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Design Aspects For Safety IN Electrical System: OISD-RP-149 For Restricted Circulation Only
Design Aspects For Safety IN Electrical System: OISD-RP-149 For Restricted Circulation Only
FOR RESTRICTED
CIRCULATION ONLY
No.
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
2nd Floor, “Kailash”
26, Kasturba Gandhi Marg
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)
An enclosure for electrical apparatus A kind of protection which does not fall
in which the entry of flammable gas or into any of the recognised techniques,
vapour is prevented by maintaining but which may be demonstrated to
the air (or other non-flammable gas) afford equivalent levels of protection
within the enclosure at a pressure to equipment intended for use in
above that of the external classified hazardous areas. This is to
atmosphere. develop new ideas before standard
specifications are available.
xxxix) Sand-filled apparatus (Ex-q) (Ref : IS :
7724)- The certificate will normally describe
the techniques and conditions of use.
Electrical apparatus which has all its
live parts entirely embedded in a
mass of powdery material, in such a 4.0 Power System Design
way that under the conditions of use
for which the apparatus has been i) The design of electrical installation
designed, no arc occurs within the shall ensure provision of a safe and
outer explosive atmosphere either by reliable supply of electricity at all
the transmission of flame or by the times. Safe conditions shall be
overheating of the walls of the ensured under all operating conditions
enclosure. including those associated with start-
up and shut down of plant, as well as
xxxx) Oil Immersed Apparatus - (Ex-o) those arising out of failure of electrical
(Ref : IS : 7693) - equipment. The isolation of a part of
system of electrical equipment due to
Electrical apparatus in which all parts either maintenance or shutdown shall
on which are may occur in normal not compromise safety. Power
distribution system shall constitute - Critical loads (e.g. computer, fire
sub-stations located near load centres water pumps, communication,
as far as practical. instrumentation controls etc.)
ii) The design shall be broadly based iii) Required redundancy (based on specific
upon the following factors: process/operating needs) shall be built in
the substation which feeds power supply
- Safety to personnel and equipment to the process units/important facilities so
during operation and maintenance, that in case of tripping of one feeder, the
unit/facility may not be adversely affected.
- Reliability of service,
iv) The power system design shall ensure
- Ease of maintenance, system reliability. This assumes particular
significance where inplant generation
- Convenience of operation, supplements the external power supply.
For this, quick isolation of inplant system
- Maximum interchangeability of from faulty grid, inplant load shedding etc.
equipment, may need detailed consideration.
a) Solid earthing for low, medium voltage i) Each short-circuit interrupting device shall
system (upto 650V) and for high have fault duty higher than the maximum
voltage above 11 K.V. value of short circuit current calculated at
its location. The related switchgear and bus
b) Resistance earthing for 3.3 KV to 11KV ducts shall withstand the above maximum
system. fault current (mechanical and thermal
stresses) for a minimum duration of one
iii) The values of neutral earthing resistors second.)
normally applied in industrial power
system are selected to meet the governing ii) The sizing of high voltage cables shall be
criteria for limiting transient over-voltages, based on the short circuit withstand
i.e. earth fault current should not be less capacity for a minimum time period as
than the system charging current. dictated by the protection system in
Besides, the value of neutral earthing addition to the maximum anticipated load
resistor selected shall limit the earth fault current carrying capacity.
current to a value, which shall be sufficient
for selective and reliable operation of iii) It is to be noted that in the case of
earth fault protection system. generators, whose excitation power is
terminal dependent, short circuit in the
However, where an earthing transformer is system will result in drop of the terminal
used for obtaining the system neutral, the voltage and consequently the over-current
zero sequence reactance limit (i.e. RO > 2 protective devices may not get adequate
X0) should also be considered. (R0 - zero current for operation. To avoid such a
sequence resistance of the circuit situation, necessary excitation support shall
including neutral resistor and X0 zero be provided unless & otherwise required.
sequence inductive reactance of the
circuit). iv) While sizing, the system necessary
consideration shall be given to restrict the
iv) The neutral earthing resistor shall be able system voltage drop within permissible
to carry at least 10% of its rated current limits during starting of large rated motor
continuously, unless otherwise required, or group of motors. At the same time, the
and full rated current (100%) for a short circuit current shall be kept within
minimum duration of 10 seconds. limits keeping in view of the market
availability of switchgears. Reduced
4.2.2 Unearthed System voltage starting (soft start feature) for
motors may be considered as per system
i) It is recommended that use of unearthed requirements.
