F08941C-D02-01 - 0 Design Criteriafor Electrical Engineering of Power Plant

DESIGN CRITERIA FOR ELECTRICAL ENGINEERING of POWER PLANT
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•
PT BORNEO ALUMINA INDONESIA
•
1,000,000 TPA (EXPANDABLE) SMELTER GRADE
ALUMINA REFINERY MEMPAWAH PROJECT
CONTRACT NO :
PROJECT CODE:
DOC NO : F08941C-D02-01
PURPOSE : ISSUED FOR REVIEW
CONSULTANT :
CONTRACTOR :
Consortium CHALIECO - PT PP (Persero) Tbk
SUB-CONTRACTOR :
REV. NO. DATE DESCRIPTION Prepared Checked Approved
B 20/06/2023 For Review 龚迅周婉亚王茜叶学勇胡振兴郭世峥

A 14/03/2021 For Review 龚迅周婉亚王茜叶学勇胡振兴唐俊
PROJECT CODE :
DESIGN CRITERIA FOR DOCUMENT NO : F08941C-D02-01

ELECTRICAL DATE : 20/06/2023
ENGINEERING REV : B
PAGE : 1 / 27
REVISION CONTROL SHEET
REV.NO. DATE DESCRIPTION
A 14/03/2021 1st Issued
B 20/06/2023 2nd Issued
DISTRIBUTION ORDER
EXTERNAL ISSUE CHALIECO-INTERNAL ISSUE
PT BORNEO ALUMINA INDONESIA PROJECT MANAGER
PMC ENGINEERING MANAGER
CONSTRUCTION MANAGER
PROCUREMENT MANAGER
PROJECT CONTROL MANAGER
SHE MANAGER
QC MANAGER
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Table of Contents
1. Introduction .............................................................................................................................................. 6
2. Scope ........................................................................................................................................................ 6
3. Reference ..................................................................................................................................................6
3.1 Standards and Code ......................................................................................................................... 6
3.2 Main Abbreviation and Definition ...................................................................................................... 7
3.3 Reference drawing/document ........................................................................................................... 8
4. Environmental Condition ........................................................................................................................ 8

4.1 Indoors .............................................................................................................................................. 8
4.2 Outdoor ............................................................................................................................................. 8
5. Design principles .....................................................................................................................................8

5.1 Power supply .....................................................................................................................................8
5.2 Voltage Level .....................................................................................................................................8
5.3 Electrical system structure ................................................................................................................ 8
6. Equipment Requirement ......................................................................................................................... 9

6.1 Dry type transformer ......................................................................................................................... 9
6.2 Oil Immersed Power Transformer .....................................................................................................9
6.3 Synchronous Generator .................................................................................................................. 10
6.4 Generator Bus Duct ........................................................................................................................ 11
6.5 High Voltage Switchgear .................................................................................................................11
6.6 Low Voltage Switchgear ..................................................................................................................11
6.7 Motor ............................................................................................................................................... 11
6.8 Current limiting reactor ....................................................................................................................11
6.9 UPS Power ......................................................................................................................................12
6.10 DC Power Systems ....................................................................................................................... 12
6.11 Low Voltage MCC (Motor Control Centre) ....................................................................................12
6.12 Variable-frequency Drive ...............................................................................................................12

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6.13 Power Sockets in Buildings ...........................................................................................................12
6.14 Sockets For Welding and Convenient Outlet ................................................................................12
6.15 Switch disconnector fuse .............................................................................................................. 12
6.16 Local Control Box ..........................................................................................................................12
6.16.1 Button box ......................................................................................................................... 12
6.16.2 Push Button Assemblies ................................................................................................... 12
6.17 Outdoor Junction Boxes ................................................................................................................13
6.18 Package Equipment ...................................................................................................................... 13
6.19 Local Distribution Board/Panel ......................................................................................................13
6.20 Hazardous area division and corresponding equipment selection ............................................... 13
7. Design Calculations and Studies .........................................................................................................14

8. Operational Modes ................................................................................................................................ 14
8.1 General ............................................................................................................................................14
8.2 Normal Mode ...................................................................................................................................14
8.3 Maintenance Mode ..........................................................................................................................14
8.4 Emergency Mode ............................................................................................................................ 15
8.5 Black start facility ............................................................................................................................ 15
8.6 Diesel generator ..............................................................................................................................15
9. Power distribution and substations .................................................................................................... 16

9.1 Location ...........................................................................................................................................16
9.2 Temperature of Substation ............................................................................................................. 16
9.3 Doors, Windows and Wall Penetrations ......................................................................................... 16
9.4 Building Sizing and Equipment Arrangement ................................................................................. 16
9.5 Warning Signs ................................................................................................................................. 18
10. Electrical control ..................................................................................................................................18

10.1 Operation Mode ............................................................................................................................ 18
10.2 Motor Control .................................................................................................................................18
11. Protection configuration .....................................................................................................................18

12. Metering and Measuring ..................................................................................................................... 19
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13. Lighting .................................................................................................................................................19

13.1 Lighting Type .................................................................................................................................20
13.2 Selection of Lighting Sources and Lamps .................................................................................... 21
13.3 Illumination and Quality .................................................................................................................21
13.4 Lighting Distribution and Control ...................................................................................................23
13.4.1 Lighting Distribution System ............................................................................................. 23
13.4.2 Lighting Control .................................................................................................................23
14. Cable ..................................................................................................................................................... 23

