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ELECTRICAL CONCEPT NOTE OSD FORMULATION FACILITY National Pharmaceutical Industries
DOC.NO.: NPI_SA_EL_CN_V.0
DL International
NATIONAL PHARMACEUTICAL INDUSTRIES JEDDAH , KINGDOM OF SAUDI ARABIA
OSD FORMULATIONA FACILITY AT SAUDI ARABIA
ELECTRICAL CONCEPT NOTE
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ELECTRICAL CONCEPT NOTE OSD FORMULATION FACILITY National Pharmaceutical Industries
DOC.NO.: NPI_SA_EL_CN_V.0
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CONTENTS S. No.
Description
Page No.
1.
Project Information
2
2.
Introduction
2
3.
Design Basis
2
4.
Scope of Work
2
5.
Abbreviations used
2
6.
Basic Design Philosophy for Electrical System Design
3
7.
Proposed Distribution Scheme (Attached separately)
4
8.
Load Assessment sheet (Attached separately)
4
9.
Primary Power Distribution / Control /Operation system
4
10.
Power Factor Compensation
5
11.
Philosophy For Selection of Electrical Equipments-
6
HT Switchgear, Transformer, DG set, LT s, HT/LT Cables, UPS etc. 12.
Illumination system
11
13.
Power Outlets
13
14.
Wiring/Cabling
13
15.
Low Voltage System
13
16.
Cable Trays & Cable Glands
16
17.
Earthing and Lightening Protection System
16
18.
Work Scope of Electrical Contractor
17
19.
Tender Document
17
20.
Detailed Drawings and Documents
18
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DOCUMENT REVISION HISTORY Document name
Revision
Revision by
Date
Status note
NPI_SA_ EL_CN_V.0
0.0
B.Patel
15/09/2017
First release for comments
PROJECT INFORMATION
1.
2.
Owner-
M/s National Pharmaceutical Industries
Project Title-
OSD Formulation Facility
Project Location-
M/s National Pharmaceutical Industries At KAEC, Kingdom of Saudi Arabia
Engineering Consultant -
M/s DL International.
INTRODUCTION Description of documentThe purpose of this document is to specify the requirements and general scheme of Electrical system for proposed Formulation facility. This document concludes design and distribution concept based on the requirement of Process, HVAC, Utility equipments, Power & Lighting.
3.
DESIGN BASIS Electrical design criteria used in the design and detail engineering of Electrical System Design is based on project’s present requirements, various codes and standards, good engineering practice and local climatic conditions.
4.
SCOPE OF WORK Design of electrical distribution system for the proposed facility as per the standards which includes HT/LT distribution system, LT PCC, Distribution s, Power & Lighting DBs, Internal/External Lighting Layouts, Power Layouts, Cable tray Routing, System Earthing, Low voltage (CCTV/ Networking/ Door Interlocking (Infra Red sensing device)/ Access control (Bio Metric type) / Digital clock etc. system design, Equip. Specifications, BOQ, Cable Schedule, Tendering etc..
5.
ABBREVIATIONS (list of abbreviations is too small. Many abbreviations are missing. Highlighting them in red and underlining throughout the document. HV MV LV PCC DB LSDB ELDB PSDB UPSDB MLDB MPDB RTPFC 15/09/2017
- High Voltage - Medium Voltage - Low Voltage - Power Control Centre - Distribution Board - Lighting Sub Distribution Board - Emergency Lighting Distribution Board - Power Sub Distribution Board - UPS Fed Distribution Board - Main Lighting Distribution Board - Main Power Distribution Board - Real Time Power Factor Compensation /correction Page 2 of 19
ELECTRICAL CONCEPT NOTE OSD FORMULATION FACILITY National Pharmaceutical Industries MFM
DOC.NO.: NPI_SA_EL_CN_V.0
DL International
- Multi Functional Meter
BASIC DESIGN PHILOSOPHY FOR ELECTRICAL SYSTEM DESIGN
6.
6.1. Area Classification: Most of the plant area is classified as clean room type & shall be equipped with clean room fixtures except few areas such as /Store which will be equipped with Non clean room fixtures. For Flame proof classified areas (Like: Granulation and Coating etc.), it shall be equipped with Flameproof Fixtures &and other essentials. 6.2. Design Ambient / Service Condition: All electrical equipment shall be designed for tropical climatic conditions. The ambient temperature and relative humidity to be considered for design of electrical equipment shall be 50oC max. and 80% average respectively. All electrical equipment, materials and installation shall be designed for suitable for operation under site conditions. Electrical equipment intended for outdoor installation shall have minimum protection of IP 65 (in accordance with SBC 401 standards). Electrical equipment intended for indoor installation shall have minimum protection of IP 42 (in accordance with SBC 401 standards). 6.3. Codes & Standards: Equipment, material and installation shall confirm to the latest edition of relevant Saudi Arabia Standards, Saudi Arabia Electricity Act, Saudi Building Code Electrical Requirement (SBC 401), TAC recommendations, Loss prevention Association of International and National Code of practice for electrical installation. Electrical systems design and installation shall be carried out in accordance with International Electro technical commission and Saudi Arabia Standards, in particular:
Saudi Arabia Act Saudi Arabia Rules Saudi Building Code Electrical Requirement (SBC 401) IEC code IEEE Code Classification of Hazardous Areas for Electrical Installations
6.4. Inspection & Testing: All equipment shall be inspected and routine tested as per relevant Saudi Arabia Standards at the manufacturer’s works and type tested as per purchase order prior to dispatch to site. After receipt on site, the equipment will be again inspected for any damage in transit. After installation and before commissioning, pre-commissioning tests will be carried out. 6.5. Incoming Supply & Metering: 13.8KV/0.380KV Substation shall be considered. 13.8 KV supply is available from local network of (SAEB). Supply is tapped from nearest overhead network to 4 pole structure for Proposed Facility supply arrangement. 6.6. Sub Station:
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Proposed 13.8/0.380KV, 3 phase, frequency 60Hz Oil Immersed Transformer’s (1600KVA approx.) primary through underground HT cable. The Transformers shall be kept out door, near the proposed Utility Block. The LT PCC shall be placed in LT room inside the Utility Block. Power distribution system shall be designed centralized for proposed facility. 6.7. Fault Levels At Various Voltage Levels: considered:
Following voltage levels and fault levels shall be
6.8. (did you consider the soil resistivity from the soil testing report? If not put a disclaimer here) Voltage Level a) 13.8 KV b) 380 V
Maximum Fault Level 32KA for 1 sec. 50KA for 1 sec. at transformer sec.
7.
PROPOSED DISTRIBUTION SCHEME- (SEPARATE SHEET ATTACHED)
8.
LOAD ASSESSMENT SHEET- (SEPARATE SHEET ATTACHED) The total connected load requirement for all facilities (Granulation, Coating & RMG) is estimated as *** why is the load missingKW (Preliminary). This shall include the Machine process equipment loads, HVAC loads, Utility Loads, Lighting loads and other misc. load for proposed facilities. Detailed sheet is attached separately.
9.
POWER DISTRIBUTION /OPERATION AND CONTROL SCHEME 9.1. The 13.8KV incoming supply from VCB will feed the 1600kVA (approx.) Transformers. The transformers shall be ONAN cooled. The transformer will have on load tap changer (OLTC). The range of tap change shall be + 10% to - 10%. Thus 380V LT outgoing shall feed the LT PCC which shall be placed in LT room in Utility Block. 9.2. From LT PCC power will be distributed through XLPE insulated armored cables to the individual blocks Main s, Chiller , MLDB, Common Utility (feeding common utility equips.), Fire etc. considering convenience of distribution and operation. 9.3. LT Supply from Transformer through bus bar shall be connect in LT PCC . 9.4. Chiller & Utility shall be placed at Utility block portion. Chiller shall feed to all HVAC high side requirements like- Chillers and relevant pumps where as Utility shall feed to all utility equipments located in the building. The same shall have additional feeders for miscellaneous outdoor requirements. E.g. Boiler house, ETP, Fuel Pumps, Bore well, Raw Water Pumps etc.
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9.5. Individual block’s Main s will feed Process s and HVAC s, & PDB etc. Process in turn will distribute power locally to individual process equipments. MLDB shall feed floor wise/ Area Wise Lighting Dist. Boards; whereas HVAC shall feed HVAC units (Low side) and PDB will feed Local PSDBs etc. These s shall be placed at convenient location @ Technical area on service floors. 9.6. Proposed Single phase power sockets shall be powered through PSDBs for raw power and UPSDBs for UPS connected power socket outlets. Three Phase power sockets outlets shall be powered through PSDBs (3ø). These DBs shall be fed through the PDB . 9.7. Proposed Lighting shall be powered through LSDBs for raw power connected Light fixture and ELDBs for Inverter/UPS fed Light fixture and these Lighting DBs shall be fed through respective block’s MLDBs/ PDBs. 9.8. The PSDB’s, LSDB’s, ELDB’s & UPSDB’s shall be installed at Technical area to supply power to sockets. 9.9. Provision for Separate UPS systems (For Lighting & Power) will be kept for equipment s under Low Current category and other specified equipments. It is suggested for the following equipment’s:
o o o o o
10.