system may be avoided since arcing
ground faults can result in severe over 4.4 Insulation coordination
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
the over-voltages resulting due to system general, and plant feeders connected to a
fault, switching or lightning surges. The captive power plant bus in particular.
insulation co-ordination between the Wherever the system is resistance
electrical equipment and the protective earthed, restricted earth fault protection
devices shall be done in line with IS: 3716 may be provided for transformer
and IS: 2165. secondary.
ii) Insulation coordination is a correlation of iv) Particular care should be taken in the
insulation of equipment and circuit with selection of protective devices for
the characteristic of protective devices machines and equipment operating in
such that the insulation is protected from hazardous areas, so as to isolate the
over voltages. faulty section in the shortest time possible.
For high voltage system, protective relays
iii) The rated insulation level of Switchgears shall be used. For medium voltage
shall refer to the power frequency systems, direct acting releases and/or
withstand voltage and impulse voltage protective relays may be employed.
withstand values which characterise the
insulation. In respect of systems with In general, quick acting relays (with time
nominal voltage of 132 KV and above, full delays if necessary) shall be used and all
insulation values shall be considered for fault tripping shall be done through high
non-effectively earthed system, and speed tripping relays.
reduced insulation values may be used for
effectively earthed system. v) The supply of Energy to every electrical
installation other than low voltage
4.5 Protection and Metering installations below 5 KW and those low
voltage installations which do not attract
i) The protective system shall be selected provisions of Section 30 of the Indian
and coordinated to ensure the following: Electricity Act, 1910, shall be controlled by
an earth leakage protective device so as
a. Protection of equipment against to disconnect the supply instantly on the
damage which can occur due to internal occurrence of earth fault or leakage of
or external short circuits, overloading, current (IE Rule 61A).
abnormal operating conditions,
switching, lightning surges, etc. Provided that the above shall not apply to
overhead supply lines having protective
b. The continuity of operation of those devices which are effectively bonded to
parts of the system not affected by the the neutral of supply transformers and
fault, is maintained. conforming to Rule 91 of I.E. Rules, 1956.
- 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
- Under frequency protection (81) be 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
i) This is an independent back-up source of alarm 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 4.7.1 Un-interrupted Power Supply (UPS)
time 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
- Auxiliaries of emergency set as available for at least 30 minutes or as
applicable determined by 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 remain inside the cubicle even in the test
CIRCUIT TAP changers. position. There shall be distinct overall
door for the breaker compartment and it
iii) In addition to standard accessories, the should be lockable. All circuit breaker
transformer shall be provided with trucks of the same rating shall be
auxiliary devices/protective devices such interchangeable.
as Buchholz relay, oil level and oil temp.
indicator with alarm trip output contacts vi) Suitable interlocks shall be provided to
and current transformers for the prevent faulty operation such as:
secondary side neutral for Protection.
Transformers of rating above 2000 KVA - ‘Pluging in’ or ‘drawing out’ of a closed
may be preferably have winding breaker.
temperature indicators with Alarm/Trip
provisions. - ‘Pluging in’ a breaker with earthing
isolator closed.
7.2.2 High Voltage (H.V)/Medium Voltage
(M.V) Switchboards - ‘Closing’ of earthing isolator with the
breaker ‘Plugged in’.
i) These shall be designed to ensure
maximum safety during operation, - Pulling out of auxiliary circuit plug with
inspection, connection of cables and breaker in service position.
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
connection work with switchgear below 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
connections should be accessible to shall be provided. On removing the eye
facilitate working and testing with breaker bolts, no holes offering access to panel
in test/service condition and while the shall be 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
busbar of adequate size. The switchgear iii) High voltage motors shall be suitable for
drawout trolley (in case of drawout starting under specified load conditions with
design) shall have suitable scraping earth 80% of the rated voltage at the terminals
connection. Feeder tag plates shall be and medium voltage motors 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
ix) All non-current carry metallic parts of 34-9.