14.1 General ..........................................................................................................................................23
14.2 Cable Type and Section Selection ................................................................................................24
14.2.1 Cable Conductor Material ................................................................................................. 24
14.2.2 Cable Insulation Level and Type ...................................................................................... 24
14.2.3 Cable Sheath Type ........................................................................................................... 24
14.2.4 Control Cable and Its Metal Shield ................................................................................... 24
14.2.5 Power Cable Section ........................................................................................................ 24
14.3 Selection and Configuration of Cable Accessories ......................................................................24
15. Cable laying ..........................................................................................................................................24

15.1 General ..........................................................................................................................................24
15.2 Laying Method ...............................................................................................................................24
15.2.1 Cable Tray Laying .............................................................................................................24
15.2.2 Direct Buried Laying ..........................................................................................................24
15.2.3 Conduit Layin .................................................................................................................... 24
15.2.4 Laying of Cable Structures ............................................................................................... 24
15.3 Cable Support and Fixing ............................................................................................................. 24
15.3.1 General ............................................................................................................................. 24
15.3.2 Cable Support and Cable Tray. ........................................................................................ 24
15.4 Fire Proof Sealing System For Cable ........................................................................................... 24
16. Grounding and Lightning Protection ................................................................................................ 25

16.1 Basic Design Condition ................................................................................................................. 25
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16.2 Ground Network ............................................................................................................................ 25
16.3 Equipment Grounding Requirements ............................................................................................25
16.4 Grounding Electrode ..................................................................................................................... 25
16.5 Lightning Protection ...................................................................................................................... 25
17. ECMS .....................................................................................................................................................25

18. SPECIFICATIONS FOR ELECTRICAL ENGINEERING DESIGN of power plant .............................25
18.1 GENERAL ..................................................................................................................................... 25
18.2 Standards and Code ..................................................................................................................... 26
18.3 Main Abbreviation and Definition .................................................................................................. 26
18.4 VENDOR DOCUMENTATION ......................................................................................................26
18.5 TECHNICAL AND DESIGN REQUIREMENTS ............................................................................ 27
18.5.1 Electrical Supply ............................................................................................................... 27
18.5.2 Low Voltage MCC (Motor Control Centre) ........................................................................27
18.5.3 Distribution Board ............................................................................................................. 27
18.5.4 Variable Frequency Drives ............................................................................................... 27
18.5.5 Power sockets in buildings ............................................................................................... 27
18.5.6 Sockets for welding and convenient outlet ....................................................................... 27
18.5.7 Local Control Panel ...........................................................................................................27
18.5.8 Outdoor junction boxes ..................................................................................................... 27
18.5.9 Equipment Nameplates .....................................................................................................27
18.5.10 Terminal Blocks .............................................................................................................. 27
18.5.11 Cable Design Requirements ...........................................................................................27
18.5.12 Cable Tray Material of Construction ............................................................................... 27
18.5.13 Conduits .......................................................................................................................... 27
18.5.14 Grounding and Bonding ..................................................................................................27

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1. INTRODUCTION
The Project is designed with a capacity of 1,000 ktpa (expandable) located at Bukit Batu
Village, Sungai Kunyit District, Mempawah Regency, West Kalimantan, Indonesia and it will
be dedicated to fulfill the Owner's requirements in operation of an alumina refinery.
2. SCOPE
This document, in conjunction with the EPC contract requirement,design standards and
engineering practices, provides the basis for the electrical engineering design of power plant.
The design criteria defined in this document shall be adhered to during the execution of the
electrical design and shall govern the production and contents of all project deliverables
produced by the electrical discipline.
CAS1969-2G00-31-110-01 shall always takes precedence than this one unless more strigent
requirement is in this criteria or requirement is not defined in CAS1969-2G00-31-110-01 and
not conflict with main contract.
3. REFERENCE
3.1 Standards and Code
This design references but is not limited to the following standards. The latest issues,
amendments, and supplements to these documents shall apply unless otherwise indicated.
Table 3- 1: Standards and Code
Document Number Description
IEC 60034(series) Rotating Electrical Machines
IEC 60038 IEC standard voltages
IEC 60044(series) Instrument transformers
IEC 60076(series) Power transformers
IEC 60255(series) Measuring relays and protection devices
IEC 60287(series) Electrical Cables-Calculation of Current Ratings
IEC 60309(series) Socket-outlets and couplers for industrial purposes
IEC 60364-5-52 Electrical installations of buildings – Part 5-52: Selection and

erection of electrical equipment – Wiring systems
IEC 60364-5-54 Electrical Installation of Buildings – Selection and erection of

electrical Equipment-Earthing arrangements and protective
conductors and protective bonding conductors
IEC 60502(series) Power Cables with Extruded Insulation and their Accessories for
rated Voltages from 1 kV up to 30 kV
IEC 60529 Degrees of protection provided by enclosures (IP Code)
IEC 60870-5-103 Telecontrol equipment and systems, Transmission protocols
IEC 60947(series) Low-voltage switchgear and controlgear

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Document Number Description
IEC 61537 Cable Tray Systems and Cable Ladder Systems for Cable
Management
IEC 61850 Communication networks and systems in substations
IEC 61869(series) Instrument transformers
IEC 62040(series) Uninterruptible power systems (UPS)
IEC 62271(series) High-voltage switchgear and controlgear
IEC 62305(series) Protection against lightning

IEC 60598-1：2003 Luminaires
IEC 60364-5- Low-voltage electrical installations - Part 5-54: Selection an