For critical production equipment having separate UPS to be considered for equipments. For critical HVAC system, like: Class B AHUs, QC Micro labs AHUs, RLAF, All LAF related to Class A, etc. Why do you want AHUs on UPS? BMS/IT/Security/Communication systems QC/ Lab Instruments having separate UPS. Emergency Lighting to be considered on separate UPS. (This list should be made and confirmed from Client)
POWER FACTOR COMPENSATION DEVICES Power factor of the electrical system shall be improved by incorporating power factor improvement capacitors on 380 V bus of LV switchgear at load centre i.e in LT Room, such that overall system PF shall not be less than 0.99 lag. One Real Time power factor controller shall be provided in LT room for total load on the transformer. The Real Time power Factor controller (RTPFC) shall constantly monitor the power factor of distribution system and based on that , cyclically select capacitor units to be switched ON/OFF so as a result, the power factor is controlled within preset range. PF improvement capacitors shall be complete with discharge resistors. Each bank shall comprise of suitable combination of capacitors of different size. Number of banks shall be decided as per design. transformer lagging power factor compensating capacitor shall be tapped on busbar before power factor correction CT and shall be ON permanently. We can also considered additional capacitor bank for PF correction for Utility which is having maximum electrical load.
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11.
DOC.NO.: NPI_SA_EL_CN_V.0
DL International
PHILOSOPHY FOR SELECTION OF ELECTRICAL EQUIPMENT : 11.1.HT Switchgear:
11.1.1. 13.8KV HT Switchgear shall be in accordance with specification. Minimum Rating for HT shall be 800 Amp for 13.8 KV System. It shall be Indoor, fully draw out type with natural air-cooled design, with degree of enclosure protection of IP55 and shall be in accordance of standards. 11.1.2. Switchgear, bus bar, CT shall be designed for minimum 32kA fault level for 1 sec. The current transformers and potential transformers shall be of epoxy resin cast type. CT secondary shall be rated for 5A continuous current ratings of the breakers shall be decided based on the application requirement and after considering appropriate derating factors on of site ambient and mounting conditions. 11.1.3. Breaker shall be provided with draw out type on line PT. All bus sections shall be provided with draw out type bus PTs. All PTs shall be provided with primary and secondary fuses. 11.1.4. The circuit breaker shall be provided with trip coil and suitable trip circuit supervision relay and other necessary Numerical protection relays. Control voltage for circuit breakers shall be 110 V DC supply. 110 V DC supply shall be provided through a power pack. 11.1.5. Provision of power and control cables entries shall be from bottom. 11.1.6. Internal control wiring shall be carried out with 1.5 mm2 stranded copper conductor 1.1 KV FRLS grade PVC insulated flexible wires. However, CT circuit wiring shall be carried out with 2.5 mm2 stranded FRLS copper conductor flexible wires.
11.1.7. Suitable extension facility on switchgear shall be provided for addition of switchgear s at a later date. 11.2.Transformer: 11.2.1. 1600kVA (approx.). ONAN transformer will be installed outdoor near Utility Block.
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11.2.2. Voltage ratio of the transformers shall be 13800/380 volts. The transformer vector group shall be Dyn11. Transformer loading should not exceed more than 90% of rated capacity. 11.2.3. Transformer shall be provided with ON circuit taps in the range of +10% to -10%. There will be motorized tap changer on the H.T. winding controlled by automatic voltage regulator to maintain constant voltage in specified range of variation. The taps will be in the range of 1.25% voltage steps. 11.2.4. For transformer’s protection necessary protection relays shall be provided in respective 13.8 KV switchgear. Additionally provisions for protection against winding temperature high, oil temperature high, any internal fault conditions (Buchholz Relay), oil level low is made. 11.2.5. Transformer shall be provided with standard accessories like conservator, Buchholz relay, marshalling box, OTI, WTI, magnetic oil level gauge, silica gel breather, explosion vent, drain valves, grounding lugs, jacking pads, filter valves, disconnecting chamber, cable end boxes, radiators with shut off valves, lifting lugs, bi-directional rollers, oil surge relay for OLTC etc. 11.2.6. Cable box on HT side shall be detachable type complete with disconnecting chamber; LT side shall be suitable disconnecting chamber for Bus Duct. 11.2.7. Detailed features of transformer shall be given in the technical specification . 11.3.Power Control Centre11.3.1. LT PCCs shall be indoor type of metal clad construction, partly draw out type having self-aligning type auxiliary s for circuit breakers and draw out modules. All Air Circuit Breaker modules shall be draw out type; other feeders like MCCBs shall be fixed type. The LT PCC shall be located in LT room proposed in Utility Block. 11.3.2. Dual power supply shall be provided to LT PCC which shall provide continuous supply to electrical loads of the proposed facility. 11.3.3. Air circuit breakers of incoming transformer shall be with current display feature, within built microprocessor based overload, short circuit, earth fault release and should be communication (RS 485 port to be considered) with EMS (energy monitoring system). In addition shunt trip coil and closing coil shall be provided. 11.3.4. TPNE (three phases – neutral earth) Bus bars and air circuit breakers shall have short circuit withstand capacity of 50/65 KA for 1-second duration. 11.3.5. All the Incomer and outgoing switchgears should be 4P. 11.3.6. For all incomers shall be having Load Manager with Demand shall be provided. For other feeders digital MFM shall be provided. And all the meters of LT PCC s shall be having comm. port – RS 485. 11.3.7. Cable shall be laid from LT PCC to individual block’s Main s, the LT PCC shall be located in LT room proposed in Utility Block.
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11.3.8. 20% spare feeders/modules shall be provided on the switchboard with at least one spare feeder module of each rating and type. 11.3.9. Control supply voltage for various starter modules shall be 220V AC. For control supply separate control bus shall be provided in the and control voltage for individual module shall be tapped from control bus. Individual module, DP MCB is to be provided which can be accessed only after opening the module door. This MCB will isolate the control supply of individual module whenever required. The control bus will be tapped from any one phase and neutral of the main bus bar. 11.3.10.
All cable entries to s shall have provision of top/bottom as specified on SLD.
11.3.11.
Heavy Duty Exhaust System will be considered for each Vertical Busbar section/Alley and ACB feeders/compartments above 1000A rating.
11.3.12.
Max height of LT PCC shall be 2375 mm. and operating height shall be 2000mm.
11.3.13.
Suitable extension facility on switchgear shall be provided for addition of switchgear s at a later date.
11.4.Power Distribution s11.4.1. Distribution s shall be indoor type, sheet steel enclosed, compartmentalized, single front. The modules shall be non-draw out type for outgoing feeders and draw out for incoming/outgoing feeders if it is ACB. 11.4.2. TPNE (three phase – neutral – earth) Bus bars and air circuit breakers shall have 50/35/25kA short circuit withstand capacity for 1-second duration. 11.4.3. Each Distribution s shall be provided with 100% rated Incomer. Incomer shall be MCCB up to 630A rating and above the same shall be ACB. 11.4.4. All MCCBs of 250A and above shall be of Microprocessor Based with Overload, Short Circuit and Earth Fault Protection. There should be fault indication and fault differentiation between S/C & E/F. 11.4.5. MCCBs up to 200A shall be with Thermal release. 11.4.6. All switchgears incoming and outgoing shall be 4P. 11.4.7. Distribution shall house DOL starters for motors rated up to 7.5 KW OR Star Delta starters for all motors rated above 7.5 KW. For individual motor starter module, MPCB/MCCB/ors/Relay etc. as per manufacturer’s Type-2 coordination chart. 11.4.8. Motor starters rated up to 7.5 KW shall not be provided with ammeter. Motor starter modules rated 10 KW and above shall be provided with CT + Ammeter for current indication. Each starter module shall be provided with ON, OFF push buttons in addition to ON, OFF and TRIP indication lamps with MPD protection device instead of thermal over load.
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11.4.9. Motor Starters rated above 30kW shall be fed from the means of MCCB + VFD/Star Delta as per requirement. 11.4.10. All CTs and PTs shall be Resin cast type. Secondary of all CTs shall be rated for 5A. 11.4.11.
Each ’s incomer shall have Multi Function meter with Communication port.
