ELECTRICAL
DESIGN MANUAL
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1 INTRODUCTION...................................................................... 1-1
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TABLE OF CONTENTS MWD Electrical Design Manual
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TABLE OF CONTENTS MWD Electrical Design Manual
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TABLE OF CONTENTS MWD Electrical Design Manual
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TABLE OF CONTENTS MWD Electrical Design Manual
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TABLE OF CONTENTS MWD Electrical Design Manual
2-1 Motor Circuit Design Data--480 Volt, Three-Phase Motors ....... 2-12
2-2 480-Volt Lighting Transformer Circuit Design Chart (75o C) ...... 2-17
2-3 Three-Phase Line-to-Line Voltage Drop for 600 V Single-
Conductor Cable per 10,000 A-ft ............................................... 2-21
2-4 Coefficient of Utilization Zonal Cavity Method ........................... 2-27
2-5 Candlepower Distribution Curve ................................................ 2-31
3-1 Losses in Electrical Equipment................................................... 3-8
3-2 Recommended Illumination Levels............................................ 3-45
3-3 Requirements for Fire Alarm and Detection Devices................. 3-65
4-1 Annunciator Sequences ............................................................. 4-4
A Conductor Voltage Level Color Codes ....................................... F-7
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Chapter 1
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1.1 OBJECTIVE
The objective of these electrical design standards is to provide a guide
that can be used for Metropolitan Water District of Southern California's
(Metropolitan) electrical practice. Anticipated users of this manual include
the engineer/designer with limited experience, management staff, and the
more experienced engineer/designer. The senior staff may find the
manual useful as a training tool for subordinates. The information
contained herein has been assembled from a number of sources; a list of
the readily available sources is contained in Appendix A, References.
These electrical design standards shall be used as the basis for all
designs prepared for Metropolitan. Outlined within these standards are
procedures for preparing design instructions, procedures for making most
of the calculations that will be required for a design, a data table that can
be used in making those calculations, drawing presentation formats,
standard legend items and abbreviations, descriptions of materials to be
used, and a number of informative memos. This information, used with
engineering judgment in conjunction with appropriate codes, national
standards, and other reference information, will provide electrical systems
that are safe and electrically suited for the intended application.
x Communication systems;
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2.1.2 Drawings
The purpose of a design is to develop a set of instructions and rules that a
contractor can use to bid the project and, if awarded the contract, build
what the designer had in mind. The drawings are a part of that installation
instruction set and describe the location and quantity of materials and
equipment needed for the project; the text specifications describe the type
and quality of materials and equipment and the quality of workmanship.
See paragraph 2.4, Drawings, for a description of the drawings to be
included in a construction package.
2.1.3 Specifications
The text specifications shall describe the materials to be furnished by the
contractor and the requirements for the products themselves, the
requirements for installing the products, and the quality control measures
that will be used to check the products and the execution of construction.
Moreover, the text specifications provide these descriptions in one place
for the general contractor's comprehension and use. As an electrical
engineer/designer, one may think that the electrical text specifications are
written for the electrical contractor, subcontractor, or equipment supplier,
but this is not the case. The text specifications are addressed to the
general contractor, who decides who shall do the work.
x Part 1--General;
x Part 2--Products;
x Part 3--Execution.
E = voltage (volts)
I = current (amps)
R = resistance (ohms)
X = reactance (ohms)
Z = impedance (ohms)
P = power (watts)
VA = voltampere
W = watt
ș = angle whose cosine is the power factor
ĭ = phase
Eff = efficiency
P = I2 x R (Eq. 2-3)
where:
where:
2.2.5 Motors
Motor (general) formulas include:
Synchronous Speed: ns =
(120)(Frequency)/(# Poles) (Eq. 2-26)
Horsepower = (E x I x 31/2 x Eff x PF)/746 (Eq. 2-27)
2.3.1 General
Electrical calculations shall be made for all projects and filed in the project
notebook. They may be made either manually or by computer programs
approved by Metropolitan. As a minimum, the following types of
calculations shall be made where applicable and submitted to Metropolitan
for review:
x Load calculations;
x Conductor sizing;
x Conduit sizing;
x Voltage drop;
x Lighting levels;
x Grounding in substations.
If computer programs are used to make the calculations, the name and
version of the software, along with all input and output data, shall be
included in the submittal to Metropolitan. All calculations shall be certified
by the signature and stamp of a registered professional electrical
engineer.
2.3.2 Load
Load calculations shall be made using applicable sections of Articles 220,
430, and other sections of the NEC. The following load calculations will be
used for sizing:
Load calculations must include all loads and should be made by summing
all of the loads, using appropriate diversity factors as allowed by NEC
Article 220, that are connected to each panelboard, switchboard, and
motor control center. The loads for each branch of the distribution system
can then be summed back to the service entrance equipment.
Paragraphs 210.19 and 215.2 of the NEC require that branch circuit and
feeder conductors have an ampacity not less than the load to be served.
NEC Paragraph 220.18 contains additional information relative to branch
circuit loads. Once branch circuit and feeder loads have been determined
using applicable sections of NEC Article 230 and other applicable articles,
conductor sizes shall then be determined using Tables 310.16 through
310.20 of the NEC for conductors zero through 2,000 volts and
Tables 310.67 through 310.86 of the NEC for conductors rated above
2,000 volts. The four examples presented below are based on the
ampacities presented in NEC Table 310.16 as modified by the applicable
correction factors for temperature and conduit fill.
See NEC Table 3C.8 for conduit size required for three 4/0
AWG conductors with RHH/RHW insulation.
then be used.
Because more than two conductors that are not lead covered
are being installed, the column for 40 percent fill in Table 4 in
Chapter 9 of the NEC can be used.
The following calculations and the accompanying table are based on the
applicable provisions of NEC Article 430 and are provided as a guide for
performing motor branch circuit and feeder calculations and for sizing
components for motor branch circuits as part of a design. The typical
calculations that are required are demonstrated by the following examples.
Note: 60o C ampacity rating of conductors No. 1 AWG and smaller must
be used unless the engineer is sure that all terminals are rated for use at
75o C--see the Underwriters Laboratories, Inc. General Information
Directory for more details on this subject.
See Table 2-1 for the conduit and conductor requirements for
motors typically found in design projects.
NEC paragraph 430.24 requires that the conductors supplying the motor
control center have an ampacity not less than 125 percent of the full-load
current rating of the highest rated motor plus the sum of the full-load
current ratings of all other motors in the group, as determined by
Paragraph 430.6(A), plus the ampacity required for the other loads.
Conductors may be either one 500 kCMIL or two No. 3/0 AWG
per phase (one 500 kCMIL = 380 amps, two No. 3/0 =
400 amps).
NEC Paragraph 430.62 covers the requirements for sizing the motor
feeder short-circuit and ground-vault protection.
NEC Paragraph 430.63 covers the requirements for sizing the feeder
protection when the feeder supplies a motor load and other power and
lighting loads.
Table 2-1. Motor Circuit Design Data 480 Volt, Three-Phase Motors
Figure 2-1 is provided to show the relation that exists between apparent
power, real power, and reactive power (kvar). By definition, the power
factor is the cosine of the angle that exists between the real power and
apparent power phasors.
RESULTANT REACTIVE
REAL POWER (KW)
POWER (kV AR)
T1
T2
RESULTANT POWER
SUPPLIED BY CAPACITATORS
APPARENT POWER (kV AR)
(kVA)
REQUIRED
REACTIVE POWER
(kV AR)
Because the real power of a load is not changed when the power factor is
improved, we can use the known real power and desired power factor to
calculate the new kvar value in the phasor triangle.