54:2011 d erection of electrical equipment - Earthing arrangements
and protective conductors
IESNA Lighting Handbook
CIE S 008/E 2001 Lighting of Indoor Work Places
CIE S 015/E 2019 Lighting of Outdoor Work Places
CIE S 020/E 2007 Emergency Lighting
3.2 Main Abbreviation and Definition
Table 3- 2: Abbreviation and Definition
Abbreviation Definition
HV High Voltage above 1,000V
LV Low voltage equal or lower than 1,000V but higher than 50V.
UPS Uninterruptable Power Supply
PC Power Central
MCC Low Voltage Motor Control Center
PT Voltage Transformer
CT Current Transformer
LA Lightning Arrester
MOA Metal Oxide Arrester
DG Diesel generator
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NLTC No Load Tap-changer
VFD Variable-frequency Drive
SST Soft Starter
EDG Emergency Diesel Generator
ECMS Electrical Control and Management System
3.3 Reference drawing/document

CAS1969-2G00-31-111-002 Technical Specification of Motors
CAS1969-2G00-05-111-001 Engineering Specifications for Painting
4. ENVIRONMENTAL CONDITION
4.1 Indoors
According to CAS1969-2G00-31-110-001_0 section 4.1
4.2 Outdoor
5. DESIGN PRINCIPLES
5.1 Power supply
5.2 Voltage Level

For thermal power plant, the control voltage for LV air circuit breaker ( ACB) is DC 220V, and
for other LV breaker control voltage is 220V single phase.
5.3 Electrical system structure

The main 10kV power distribution system of the thermal power plant adopts the connection
mode of single bus section with standby bus, with a total of four bus sections. The working
bus is divided into three sections(10kV Main Bus I, II, III), and the standby bus is one section.
Bus coupler breaker is set between working buses and standby bus, and section breaker is
set between the bus I and the bus II and between the bus II and the bus III .Each section is
connected with a turbine generator unit, and supplies 10kV power to other 10kV power
distribution systems in the Alumina plant, the thermal power plant and the coal gas station;
When one of main 10kV bus of the bus failure and out of operation, the load and power circuit
are switched to the standby bus. At this point, in order to ensure the stability of the system,
the coupler breaker between the normal bus and the standby bus is closed, so that all power
supplies run in parallel.
Other 10kV power distribution systems provides power for the 10 / 0.4kV auxiliary
transformer and 10kV motors;
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Each auxiliary system has 2 x 100% transformers or several transformers with one 100%
spare transformer to supply to 0.38kV system; transformer capacity is 120 % calculation
load for dry type transformer.
The MCC power distribution system of power load for continuous production of process
adopts single bus mode, with two power incoming lines;
The UPS system serves as the standby power supply for the communication system, DCS
and PLC cabinet (Include HMI communication interface with UPS).
The protection and control power of high-voltage equipment are supplied by the DC system.
Battery discharge time of control load is calculated according to 8 hours, and power load
such as DC lubricating oil pump motor is calculated according to the unit accident stop time.
6. EQUIPMENT REQUIREMENT
6.1 Dry type transformer
The 10/0.4kV transformer in main building and Electrostatic precipitator system will be dry-
type, AN, indoor type and copper winding, NLTC, and the tap-changer is ± 2×2.5%.
The transformer is insulated with flame retardant resin and poured in vacuum. Case
protection up to IP32.
The Vector group is Dyn11, insulation class is grade F, temperature rise is grade B insulation
assessment. When the transformer is operated with the maximum rated capacity, its
maximum temperature rise shall not exceed 80K.
Table 6- 2: Dry type Transformer list（provisional）
Impedance
Capacity (design
No Tap-changer (design Use range KKS code
value)
value)
LV Emergency
1 10±2X2.5%/0.4kV 630kVA 4% S0BMT01
system
Unit system and
Electrostatic
2 10±2X2.5%/0.4kV 1000kVA 6% 1/2/30BFT02
precipitator
system
3 10±2X2.5%/0.4kV 1600kVA 8% Station system S0BHT01
6.2 Oil Immersed Power Transformer

The 10/0.4kV transformer shall be oil-immersed, ONAN, outdoor type, copper winding and
the transformer capacity is 120% calculated load. The vector group is Dyn11
The insulation of oil-immersed transformer is insulating oil.The transformer adopts NLTC, and
the tap is ± 2×2.5%
Winding insulation class and temperature rise information of Oil Type Transformer is A class
and 55K(average)
Table 6- 1: Oil-immersed type Transformer list（provisional）

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Rated
Impedance
Capacity
No Tap-changer (design Use range KKS code
(design
value)
value)
Water
1 10±2×2.5%/0.4kV 800kVA 6% treatment S0BHT21/22
system
Coal handing
2 10±2×2.5%/0.4kV 1600kVA 8% S0BHT31/32
system
6.3 Synchronous Generator

The generator will be two-pole, direct-connected, three phase connected, 50Hz. The
main parameter of Generator shall be as follows:
Rated output 30MW/37.5MVA
Match turbine output 25MW/31.25MVA
Rated speed 3000 rpm
Rated terminal voltage 10.5 kV
Rated power factor 0.8(Lagging)~0.95(leading)
frequency 50 Hz
Rated current 2062 A
Current(Match turbine output) 1718 A
Short circuit ratio ≥0.5
Rated Efficiency 98.2%
Efficiency(Match turbine output) 98.1%
Excitation system Static Thyristor Excitation
Cooling method Air Cooling
A complete generator excitation and voltage regulating system will be provided with the
generator. The excitation system shall be static and the excitation system shall meet the
performance requirements of generator.
The excitation system consists of the following main equipment: Excitation

transformer(ET), Automatic Voltage Regulator(AVR), thyristor rectifier cubicle, field
breaker cubicle, excitation-starting device, excitation control and protection devices, etc.
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The data of Excitation transformer(ET) as follow：
Rated capacity：315kVA
Phase number：3
Rated transformation ratio：10.5±2×2.5/0.42kV
Rated Impedance：4%
6.4 Generator Bus Duct