11.4.12. Internal wiring of Distribution modules shall be carried out using 1.5 mm2; copper conductor PVC insulated flexible wires. For CT wiring conductor size shall be 2.5 mm2 copper. 11.4.13. All cable entries to s shall have provision of top/bottom as specified on particular SLDs. 11.4.14. 20% spare modules of each rating shall be provided on with at least one spare module of each rating and type. 11.4.15. Current density for Copper bus bar shall be considered 1.2 A/mm². 11.4.16. Tinned copper earth bus shall run all along the for earthing. 11.4.17. Wall mounting type Lighting and small power distribution boards shall be located in room, strategic location, Technical area or inside Block. The distribution switchboards shall be in accordance with specification. The distribution switchboards shall be suitable for indoor having IP-42 protection. 11.4.18. Suitable extension facility on switchgear shall be provided for addition of switchgear s at a later date. 11.4.19. Maximum height of Distribution s shall be 2.2 Mtr. And operating height shall be 1.8 Mtr. 11.5.DBs configuration shall be as under – 11.5.1. Lighting DBs – Incomer – TPN MCB, Sub Incomer DP RCCB (100mA), Outgoings 10/16 Amp SP MCBs. 11.5.2. Raw Power DBs- Incomer-TPN MCB, Sub Incomer DP RCCB (100mA), Outgoings 10/16 Amp SP MCBs. 11.5.3. UPS Power connected DBs- Incomer -2P/4P RCCB (30mA), Outgoings 10 Amp SP MCBs for Lighting Purpose and 10/16 Amp SP MCB for Power socket outlet purpose. 11.6.AC Uninterruptible Power Supply (UPS) SystemAC UPS systems shall be in accordance with specification. On line three phase input – three phase output Centralized AC UPS system to provide continuous power supplies to the following systems shall be considered:
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DOC.NO.: NPI_SA_EL_CN_V.0
PC/LAN System Access Control System (Bio Metric type) AV System CCTV System Door Interlock (Infra Red type sensing device) Digital Clock (with real time and date) Critical Production Equipments Specified QC / Lab Instruments (Dedicated UPS shall be provided for all QC instruments as reqd.)
11.7.UPS System UPS systems shall be in accordance with specification as an option to control Emergency lighting system of the facility. Single phase input- single phase output UPS shall be considered for Emergency Lighting system. Static type UPS shall be considered for Injectable critical equipments. The UPS systems shall be designed for uninterrupted power supply for 30 minutes in case of power failure. 11.8.HT/LT Cables SelectionSelection of cables shall be done on the basis of the following guidelines: 11.8.1. HT Cable- Cu XLPE insulated Ar. unearthed FRLS Grade cable shall be suitable for system. 11.8.2. All power cables shall be of copper multi strength armored conductor XLPE insulated, 1.1 KV FRLS grade, XLPE insulated type. Low voltage power cables 1.5 mm² and less size shall have PVC insulation. (SBC / IEC standard) 11.8.3. All control circuits cables shall be of stranded copper conductor, with minimum conductor size of 1.5 mm2, 1.1 KV FRLS grade, PVC insulated type. 11.8.4. Cables sizing shall be done based on continuous current rating of equipment and after applying de-rating factors on environmental and laying conditions. Incomer cable to 13.8KV switchgear shall be sized considering load and fault current. 11.8.5. Voltage drops in various cables are restricted to the following limits while sizing the cables:
i)
Between 13.8 KV receiving point & Transformer.
3% of 13.8 KV
ii)
Between 415 V switchgear terminals (LT PCC to PDB, MCC)
2% of rated voltage
iii)
Under full load running
3% of rated voltage
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DOC.NO.: NPI_SA_EL_CN_V.0
iv)
Under starting
15% of rated voltage
iv)
Lighting main circuits (up to LSDB)
2% of rated voltage
v)
Lighting sub circuits
2% of rated voltage
11.8.6. Short circuit withstand capacities of various cables shall be as under:
Sr. no.
Description
S/C Current Value & Its duration
i)
13.8KV incoming cables
:
32 KA for 1 second
ii)
13.8 KV outgoing cables to Transformer
:
32 KA for 1 second
iii)
380 V cable between LT PCC outgoing ACB/MCCB and Incomer to MCC / Power Distribution Boards
:
50 KA for 1 second
iv)
380 V Cable between MCC / Power Distribution Boards and motors / Power Sub Distribution Board
:
50/35/25kA (As per Calculation)
12. ILLUMINATION SYSTEM For proper and safe operation of plant, a complete and adequate lighting illumination shall be provided as under: Illumination (Lux)
Area i)
Manufacturing, Process, packing
:
400-500
ii)
Aisles, Corridors in manufacturing Areas
:
250
iii)
Offices
:
250-300
iv)
Utility / Technical Areas
:
200
vii
Laboratories /QC/QA
:
400-500
viii)
Inspection
:
NLT 500
ix)
External Lighting
:
15-20
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Level
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Adequate lighting (approx. 5-10%) in entire plant shall be provided from emergency AC source. The emergency lights shall be identical to normal lights in those areas, but they shall be connected through centralized UPS systems located at strategic locations. Such that in case of power failure there will not be complete blackout in areas to avoid accidents.
12.1. In Clean Room areas – In Main Process Area Clean Room Fixtures with SS304 shall be top open able & other area shall be Bottom Cover- with LED lamps will be used. (Bottom open able light fixture to be consider where at no space between walkable ceiling and Main ceiling).
12.2. Lighting fixtures for general area will be operable from the bottom (Surface / recess mounted) with LED lamps.
12.3. Medium Bay / High Bay type 80W or 100W or 150W LED luminaries shall be used in appropriate non hazardous locations such as warehouses, workshops, Utility area etc. And LED type Industrial fixtures shall be used for Tech. Areas.
12.4. In hazardous classified Clean room areas (Coating, Solvent Rooms) light fixtures (suitable for 2X20W or 2X30W LED lamps) will be flame proof type.
12.5. Suitable Nos. of Sodium Vapor Lighting Fixtures shall be used in specified areas for light sensitive products. The room lux level to be minimum 90 to be considered. 12.6. In addition to normal plant lighting, Solar or normal LED street lighting shall be provided on street lighting poles.
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13. POWER OUTLETS: 13.1. For general areas switches/socket outlets and other devices will have Poly carbonate front cover plate. 13.2. In hazardous classified areas Power outlets (Industrial) will be flame proof type as per standards. 13.3. In Clean room areas switches/socket outlets and other devices will be with SS 304 cover Plate type as per standards. 13.4. Equip. Up 7.5KW shall be fed through the dedicated 3-Phase Industrial Sockets or through SS Pendant. 13.5. The cable tray will be installed above modular false ceiling and below the RCC slab for taking connection to various equipment in clean rooms throughu common SS pendant or an individual SS pendant from false ceiling up to the point of connection on individual equipment. 13.6. The electrical connection for light switches and power switch sockets to be installed on modular wall s will be taken from cable trays throughu conduits provided in modular partition wall s as per design and connected to individual connections. 14. WIRING/CABLING: The points and circuit wiring in the Non flameproof area shall be provided with PVC FRLS grade Copper flexible cable in recessed/surface Heavy duty PVC FRLS conduit. The wiring/cabling installations shall confirm to IS latest addition. In Flameproof areas point wiring and circuit wiring shall be done by Cu. Ar. Cable using double compression glands. For Equipments 1.1KV Grade XLPE insulated Cu. Ar. Cable shall be provided. 15. LOW VOLTAGE SYSTEM: Low Voltage System concludes Data Point, Voice Point, CCTV, Access Control, Door Interlocking, Digital clock, Attendance Recording, PAS, FAS etc. Occupancy sensor to be considered in the area, to considering energy conservation of lighting load. 15.1. Data and Voice System:
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Data system for the computers shall be provided as per the requirement.
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Data Cable shall be CAT6/ CAT6A (U/FTP Cable , up to 650 MHz )
Data Cable with Conduits and data I/Os and Face plate for Computer Network, Loaded Patch , Network Rack, Patch cord, Network switch, LIU shall be designed.
Voice point shall be provided as per the requirement.
Telephone Cable shall be CAT6/ CAT6A (U/UTP Cable , up to 450 MHz )
Telephone cable shall be distributed to all areas through a net-work of cables in PVC conduit.
Multi-core telephone cables shall be provided between the EPABX and individual floor/block Network rack.
15.2. Door Interlocking System:To control more than one door such that only one door can open at a time and all doors controlled through a central monitor having emergency defeat facility. Door Interlock system is used to prevent the simultaneous Opening of Airlock /Change room doors. The system thus aids in minimizing the microbial, particulate contamination and also the disturbance of Area Conditions.
Combined/room wise door interlock system shall be provided along with the access control and biometric access control system to be used.
The Door Interlock System comprises of Door Controller, Door Stations, Electromagnetic Locks, Door Position Indicators base on Infra Red sensing device and Power supply unit.