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
& MEDIUM VOLTAGE (M.V) from zero to rated speed under starting
requirements as stipulated by process
7.2.3.1 General operating conditions. Normally, the
starting time shall be less than the hot
(1) Motors shall be totally enclosed, withstand time of the motor.
fan cooled type as far as
practicable. As a minimum, all viii) M.V. Motors in general and H.V. Motors
H.V. motors shall have anti where required shall be suitable for
condensation heaters. The restarting under full load after a
minimum degree of enclosure momentary loss of voltage with the
protection for motor shall be possibility of application of 100 percent of
preferably IP 44 for indoor use the rated voltage, when the residual
and IP 55 for outdoor duty motors. voltage has dropped down to 50 percent
and is in phase opposition to the applied
ii) Generally Motors upto and including 160 voltage.
KW shall be rated for medium voltage and
motors of rating above 160 kw shall be ix) Motor bearings shall be selected to give a
rated for high voltage. If required, the rating minimum L-10 life rating of 5 years
of medium voltage motors may be (40,000 hours) at rated operating condition
extended upto and including 200 KW. (the L-10 rating life is the number of hours
Sleeve or anti friction type bearings shall at constant speed that 90% of a group of
be used. Vertical motors shall have thrust identical bearings will complete or exceed
bearings suitable for the load imposed by before the first evidence of failure). The
the driven machinery. Unless otherwise bearings shall be adequate to absorb axial
specified, all motors shall be designed for thrust in either direction produced by the
‘Direct ON line’ starting. motor itself or due to shaft expansion. On
line greasing facility should be provided
on motor for all grease lubricated bearings
(anti friction bearings). Wherever and a decay time to half the peak voltage
spaceheaters are provided for motors, a of between 3 & 10 (microsecond).
separate terminal box should be provided Un = rated line to line voltage.
for termination of spaceheater cables, as
far as practicable. ix) Polarisation index
viii)The interturn insulation of H.V. motors 7.2.4 Battery Charger and D.C.
shall be able to withstand a peak voltage of Distribution Board
at least 0.5 (4Un+5) KV with a wave front
rise time between 0.5 & 1.5 microsecond Charger and D.B. shall be floor mounted,
free standing, metal enclosed and vermin
proof type having front access hinged door the battery set. In case of mains failure, the
and suitable for indoor use. battery shall supply the necessary power to
the inverter. The inverter in turn feeds the
This shall consist of battery load through the static switch. If the
charger/rectifier, which shall feed the load inverter malfunctions or is overloaded, the
and keep the batteries under fully charged load shall be instantaneously transferred to
condition. Provision shall also be made for the by-pass line through the static switch.
necessary boost charging/initial charging of Normally 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
envisaged in the duty cycle. Accessories a 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
insulators. 4 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
i) The emergency generating sets shall form i) In order to avoid spread of fire due to
a complete package and shall be designed cables, it is recommended that the outer
to start automatically on power failure and PVC sheath of all cables used in industry
feed the selected loads. It shall be capable shall be flame retardant type conforming to
of taking care of the load variations (e.g. category AF as per IS: 10810. The cable
the starting of largest rated motors on a shall have a low smoke property. The
preloaded system). The unit shall be minimum Oxygen Index shall be 29 Note 3.
complete with necessary starting
equipment, associated control panel and ii) High voltage cables may be
shall be suitable for remote starting. Aluminium/Copper Conductor XLPE
insulated PVC sheathed, armored type.
ii) The regulation of generator voltage shall
be automatic and necessary instruments The conductor screen, XLPE insulation
for metering viz. Ammeter, Voltmeter, screen shall all be extruded in one
Frequency meter, KWH meter, Power operation by ‘Triple Extrusion’ process.
Factor, Hour run counter etc. shall be
included in control panel. iii) 1.1 K.V. grade cables may be
Aluminium/Copper Conductor PVC
iii) Warning of abnormal conditions shall be insulated, PVC sheathed, armored type.
incorporated prior to automatic trip to
prevent unnecessary shutdown. iv) All power and control cables shall
preferably have extruded inner and outer
All the six stator winding ends shall be sheaths.
brought out to an externally mounted
terminal box and shall be connected in star. v) Where single core cables are armored and
Necessary temperature detectors shall be are meant for use on A.C circuits,
provided for the stator winding. The armouring with non-magnetic material (e.g.
terminal box shall have sufficient space to Aluminium) shall be given.
receive the cables of specified size.