NEC Paragraph 460.8 contains two criteria that must be met when sizing
branch circuit conductors to capacitors. First, the ampacity of the
conductors must be at least 135 percent of the rated current of the
capacitors. Second, if the capacitors are connected to a motor circuit, the
conductors to the capacitor shall have an ampacity not less than one third
of the ampacity of the motor branch circuit conductors.
The following calculations and Table 2-2 are based on the provisions of
NEC Paragraph 450.3(B). Primary conductors and feeder overcurrent and
ground fault protection devices (feeder breakers) are sized for the next
larger device above 150 percent of the transformer full-load amps to
minimize the possibility of the feeder breaker tripping on transformer
inrush (NEC would allow breaker to be sized up to 250 percent of primary
full load amps). The secondary conductors and secondary breaker are
sized at the standard rating that is nearest to 125 percent of the calculated
secondary full load current as required by the NEC. Note 1 to Table
450.3(B) of the NEC allows moving up to the next higher standard rating.
Following are two examples to show the calculations that are required for
three-phase and single-phase transformers.
KVA Phase Volts Amps Ckt. Amps Ckt. Conduit & Wire Ckt. Breaker Volts Amps Ckt. Amps Ckt. Conduit & Wire Ckt. Breaker
5 1 480 10 15.00 3/4" C-2# 12,1#8G 20A/2P 240 21 26.25 3/4" C-3# 10,1#8G 30A/2P
7.5 1 480 16 24.00 3/4" C-2# 10,1#8G 25A/2P 240 31 38.75 1" C-3# 8,1#8G 40A/2P
10 1 480 21 31.50 1" C-2# 8,1#8G 30A/2P 240 42 52.50 1 1/2" C-3# 6,1#8G 60A/2P
PROJECT DESIGN ELEMENTS
15 1 480 31 46.50 1 1/4" C-2# 6,1#8G 50A/2P 240 63 78.75 1 1/2" C-3# 4,1#8G 80A/2P
25 1 480 52 78.00 1 1/4" C-2# 3,1#8G 80A/2P 240 104 130.00 2" C-3# 1,1#6G 150A/2P
37.5 1 480 78 117.00 1 1/2" C-2# 1,1#6G 125A/2P 240 156 175.00 2”6,3#3/0,1#4G 200A/2P
2-18
50 1 480 104 156.00 2" C-2#2/0,1#6G 175A/2P 240 208 260.00 2 1/2" C-3# 4/0,1#2G 250A/2P
9 3 480 11 16.50 3/4" C-3# 12,1#8G 20A/3P 208 25 31.25 1" C-4# 10,1#8G 35A/3P
15 3 480 18 27.00 3/4" C-3# 10,1#8G 30A/3P 208 42 52.50 1 1/2" C-4# 6,1#8G 60A/3P
30 3 480 36 54.00 1" C-3# 6,1#8G 60A/3P 208 83 103.75 1 1/2" C-4# 2,1#6G 110A/3P
45 3 480 54 81.00 1 1/2" C-3# 3,1#8G 90A/3P 208 125 156.25 2 1/2" C-4# 2/0,1#4G 175A/3P
75 3 480 90 135.00 2" C-3#1/0,1#6G 150A/3P 208 208 260.00 2 1/2" C-4# 4/0,1#2G 250A/3P
______________________________________________________________________________________________________________________________________________
Rules Used: 1) Feeder circuit breaker at next size larger than 1.5 times primary amps (NEC 450.3(b) allows up to 250% of primary amps).
2) Panel main breaker sized at next size larger than 1.25 times secondary amps. (NEC 450.3(B) allows up to next larger than 125% of sec. Amps)
3) All conductors No.1 AWG and smaller sized based on 60q C ampacities, larger conductor sizes based on 75q C ampacities. (Conductors sized per
NEC 240-4 including exceptions.
4) Minimum ground conductor sized at #8; Table 250.122 used for other primary side grounds and Table 250.66 used for secondary side grounds.
5) Conduit size based on NEC Chapter 9 Table 3C.
______________________________________________________________________________________________________________________________________________
MWD Electrical Design Manual
*
Conductor sizes for examples No. 1 and No. 2 are based on the use of 60q C wire for sizes Nos.
14 through 1 AWG and 75q C wire for sizes No. 1/0 and larger as required by the General
Information Directory 1988, published by Underwriters Lab, Inc., because many items of
equipment are still not rated with 75q C terminals in these sizes.
where:
The voltage drop calculated using this formula must be multiplied by 2 for
single-phase circuits and 1.73 for three-phase circuits.
Calculations using the above formula are not required for most designs
*
Conductor sizes for examples No. 1 and No. 2 are based on the use of 60q C wire for sizes Nos.
14 through 1 AWG and 75q C wire for sizes No. 1/0 and larger as required by the General
Information Directory 1988, published by Underwriters Lab, Inc., because many items of
equipment are still not rated with 75q C terminals in these sizes.
Factors are provided at the bottom of Table 2-3 and are to be used to
convert the calculated voltage drop to single-phase line-to-line and single-
phase line-to-neutral values.
ESD-106
Load Power
factor
Lagging 1000 900 800 750 700 600 500 400 350 300 250 4/0 3/0 2/0 1/0 1 2 4 6 8* 10* 12* 14*
Section 1: Copper conductors in magnetic conduit
1.00 0.28 0.31 0.34 0.35 0.37 0.42 0.50 0.60 0.68 0.78 0.92 1.1 1.4 1.7 2.1 2.6 3.4 5.3 8.4 13 21 33 53
0.95 0.50 0.52 0.55 0.57 0.59 0.64 0.71 0.81 0.88 1.0 1.1 1.3 1.5 1.9 2.3 2.8 3.5 5.3 8.2 13 20 32 50
0.90 0.57 0.59 0.62 0.64 0.66 0.71 0.78 0.88 0.95 1.1 1.2 1.3 1.6 1.9 2.3 2.8 3.4 5.2 8.0 12 19 30 48
0.80 0.66 0.68 0.71 0.73 0.74 0.80 0.85 0.95 1.0 1.1 1.2 1.4 1.6 1.9 2.3 2.6 3.2 4.8 7.3 11 17 27 43
0.70 0.71 0.73 0.76 0.78 0.80 0.83 0.88 0.97 1.0 1.1 1.2 1.3 1.5 1.8 2.1 2.5 3.0 4.4 6.6 9.9 15 24 38
0.95 0.40 0.43 0.45 0.47 0.50 0.54 0.62 0.71 0.80 0.92 1.0 1.1 1.5 1.8 2.2 2.7 3.4 5.3 8.2 13 20 32 50
0.90 0.47 0.48 0.52 0.54 0.55 0.59 0.68 0.76 0.85 0.95 1.1 1.1 1.5 1.8 2.2 2.7 3.3 5.1 7.9 12 19 30 48
0.80 0.54 0.55 0.57 0.59 0.62 0.66 0.73 0.81 0.88 0.97 1.1 1.1 1.4 1.7 2.1 2.5 3.1 4.7 7.2 11 17 27 43
0.70 0.57 0.59 0.62 0.64 0.66 0.69 0.74 0.83 0.88 0.97 1.1 1.1 1.4 1.6 2.0 2.4 2.8 4.3 6.4 9.7 15 24 38
2-22
Section 4: Aluminum conductors in nonmagnetic conduit
1.00 0.36 0.39 0.44 0.47 0.51 0.59 0.70 0.88 1.0 1.2 1.4 1.7 2.1 2.6 3.3 4.2 5.2 8.4 13 21 33 52 --
0.95 0.52 0.56 0.60 0.63 0.67 0.74 0.85 1.0 1.1 1.3 1.5 1.8 2.2 2.7 3.4 4.2 5.2 8.2 13 20 32 50 --
0.90 0.57 0.61 0.65 0.68 0.71 0.79 0.89 1.1 1.2 1.3 1.5 1.8 2.2 2.6 3.3 4.1 5.0 7.9 12 19 30 48 --
0.80 0.63 0.66 0.71 0.7 0.76 0.83 0.92 1.1 1.2 1.3 1.5 1.7 2.1 2.5 3.1 3.8 4.6 7.2 11 17 27 42 --
0.70 0.66 0.69 0.73 0.75 0.78 0.83 0.92 1.1 1.1 1.3 1.4 1.6 1.7 2.3 2.8 3.4 4.2 6.4 9.9 15 24 37 --
Reproduced from IEEE Std 141-1993, IEEE Recommended Practice for Electric Power
Distribution for Industrial Plants, © 1994, by the Institute of Electrical and Electronics
Engineers, Inc., with the permission of the IEEE.
