum Rules 1976 (Ministry of
d) All components shall be accessible for Industry, Government of India)
maintenance/repairs.
v) Oil Mines Regulations
e) All remote control or interlock circuits
associated with restrained plug and socket vi) C.B.I.P. (Central Board of Irrigation &
coupling should be intrinsically safe. Power) Technical Report No. 3 ‘Manual on
Layout of Substations’.
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