The Door Controller monitors the status of the Doors and controls the locking and release sequence of the Doors.
The can request for release of the door by pressing the emergency push button.
The Door Emergency Station is provided to override the Interlock logic and release all the doors and allow free age during an Emergency event.
All service entry door will have access control system.
15.3. IP based CCTV Surveillance System:Our Concept covers the CCTV system consists of IP based cameras connected with centralize monitoring / NVR system through CAT6/ CAT-6A cable. Requirements associated with regards to CCTV shall be established, IP based cameras and associated equipments like NVR system etc. will be provided to cover internal footprints of the general areas. Control and monitoring equipment will be provided together with remote connection facilities.
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CCTV cameras shall be located at the convenient/required locations i.e. All process area/ages/Stores/Work stations and at entrance of each block etc.
CCTV Camera shall be IP based Dome type, fixed type, PTZ type, motion base type, 360 degree rotate type, etc. as per applicable. All Camera shall have separate UPS power socket outlets.
The system shall be comprised Cameras, PoE Switches, Data Cable, Network video recorder, TV Monitor etc.
All the cameras shall be connected through Data point to Network switch to NVR and the unit shall record all the cameras full scale images for 180 Days recording storage facility.
Control monitors shall be in Low Voltage room.
Emergency door will have motion sensing based camera system and rest it is fixed type. Also all process rooms, service area and engineering department will have fixed type camera system.
Outer side will have PTZ type camera system.
Security gate 1 & 2 will have 360 degree rotate type camera system.- To check and consider accordingly.
15.4. Access Control System (Card Reader):Access control shall be provided at the main access points (of specified areas) to restrict and monitor personnel flow into and out of the room to allow only authorized staff entry to the restricted areas through thumb print or any other matrix. The systems will have the facility to monitor and record personnel access and egress from the Room. The unit shall be mounted near the controlled door and shall require single phase control. The control wiring to be hooked to the electrical lock of door which is to be controlled and having networking inter connectivity.
15.5. Public Address System (PAS): Public address system will be provided in , Stores, Corridors/ages, Canteen, Service floors etc. There will be one microphone station near security office, from which announcements can be made to reach whole plant. The speakers will be looped zone wise and with a selector switch the required zones or all zones can be selected. The same system can be used as music system if required. 15.6. Fire Alarm System: The Fire alarm system with multi criteria detectors will be provided. The detectors will be provided in AC duct also in case any smoke is detected in the duct the AHU will be switched off. This output can be linked with FA System to give alarm. The FA system will
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be addressable type and exact location of detector device operation will be known in room. Optical multi criteria detectors, intrinsically safe flame proof detectors in Flame proof areas and Hooters /Strobes, Fire Alarm control , Manual call points, Control Modules, Monitor Modules and Isolator Modules etc will be provided in the area at certain intervals depending on the layout of the area. Fire detection & alarm system has been considered in all classified areas, Technical and general areas. The zoning shall be carried out based on all areas for easy location of fault in display The multi criteria detectors will be ceiling mounted, hooters and M will be mounted on wall and will be concealed. In Security Room, LCD display will be used to indicate exact location where the alarm is activated so that the Security/Fire Officer can immediately proceed to the exact point of fire where it is detected. 16. CABLE TRAYS & CABLE GLANDS 16.1. Cable Trays shall be of SS304 or Hot Dipped G.I. (80 micron thickness) Perforated or ladder type construction for power cables & Control cables. Standard tray widths shall be 750 & 1000mm for ladder type trays and 100, 150, 300 & 400, 600 & 1000MM for G.I. perforated with 100/50/25mm of collar. Thickness of material shall be 2.5/3 mm. 16.2. Standard tray length shall be 3 m and trays shall be ed at every 1.5 m interval. 16.3. Cable glands shall be made of Nickel-plated brass, single compression type. However flame proofs terminations shall be with double compression type flame proof glands. 16.4. Minimum distance of 400mm shall be maintained between Low voltage cable Tray (Instruments control supply) and Power Cable tray. (Both are separate cable tray to avoid the harmonics distortion and data corruption). 16.5. In process area for the equipment above 7.5KW as far as possible the cables shall be dropped through SS Pendant of 25mm/50mm/75mm dia. From the technical areas to near/on the power supply point of the machine through the opening in the ceiling. These openings will be properly sealed. 17. EARTHING & LIGHTNING PROTECTION SYSTEM 17.1. Earthing system shall be designed as per IEEE80 or SBC 401 and other statutory regulations. 17.2. Material of earthing conductor in plant area shall be chemical base earthing. All earth electrodes shall be interconnected using G.I. conductor. 17.3. Power system earthing and equipment body earthing bonding shall be achieved by a common system. All units shall be bonded together to form a single continuous earthing system expect electronics earthing. 17.4. Earthing conductors shall be sized to carry fault current of respective systems for 1 second duration for all the areas. 17.5. Earthing Pits shall be Plate Type or Chemical type with suitable (Cu/ GI) electrode.
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17.6. Each earth pit shall have disconnecting/testing facility to check the loop resistance. 17.7. All electrical equipment such as transformers, switchgear, motors and motor controllers connected to systems at 380 Volts and higher are to be connected to earth system through minimum of two paths. Neutrals of transformers and D.G. set Alternator shall be directly earthed through a conductor of appropriate size at two separate Earth pits. For transformer and D.G. neutral earthing copper earth electrodes and copper strips earth conductor will be used. 17.8. 1 No. earthing strip shall be installed in all cable trays. This earthing conductor is to be connected to the tray at every 20 m. 17.9. Dedicated earthing pits for Lightning protection system with ESE Air Terminal (Confirms to NFC 17-102) shall be designed in accordance with IEC. 17.10. The lightning protection system shall comprise air terminations, mounting structure, Down Conductor, Discharge Counter, Test Terminal etc and earth electrodes. 17.11. Dedicated earthing pits for safeguard against static charges will be provided as per IS provision. All equipment likely to generate static charges will be grounded individually with earthing grid. 17.12. Die electrical floor to be considered in the FLP area. 17.13. All Earthing Pit shall be loop or connected with common grid Earthing Network through Earthing Strip. 18. WORK SCOPE OF CONTRACTOR The installation of the electrical system and equipment shall be given on contract. The supply of following main electrical equipment by client
HT Transformer D.G. Sets HT/LT Cables LT s Lighting Fixtures UPS
Work scope of Electrical Contractor will be to install above free issue material including loading /unloading of above such electrical equipments. Supply and installation of other electrical items like distribution boards, cable glands, Domestic and Clean room area modular switch / Sockets outlets , Industrial socket outlets, Wiring/cabling material including conduit and conduit accessories, Earthing system material, Cable tray & Cover, Safety items, sand for cable bedding and cover, cable tiles, trench markers, installation of internal/external lighting fixtures , Street lighting poles, all hardware and consumable for free issue material as well as own supply material etc. in scope of Electrical contractor including consumable materials and their installation like fixing hardware, steelwork for site fabricated s. 19. TENDER & PROCUREMENT SCOPE Detailed Tender Document with essential commercial & conditions, conditions of contract, technical specifications for supply items and electrification work, applicable standards, approved make list, BOQ and drawings shall be prepared and floated to recommended/ mutually selected bidders. Confirm this procurement philosophy from client.
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Following high cost items will be procured directly from OEM:
HT Transformer–. D.G. Sets-. HT/LT Cables –. LT s – Safe area Lighting Fixtures – Hazardous area lighting fixtures-. UPS –.
Procurement shall be in scope of installation contractor:
Cable TraysG.I. /Cu. EarthingLightening ArrestorIndustrial Sockets – Modular Switches / sockets – Wires
20. DETAILED DRAWINGS AND DOCUMENTS Based on the approval on this document, Tender document, BOQ, Technical specs of major equipments and execution Drawings shall be prepared. Following shall be provided along with the Electrical tender during the detailed engineering.
Tender Document with General information, Conditions of contract, Description / scope of work. Technical specifications Bill of quantities Relevant tender drawings List of approved makes
Detailed coordinated drawings required for the successful completion of the electrical works / CRP installation shall be provided at the time of execution.
------000-----
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NATIONAL PHARMACEUTICAL INDUSTRIES JEDDAH , KINGDOM OF SAUDI ARABIA
OSD FORMULATIONA FACILITY AT SAUDI ARABIA
ELECTRICAL CONCEPT NOTE
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CONTENTS S. No.
Description
Page No.
1.
Project Information
2
2.
Introduction
2
3.
Design Basis
2
4.
Scope of Work
2
5.
Abbreviations used
2
6.
Basic Design Philosophy for Electrical System Design
3
7.
Proposed Distribution Scheme (Attached separately)
4
8.