MWD Electrical Design Manual
The basic formula for calculating short circuit current when the per-unit
method is used is:
Because we have let base kVA = transformer kVA and transformer kVA y
(1.73 x kV) = Transformer load current for three phase transformers, we
can simplify the above formula to:
The resulting short circuit current let through by the transformer in our
example would be:
The total short circuit current available at the point of the fault
would be the total of the contribution from the transformer plus
the contribution for the motor load
Because neither the serving utilities' source impedance nor the imped-
ances of the interconnecting conductors and equipment are included in
this calculation, this value can be very conservative and must be used
carefully.
2.3.10 Lighting
Lighting calculations shall be made using the recommended procedures
established by the Illuminating Engineering Society and outlined in the IES
Lighting Handbook. Two methods are available for calculating the lighting
levels in a space. The first is the lumen or zonal cavity method and the
second is the point-by-point method. The zonal cavity method is used to
calculate the average footcandle level within the space and the point-by-
point method is used to predict the illumination for a specific visual task.
The following examples are provided to demonstrate these two calculation
methods.
Basic equations:
where:
CU = coefficient of utilization
LLF = light loss factor, which is made up of a number of
factors. The ones to be included in most calculations
are the LLD, LDD, and RSD
LLD = lamp lumen depreciation
LDD = luminaire dirt depreciation
RSD = room surface depreciation
Most CU tables are based on a floor cavity ratio (pfc) of 20, so that figure
will be used for this example (Table 2-4).
If the suspension length of the luminaire below the ceiling is zero, which it
is for this example, the ceiling cavity ratio is equal to the ceiling
reflectance. If the luminaire is suspended, a ceiling cavity ratio must be
calculated before the effective ceiling cavity reflectance can be
determined. Reflectance values for various surfaces are available in the
IES Lighting Handbook. For this example, 70 percent will be used.
The wall reflectance of materials can again be obtained from the IES
The room cavity ratio (RCR) must be calculated and it is equal to 2.5 times
the area of the walls divided by the area of the work place.
The work plane height is the level at which most tasks will be performed
and is assumed to be 30 inches for this example.
Values for LLD, LDD, RSD, and a number of other factors that cause light
loss in the space can be found in the IES Lighting Handbook but for most
calculations dealing with lighting in noncritical areas all of these factors
can be combined into a single factor, which is often referred to as the light
loss factor (LLF). For this calculation, an LLF of 0.75 has been assumed.
Put all of the numbers into a basic equation (Eq. 2-41) and solve it for the
number of lamps required:
No lamps = 30.4
The next task is to lay out the luminaries in the room to determine if they
will fit in a logical arrangement. Since the luminaries are being installed in
a lay-in ceiling, spacing can only be in multiples of 2 feet.
For this example, installation of eight luminaries would require two rows of
four luminaries each.
The maximum spacing of the luminaries shall also be checked against the
mounting height above the work plane (S/MH ratio) to determine if it is
within the ratio of the luminaire being used.
This is well within the 1.3 S/MH ratio of the luminaire used in the example.
If the luminaries required could not have been fit into the space in a
reasonable layout, or the footcandle levels that resulted from the selected
layout were not acceptable, or the S/MH ratio calculated was not less than
that of the luminaire being used, then the layout would need to be revised
using a luminaire with a different number of lamps or different
characteristics.
The footcandle level calculated tells us the quantity of light that reaches
the work surface. Other factors that affect visual comfort and ability to see
include direct glare, indirect glare, reflected glare, and veiling reflections.
In areas where seeing tasks are critical, these must also be evaluated.
See the IES Lighting Handbook and other lighting design and application
Basic equations:
candlepower x cos ș
distance2 (Eq. 2-43)
candlepower x sin ș
distance 2 (Eq. 2-44)
where:
Using the above data, calculate the horizontal footcandles on the work
surface 4 feet horizontal from the luminaire. (Figure 2-4)
H
8.5 FT
ACTUAL DISTANCE OF
LIGHT SOURCE FROM
TASK POINT
VERTICAL HEIGHT
OF LIGHT SOURCE
FROM WORK SURFACE
WORK SURFACE
R
4 FT
HORIZONTAL DISTANCE
OF LIGHT SOURCE
FROM TASK POINT
To determine the total footcandles on the task, the same calculation must
be made for each luminaire that could contribute to the illumination level.
All of the contributions would then be totaled.
Contribution from the luminaire on the opposite side of the point will be the
same as calculated above. The next pair of luminaries are close enough
that their contribution must also be checked.
Use value for candlepower at 45o with respect to the luminaire and
interpolate between 35o and 45o values (Table 2-5).
The footcandle level on the task is the sum of the contributions from the
four closest luminaries.
the luminaire.
2.3.11 Grounding
Grounding system calculations shall be made for substation and other
areas where step potential will be of concern. The subject is too complex
for presentation in this design guide. Grounding system calculations shall
be in accordance with applicable sections of ANSI/IEEE Standard 80.
2.4 DRAWINGS
2.4.1 General
The purpose of a design is to develop a set of instructions and rules
whereby a contractor can bid the project and, if awarded the contract,
build what the designer had in mind. The drawings are a part of that
instruction set and describe the location and quantity of materials and
equipment needed for the project; the text specifications describe the type
and quality of materials and equipment and the quality of workmanship.
2.4.2 Organization
The drawings are generally divided into the following groups and appear in
the order shown below:
x Installation Details;
x Electrical Schedules.
2.4.3 Legend
The legend is a list of the symbols to be used on the design drawings.
Generally, they are based on the standard legend symbols contained in
NEMA, ICS, and ANSI Standard Y32. Where a design requires the use of
a symbol that is not present on the legend, the symbol shall be added to
the legend if it is used on more than one sheet of the design. If it is used
on only one sheet, it may be described on that sheet. The standard
legend symbols shall be used wherever practical to reduce confusion and
time spent on inventing unnecessary new symbols.
2.4.4 Abbreviations
The abbreviations used on the electrical drawings shall be listed on the
electrical legend sheet to minimize possible confusion with similar
abbreviations that are used on the sheets prepared by other disciplines.
All abbreviations used on the drawings shall be included in the
abbreviations list. Unless a word is used often, it should not be abbrevi-
ated.
x Motor sizes;
The electrical facility power plans show the general location of equipment
to be wired and connected under the electrical specifications, and show
the necessary conductors and raceways associated with the work. For
facilityexpansions, the power plan shall show the interface with existing
facility power system. Symbols used on the drawings are usually not to
scale but, by definition, tell the contractor how a particular device is to be
connected to the electrical system.
x Panel size;
x Major panel components and their layout;
x Panel installation.
x Show full views of the front of the panel. (Partial views may
be used for details.)
x Show location key plans for each panel and include the
sheet number of the mechanical plan where the panel is
located, building and room names where the panel is
located, title (e.g., LP-XXX LOCATION PLAN), scale
(1s=100c or 1s=50c), panel name (e.g., LP-XX), and north
arrow.