The generator outlet adopts from the bottom, which is connected to the generator outlet
10kV equipment through bare copper conductor, and connected to the main 10kV
switchgear through self-cooled Isolated Phase Bus Duct after generator outlet circuit
breaker(GCB).
The generator bus duct system will consist of the following major components:
-Isolated phase bus duct
-Potential Transformer(PT)
-Current Transformer(CT)
-Metal Oxide Arrester(MOA)
-Current Limiting Reactor(CLR)
-Generator Circuit Breaker（GCB）
-Supports and hangers
-Micro positive pressure system
6.5 High Voltage Switchgear

6.6 Low Voltage Switchgear

6.7 Motor
6.8 Current limiting reactor

The current limiting reactor is to limit the short-circuit current and ensure that the residual
voltage of the bus does not fall below 70% in the case of feeder has short-circuited so
that ensuring the stable operation of the system.
The main parameters of current limiting reactor is as follows:
• Type: dry-type & air-core

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• Rated voltage: 10kV

• Max Voltage: 12kV
• Rated frequency: 50Hz
• rated continuous current: According to the circuit current
• Rated short time current and time: 40kA/3s(tentative)
• Xk%: 4% to 11%
• 1min frequency voltage withstand (effective value): 30/42kV(internal/external)
6.9 UPS Power
6.10 DC Power Systems

DC power system voltage is 220V.
DC power system for protection and control of HV switchgear breakers and DC consumers
and emergency lighting. Batteries will be designed for 8 hours operation after a failure with a
maximum voltage drop of 10% for control load..
2 x100 % charger with at least 2 x 50 % battery.
DC power system shall include insulation monitoring, voltage regulator (dropped diode), short
circuit, overcurrent protection, and undervoltage alarm functions.
DC power system adopts RS485 communication interface, which can upload the signal to
Electrical Control and Management System (ECMS).
6.11 Low Voltage MCC (Motor Control Centre)

6.12 Variable-frequency Drive

6.13 Power Sockets in Buildings

6.14 Sockets For Welding and Convenient Outlet

6.15 Switch disconnector fuse

The switch disconnector fuse is used for the crane equipment maintenance isolation and will
be installed in switch box with .IP54(Indoor installation) or IP65(outdoor installation)
6.16 Local Control Box

6.16.1 Button box
According to CAS1969-2G00-31-110-001_0 section 6.16.1
6.16.2 Push Button Assemblies

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6.17 Outdoor Junction Boxes

6.18 Package Equipment

6.19 Local Distribution Board/Panel

Adopt fixed closed metal switch cabinet with the Form of construction 2bThe Distribution
cabinet shall comprise ：cubicles, copper bus-bar system, earthing studs, circuit breaker
and auxiliary relays, incoming power on/off indication lights.
• System rated current does not exceed 630A in principle, Withstand current
50kA/1S(The short circuit level is subject to the final calculation result.);
• The circuit breaker of Distribution cabinet is equipped with manual operation handle;
• Protection grade: IP54(indoor)/IP55(outdoor);
• Cabinet colour: RL7035;
• Floor mounted, cable in and out of cabinet bottom;
6.20 Hazardous area division and corresponding equipment selection
The hazardous area division in coal handing system of power plant is refer to document
F08941C-M02-01 section 8.
The selection of electrical and control device explosion-proof equipment should match
the grade of the explosion-proof area. The selection of explosion-proof grade for
electrical equipment is as follows：
Table 6- 2: Selection of explosion-proof electrical equipment
Substance
Area Classification
Classification
Release Source Method of
Ventilation
Description Dust type or Protection
Vert. Hor. Rad
Zone Temperature Zone
(M) (M) .(M)
Class
Ex iD,
IIIC(lignite
lignite powder ),Da,
Coal dust 20 Well Ventilated 20 0 0 0
powder T1
Ex iD,
IIIC(lignite
lignite powder ),Db,
powder T1
Ex iD,
IIIC(lignite
lignite powder ),Dc,
powder T1
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Ex d IIAT3
Leaked fuel oil 2 T3 Well Ventilated 2 1 - 1 Gb
For valve-controlled lead-acid battery room, during normal operation, the battery does
not produce hydrogen.Under abnormal conditions, only a tiny amount of hydrogen is
produced.The fans and lighting fixtures in the battery room are explosion-proof, and the
hydrogen leakage detector is set, which is interlocked with the fans.Once hydrogen
leakage is detected, detector will turn on the fan to drain hydrogen immediately.
7. DESIGN CALCULATIONS AND STUDIES

According to CAS1969-2G00-31-110-001_0 section 7
8. OPERATIONAL MODES
8.1 General
The power supply of the project shall be supported from the thermal power plant, there is no
external power supply. In order to ensure the production safety, the diesel generator is also
set as the emergency and black start power supply.
During normal operation, all electrical equipment shall be supplied by the steam turbine
generator. When the normal power supply is not available, the emergency power will supply
all the emergency load.
For the electrical power system, the following modes are defined:
• Normal Operation Mode;

• Maintenance Mode;
• Emergency Mode;
8.2 Normal Mode
1) In this mode, all electrical loads are supplied by the generator of Power plant;
2) The main 10kV working bus shall be operated. The standby bus shall not be operated.
The busbar section breaker is open, and the coupler breaker is closed;
3) The two power sources of the 10kV distribution substation in Alumina plant are operated,
and the bus coupler breaker is opened;
4) The two power sources of the 10 / 0.4kV substation are operated, and the bus coupler
breaker is opened;
5) Emergency diesel generator does not start;
6) Batteries are in float charging state, and the DC loads are powered by the chargers
connected to system power.
8.3 Maintenance Mode