The communication cables shall conform to
iv) Emergency D.G. set shall have Auto ITD specification. For fire alarm systems,
starting arrangement but only with manual PVC insulated, armoured and overall PVC
switching off features. The rating (Ampere sheathed cable with 1.5 mm2 copper
Hours) of battery, for cranking the engine conductors may be used.
shall be adequate to make three attempts
with an interval of 5 to 10 seconds, if vi) The power and control cables shall have
required. In case the engine fails to start the following minimum cross sectional
‘FAIL TO START’ annunciation shall be areas :
provided in substation or in control room.
a) Medium voltage 4mm 2
v) The generator set shall be provided with powercable Aluminium or
complete protection against overloads, 2.5 mm 2 Copper
short circuits, ground faults, excitation
failure, prime mover failure and shall b) Control cables 2.5 mm 2(Copper)
include other connected instrumentation (See Note 1 below)
interlocks.
c) Lighting 2.5 mm2 (Copper)/
vi) The load shall be switched on to the 4mm2 (Aluminium)
generator only after the requisite voltage (See Note 2 below).
build-up.
Note 1 In case of difficulty in connecting the
cables to instrument relay Annuciation
terminals, the minimum cross section ii) The control station enclosure shall have
may be reduced to 1.5 mm2 copper. suitable protection for site conditions such
as flameproof, weather-proof, dust-proof,
Note 2 For lighting inside the building copper corrosion resistant, etc.).
conductor cables shall be used.
Where conduit wiring is adopted, iii) The control station shall include the
minimum 1.5 mm2 copper conductor following equipment as per individual
PVC insulated wire may be used. requirements :
Note 3 Conductor size for wiring inside the - Start/stop push button/close,
panel for electronic neutral, Trip Switch
circuits/components shall be as per
manufacturer’s standard. - Ammeter,
i) Valves with electrical actuators shall - It should be noted here that the
generally be provided with integral current rating of cables will vary
starters. depending upon laying formation,
method of sheath bonding etc.,
ii) The necessary local/remote selector apart from other derating factors
switch, start/stop control switches or push normally considered. (Ambient
button, torque limit switches etc. shall be temp., depth of laying etc.)
provided on actuator for local/remote
control depending on mode of selection. In iii) All trenches shall be sized depending upon
case of failure of torque limit switches, the the number of cables, and its voltage
mechanical design shall be adequate to grade. High voltage, medium voltage and
stall and trip the motor without damage. other control cables shall be separated
from each other by required spacing or
iii) The control circuits shall AC operated for running through independant pipes,
short distance or DC operated for trenches or cable trays as applicable.
extended distance. The actuator shall be Cable trenches inside substations shall be
provided with an anti condensation heater. filled with sand, pebbles or similar non-
flammable materials or covered with
8.0 Plant Cabling incombustible slabs. If a significant number
of cables are taken on racks/supports
i) Cables below ground may be laid in provided on the side wall of trench.
concrete trench/tunnel or directly buried.
Cables above ground shall be laid in cable iv) RCC covers of trenches shall be effectively
trays/cable racks. sealed to avoid ingress of chemicals and
oils.
However cabling for fire water system
shall as far as possible be taken in v) In unpaved areas, cables may be directly
exclusive route through underground buried in ground. Where underground
trench. cables cross roadways or pipe sleepers at
grade etc., they shall be protected by being
ii) While designing layout with single core drawn through sleeves/ducts to provide a
cable installations following factors shall permanent crossing. Sleeves/ducts ends
be considered : shall be effectively sealed thereafter.
a) Cables are laid as a general practice in vi) Concrete lined trenches shall have suitable
trefoil formation touching each other. drainage arrangement to avoid water
collection. Concrete lined cable trenches
or shall be sealed against ingress of liquid and
gases wherever the trenches leave a
b) flat formation with spacing as per hazardous area or enter control room or
requirement. substation. Pipes laid for mechanical
protection shall be sealed at both ends.