At the completion of the project, each individual shall purge the file of the
project instructions and other memos that were originated by other team
members and submit the purged project files to the project manager for
inclusion in the overall project file. Any memos, instruction sets, and
similar items prepared by the individual shall be left in his or her project file
so that originals of all material prepared or used on the project are
contained within the overall project files.
24” 8”
FULL LENGTH 1
PIANO TYPE 2
HINGE 3 6 9
4 7 10
5 8 11
12 15 18
13 16 19
30”
14 17 20
21 24 27
22 24 25
23 24 29
30
31
32
33
FRONT SIDE
SCALE 1 ½“ = 1’-0” SCALE 1 ½“ = 1’-0”
STANDARD ELECTRICAL
DESIGN PROCEDURES MWD Electrical Design Manual
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Note: All references to the National Electrical Code (NEC) are based on
the 2005 Edition of the NEC.
This chapter discusses many of the basic decisions that shall be made
during a design, identifies reference sources that shall be used to help
make those decisions, and outlines the materials that shall be used in
implementing those decisions.
3.1.2 References
There have been a number of codes, standards, and handbooks prepared
on the basic subjects covered by this design guide. A brief list of some of
the more applicable references, many of which have been used in the
preparation of this design guide are contained in Appendix A. The latest
edition of each of these references shall be used.
The first step is the analysis of the plant process to determine its reliability
need and potential losses and costs in the event of power interruption.
Some plant processes are minimally affected by interruption. Other plant
processes may sustain long-term damage or experience excessive cost
by even a brief interruption, therefore, a more complex system with an
alternate power source for critical loads may be justified.
BUS DUCT
PANEL
SECONDARY
UNIT
SUBSTATION
SECONDARY SECONDARY
UNIT UNIT
SUBSTATION SUBSTATION
The nominal voltage of the systems covered by this design guide will be in
either the low or medium voltage class. Table 3-1, Standard Nominal
System Voltages and Voltage Ranges in Chapter 3 of ANSI/IEEE Std 141-
1993 lists the standard and nonstandard nominal system voltages within
all three of the voltage classes. The table uses a system voltage
nomenclature that describes how the nominal voltage is supplied.
1. Classifications:
a. Low-voltage power circuit breakers
b. Molded-case circuit breakers
2. Types:
a. Low-voltage power circuit breakers (LVPCBs)
b. Molded-case circuit breakers (MCCBs)
c. Insulated-case circuit breakers (ICCBs)
3.1.7.2 Application.
Safety of life is always the most important consideration. The system shall
preserve the safety of the general public and be capable of safe operation
by plant personnel. The second consideration should be the preservation
of property. Next, the need for reliability must be balanced against the
cost of providing the electrical system that provides the level of reliability
desired. If the impact of a short outage has little affect on the cost of plant
operation, additional expense to provide a fully coordinated system is
x 10-200 hp 6.00-12.00
x 200-1,500 hp 4.00-7.00
Static variable speed drives 6.00-15.00
Note: Use high end of range except when more accurate data are known
or provided.
x NEMA Type 1;
x NEMA Type 3R;
x NEMA Types 4 and 4X;
x NEMA Type 7, Class I, Group A, B, C, or D;
x NEMA Type 12.
3.3 SWITCHGEAR
Switchgear is a general term covering switching and interrupting devices
alone or in combination with other associated control, metering, protective,
and regulating equipment. A power switchgear assembly consists of a
complete assembly of one or more of the above-noted devices and main
bus conductors, interconnecting wiring, accessories, supporting
structures, and enclosures. Both medium voltage and low voltage
enclosed switchgear will be reviewed in this design guide. See
Chapter 10 of ANSI/IEEE Std 141-1993 and ANSI/IEEE C37.20-1,
C37.20-2, C37.20-3, and C37.100 for additional information on
switchgear.
Both the main and feeder circuit protective devices shall be drawout type
in individually mounted configurations. Circuit protective devices shall be
applied in a manner consistent with applicable portions of Section 3.1.6,
Protection and Coordination Philosophy. The standard short circuit rating
for switchboards with individually mounted drawout circuit breakers is
50,000 amps RMS symmetrical, but higher ratings are available. See
Metropolitan's Standard Specifications Sections Catalog for more
complete and detailed requirements for this equipment.
3.4 TRANSFORMERS
Unit substations and pad-mounted transformers are both available to
transform medium voltage primary power to lower utilization voltages. The
lower voltage may be either a low voltage class such as 480 volts or a
medium voltage class such as 4,160 volts. There are several basic
differences between these transformer types that must be kept in mind
when selecting one for an application.
3.4.1 Pad-Mounted
Pad-mounted transformers are intended for use with underground power
distribution systems. They offer flexibility and provide a pleasing
installation. Their tamperproof construction allows installation in locations
accessible to the general public without the need for protective fencing or
vaults. They are oil-filled and are not suitable for indoor installation.
3.4.2.1 Primary Switch. Several options are offered for the primary
switch of a unit substation. A metal-clad nonfused interrupter switch shall
be provided where transformer protection is provided elsewhere. Should
transformer protection be required, a metal-clad vacuum circuit breaker
shall be bolted to the high voltage flange of the transformer. Should a
loop feed or primary selective switching be required, a metal-clad
switchgear assembly shall be bolted to the high voltage throat of the
transformer to provide both transformer protection and flexibility in the
distribution system.
The two types of circuit breakers used in low voltage motor control,
magnetic-only and thermal magnetic, are discussed below.
breaker.
Class I Type B wiring shall be specified for all motor control centers unless
significant amounts of wiring are required between control units, and then
Class II Type B wiring shall be specified.
The short circuit rating of the motor control center shall be greater than the
fault current available at the line side terminals of the MCC plus the motor
contribution, as required by NEMA ICS 2-322. The short circuit rating of
an MCC is equal to the interrupting capacity of the lowest rated device in
the assembly. Circuit breaker type combination motor starters are UL
listed for 22,000 amps interrupting capacity (AIC). Higher short circuit
ratings are available by the substitution of high interrupting circuit breakers
or the addition of current limiters. Where fault currents above
22,000 amps symmetrical are available, circuit breakers with current
limiters or current limiting circuit breakers shall be specified.
3.5.3.1 DC devices
DC motors have been the prime choice for speed control based on their
adaptability to wide ranges of speed-serving duties of small to several
thousand horsepower mechanical demands. Varying the armature voltage
or field current can change a DC motor’s speed.
3.5.3.2 AC Drives
Advances in solid-state electronics have resulted in AC drives that have
high reliability and low maintenance. AC drives, which are commonly called
inverters, are designed to operate standard squirrel cage induction motors.
The basic drive consists of an inverter which converts the 60 Hz incoming
power to a variable frequency and variable voltage.
The AC input line harmonic current magnitudes vary with the design of the
drive. The power distribution system impedance at the installation and the
drive input design determines the actual magnitude of th eline harmonic
currents.
A) Design Techniques
B) Line Impedance
D) Harmonic Filters
3.6 MOTORS
The subject of motors is a very broad topic and will not be dealt with in any
detail in this section. The text Motor Applications and Maintenance
Handbook is an excellent reference on the subject and should be reviewed
for specific questions that are not addressed in this manual. In addition,
NEMA standard MG 1 Motors and Generators covers the construction and
testing of all types of motors and should be consulted for the general
standards of the industry.
Integral thermostat devices are adequate for small motors but larger
motors shall be protected by thermistors or resistance temperature
devices (RTDs). Thermistors should be used for motors 100 hp and larger
at 480 volts with RTDs being used for all medium-voltage motors.
The need for special protection schemes needs to be evaluated for each
of the other possible causes of motor overheating. The larger the motor,
the higher the operating voltage. The more critical the drive, the more
likely that special protection shall be provided.