1) When a generator needs maintenance, start the standby generator and then shut down
the maintenance generator;
2) When 1 generator is in maintenance mode, the main bus does not shut down, and the
main bus of 10kV in 3 section are still in parallel state;
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3) 10kV distribution substation: when one 10kV incoming power supply needs maintenance,
close the bus coupler breaker and the standby power circuit switch, then disconnect the
working power circuit switch, and the 10kV distribution system is supplied by the another
incoming power;
4) 10 / 0.4kV substation: when one 10 / 0.4kV transformer needs maintenance, close the
bus coupler breaker, disconnect the low-voltage side switch of the working transformer,
and the system is powered by another transformer;
5) In maintenance mode, Emergency diesel generator does not start;
6) Batteries are in float charging state, and the DC loads are supplied by the chargers
connected to system power.
8.4 Emergency Mode

When the power supply system of the thermal power station fails, the power supply system of
the whole plant loses power or emergency load loses power, the emergency diesel generator
and batteries and UPS starts to supply power for the plant's emergency load, and provides
power for the black restart of the thermal power station. When the power supplies to LV
emergency bus are lost, diesel shall be started.
8.5 Black start facility

The facility shall be capable of restarting any unit from complete blackout conditions
without other power network. Black start diesel generator of suitable rating will be set in
the same house with EDG.
The black start diesel generator will be connected to standby 10kV switchgear which can
supply power to 10kV auxiliary switchgear of any unit in power plant. The blackout
condition occurs when there is no power to restart the unit. The black start diesel
generator will be running and supplying power to all necessary loads for restarting of any
unit.
The black start facility is manual start mode. In the process of starting, with the input of
load in batches, the output of black starting diesel generator is constantly increasing, and
the unit is also started. This process should ensure the stable start of the diesel
generator set. When the unit starts and the power supply is switched to the unit, the
black start diesel generator will be rolled out and complete the black start unit. Diesel
generator will automatically start after manual start initiation.
8.6 Diesel generator
Diesel generators supply power to emergency load in power plant and alumina plant and
black start of power plant unit. Six diesel generators according to preliminary calculation.
The parameters of diesel generator is as follows:
• Rated power:4X2000kW(for emergency load and black starting of power plant, refer
to F08941C-D03-01 Diesel Generator Sizing Selection)
• Rated power:2X1800kW(for emergency load of alumina plant, refer to F08941C-D03-
01 Diesel Generator Sizing Selection)
• Rated voltage: 10.5kV
• Rated frequency:50Hz
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• Rated power factor:0.8

• Rated insulation: F class
• The 1m noise outside the exhaust vent of diesel generator is not higher than 90 db,
and the 1m noise outside the shell is not higher than 110 dB.
• Exciting Mode: Rapid response excitation system with AVR device.
• Fuel type:0 # diesel oil
The capacity selection of diesel generators requires the following considerations(refer to
F08941C-D03-01 Diesel Generator Sizing Selection):
• The continuous output capacity of the diesel generator set shall be greater than the
maximum starting calculated load.
• When the diesel generator starts the maximum motor with other load, it shall meet
the requirement of overload capacity in a short time.
• When the diesel generator starts with the maximum motor, the bus voltage shall not
be less than 80% of the rated voltage.
9. POWER DISTRIBUTION AND SUBSTATIONS

9.1 Location
9.2 Temperature of Substation

9.3 Doors, Windows and Wall Penetrations

9.4 Building Sizing and Equipment Arrangement

The requirements of passageway in the distribution room is shown in the table below：
Table 9- 1: Minimum width of all passageways in high voltage panel room（mm）

Maintain access Operation passageway in front of
behind the cabinet(minimum distance)
Switch cabinet layout
cabinet(minimum
Fixed switchgear Removable switchgear
distance)
1600(single truck length
Single row arrangement 800 1500 + 1200" or "double truck
length + 900)
2000(single truck length
Double row face-to-face
800 2000 + 1200" or "double truck
arrangement
length + 900)
Table 9- 2: Minimum width of all passageways in low voltage panel（m）

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Double row face- Double row back

Single row Multiple rows in the
to-face to back
arrangement same direction
arrangement arrangement
Back of panel
Back of panel
Back of panel
from the wall

rear panel
Front and
panel
between of panel
Type of
Front of panel
Front of panel
Front of panel
side
distribution
passage
Behind the rear panel

panel
Front of front panel

way
operating
operating
operating
maintain
maintain
maintain
F
i Unrestricted 1.5 1.0 1.2 2.0 1.0 1.2 1.5 1.5 2.0 2.0 1.5 1.0 1.0
x
e restricted 1.3 0.8 1.2 1.8 0.8 1.2 1.3 1.3 2.0 1.8 1.3 0.8 0.8
d
D
r Unrestricted 1.8 1.0 1.2 2.3 1.0 1.2 1.8 1.0 2.0 2.3 1.8 1.0 1.0
a
w
-
o restricted 1.6 0.8 1.2 2.1 0.8 1.2 1.6 0.8 2.0 2.1 1.6 0.8 0.8
u
t
Note:
1. When restricted, it means restricted by the building plane and obstacles such as columns in the
passageways.
2. Panel back operation passageway means the passageway behind the panel that is used for
operating the switching equipment .
3. LV cabinet is allowed to be arranged against the wall, leaving a space of more than 200mm.
Table 9- 3: Minimum width of all passageways of electrical control panel ,

DC panel and UPS panel（m）
Name Restricted width Unrestricted width
Width between panel
1.4 1.8
front and panel front
Width between panel
1.2 1.5
front and panel back
Width between panel
0.8 1
back and panel back
Width between panel
1.2 1.5
front and wall
Width between panel
0.8 1.2
back and wall
Panel side passage way 0.8 1.2
PROJECT CODE :