Load Assessment sheet (Attached separately)
4
9.
Primary Power Distribution / Control /Operation system
4
10.
Power Factor Compensation
5
11.
Philosophy For Selection of Electrical Equipments-
6
HT Switchgear, Transformer, DG set, LT s, HT/LT Cables, UPS etc. 12.
Illumination system
11
13.
Power Outlets
13
14.
Wiring/Cabling
13
15.
Low Voltage System
13
16.
Cable Trays & Cable Glands
16
17.
Earthing and Lightening Protection System
16
18.
Work Scope of Electrical Contractor
17
19.
Tender Document
17
20.
Detailed Drawings and Documents
18
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DOCUMENT REVISION HISTORY Document name
Revision
Revision by
Date
Status note
NPI_SA_ EL_CN_V.0
0.0
B.Patel
15/09/2017
First release for comments
PROJECT INFORMATION
1.
2.
Owner-
M/s National Pharmaceutical Industries
Project Title-
OSD Formulation Facility
Project Location-
M/s National Pharmaceutical Industries At KAEC, Kingdom of Saudi Arabia
Engineering Consultant -
M/s DL International.
INTRODUCTION Description of documentThe purpose of this document is to specify the requirements and general scheme of Electrical system for proposed Formulation facility. This document concludes design and distribution concept based on the requirement of Process, HVAC, Utility equipments, Power & Lighting.
3.
DESIGN BASIS Electrical design criteria used in the design and detail engineering of Electrical System Design is based on project’s present requirements, various codes and standards, good engineering practice and local climatic conditions.
4.
SCOPE OF WORK Design of electrical distribution system for the proposed facility as per the standards which includes HT/LT distribution system, LT PCC, Distribution s, Power & Lighting DBs, Internal/External Lighting Layouts, Power Layouts, Cable tray Routing, System Earthing, Low voltage (CCTV/ Networking/ Door Interlocking (Infra Red sensing device)/ Access control (Bio Metric type) / Digital clock etc. system design, Equip. Specifications, BOQ, Cable Schedule, Tendering etc..
5.
ABBREVIATIONS (list of abbreviations is too small. Many abbreviations are missing. Highlighting them in red and underlining throughout the document. HV MV LV PCC DB LSDB ELDB PSDB UPSDB MLDB MPDB RTPFC 15/09/2017
- High Voltage - Medium Voltage - Low Voltage - Power Control Centre - Distribution Board - Lighting Sub Distribution Board - Emergency Lighting Distribution Board - Power Sub Distribution Board - UPS Fed Distribution Board - Main Lighting Distribution Board - Main Power Distribution Board - Real Time Power Factor Compensation /correction Page 2 of 19
ELECTRICAL CONCEPT NOTE OSD FORMULATION FACILITY National Pharmaceutical Industries MFM
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- Multi Functional Meter
BASIC DESIGN PHILOSOPHY FOR ELECTRICAL SYSTEM DESIGN
6.
6.1. Area Classification: Most of the plant area is classified as clean room type & shall be equipped with clean room fixtures except few areas such as /Store which will be equipped with Non clean room fixtures. For Flame proof classified areas (Like: Granulation and Coating etc.), it shall be equipped with Flameproof Fixtures &and other essentials. 6.2. Design Ambient / Service Condition: All electrical equipment shall be designed for tropical climatic conditions. The ambient temperature and relative humidity to be considered for design of electrical equipment shall be 50oC max. and 80% average respectively. All electrical equipment, materials and installation shall be designed for suitable for operation under site conditions. Electrical equipment intended for outdoor installation shall have minimum protection of IP 65 (in accordance with SBC 401 standards). Electrical equipment intended for indoor installation shall have minimum protection of IP 42 (in accordance with SBC 401 standards). 6.3. Codes & Standards: Equipment, material and installation shall confirm to the latest edition of relevant Saudi Arabia Standards, Saudi Arabia Electricity Act, Saudi Building Code Electrical Requirement (SBC 401), TAC recommendations, Loss prevention Association of International and National Code of practice for electrical installation. Electrical systems design and installation shall be carried out in accordance with International Electro technical commission and Saudi Arabia Standards, in particular:
Saudi Arabia Act Saudi Arabia Rules Saudi Building Code Electrical Requirement (SBC 401) IEC code IEEE Code Classification of Hazardous Areas for Electrical Installations
6.4. Inspection & Testing: All equipment shall be inspected and routine tested as per relevant Saudi Arabia Standards at the manufacturer’s works and type tested as per purchase order prior to dispatch to site. After receipt on site, the equipment will be again inspected for any damage in transit. After installation and before commissioning, pre-commissioning tests will be carried out. 6.5. Incoming Supply & Metering: 13.8KV/0.380KV Substation shall be considered. 13.8 KV supply is available from local network of (SAEB). Supply is tapped from nearest overhead network to 4 pole structure for Proposed Facility supply arrangement. 6.6. Sub Station:
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Proposed 13.8/0.380KV, 3 phase, frequency 60Hz Oil Immersed Transformer’s (1600KVA approx.) primary through underground HT cable. The Transformers shall be kept out door, near the proposed Utility Block. The LT PCC shall be placed in LT room inside the Utility Block. Power distribution system shall be designed centralized for proposed facility. 6.7. Fault Levels At Various Voltage Levels: considered:
Following voltage levels and fault levels shall be
6.8. (did you consider the soil resistivity from the soil testing report? If not put a disclaimer here) Voltage Level a) 13.8 KV b) 380 V
Maximum Fault Level 32KA for 1 sec. 50KA for 1 sec. at transformer sec.
7.
PROPOSED DISTRIBUTION SCHEME- (SEPARATE SHEET ATTACHED)
8.
LOAD ASSESSMENT SHEET- (SEPARATE SHEET ATTACHED) The total connected load requirement for all facilities (Granulation, Coating & RMG) is estimated as *** why is the load missingKW (Preliminary). This shall include the Machine process equipment loads, HVAC loads, Utility Loads, Lighting loads and other misc. load for proposed facilities. Detailed sheet is attached separately.
9.
POWER DISTRIBUTION /OPERATION AND CONTROL SCHEME 9.1. The 13.8KV incoming supply from VCB will feed the 1600kVA (approx.) Transformers. The transformers shall be ONAN cooled. The transformer will have on load tap changer (OLTC). The range of tap change shall be + 10% to - 10%. Thus 380V LT outgoing shall feed the LT PCC which shall be placed in LT room in Utility Block. 9.2. From LT PCC power will be distributed through XLPE insulated armored cables to the individual blocks Main s, Chiller , MLDB, Common Utility (feeding common utility equips.), Fire etc. considering convenience of distribution and operation. 9.3. LT Supply from Transformer through bus bar shall be connect in LT PCC . 9.4. Chiller & Utility shall be placed at Utility block portion. Chiller shall feed to all HVAC high side requirements like- Chillers and relevant pumps where as Utility shall feed to all utility equipments located in the building. The same shall have additional feeders for miscellaneous outdoor requirements. E.g. Boiler house, ETP, Fuel Pumps, Bore well, Raw Water Pumps etc.
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9.5. Individual block’s Main s will feed Process s and HVAC s, & PDB etc. Process in turn will distribute power locally to individual process equipments. MLDB shall feed floor wise/ Area Wise Lighting Dist. Boards; whereas HVAC shall feed HVAC units (Low side) and PDB will feed Local PSDBs etc. These s shall be placed at convenient location @ Technical area on service floors. 9.6. Proposed Single phase power sockets shall be powered through PSDBs for raw power and UPSDBs for UPS connected power socket outlets. Three Phase power sockets outlets shall be powered through PSDBs (3ø). These DBs shall be fed through the PDB . 9.7. Proposed Lighting shall be powered through LSDBs for raw power connected Light fixture and ELDBs for Inverter/UPS fed Light fixture and these Lighting DBs shall be fed through respective block’s MLDBs/ PDBs. 9.8. The PSDB’s, LSDB’s, ELDB’s & UPSDB’s shall be installed at Technical area to supply power to sockets. 9.9. Provision for Separate UPS systems (For Lighting & Power) will be kept for equipment s under Low Current category and other specified equipments. It is suggested for the following equipment’s:
o o o o o
10.