Motors larger than 5 hp that are located in indoor dry areas may be
specified to have drip-proof enclosures. Totally enclosed fan-cooled
enclosures shall be specified for motors smaller than 5 hp in all locations
and for larger motors located outdoors and in wet areas, except for the
following two exceptions. Very small motors may also be specified to
have totally enclosed nonventilated enclosures when these are the
standard of the manufacturer supplying the equipment. Motors 200 hp
and larger that are installed outdoors shall be specified to have weather-
protected Type I enclosures. All motors to be located outdoors and in wet
and/or corrosive indoor locations shall be specified to have sealed winding
insulation.
Single-phase motors are available for operation at 115 volts, 208 volts, or
230 volts single-phase, which will allow their connection to most low-
voltage systems.
The galvanized coating of EMT resists corrosion well but the walls are so
thin that it does not resist physical damage well. EMT shall be used in dry
areas above ceilings and concealed in walls for lighting, receptacle, and
HVAC circuits.
Articles 344, 350, 352, 353, and 358 of the NEC contain additional
information pertaining to the installation of conduit systems and shall be
consulted during design.
3.7.3 Wireway
Wireways with conduit nipples shall be used to interconnect electrical
equipment where there will be a number of separate enclosures located
close to each other. The wireway provides an ideal pathway between the
enclosures, it provides space for tapping of conductors, if necessary, and
it makes grouping of conductors from the various enclosures into conduits
leaving the area very easy. Article 376 of the NEC contains additional
information pertaining to the application of wireway and shall be consulted
during design.
Article 392 of the NEC covers the installation of cable tray systems and
the installation of conductors and cables in them. Single conductors shall
be No. 1/0 AWG or larger and labeled for installation in a cable tray. All
multiconductor cables shall also be tray cable (TC) rated to be installed in
a cable tray system.
Solid bottom steel cable trays with steel covers provide EMI/RFI shielding
protection for sensitive circuits and shall be used to route instrumentation
cables.
Trench systems shall be open bottom with a crushed rock fill to provide
drainage and cable and conductor support. The trench shall be covered
by removable fiberglass reinforced concrete panels. Special sections shall
be provided where equipment will be expected to cross the trench system
that are designed to carry traffic loads and meet the requirements of
applicable portions of AASHTO H-20.
The largest ducts shall be installed at the bottom of each ductbank with all
of the spare ducts being provided at the top of the ductbank. Even though
different sizes of ducts may be required by the conductors and cables to
be installed, the number of sizes being installed shall be kept to a
minimum. Each row in the ductbank shall be the same size throughout its
width and the minimum size conduit to be installed shall be 1 inch.
3.8 CONDUCTORS
All conductors, regardless of use, shall be copper and shall be stranded.
This section will cover both low-voltage, including conductors and cables
for instrumentation and control systems, and medium-voltage wiring
systems and their related appurtenances.
Where conductors for power circuits are to be installed in cable trays, they
shall be UL-listed as suitable for that use. The NEC does not allow single
conductors smaller than No. 1/0 AWG to be installed in cable trays.
Smaller feeder and branch circuit conductors to be installed in cable tray
shall be multiconductor power cable rated type TC.
Terminals for larger conductors are rated for use with conductors rated
75o C. The 90o C ampacities of conductors larger than No. 1 can be used
in determining the size of the conductor to be used, if:
All instrument cables shall be terminated with locking forked tongue lugs
on numbered screw type terminal blocks. Terminal blocks shall be
constructed of UL- recognized component plastic, phenolic, and have
nickel-plated brass, binder head type screws.
The ampacity tables of Article 310 of the NEC shall be used in selecting
conductor sizes for medium- and high-voltage circuits but the Engineer
must not forget the effects of short circuit currents on these conductors.
The application of each medium- and high-voltage conductor shall be
reviewed with respect to allowable short circuit current for the conductor
size required and allowable temperature rise of the insulation before the
short circuit protective device trips. Chapter 12, Cable Systems, of IEEE
Standard 141-1993 should be consulted for additional information on this
subject. In addition, several manufacturers have published data and
graphs that are useful in selecting conductors that are properly sized for
applications where fault currents are high.
The boxes used in indoor locations must be able to withstand the physical
abuse they are likely to receive, stand up to the environment, and keep
water out of the raceway system.
Boxes used in dry areas may be manufactured of either sheet steel or cast
metal. Small boxes that may be subject to physical damage shall be
manufactured of cast metal, whereas larger boxes in such locations shall
be manufactured of sheet steel. Small boxes located 4 feet above
finished floor in lighting, and receptacle circuits and concealed boxes in all
raceways, shall be constructed of sheet steel.
Cast metal conduit fittings may be used as junction boxes in both dry and
wet areas if the box contains no splices; large device boxes shall be used
wherever splices are necessary.
3.10.1 Handholes
Handholes shall be precast concrete, shall contain blockouts or knockouts
on all four sides, and shall have a square or rectangular opening in the
cover. The opening in the cover shall be equipped with a hinged cover
that is suitable for the location where the handhole is to be installed.
Handholes that will be installed in driveways, parking areas, or other areas
where vehicle travel can be expected shall be equipped with covers that
are rated for AASHTO H-20 loading. Handholes in other areas may have
covers with a lower loading class.
Handholes that are smaller than 4 feet by 4 feet by 4 feet need not be
equipped with cable racks and insulators, but the contractor shall be
required to provide adequate support for all conductors and cable to keep
them from laying on the floor of the handhole.
3.10.2 Manholes
Manholes shall be precast concrete, shall contain blockouts or knockouts
on all four sides, and shall have a round opening in the top. The opening
in the top shall be equipped with a cast metal cover that is suitable for
AASHTO H-20 loading. The manhole shall be a minimum height of
6-1/2 feet clear inside so that a person can stand full erect within the
manhole.
Manholes shall be equipped with heavy duty inserts and cable racks to
provide support for conductors and cables that pass through them. All
conductors and cables shall be trained around the perimeter of the
manhole and shall be tied into place with suitable wire ties or similar
banding material.
Fluorescent lamps are available in several types and each has very
specific characteristics. Because of their long life expectancy, the
fluorescent lamps most often used are the 48-inch, 40-watt (34-watt
energy saver) preheat rapid start; the 96-inch, 75-watt (60-watt energy
saver) slim line; and the 96-inch, 110-watt (95-watt energy saver) high
output lamps. They are available in several color classifications, but the
only ones that will be considered here are the cool white and warm white
classifications.
Although warm white lamps produce a higher light output, cool white
lamps are recommended for most applications because they provide truer
color rendition and thus better visibility. Warm white may be selected for
industrial type applications where color rendition is not important.
HPS lamps are available in a number wattages and are suitable for
burning in any position. Even though their color rendition is not equivalent
to that of fluorescents, their increased efficacy (lumens per watt) and their
longer life make them the best choice for outdoor and hard to relamp
indoor areas. One characteristic of all high- intensity discharge lamps
(mercury vapor, HPS, and metal halide) is that they require a warm-up
and restrike time, they are not immediately on as is a fluorescent or
incandescent lamp. The warm-up time for a HPS can be as much as 3 to
4 minutes, during which time the light output is greatly reduced. The
restrike time for a HPS is usually 1 minute or less. Where immediate light
output is necessary on re-energization, an auxiliary quartz lamp can be
provided by some luminaire manufacturers.
Other lamps that may be used include the incandescent, the mercury
vapor, and the metal halide or multivapor lamps. The incandescent has
very low efficacy and short life, but it is on immediately when energized
and is very low cost. It has applications in out-of-the-way places that are
not visited frequently, and where low temperatures or hazardous
environments make the selection of other sources difficult. Mercury vapor
and metal halide could be applied in the same areas where HPSs have
3.11.4 Luminaires
There are too many companies that manufacture luminaires to list them or
the types of luminaire that they manufacture. In this section, some of the
general types of luminaires available will be discussed and
recommendations for their use will be made.