ENGINEERING REV : B
PAGE : 18 / 27
9.5 Warning Signs

10. ELECTRICAL CONTROL

The remote control for each generator and its auxiliary electrical equipment and part
equipment of auxiliary power supply system shall be completed in ECMS. Two operator
stations and one engineer station for ECMS are located in CCR of power house.
Each integrated protection measurement and control device of ECMS system has its own
fault recording function, and the generator unit considers to set up independent fault
recording device.
For the process equipment with control interlocking and which needs to be controlled in the
control center room, DCS control system is used to control starting and stopping sequence of
motors according to the process requirements.
For main 10kV distribution system, soft interlock and hard-wired interlock will be provided.
More detailed logic and philosophy information will be provided by ECMS manufacturer.
10.1 Operation Mode

HV switchgear circuit breaker shall be operated by local manual control and remote control.
For motor feeder switchgear, the auto control can be completed by DCS as need.
Incoming line and bus tie breaker of the 10/0.4kV substation system shall be operated by
local manual control (switchgear location )and remote control.
Feeder breakers of 10/0.4kV substation system are operated by local manual control
(switchgear location ) and remote control.
MCC motor circuit breakers are operated by local manual control (MCC location ).
LV distribution board circuit breakers are operated by local manual control (board location ).
10kV unit auxiliary distribution section incoming circuit breakers are set to fast bus transfer
device, 10/0.4 kV substation line incoming circuit breakers are set to ATS, 0.38kV MCC
distribution line incoming switch is set to auto transfer isolation switch.
10.2 Motor Control

11. PROTECTION CONFIGURATION

High and low voltage systems shall be protected according to the specific requirement of the
project and IEC standards (not limited if applied).
l Generator protection
l Main 10kV feeder line

PROJECT CODE :

ENGINEERING REV : B
PAGE : 19 / 27
l 10kV incoming line protection:
l 10kV busbar:
u Differential protection 87
u Instantaneous overcurrent 50
u Time overcurrent 51
l 10kV feeder line
l 10 / 0.4kV transformer
l 10kV PT
l 10kV motor
l Motor body protection
l Low voltage motor protection
l Low voltage distribution line protection
l 10 / 0.4kV transformer secondary side power line protection
l Low voltage bus section protection
12. METERING AND MEASURING

13. LIGHTING
PROJECT CODE :

ENGINEERING REV : B
PAGE : 20 / 27
13.1 Lighting Type

The determination of lighting types shall comply with the following requirements:
• The lighting shall include normal lighting, escape lighting and stand-by lighting
system throughout the plant. Normal lighting is used under normal conditions. Standby
lighting used to ensure that normal activity continues after normal lighting power lost.
Escape lighting used to ensure that evacuation routes are effectively identified and used
in the event of an accident
• The normal lighting system shall be provided for throughout the power plant part. The
lighting of power house is power supplied by unit PC which installed in LV auxiliary
switchgear room. The lighting of other auxiliary building is supplied by the PC or MCC
nearby.
• The stand-by lighting in power house is power supplied by the Emergency
Lighting Inverter Cabinet. The Emergency Lighting Inverter Cabinet is power supplied
by the 380/220V unit PC and automatic switch to DC system in the emergency
conditions. The lamp with self-contained battery is used for the stand-by lighting in
isolated areas, such as coal handling system, water treatment building. The standby
lighting is also turned on under normal condition. As part of normal lighting.
• The emergency D.C. lighting shall be arranged in the central control room and
diesel motor building. The D.C emergency lighting system voltage shall be of 220V.
The escape lighting shall be installed on the building‘s entrance and staircase and main
pass-way.
The determination of lighting types shall comply with the following requirements:
• Normal lighting shall be provided for work and relevant auxiliary places
• Normal lighting shall reach the required lighting level in the utility area, process
area, loading area and auxiliary area according to the lighting level in table 13-2.
• When the normal lighting power fails in the following places, emergency lighting
shall be set:
• The main control room, fire control room, shall be provided with standby lighting;
• Emergency safety lighting shall be set in the following areas:
u Control room, switch room and generator room, power plant boiler room.
u Fire control panel and fire pump surrounding area.
• Exits and passageway, that need ensuring the safe evacuation of people should
be provided with Escape lighting.
Table 13- 1:Utilization of Lighting Mode
Area Lighting
PROJECT CODE :

ENGINEERING REV : B
PAGE : 21 / 27
Area Lighting
Main control room，switchroom Normal Lighting, Escape Lighting，Standby Lighting
Power house Normal Lighting, Escape Lighting，Standby Lighting
Boiler room & walkways Normal Lighting, Escape Lighting，Standby Lighting
Coal transfer Tower Normal Lighting, Escape Lighting
Coal Conveyor Normal Lighting, Escape Lighting
Coal handling control building Normal Lighting, Escape Lighting，Standby Lighting
Water Treatment system Normal Lighting, Escape Lighting，Standby Lighting
Ash system Normal Lighting, Escape Lighting
Outside plant Normal Lighting
13.2 Selection of Lighting Sources and Lamps
Table 13- 2: Type of lamp
Area Type of luminaire/light source
Workshop Floodlights，LED
Coal Transfer Tower, Coal Conveyor Floodlights，LED
Distribution room LED
Office, laboratory, etc LED
Standby lighting LED/ Built-in battery pack or DC panel
Emergency safety lighting LED/ Built-in battery pack
Escape lighting LED/ Built-in battery pack
Roads Road lamp，LED
Lightings shall be selected in accordance with the following requirements
• Dusty places shall adopt lightings with protection grade not lower than IP55;
• In outdoor places, lightings with a protection rating not less than IP65 shall be used;
13.3 Illumination and Quality
Illuminance standard values are shown in the table below. The deviation between design and
standard illuminance values should not less than - 10%.
PROJECT CODE :