For critical production equipment having separate UPS to be considered for equipments. For critical HVAC system, like: Class B AHUs, QC Micro labs AHUs, RLAF, All LAF related to Class A, etc. Why do you want AHUs on UPS? BMS/IT/Security/Communication systems QC/ Lab Instruments having separate UPS. Emergency Lighting to be considered on separate UPS. (This list should be made and confirmed from Client)
POWER FACTOR COMPENSATION DEVICES Power factor of the electrical system shall be improved by incorporating power factor improvement capacitors on 380 V bus of LV switchgear at load centre i.e in LT Room, such that overall system PF shall not be less than 0.99 lag. One Real Time power factor controller shall be provided in LT room for total load on the transformer. The Real Time power Factor controller (RTPFC) shall constantly monitor the power factor of distribution system and based on that , cyclically select capacitor units to be switched ON/OFF so as a result, the power factor is controlled within preset range. PF improvement capacitors shall be complete with discharge resistors. Each bank shall comprise of suitable combination of capacitors of different size. Number of banks shall be decided as per design. transformer lagging power factor compensating capacitor shall be tapped on busbar before power factor correction CT and shall be ON permanently. We can also considered additional capacitor bank for PF correction for Utility which is having maximum electrical load.
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11.
DOC.NO.: NPI_SA_EL_CN_V.0
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PHILOSOPHY FOR SELECTION OF ELECTRICAL EQUIPMENT : 11.1.HT Switchgear:
11.1.1. 13.8KV HT Switchgear shall be in accordance with specification. Minimum Rating for HT shall be 800 Amp for 13.8 KV System. It shall be Indoor, fully draw out type with natural air-cooled design, with degree of enclosure protection of IP55 and shall be in accordance of standards. 11.1.2. Switchgear, bus bar, CT shall be designed for minimum 32kA fault level for 1 sec. The current transformers and potential transformers shall be of epoxy resin cast type. CT secondary shall be rated for 5A continuous current ratings of the breakers shall be decided based on the application requirement and after considering appropriate derating factors on of site ambient and mounting conditions. 11.1.3. Breaker shall be provided with draw out type on line PT. All bus sections shall be provided with draw out type bus PTs. All PTs shall be provided with primary and secondary fuses. 11.1.4. The circuit breaker shall be provided with trip coil and suitable trip circuit supervision relay and other necessary Numerical protection relays. Control voltage for circuit breakers shall be 110 V DC supply. 110 V DC supply shall be provided through a power pack. 11.1.5. Provision of power and control cables entries shall be from bottom. 11.1.6. Internal control wiring shall be carried out with 1.5 mm2 stranded copper conductor 1.1 KV FRLS grade PVC insulated flexible wires. However, CT circuit wiring shall be carried out with 2.5 mm2 stranded FRLS copper conductor flexible wires.
11.1.7. Suitable extension facility on switchgear shall be provided for addition of switchgear s at a later date. 11.2.Transformer: 11.2.1. 1600kVA (approx.). ONAN transformer will be installed outdoor near Utility Block.
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11.2.2. Voltage ratio of the transformers shall be 13800/380 volts. The transformer vector group shall be Dyn11. Transformer loading should not exceed more than 90% of rated capacity. 11.2.3. Transformer shall be provided with ON circuit taps in the range of +10% to -10%. There will be motorized tap changer on the H.T. winding controlled by automatic voltage regulator to maintain constant voltage in specified range of variation. The taps will be in the range of 1.25% voltage steps. 11.2.4. For transformer’s protection necessary protection relays shall be provided in respective 13.8 KV switchgear. Additionally provisions for protection against winding temperature high, oil temperature high, any internal fault conditions (Buchholz Relay), oil level low is made. 11.2.5. Transformer shall be provided with standard accessories like conservator, Buchholz relay, marshalling box, OTI, WTI, magnetic oil level gauge, silica gel breather, explosion vent, drain valves, grounding lugs, jacking pads, filter valves, disconnecting chamber, cable end boxes, radiators with shut off valves, lifting lugs, bi-directional rollers, oil surge relay for OLTC etc. 11.2.6. Cable box on HT side shall be detachable type complete with disconnecting chamber; LT side shall be suitable disconnecting chamber for Bus Duct. 11.2.7. Detailed features of transformer shall be given in the technical specification . 11.3.Power Control Centre11.3.1. LT PCCs shall be indoor type of metal clad construction, partly draw out type having self-aligning type auxiliary s for circuit breakers and draw out modules. All Air Circuit Breaker modules shall be draw out type; other feeders like MCCBs shall be fixed type. The LT PCC shall be located in LT room proposed in Utility Block. 11.3.2. Dual power supply shall be provided to LT PCC which shall provide continuous supply to electrical loads of the proposed facility. 11.3.3. Air circuit breakers of incoming transformer shall be with current display feature, within built microprocessor based overload, short circuit, earth fault release and should be communication (RS 485 port to be considered) with EMS (energy monitoring system). In addition shunt trip coil and closing coil shall be provided. 11.3.4. TPNE (three phases – neutral earth) Bus bars and air circuit breakers shall have short circuit withstand capacity of 50/65 KA for 1-second duration. 11.3.5. All the Incomer and outgoing switchgears should be 4P. 11.3.6. For all incomers shall be having Load Manager with Demand shall be provided. For other feeders digital MFM shall be provided. And all the meters of LT PCC s shall be having comm. port – RS 485. 11.3.7. Cable shall be laid from LT PCC to individual block’s Main s, the LT PCC shall be located in LT room proposed in Utility Block.
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11.3.8. 20% spare feeders/modules shall be provided on the switchboard with at least one spare feeder module of each rating and type. 11.3.9. Control supply voltage for various starter modules shall be 220V AC. For control supply separate control bus shall be provided in the and control voltage for individual module shall be tapped from control bus. Individual module, DP MCB is to be provided which can be accessed only after opening the module door. This MCB will isolate the control supply of individual module whenever required. The control bus will be tapped from any one phase and neutral of the main bus bar. 11.3.10.
All cable entries to s shall have provision of top/bottom as specified on SLD.
11.3.11.
Heavy Duty Exhaust System will be considered for each Vertical Busbar section/Alley and ACB feeders/compartments above 1000A rating.
11.3.12.
Max height of LT PCC shall be 2375 mm. and operating height shall be 2000mm.
11.3.13.
Suitable extension facility on switchgear shall be provided for addition of switchgear s at a later date.
11.4.Power Distribution s11.4.1. Distribution s shall be indoor type, sheet steel enclosed, compartmentalized, single front. The modules shall be non-draw out type for outgoing feeders and draw out for incoming/outgoing feeders if it is ACB. 11.4.2. TPNE (three phase – neutral – earth) Bus bars and air circuit breakers shall have 50/35/25kA short circuit withstand capacity for 1-second duration. 11.4.3. Each Distribution s shall be provided with 100% rated Incomer. Incomer shall be MCCB up to 630A rating and above the same shall be ACB. 11.4.4. All MCCBs of 250A and above shall be of Microprocessor Based with Overload, Short Circuit and Earth Fault Protection. There should be fault indication and fault differentiation between S/C & E/F. 11.4.5. MCCBs up to 200A shall be with Thermal release. 11.4.6. All switchgears incoming and outgoing shall be 4P. 11.4.7. Distribution shall house DOL starters for motors rated up to 7.5 KW OR Star Delta starters for all motors rated above 7.5 KW. For individual motor starter module, MPCB/MCCB/ors/Relay etc. as per manufacturer’s Type-2 coordination chart. 11.4.8. Motor starters rated up to 7.5 KW shall not be provided with ammeter. Motor starter modules rated 10 KW and above shall be provided with CT + Ammeter for current indication. Each starter module shall be provided with ON, OFF push buttons in addition to ON, OFF and TRIP indication lamps with MPD protection device instead of thermal over load.
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11.4.9. Motor Starters rated above 30kW shall be fed from the means of MCCB + VFD/Star Delta as per requirement. 11.4.10. All CTs and PTs shall be Resin cast type. Secondary of all CTs shall be rated for 5A. 11.4.11.
Each ’s incomer shall have Multi Function meter with Communication port.
11.4.12. Internal wiring of Distribution modules shall be carried out using 1.5 mm2; copper conductor PVC insulated flexible wires. For CT wiring conductor size shall be 2.5 mm2 copper. 11.4.13. All cable entries to s shall have provision of top/bottom as specified on particular SLDs. 11.4.14. 20% spare modules of each rating shall be provided on with at least one spare module of each rating and type. 11.4.15. Current density for Copper bus bar shall be considered 1.2 A/mm². 11.4.16. Tinned copper earth bus shall run all along the for earthing. 11.4.17. Wall mounting type Lighting and small power distribution boards shall be located in room, strategic location, Technical area or inside Block. The distribution switchboards shall be in accordance with specification. The distribution switchboards shall be suitable for indoor having IP-42 protection. 11.4.18. Suitable extension facility on switchgear shall be provided for addition of switchgear s at a later date. 11.4.19. Maximum height of Distribution s shall be 2.2 Mtr. And operating height shall be 1.8 Mtr. 11.5.DBs configuration shall be as under – 11.5.1. Lighting DBs – Incomer – TPN MCB, Sub Incomer DP RCCB (100mA), Outgoings 10/16 Amp SP MCBs. 11.5.2. Raw Power DBs- Incomer-TPN MCB, Sub Incomer DP RCCB (100mA), Outgoings 10/16 Amp SP MCBs. 11.5.3. UPS Power connected DBs- Incomer -2P/4P RCCB (30mA), Outgoings 10 Amp SP MCBs for Lighting Purpose and 10/16 Amp SP MCB for Power socket outlet purpose. 11.6.AC Uninterruptible Power Supply (UPS) SystemAC UPS systems shall be in accordance with specification. On line three phase input – three phase output Centralized AC UPS system to provide continuous power supplies to the following systems shall be considered:
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DOC.NO.: NPI_SA_EL_CN_V.0
PC/LAN System Access Control System (Bio Metric type) AV System CCTV System Door Interlock (Infra Red type sensing device) Digital Clock (with real time and date) Critical Production Equipments Specified QC / Lab Instruments (Dedicated UPS shall be provided for all QC instruments as reqd.)