Enclosed and gasketed luminaires shall be specified for damp and wet
locations. They shall be UL-listed as suitable for the type of area that they
will be installed in. Luminaires shall be manufactured of molded, high-
impact resistant ABS plastic or reinforced fiberglass with a diffuser of high-
impact resistant acrylic.
The NEC requires that all unit type emergency lighting systems be
supplied power from the circuit that normally supplies the lighting in the
area where the unit is to be located. Where more than one circuit supplies
the area, the one that supplies the largest part of the traveled area shall
be selected as the source of power.
3.11.7 Controls
Controls for lighting systems shall be designed to meet the needs of the
space where the lighting system equipment is to be installed. Areas that
will require illumination 24 hours per day shall be provided with switching
duty circuit breakers and no local switches. In all office and process areas
where illumination is not required continuously, provide a separate switch
for each room. Where large rooms are encountered, at least one switch
shall be provided for each two 20-amp lighting circuits.
In office areas where lighting requirements will vary depending on the task
at hand, dimmers, two-level switching, or occupancy lighting control
sensors shall be provided to maximize energy savings.
3.12.2 Panelboards
Panelboards shall be installed as necessary to provide power to the
120-volt, single- phase and 208-volt, single- and three-phase loads shown
on the drawing. Branch circuit breakers shall be thermal-magnetic type
and sized in accordance with applicable paragraphs of Articles 210, 220,
225, and 430 of the NEC. Where Article 220 allows the use of demand
factors, they shall be used with caution. Demand factors may be used for
feeder and transformer sizing calculations but not branch circuit
calculations.
The load on 20-amp branch circuits that supply lighting and receptacles
must be limited to 80 percent of the rating of the branch circuit protective
device, a 20-amp molded case circuit breaker per Article 210 of the NEC,
because lighting and receptacle loads must be considered "continuous." It
is recommended that the load on these circuits be limited further to
1,800 VA to limit voltage drop on these circuits.
The Engineer shall make an effort to group circuits that perform a common
function together within a panelboard (e.g., all lighting together, all
receptacles together). In addition, three- and four-wire branch circuits
should be shown on the drawings wherever they are appropriate to
minimize the amount of conduit that is required. These circuits should be
connected to adjacent circuit breakers in the panelboard.
Ground fault interrupter type outlets shall be installed in all outer locations
and locker rooms and bathrooms where personal hygiene items may be
used.
3.13 GROUNDING
3.13.1 General
Electrical circuits, equipment, and equipment enclosures shall be bonded
and grounded as required by Article 250 of the NEC. All process
equipment and structures subject to potential and current flow due to
lightning, static accumulation, or other abnormal conditions shall be
grounded by two ground connections.
However, because of galvanic action between buried steel pipes and other
nearby dissimilar metals, Metropolitan does not use buried large diameter
steel pipes in its distribution system as grounding electrodes.
Because copper and copper-plated steel form galvanic cells with buried
steel pipes and conduits, the design of the substation grounding system
must be coordinated with other designs to minimize the effects of
corrosion.
3.14.1 General
Because emergency and standby power systems both use the same
equipment and often serve the same purpose, they are both discussed in
this section. For the purposes of this manual, the following definitions of
emergency power and standby power systems will be used:
The first option to consider in getting the users their preferred type of
telephone system is to exclude it from the design package or include it as
an allowance. The reasons for this are:
3.15.2.3 Design Criteria. Where fire alarm systems are required, alarm
and detection devices shall be provided as shown in Table 3-3.
1
Table 3-3. Requirements for Fire Alarm and Detection Devices
Area Initiation Notification
Industrial occupancy Manual or automatic Audible alarm in continuously attended location for
initiating action
Business occupancy Manual or automatic detection General audible alarm or live public address from
or sprinkler alarm at continuously attended location
Underground structure Manual or automatic Audible alarm in continuously attended location for
initiating action
Windowless structure Manual or automatic Audible alarm in continuously attended location for
initiating action
Laboratory (not specified) All persons endangered and local fire department
to be alerted
In general, the electrical testing and system checkout should include the
following:
x Grounding;
x Applied potential;
x Induced potential;
x No load losses;
x Voltage ratio;
x Polarity;
x Continuity.
The manufacturer will also perform the following additional tests on units
identical to the design type being supplied:
x Sound level;
x Temperature rise;
x Full-load losses;
x Regulation;
x Impedance.
After a transformer has been energized, the contractor should make the
following checks and/or tests:
3.16.4 Conductors
After the engine generator has been installed, the contractor should
perform an onsite test at full load using resistive load banks for a minimum
of 4 hours. Results of this test should be compared with the test
performed by the manufacturer and the requirements of the specifications.
3.16.6 Grounding
The basic test method used to determine earth resistance is the direct
method (known as the Two-Terminal Test) and the fall-of-potential method
(known as the Three-Terminal Test). The direct method is the simplest
way to make an earth-resistance test because only two electrodes in
series are measured; however, this method is not as accurate at the fall-
of-potential method, which requires three electrodes.
CONTROL SYSTEM
DESIGN PROCEDURES MWD Electrical Design Manual
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Control panels shall provide the means for the operator to take over
control from remote terminal units (RTU). The panels shall only be used
in case of RTU unavailability. The panel design shall consolidate
functions wherever possible.
Indicating lights shall be LED type. Indicating lights shall have bulb
removal and bulb replacement possible from the front of the panel. A
push-to-test feature shall be provided for lamp testing.
Panel indication lamps--the color of indicator lights shall denote the lamp
functions as follows:
Color Function
AmberOverload
Red Equipment running, valve fully open, circuit
breaker closed, or high speed
Green Equipment stopped (safe), valve closed, circuit
breaker open, or low speed
White Valve intermediate position or alarm and
automatic or manual
4.1.5 Annunciators
Indication of alarms shall be displayed on a panel-mounted, internally
illuminated, solid-state annunciator.
Lamps shall have a nominal 20,000 hours minimum life at rated voltage.
All positions in the annunciator cabinet shall contain one solid state alarm
plug-in module. Each annunciator alarm point shall have one alarm
module. The alarm module shall be capable of accepting a normally open
field contacts that close on alarm or normally closed contacts that open on
alarm, selectable by a slide switch.
The annunciator shall be provided with horn and pushbuttons for reset,
silence (acknowledge), and lamp test functions.
Color Function
Green Reset
Blue Test
Yellow Acknowledge
All panels for a given facility shall be designed with the same format so
that the operator need not relearn panel configuration concepts while
moving around the plant.
Plastic wiring wraps shall be used to bundle wires, except within wiring
ducts. The bundles shall be securely fastened to the steel structure at
intervals not exceeding 12 inches.
Solderless ring lug connectors with insulating sleeves shall be used for
connecting wires to terminal blocks.
Power wiring insulation shall be rated to 600 volts and be type MTW.
Conductors shall be stranded copper. No wire smaller than 12 AWG
90o C shall be used for power wiring.
Wiring must not be spliced. Wire must be run in continuous lengths from
screw terminal to screw terminal. Wire service loops shall be provided to
permit device removal and to permit front door of control cabinet, if
equipped and wired with door-mounted devices, to open 90 degrees.
Terminal blocks shall be rated 300 volts for NEMA general industrial
control devices and 600 volts NEMA for power circuits. No miniature
terminal blocks shall be permitted. The terminals shall have a continuous
marking strip. Separate terminals shall be provided for terminating the
shield wire for each signal.
The terminal blocks shall have point identification strips. Terminal strips
shall be labeled horizontally from left to right (facing enclosure front) 1F,
2F, 3F, 4F, etc., and facing rear of enclosure 1R, 2R, 3R, 4R, etc.