ENGINEERING REV : B
PAGE : 22 / 27
Table 13- 3: Illumination level of lighting design
Installation Location Illumination level (Lux) *1 Highly Remarks
Main Power Block
Turbine house Operating 200 Ground

Floor
Turbine house 100 Ground 200lx

for device needs to
be operated
Boiler Platform 30 Floor
Boiler Walkways 50 Floor
Pumps rows 100 Ground
Walkways, ladders, and 50 Floor For frequently used

stairs only, other 30 Lux
Control room，Switch Room
Main control room and 500 Floor

instrument panels
Switch Room 200 Floor
Back of panels 100 Floor
Auxiliary Buildings & Structures
Workshop 200 Floor
Coal Transfer Tower, 100 Floor
Coal Conveyor 50 Ground
Fire pump room 100 Floor
Tank Room 50 Floor
Bottom ash silo，ect 30 Floor
Storage room, warehouse 100 Floor
Electrical Switchgear
Outdoor Switchgear 20 Ground
Indoor Switchgear 200 Floor
Laboratories
PROJECT CODE :

ENGINEERING REV : B
PAGE : 23 / 27
Installation Location Illumination level (Lux) *1 Highly Remarks
Qualitative, quantitative 500 700 mm

and physical test
Road lighting
main road 5 Ground
subsidiary road 3 Ground
The emergency lighting illumination requirements are as follows:
The illumination of escape lighting shall be no less than 1 Lux in the area below 2 meters
along the route of evacuation center.
Emergency safety lighting shall be no less than 10% of normal illumination and no less than
15 Lux.
Standby lighting is consistent with normal lighting illumination in fire pump house, central
control room.
13.4 Lighting Distribution and Control

13.4.1 Lighting Distribution System
13.4.2 Lighting Control

Table 13- 3: Lighting control mode classification
Lighting control mode

Lighting area
Lighting box Field control Photoelectric
Remarks
circuit breaker switch control
Frequent access to
Turbine house √ √(Remark) and use of the room
Frequent access to
boiler √ √(Remark) √ and use of the room
Frequent access to
Workshop √ √(Remark) and use of the room
Laboratory √
Switchgear room √ √
Corridor stairwell √
Street lamp √ √
14. CABLE
14.1 General
PROJECT CODE :

ENGINEERING REV : B
PAGE : 24 / 27
14.2 Cable Type and Section Selection

14.2.1 Cable Conductor Material
14.2.2 Cable Insulation Level and Type

14.2.3 Cable Sheath Type

14.2.4 Control Cable and Its Metal Shield

14.2.5 Power Cable Section

14.3 Selection and Configuration of Cable Accessories

15. CABLE LAYING

15.1 General
15.2 Laying Method

15.2.1 Cable Tray Laying
15.2.2 Direct Buried Laying

15.2.3 Conduit Layin

15.2.4 Laying of Cable Structures

15.3 Cable Support and Fixing

15.3.1 General
15.3.2 Cable Support and Cable Tray.

15.4 Fire Proof Sealing System For Cable

PROJECT CODE :

ENGINEERING REV : B
PAGE : 25 / 27
16. GROUNDING AND LIGHTNING PROTECTION

16.1 Basic Design Condition
16.2 Ground Network

16.3 Equipment Grounding Requirements

16.4 Grounding Electrode

16.5 Lightning Protection

17. ECMS
The ECMS is used for electrical power system data acquisition and system condition
monitoring and control function of electrical devices.
The ECMS shall set control&monitoring cell, fiber-optic cable redundant communication
buses, two computerized operator stations, engineering station, man-machine interfaces
(MMI), printers, gateways modems, etc.
The power system is connected to ECMS through communication or hard wiring(internal

switchgear wiring). The meters and protection devices in the high-voltage switchgear are
connected to ECMS through communication.
The ECMS and DCS are connected through suitable, fast, reliable and redundant
communication. ECMS monitors and controls all electrical equipment (including generator
and excitation system, high-voltage and part of low-voltage distribution swithgear, diesel
generator and emergency auxiliary power system, DC and UPS system (only for supervising),
excluding motor). DCS only monitors electrical equipment of ECMS system and does not
participate in control operation.
The ECMS shall be engineered and designed as a complete system with an open
architecture (system communications shall be Profibus DP, Modbus TCP, RS-485,
Modbus RTU, Ethernet TCP/IP, IEC 61850 or equal).
Communication interface between ECMS and the main monitoring&control system in

alumina plant shall be reserved.
18. SPECIFICATIONS FOR ELECTRICAL ENGINEERING DESIGN OF POWER PLANT

18.1 GENERAL
This specification defines the requirements for the electrical engineering design, manufacture,
factory testing and delivery of package electrical equipment for process equipment and
materials supplied of thermal plant.
PROJECT CODE :