11.7.UPS System UPS systems shall be in accordance with specification as an option to control Emergency lighting system of the facility. Single phase input- single phase output UPS shall be considered for Emergency Lighting system. Static type UPS shall be considered for Injectable critical equipments. The UPS systems shall be designed for uninterrupted power supply for 30 minutes in case of power failure. 11.8.HT/LT Cables SelectionSelection of cables shall be done on the basis of the following guidelines: 11.8.1. HT Cable- Cu XLPE insulated Ar. unearthed FRLS Grade cable shall be suitable for system. 11.8.2. All power cables shall be of copper multi strength armored conductor XLPE insulated, 1.1 KV FRLS grade, XLPE insulated type. Low voltage power cables 1.5 mm² and less size shall have PVC insulation. (SBC / IEC standard) 11.8.3. All control circuits cables shall be of stranded copper conductor, with minimum conductor size of 1.5 mm2, 1.1 KV FRLS grade, PVC insulated type. 11.8.4. Cables sizing shall be done based on continuous current rating of equipment and after applying de-rating factors on environmental and laying conditions. Incomer cable to 13.8KV switchgear shall be sized considering load and fault current. 11.8.5. Voltage drops in various cables are restricted to the following limits while sizing the cables:
i)
Between 13.8 KV receiving point & Transformer.
3% of 13.8 KV
ii)
Between 415 V switchgear terminals (LT PCC to PDB, MCC)
2% of rated voltage
iii)
Under full load running
3% of rated voltage
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DOC.NO.: NPI_SA_EL_CN_V.0
iv)
Under starting
15% of rated voltage
iv)
Lighting main circuits (up to LSDB)
2% of rated voltage
v)
Lighting sub circuits
2% of rated voltage
11.8.6. Short circuit withstand capacities of various cables shall be as under:
Sr. no.
Description
S/C Current Value & Its duration
i)
13.8KV incoming cables
:
32 KA for 1 second
ii)
13.8 KV outgoing cables to Transformer
:
32 KA for 1 second
iii)
380 V cable between LT PCC outgoing ACB/MCCB and Incomer to MCC / Power Distribution Boards
:
50 KA for 1 second
iv)
380 V Cable between MCC / Power Distribution Boards and motors / Power Sub Distribution Board
:
50/35/25kA (As per Calculation)
12. ILLUMINATION SYSTEM For proper and safe operation of plant, a complete and adequate lighting illumination shall be provided as under: Illumination (Lux)
Area i)
Manufacturing, Process, packing
:
400-500
ii)
Aisles, Corridors in manufacturing Areas
:
250
iii)
Offices
:
250-300
iv)
Utility / Technical Areas
:
200
vii
Laboratories /QC/QA
:
400-500
viii)
Inspection
:
NLT 500
ix)
External Lighting
:
15-20
15/09/2017
Level
Page 11 of 19
ELECTRICAL CONCEPT NOTE OSD FORMULATION FACILITY National Pharmaceutical Industries
DOC.NO.: NPI_SA_EL_CN_V.0
DL International
Adequate lighting (approx. 5-10%) in entire plant shall be provided from emergency AC source. The emergency lights shall be identical to normal lights in those areas, but they shall be connected through centralized UPS systems located at strategic locations. Such that in case of power failure there will not be complete blackout in areas to avoid accidents.
12.1. In Clean Room areas – In Main Process Area Clean Room Fixtures with SS304 shall be top open able & other area shall be Bottom Cover- with LED lamps will be used. (Bottom open able light fixture to be consider where at no space between walkable ceiling and Main ceiling).
12.2. Lighting fixtures for general area will be operable from the bottom (Surface / recess mounted) with LED lamps.
12.3. Medium Bay / High Bay type 80W or 100W or 150W LED luminaries shall be used in appropriate non hazardous locations such as warehouses, workshops, Utility area etc. And LED type Industrial fixtures shall be used for Tech. Areas.
12.4. In hazardous classified Clean room areas (Coating, Solvent Rooms) light fixtures (suitable for 2X20W or 2X30W LED lamps) will be flame proof type.
12.5. Suitable Nos. of Sodium Vapor Lighting Fixtures shall be used in specified areas for light sensitive products. The room lux level to be minimum 90 to be considered. 12.6. In addition to normal plant lighting, Solar or normal LED street lighting shall be provided on street lighting poles.
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ELECTRICAL CONCEPT NOTE OSD FORMULATION FACILITY National Pharmaceutical Industries
DOC.NO.: NPI_SA_EL_CN_V.0
DL International
13. POWER OUTLETS: 13.1. For general areas switches/socket outlets and other devices will have Poly carbonate front cover plate. 13.2. In hazardous classified areas Power outlets (Industrial) will be flame proof type as per standards. 13.3. In Clean room areas switches/socket outlets and other devices will be with SS 304 cover Plate type as per standards. 13.4. Equip. Up 7.5KW shall be fed through the dedicated 3-Phase Industrial Sockets or through SS Pendant. 13.5. The cable tray will be installed above modular false ceiling and below the RCC slab for taking connection to various equipment in clean rooms throughu common SS pendant or an individual SS pendant from false ceiling up to the point of connection on individual equipment. 13.6. The electrical connection for light switches and power switch sockets to be installed on modular wall s will be taken from cable trays throughu conduits provided in modular partition wall s as per design and connected to individual connections. 14. WIRING/CABLING: The points and circuit wiring in the Non flameproof area shall be provided with PVC FRLS grade Copper flexible cable in recessed/surface Heavy duty PVC FRLS conduit. The wiring/cabling installations shall confirm to IS latest addition. In Flameproof areas point wiring and circuit wiring shall be done by Cu. Ar. Cable using double compression glands. For Equipments 1.1KV Grade XLPE insulated Cu. Ar. Cable shall be provided. 15. LOW VOLTAGE SYSTEM: Low Voltage System concludes Data Point, Voice Point, CCTV, Access Control, Door Interlocking, Digital clock, Attendance Recording, PAS, FAS etc. Occupancy sensor to be considered in the area, to considering energy conservation of lighting load. 15.1. Data and Voice System:
15/09/2017
Data system for the computers shall be provided as per the requirement.
Page 13 of 19
ELECTRICAL CONCEPT NOTE OSD FORMULATION FACILITY National Pharmaceutical Industries
DOC.NO.: NPI_SA_EL_CN_V.0
DL International
Data Cable shall be CAT6/ CAT6A (U/FTP Cable , up to 650 MHz )
Data Cable with Conduits and data I/Os and Face plate for Computer Network, Loaded Patch , Network Rack, Patch cord, Network switch, LIU shall be designed.
Voice point shall be provided as per the requirement.
Telephone Cable shall be CAT6/ CAT6A (U/UTP Cable , up to 450 MHz )
Telephone cable shall be distributed to all areas through a net-work of cables in PVC conduit.
Multi-core telephone cables shall be provided between the EPABX and individual floor/block Network rack.
15.2. Door Interlocking System:To control more than one door such that only one door can open at a time and all doors controlled through a central monitor having emergency defeat facility. Door Interlock system is used to prevent the simultaneous Opening of Airlock /Change room doors. The system thus aids in minimizing the microbial, particulate contamination and also the disturbance of Area Conditions.
Combined/room wise door interlock system shall be provided along with the access control and biometric access control system to be used.
The Door Interlock System comprises of Door Controller, Door Stations, Electromagnetic Locks, Door Position Indicators base on Infra Red sensing device and Power supply unit.
The Door Controller monitors the status of the Doors and controls the locking and release sequence of the Doors.
The can request for release of the door by pressing the emergency push button.
The Door Emergency Station is provided to override the Interlock logic and release all the doors and allow free age during an Emergency event.
All service entry door will have access control system.