Vertically the terminations shall be marked with a permanent, continuous
marking strip from top to bottom. One side of each terminal strip shall be
reserved for field incoming conductors. Common connections and
jumpers required for internal wiring shall not be made on the field side of
the terminal. No more than two wires shall be terminated at any one
terminal.
Two 1/4-by-1-inch copper ground buses with M5 and M6 tapped holes and
insulated mounting brackets shall be provided in each cabinet or panel,
one for shield and cabinet grounding and one for signal grounding.
4.1.9 Nameplates
Nameplates shall be installed on the doors or covers of panels, panel-
boards, starters, contactors relays, and other electrical equipment.
Equipment within panels shall be identified.
Front panel nameplates for devices shall be black laminated plastic with
white letters, attached with No. 2-56 stainless steel machine screws,
Phillips type, counter sunk head.
4.1.10 Installation
Before any circuits are energized, internal and external electrical and
mechanical clearances must be checked to assure that installed
equipment will function safely and properly.
Free standing panels shall be shimmed level and grouted. Panels shall
bear evenly over the full length and be installed plumb. Panel structures
must be accurately leveled such that panel structures will not be distorted
and all doors must operate without binding.
4.2.1.4 Color Code Identification. Each wire shall have a color code
identification to facilitate wiring and troubleshooting.
Type Description
x Analog Signals
x Contact Inputs
Type I and III wiring shall be used for individual and multi-
pair runs, respectively.
As a general rule, no wire smaller than No. 12 AWG shall be used for
power wiring.
No wire smaller than No. 14 AWG shall be used for control wiring.
4.2.1.9 Shield Grounding. Signal shields shall have one ground point
located at the source of the signal (e.g., analog transmitter or contact
closure) unless otherwise recommended by the instrument or equipment
manufacturer. Shields shall be continuous through cabinets, panels, and
junction boxes.
x Analog Signals
- 0 to 100 mV;
- 100 mV to 5 V;
- 5 V to 75 V.
x Digital Signals
4.2.2 Conduit
Control circuit diagrams for various types of field devices are shown on
Figures 4-1 through 4-10 (located at the back of this chapter).
The following are the types of field devices specifically covered in this
section. Design requirements for other field devices shall follow the
general requirements established in this section.
x Electric motors:
Constant speed;
Multiple speed;
Variable speed.
When neither contact is closed, the motor is stopped. The position of the
device shall not change during loss of remote control. In addition,
transfers between remote and local control are made without changing
position.
Throttling valves shall have limit switches for fully opened and closed
position monitoring and a 4-20 mA output signal for monitoring valve
position.
Limit switches and the position signal shall be furnished by the valve
manufacturer as an integral part of the valve assembly. Whenever
possible, a 4-20 mA position signal is preferred instead of a potentiometer.
Large motors, generally over 100 horsepower, that are critical to the
process, plant, or system shall be monitored for alarm conditions such as
high bearing temperature, high motor winding temperature, and motor
vibration.
Note: The most current edition of referenced publications applies, unless otherwise
specified.
IEEE Std 525, IEEE Guide for the Design and Installation of Cable Systetms in
Substations
IEEE Std 605, IEEE Guide for Design of Substation Rigid-Bus Structures
IEEE Std 739, IEEE Recommended Practice for Energy Management in Industrial and
Commercial Facilities
IEEE Std 979, IEEE Guide for Substation Fire Protection
IEEE Std 980, IEEE Guide for Containment and Control of Oil Spills in Substations
IEEE Std 1050, IEEE Guide for Instrumentation and Control Equipment Grounding in
Generating Stations
IEEE Std 1100, IEEE Recommended Practice for Powering and Grounding Electronic
Equipment
IEEE Std 1187, IEEE Recommended Practice for Installation Design and Installation of
Valve Regulated Lead-Acid Storage Batteries for Stationary Applications
IEEE Std C37.2, IEEE Standard Electrical Power System Device Function Numbers
IEEE Std C37.20-1, IEEE Standard for Metal-Enclosed Low-Voltage Power Circuit-
Breaker Switchgear
IEEE Std C37.20-2, IEEE Standard for Metal-Clad and Station-Type Cubicle Switchgear
IEEE Std C37.20-3, IEEE Standard for Metal-Enclosed Interrupter Switchgear
IEEE Std C37.96, IEEE Guide for AC Motor Protection
IEEE Std C37.100, IEEE Standard Definitions for Power Switchgear
IEEE Std C37.101, IEEE Guide for Generator Ground Protection
IEEE Std C37.102, IEEE Guide for AC Generator Protection
NEMA WC 74/ICEA S-93-639, 5-46 kV Shielded Power Cable for Use in the
Transmission and Distribution of Electric Energy.
Underwriters’ Laboratory
UL 845, Motor Control Centers
UL 891, Switchboards
UL 1008, Transfer Switch Equipment
Miscellaneous Documents
Electrical Installations in Hazardous Locations, Peter J. Schram and Mark W. Earley,
editors, National Fire Protection Association
Electric Service Requirements, City of Los Angeles Department of Water and Power
Electrical Service Requirements Manual, Southern California Edison
Electrical Engineer’s Portable Handbook, Bob Hickey, editor, McGraw-Hill
Electrical Systems Analysis and Design for Industrial Plants, Irwin Lazar, editor,
McGraw Hill
Handbook of Electric Power Calculations, H. Wayne Beaty, editor, McGraw-Hill
Industrial Power Systems Handbook, Donald Beeman, editor, McGraw-Hill
A or AMP Ampere
A/C Air Conditioner (Conditioning)
AC Alternating Current
AF Ampere Frame
AFF Above Finished Floor
AFG Above Finished Grave
AG Above Ground
ASD Adjustable Speed Drive
AT Ampere Trip
ATS Automatic Transfer Switch
AUX Auxiliary
AWG American Wire Gauge
BAT Battery
BC Bare Copper
BET Between
BOT Bottom
BLDG Building
BKR Breaker
BTU British Thermal Unit
BTU/H British Thermal Unit Per Hour
C Conduit
CAB Cabinet
CAT Catalog
CB Circuit Breaker
CHLOR Chlorine
CONC Concrete
CKT Circuit
CMIL Circular Mil
CNTL or CONT Control
CONT’D Continued
D Depth
DC Direct Current
DIA or Diameter
DN Down
DISC Disconnect
DIST Distribution
DPDT Double Pole Double Throw
EL or ELEV Elevation
EXIST Existing
EM Emergency
EPR Ethylene Propylene Rubber
F Frequency
FDR Feeder
FL Floor
FLEX Flexible
FS Flow Switch
FVR Full Voltage Reversing
FVNR Full Voltage Non-Reversing
G Ground
GFI Ground Fault Interrupter
GFCI Ground Fault Circuit Interrupter
GND or GRD Ground
H or HGT Height
HDAF Hot Dipped After Fabrication
HH Handhole
HOA Hand-Off-Automatic
HP Horsepower
J Junction
JB Junction Box
LP Lighting Panel
LS Level or Limit Switch
LT Liquidtight
LTG Lighting
LV Low Voltage
M Motor
mA Milliamp
MAX Maximum
MCC Motor Control Center
MCP Motor Circuit Protector
MFE Metropolitan Furnished Equipment
MFR Manufacturer
MIN Minimum
MH Manhole
MOD Module
MV Medium Voltage
MVA Megavoltampere
MWD Metropolitan Water District
NC Normally Closed
NEC National Electric Code
NEMA National Electrical Manufacturers Association
NFPA National Fire Protection Association
NIC Not In Contract
NO Normally Open
NO. or # Number
NTS Not To Scale
P Pole
PB Pullbox or Pushbutton
PDR Preliminary Design Report
PF Power Factor
PH or Phase
PLC Programmable Logic Controller
PNL Panel
PS Pressure Switch
PVC Polyvinyl Chloride
PWR Power
R Resistor
RECPT or RCPT Receptacle
RGS Rigid Galvanized Steel
RTU Remote Terminal Unit
TB Terminal Box
TC Terminal Cabinet
TD Timer Delay
TEL Telephone
TERM Terminal
THRU Through
TM Thermal Magnetic
TS Temperature or Time Switch
TSP Twisted Shield Pair
TST Twisted Shield Triad
TYP Typical
UG or U/G Underground
UPS Uninterruptible Power System
UL Underwriters Laboratories
USA Underground Service Alert
V Volt
VA Voltampere
VFD Variable Frequency Drive
W Watt
W/ With
WP Weatherproof
XDCR Transducer
XFMR Transformer
The (title of facility) is a new facility. This document is intended to provide guidance
for the electrical system design. If there is a better way to meet the design
objectives, submit a recommendation to the project lead electrical engineer for
processing.