ENGINEERING REV : B
PAGE : 26 / 27
The EPC contractor will provide a power supply to the termination point of the Vendor’s
equipment.
The Vendor is responsible for completing all electrical work within his package, including:
• Electrical design.
• Supply produced drawings.
• Software programming.
• Package assembly.
• Guide installation and commissioning.
• Factory unit test and test run.
• Maintenance manual
• Installation, operation and storage manual
• Spare parts list and special tools
• Shipping in one piece wherever possible. Any loose pieces which cannot be mounted
on the equipment must be carefully marked, tagged and boxed with the same
equipment, complete with installation instructions where applicable.
• Supply of technical information including installation instructions, operations manual,
technical manuals.
18.2 Standards and Code
According to document CAS1969-2G00-31-111-001_0 section 3.1.1, 3.1.2 and 3.1.3
Reference drawing/document:
CAS1969-2G00-31-111-002 Technical Specification of Motors
CAS1969-2G00-05-111-001 Engineering Specifications for Painting
CAS1969-2G00-31-110-001 Design Criteria for Electrical Engineering
18.3 Main Abbreviation and Definition
Table 18-1: Abbreviation and Definition
Abbreviation Definition
HV High Voltage above 1,000V
LV Low voltage equal or lower than 1,000V but higher than 50V.
UPS Uninterruptable Power Supply
Substation Transformer and Distribution(10/0.4kV)
MCC Low Voltage Motor Control Center

18.4 VENDOR DOCUMENTATION
According to document CAS1969-2G00-31-111-001_0 section 5.
PROJECT CODE :

ENGINEERING REV : B
PAGE : 27 / 27
18.5 TECHNICAL AND DESIGN REQUIREMENTS

18.5.1 Electrical Supply
According to document CAS1969-2G00-31-111-001_0 section 6.2.
18.5.2 Low Voltage MCC (Motor Control Centre)

18.5.3 Distribution Board

18.5.4 Variable Frequency Drives

18.5.5 Power sockets in buildings

18.5.6 Sockets for welding and convenient outlet

18.5.7 Local Control Panel

18.5.8 Outdoor junction boxes

18.5.9 Equipment Nameplates

18.5.10 Terminal Blocks

18.5.11 Cable Design Requirements

18.5.12 Cable Tray Material of Construction

18.5.13 Conduits
18.5.14 Grounding and Bonding


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DESIGN CRITERIA FOR ELECTRICAL ENGINEERING of POWER PLANT

PURPOSE : ISSUED FOR REVIEW

Consortium CHALIECO - PT PP (Persero) Tbk

REV. NO. DATE DESCRIPTION Prepared Checked Approved

B 20/06/2023 For Review 龚迅 周婉亚 王茜 叶学勇 胡振兴 郭世峥

DESIGN CRITERIA FOR DOCUMENT NO : F08941C-D02-01

REVISION CONTROL SHEET

REV.NO. DATE DESCRIPTION

A 14/03/2021 1st Issued

B 20/06/2023 2nd Issued

EXTERNAL ISSUE CHALIECO-INTERNAL ISSUE

PT BORNEO ALUMINA INDONESIA PROJECT MANAGER

PMC ENGINEERING MANAGER

PROJECT CONTROL MANAGER

DESIGN CRITERIA FOR DOCUMENT NO : F08941C-D02-01

3.2 Main Abbreviation and Definition ...................................................................................................... 7

3.3 Reference drawing/document ........................................................................................................... 8

4. Environmental Condition ........................................................................................................................ 8

4.2 Outdoor ............................................................................................................................................. 8

5. Design principles .....................................................................................................................................8

5.2 Voltage Level .....................................................................................................................................8

5.3 Electrical system structure ................................................................................................................ 8

6. Equipment Requirement ......................................................................................................................... 9

6.2 Oil Immersed Power Transformer .....................................................................................................9

6.3 Synchronous Generator .................................................................................................................. 10

6.4 Generator Bus Duct ........................................................................................................................ 11

6.5 High Voltage Switchgear .................................................................................................................11

6.6 Low Voltage Switchgear ..................................................................................................................11

6.7 Motor ............................................................................................................................................... 11

6.8 Current limiting reactor ....................................................................................................................11

6.9 UPS Power ......................................................................................................................................12

6.10 DC Power Systems ....................................................................................................................... 12

6.11 Low Voltage MCC (Motor Control Centre) ....................................................................................12

6.12 Variable-frequency Drive ...............................................................................................................12

DESIGN CRITERIA FOR DOCUMENT NO : F08941C-D02-01

6.13 Power Sockets in Buildings ...........................................................................................................12

6.14 Sockets For Welding and Convenient Outlet ................................................................................12

6.15 Switch disconnector fuse .............................................................................................................. 12

6.16 Local Control Box ..........................................................................................................................12

6.16.1 Button box ......................................................................................................................... 12

6.16.2 Push Button Assemblies ................................................................................................... 12

6.17 Outdoor Junction Boxes ................................................................................................................13

6.18 Package Equipment ...................................................................................................................... 13

6.19 Local Distribution Board/Panel ......................................................................................................13

6.20 Hazardous area division and corresponding equipment selection ............................................... 13

7. Design Calculations and Studies .........................................................................................................14

8.2 Normal Mode ...................................................................................................................................14

8.3 Maintenance Mode ..........................................................................................................................14

8.4 Emergency Mode ............................................................................................................................ 15

8.5 Black start facility ............................................................................................................................ 15

8.6 Diesel generator ..............................................................................................................................15

9. Power distribution and substations .................................................................................................... 16

9.2 Temperature of Substation ............................................................................................................. 16

9.3 Doors, Windows and Wall Penetrations ......................................................................................... 16

9.4 Building Sizing and Equipment Arrangement ................................................................................. 16

9.5 Warning Signs ................................................................................................................................. 18

10. Electrical control ..................................................................................................................................18

10.2 Motor Control .................................................................................................................................18

11. Protection configuration .....................................................................................................................18

DESIGN CRITERIA FOR DOCUMENT NO : F08941C-D02-01

13. Lighting .................................................................................................................................................19

13.2 Selection of Lighting Sources and Lamps .................................................................................... 21

13.3 Illumination and Quality .................................................................................................................21

B 20/06/2023 For Review 龚迅周婉亚王茜叶学勇胡振兴郭世峥