15.3. IP based CCTV Surveillance System:Our Concept covers the CCTV system consists of IP based cameras connected with centralize monitoring / NVR system through CAT6/ CAT-6A cable. Requirements associated with regards to CCTV shall be established, IP based cameras and associated equipments like NVR system etc. will be provided to cover internal footprints of the general areas. Control and monitoring equipment will be provided together with remote connection facilities.
15/09/2017
Page 14 of 19
ELECTRICAL CONCEPT NOTE OSD FORMULATION FACILITY National Pharmaceutical Industries
DOC.NO.: NPI_SA_EL_CN_V.0
DL International
CCTV cameras shall be located at the convenient/required locations i.e. All process area/ages/Stores/Work stations and at entrance of each block etc.
CCTV Camera shall be IP based Dome type, fixed type, PTZ type, motion base type, 360 degree rotate type, etc. as per applicable. All Camera shall have separate UPS power socket outlets.
The system shall be comprised Cameras, PoE Switches, Data Cable, Network video recorder, TV Monitor etc.
All the cameras shall be connected through Data point to Network switch to NVR and the unit shall record all the cameras full scale images for 180 Days recording storage facility.
Control monitors shall be in Low Voltage room.
Emergency door will have motion sensing based camera system and rest it is fixed type. Also all process rooms, service area and engineering department will have fixed type camera system.
Outer side will have PTZ type camera system.
Security gate 1 & 2 will have 360 degree rotate type camera system.- To check and consider accordingly.
15.4. Access Control System (Card Reader):Access control shall be provided at the main access points (of specified areas) to restrict and monitor personnel flow into and out of the room to allow only authorized staff entry to the restricted areas through thumb print or any other matrix. The systems will have the facility to monitor and record personnel access and egress from the Room. The unit shall be mounted near the controlled door and shall require single phase control. The control wiring to be hooked to the electrical lock of door which is to be controlled and having networking inter connectivity.
15.5. Public Address System (PAS): Public address system will be provided in , Stores, Corridors/ages, Canteen, Service floors etc. There will be one microphone station near security office, from which announcements can be made to reach whole plant. The speakers will be looped zone wise and with a selector switch the required zones or all zones can be selected. The same system can be used as music system if required. 15.6. Fire Alarm System: The Fire alarm system with multi criteria detectors will be provided. The detectors will be provided in AC duct also in case any smoke is detected in the duct the AHU will be switched off. This output can be linked with FA System to give alarm. The FA system will
15/09/2017
Page 15 of 19
ELECTRICAL CONCEPT NOTE OSD FORMULATION FACILITY National Pharmaceutical Industries
DOC.NO.: NPI_SA_EL_CN_V.0
DL International
be addressable type and exact location of detector device operation will be known in room. Optical multi criteria detectors, intrinsically safe flame proof detectors in Flame proof areas and Hooters /Strobes, Fire Alarm control , Manual call points, Control Modules, Monitor Modules and Isolator Modules etc will be provided in the area at certain intervals depending on the layout of the area. Fire detection & alarm system has been considered in all classified areas, Technical and general areas. The zoning shall be carried out based on all areas for easy location of fault in display The multi criteria detectors will be ceiling mounted, hooters and M will be mounted on wall and will be concealed. In Security Room, LCD display will be used to indicate exact location where the alarm is activated so that the Security/Fire Officer can immediately proceed to the exact point of fire where it is detected. 16. CABLE TRAYS & CABLE GLANDS 16.1. Cable Trays shall be of SS304 or Hot Dipped G.I. (80 micron thickness) Perforated or ladder type construction for power cables & Control cables. Standard tray widths shall be 750 & 1000mm for ladder type trays and 100, 150, 300 & 400, 600 & 1000MM for G.I. perforated with 100/50/25mm of collar. Thickness of material shall be 2.5/3 mm. 16.2. Standard tray length shall be 3 m and trays shall be ed at every 1.5 m interval. 16.3. Cable glands shall be made of Nickel-plated brass, single compression type. However flame proofs terminations shall be with double compression type flame proof glands. 16.4. Minimum distance of 400mm shall be maintained between Low voltage cable Tray (Instruments control supply) and Power Cable tray. (Both are separate cable tray to avoid the harmonics distortion and data corruption). 16.5. In process area for the equipment above 7.5KW as far as possible the cables shall be dropped through SS Pendant of 25mm/50mm/75mm dia. From the technical areas to near/on the power supply point of the machine through the opening in the ceiling. These openings will be properly sealed. 17. EARTHING & LIGHTNING PROTECTION SYSTEM 17.1. Earthing system shall be designed as per IEEE80 or SBC 401 and other statutory regulations. 17.2. Material of earthing conductor in plant area shall be chemical base earthing. All earth electrodes shall be interconnected using G.I. conductor. 17.3. Power system earthing and equipment body earthing bonding shall be achieved by a common system. All units shall be bonded together to form a single continuous earthing system expect electronics earthing. 17.4. Earthing conductors shall be sized to carry fault current of respective systems for 1 second duration for all the areas. 17.5. Earthing Pits shall be Plate Type or Chemical type with suitable (Cu/ GI) electrode.
15/09/2017
Page 16 of 19
ELECTRICAL CONCEPT NOTE OSD FORMULATION FACILITY National Pharmaceutical Industries
DOC.NO.: NPI_SA_EL_CN_V.0
DL International
17.6. Each earth pit shall have disconnecting/testing facility to check the loop resistance. 17.7. All electrical equipment such as transformers, switchgear, motors and motor controllers connected to systems at 380 Volts and higher are to be connected to earth system through minimum of two paths. Neutrals of transformers and D.G. set Alternator shall be directly earthed through a conductor of appropriate size at two separate Earth pits. For transformer and D.G. neutral earthing copper earth electrodes and copper strips earth conductor will be used. 17.8. 1 No. earthing strip shall be installed in all cable trays. This earthing conductor is to be connected to the tray at every 20 m. 17.9. Dedicated earthing pits for Lightning protection system with ESE Air Terminal (Confirms to NFC 17-102) shall be designed in accordance with IEC. 17.10. The lightning protection system shall comprise air terminations, mounting structure, Down Conductor, Discharge Counter, Test Terminal etc and earth electrodes. 17.11. Dedicated earthing pits for safeguard against static charges will be provided as per IS provision. All equipment likely to generate static charges will be grounded individually with earthing grid. 17.12. Die electrical floor to be considered in the FLP area. 17.13. All Earthing Pit shall be loop or connected with common grid Earthing Network through Earthing Strip. 18. WORK SCOPE OF CONTRACTOR The installation of the electrical system and equipment shall be given on contract. The supply of following main electrical equipment by client
HT Transformer D.G. Sets HT/LT Cables LT s Lighting Fixtures UPS
Work scope of Electrical Contractor will be to install above free issue material including loading /unloading of above such electrical equipments. Supply and installation of other electrical items like distribution boards, cable glands, Domestic and Clean room area modular switch / Sockets outlets , Industrial socket outlets, Wiring/cabling material including conduit and conduit accessories, Earthing system material, Cable tray & Cover, Safety items, sand for cable bedding and cover, cable tiles, trench markers, installation of internal/external lighting fixtures , Street lighting poles, all hardware and consumable for free issue material as well as own supply material etc. in scope of Electrical contractor including consumable materials and their installation like fixing hardware, steelwork for site fabricated s. 19. TENDER & PROCUREMENT SCOPE Detailed Tender Document with essential commercial & conditions, conditions of contract, technical specifications for supply items and electrification work, applicable standards, approved make list, BOQ and drawings shall be prepared and floated to recommended/ mutually selected bidders. Confirm this procurement philosophy from client.
15/09/2017
Page 17 of 19
ELECTRICAL CONCEPT NOTE OSD FORMULATION FACILITY National Pharmaceutical Industries
DOC.NO.: NPI_SA_EL_CN_V.0
DL International
Following high cost items will be procured directly from OEM:
HT Transformer–. D.G. Sets-. HT/LT Cables –. LT s – Safe area Lighting Fixtures – Hazardous area lighting fixtures-. UPS –.
Procurement shall be in scope of installation contractor:
Cable TraysG.I. /Cu. EarthingLightening ArrestorIndustrial Sockets – Modular Switches / sockets – Wires
20. DETAILED DRAWINGS AND DOCUMENTS Based on the approval on this document, Tender document, BOQ, Technical specs of major equipments and execution Drawings shall be prepared. Following shall be provided along with the Electrical tender during the detailed engineering.
Tender Document with General information, Conditions of contract, Description / scope of work. Technical specifications Bill of quantities Relevant tender drawings List of approved makes
Detailed coordinated drawings required for the successful completion of the electrical works / CRP installation shall be provided at the time of execution.
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15/09/2017
Page 18 of 19
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