- When cables are laid in a flat
formation, the individual cable fixing vii) Above ground cables shall be well
clamps, and spacers shall be of non supported suitably at every 2 to 2.5 metres
magnetic material. interval and protected against mechanical
damage. Routing shall be decided to avoid
- As a general practice, the sheath of proximity to hot sources, place subject to
single core cables shall earthed to undue fire risk, gas, water, steam oil drains,
keep sheath at earth potential. piping, air conditioning duct etc. Cable
However depending on the current trays, racks and trenches shall sized to
the cable has to carry, the feeder allow for 10 to 20% future cables reserve.
length and permissible sheath Each cable tray tier shall accommodate the
potential, various methods of sheath cables preferably in single layer.
bonding are employed, viz. single
point bonding, bonding at middle, Instrument and communication cables shall
sectionalised bonding etc., for which not be laid in the same trench/tray along
with electrical cables. The overall cable
layouts shall be designed for minimum
interference between signal and power 9.0 Plant Lighting
cables.
This can be broadly classified as under :
viii) Cable cellars and important cable
tunnels shall be provided with fire detection i. Normal lighting
and monitoring devices.
ii. Emergency lighting
ix) Trailing cables for equipment such as
cranes and excavators shall have one iii. Critical lighting
additional core for earthing and the cable
shall be well protected against mechanical i) Normal and emergency lighting system
damage. shall be on 415/240V AC supply, whereas
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
xi) Only type tested and approved make within the accessible areas of plant and to
termination kits shall be used. While perform routine operations. In the event of
selecting the type of cable kit, necessary normal power failure, emergency lighting
consideration may be given to the may be provided.
additional safety measures needed for
carrying out termination with kits of type iii) Lighting requirements provided during the
such as heat shrinkable type (particularly in failure of power supply for Normal lighting
hazardous areas). are intended broadly,
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)
conditions, necessary incandescent lamps
- Fire water pump house, Fire may be judiciously distributed throughout
stations the plant area. Incandescent lamps may be
considered for emergency lighting to
- Main sub stations achieve this objective, Fluorescent lamps
may be used for indoor lighting in non-
- Foot of stairs and ladder process buildings and control rooms. Safe
area street lighting and yard lighting may
- Platforms with ladders changing employ sodium vapour lamps. Low
direction pressure sodium vapour lamps shall not be
installed in hazardous areas.
- Other changes of floor level, that
may constitute a hazard. x) The illumination levels in different areas
shall be as per good engineering practice.
- Strategic locations in Process, utility Depending on the nature of job activities to
areas where specific safety be carried out the suggested minimum
operations are to be carried out illumination levels for various areas are as
such as : under :
--------------------------------------------------------
* Areas near heat exchangers, Areas Illumination
condensers in Lux
--------------------------------------------------------
* Barring gears of steam turbine - Main roads (along process 7 - 10
units, power houses,
* Some portions of roads workshops, etc.)
interconnecting substations and
process plants. - Secondary roads (along 3 - 5
storage tanks settling
vi) As a good engineering practice the A.C. basins etc.)
emergency load is generally considered as
20-25% of Normal Lighting load. However - Tank farm 10
for small plants, where A.C. emergency
load is not substantial/where there is no - Pump houses, sheds 100
separate standby D.G. set, D.C. critical
lighting system may take care of entire - Main operation platforms 60
emergency lighting. & access stairs
xi) The illumination level requirements (during - Equipment earthing for personnel
normal lighting source failure) depends on safety,
the nature of activities to be carried out.
The suggested minimum illumination levels - System neutral earthing, and
are as below :
- Static and lighting protection.
I) Near to areas where Spot
specific safety operations lighting ii) The earthing system envisages an earthing
(visual tasks are to be to be network with designed number of earth
carried out (e.g. control provided electrodes attached to it. The following
room) shall be earthed :
- As far as possible, all earth - For the electrical system and equipment,
connections shall be visible for inspection. a value that ensures the operation
of the protective device in the
iv) All connections shall be carefully made and electrical circuit but not in excess of
adequately locked against loosening. 5 ohms. However, for generating
Normally earthing system shall comprise of stations and large sub-stations this
GI strip as main earth grid alongwith value shall not be more than 1 ohm.
suitably located GI disconnecting plates to
provide multiple earth connections between - For lightning protection, the value of
earth grid and equipment and for 5 ohms as earth resistance shall be
connections between main earth grid and desirable, but in no case it shall be
electrodes. Alternatively, mild steel strip more than 10 ohms.
can also be used for earth grid after
providing corrosion allowance. xi) The main earthing network shall be used
for earthing of equipment to protect against
v) Connections between GI earth electrode static electricity.
and the disconnecting plates shall be done
by GI strip. For highly corrosive areas, PVC For further details on earthing installation
insulated A1 cond. cable (unarmoured) practices refer OISD standard 147.
may be used. Connections between the
disconnecting plate and various equipment TABLE - III
shall be done by GI strip, GI wire or GI wire -----------------------------------------------------------
rope, size as recommended in Table III. Type of Equipment Bare G.I. Strip/G.I.
Bare Rope or
vi) In corrosive areas, aluminium G.I. Wire
disconnecting plates alongwith suitably -----------------------------------------------------------
sized PVC insulated aluminium conductor Motors upto 3.7 KW No. 8 SWG solid
cables, may be used for earthing wire
grid/connections.
Motors 5.5 KW to 10 mm (3/8") Wire 30
vii) All utility, process pipelines and KW & welding
flanges shall be earthed on entering or receptacles
leaving the hazardous areas, except where
conflicting with the requirements of Motors 37 KW and 16 mm (5/8") above
cathodic protection. In addition, steel pipe including HT Wire Rope
racks in the process units and offsite area Motors
shall be earthed at every 25 meters.
Building Columns 40 X 5 Strip
viii) Equipment located remote from main
earth network may be earthed by means of Storage Tank (Vertical 40 X 5 Strip
individual earth conductors and earth & Horizontal)
electrodes.
Loading Racks 40 X 5 Strip
ix) Lighting protection shall be provided for the
equipment, structures and buildings which Pipe racks, Vessels 10 mm (3/8") &
are higher than 20 metres or as per the risk Heat Exchanvers Wire Rope
index analysis worked out as per IS 2309.
Self-conducting structures do not require Small Equipment & No. 8 SWG Solid
lightning protection with aerial rod and Instruments
down conductors. They shall be connected
to the earthing system at two points of the Lighting, Power & 10 mm (3/8")
Instrument Panels Wire Rope unit control rooms. Operation of each
zone panel may be indicated by audio-
Main Earth Bus/LT & As visual indication in the main control panel
HT SW. Gear Intercon- Calculated in the unit control room as well as in the
nections/Power Trans- other zone panels with distinct colour
former indicating the zone number.
EHV & HV Sub-Stations As Calculated iii) A fire detection and alarm system shall:
Push Button Stations No. 8 SWG Solid a) operate quickly enough to fulfil its
Wire intended functions;
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:
- Executive phone service shall include ii) The emergency communication system
direct unassisted (operator bypass) shall include a ‘Direct phone to phone hot
communication to external lines for both line (H.L.) system’ and a ‘Dedicated hot line
local and long distance telephone service. (D.H.L.) system’.
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’.
* IS 2189 Code of practice for selection,
f) OISD - 137 “Inspection of Electrical installation and maintenance of Automatic
Equipment” Fire Detection and Alarm System.
iii) Indian Electricity Act & Rules 1956 * IS 3034 Code practice for fire safety of
(Ministry of Irrigation & Power, Govt. of industrial buildings, electrical generating
India) and distributing stations.
iv) The Petroleum Rules 1976 (Ministry of * IS 1646 Code of practice for fire safety
Industry, Government of India) of buildings (General) Electrical
Installations.
v) Oil Mines Regulations
* IS 10028 (Part 1, 2 & 3) code of
vi) C.B.I.P. (Central Board of Irrigation & practice for selection, installation and
Power) Technical Report No. 3 ‘Manual on maintenance of transformers.
Layout of Substations’.
* IS 2165 Part (1 & 2) Insulation
vii) BIS (Bureau of Indian Standards) Coordination.
Publications
* IS 2834 Specifications of shunt
* IS 5572 Classification of hazardous capacitor for power system.
areas (other than mines) for electrical
installations. Areas having flammable * IS 13408 Code of Practice for the
gases and vapour selection, installation and maintenance of
Electrical Apparatus for use in potentially
* IS 5571 Guide for selection of explosive atmospheres (other than mining
electrical equipment for hazardous areas. applications or explosives processing and
manufacture)
* IS 13346 General requirements for
electrical apparatus for explosive gas * IS 2148 Flameproof enclosures for
atmosphere electrical apparatus
* IS 6665 Code of practice for industrial * IS 8289 Electrical equipment for type
lighting. of protection ‘n’