See the preliminary design report (PDR) for a description of the electrical system to
be provided for this project.
OBJECTIVES
The design objectives on this particular project are clarity, simplicity, and
standardization. In addition, the usual standards of the profession will apply such as
constructibility, completeness, and reasonable accuracy.
Clarity
The design and presentation must be clear. Show how you arrived at significant
decisions. If you want a specific result, show the contractor what shall be done for
the particular situation.
Simplicity
The design itself, of course, shall not be more complex than necessary to produce a
good electrical system. In addition, the presentation shall be as simple as clarity
permits. Simplicity shall not go so far as to shift tasks normally accomplished during
design into the construction phase.
Standardization
The design must show uniformity throughout so that similar problems are solved in
similar ways. If several people work on areas that can share solutions, they shall
only produce one solution and reference it elsewhere. Where possible,
manufacturers' standard assemblies shall be used.
SCHEDULING
An electrical work plan will be provided separately. This section tells what
information must be available before beginning the design for each part. The object
of having this information available before the design begins is to minimize changes
in the electrical design. If the information listed below is not available at the time the
design for a particular portion is scheduled to begin, do not begin that portion of the
design. Problems that you encounter in obtaining the necessary information will
either be immediately resolved or referred to the Design Manager and/or Project
Manager.
Single-Line Diagram
A single-line diagram for the plant electrical distribution system is included in the
PDR. I will modify this single line as necessary to accommodate changes that have
been made since the PDR was completed. Single-line diagrams for motor control
centers (MCC) will not be started until a reasonably complete motor list has been
developed for the area where the MCC is to be located. The P&IDs shall be used to
check the equipment lists given to us by the process leads. Each motor and
equipment number shall be checked against the current P&ID set before the
equipment list is considered complete.
x P&IDs completed.
Facility electrical design, lights, and outlets, for any area will be started only after the
process design is completed and building plans and sections are prepared and
drafted by the architects (changes in process design may still take place).
REFERENCE MATERIALS
Besides the usual codes and standards, the following documents are available as
information.
Standards and codes of the following organizations shall also govern where
applicable:
Local codes and standards shall be applied as appropriate. Where the requirements
of more than one code or standard are applicable, the more restrictive shall govern.
Requirements of applicable codes and standards are not repeated in this section.
Applicable state and local codes and UL listing requirements shall be followed for
electrical inspection. Exit signs, emergency egress lighting, and emergency lighting
power supply shall conform to requirements of the building inspector.
VOLTAGES
The primary distribution voltage within the plant shall be 4,160-volt, three-phase.
The secondary distribution voltage shall be 480-volt, three-phase, wye, high-
resistance grounded.
Under normal circumstances, the voltage for fluorescent, high pressure sodium, and
incandescent lighting shall be 120-volt, single-phase. This voltage also shall be
supplied to heaters up to 1,500 watts, convenience outlets, motor controls, and
motors of less than 1/2 horsepower (hp). Heaters above 1,500 watts and motors
from 1/2 to 200 hp shall be 480 volts, three-phase. Motors above 200 hp shall be
4,160 volts, three-phase.
The code allowable total voltage drop from the 480-volt source bus (excluding site
distribution) to the point of use (including feeder, branch circuit, and transformation)
shall not be exceeded.
In addition, due to the complexity and expense of providing ground fault protection
for three-phase 4-wire double ended substations with multiple grounds, no phase to
neutral loads shall be supplied directly from the 480-volt transformer secondaries.
DRAWINGS
Legend Sheet
In general, the standard Metropolitan symbols shall be used. The legend sheet shall
contain only the symbols and final abbreviations actually used in the drawing set.
The development of this sheet is my responsibility, with input from the project team.
A preliminary legend sheet is included in the PDR.
Single-Line Diagram
The single-line diagram shall show the entire electrical distribution system from the
elec trical service down to 460-volt utilization devices and 208Y/120-volt
panelboards. Circuiting of 208Y/120-volt panelboards shall be shown on the panel
schedules. Circuiting of 480Y/277-volt panelboards shall be shown on the panel
schedules where possible, but where motors are powered from panelboards, the
branch circuit, including all combination motor starters and disconnect switches,
shall be shown on the single-line diagram.
Information on single-line diagrams shall include bus capacity, short circuit ratings,
overcurrent device types and ratings, C.T. and P.T. ratios, protective relay types and
ratings, metering and load ratings (horsepower or kilowatt), and circuit breaker and
switch ratings.
Elevations
Front elevations shall be shown for all medium-voltage switchgear, low-voltage
switchboards, unit substations, and motor control centers. Elevations shall be drawn
to scale and shall show the locations of MCC units, overcurrent devices, metering,
and conductor entrances. MCC units with extra height shall be shown where
required for relays. Switchboard and switchgear elevations shall be informally
reviewed by the first-named manufacturer for placement of units and overall
dimensional accuracy. Where important, note depths of assemblies on elevations.
Elevations of the equipment shall be developed by the designer of the facility that
the equipment is located in and reviewed by me.
Remember that even one control relay in a motor starter will usually require an
additional 3 inches of compartment height. Assume that this will be the case when
you need to have relays. Two will fit in the added 3 inches; if you need 3, add
another 3 inches, etc.
x Elapsed time meters (will be provided if the motor falls into the criteria
described hereinafter)
x Metering
x Motor heaters
ECDs shalll be developed by each facility designer for the equipment located in that
facility.
Schedules
Luminaire and panel schedules shall be put on the drawings. The luminaire
schedule shall be prepared in a format similar to the lighting fixture schedule shown
on attached example. A preliminary list of luminaires shall be developed before
design is started and the same luminaire shall be used for all similar applications
throughout the plant. Addition of a new luminaire to the schedule shall require
review with the project lead electrical engineer. A preliminary list of luminaires
shown in the format to be used is enclosed hereinafter.
Panel schedules shall be prepared similar to the panel schedule shown on attached
example. The lead design engineer for each facility shall be responsible for the
preparation (and review) of all panel schedules related to that facility. A separate
panel shall be provided within each facility for the power supply to process related
instruments and equipment. In smaller facilities, this panel may be subfed from the
lighting panel, but in larger facilities it shall be fed from a transformer and transfer
switch that is separated from the building facilities power supply.
The panel schedules shall be included on the drawings with the buildings or facilities
where they are located or with the single-line diagrams or equipment elevation of the
related equipment. The panel schedule format is available upon request.
Details
Details shall be numbered as noted in the project instructions. The project lead
electrical engineer will act as, or appoint a detail coordinator. A preliminary set of
design details will be selected and a copy of each will be provided to each design
team member. Details will generally be Metropolitan standard details. When you
need to use a detail that has already been used, find out the number from the detail
coordinator. If it has not been used, obtain a new number from the detail coordinator
and tell the coordinator the standard detail number, whether you are modifying the
detail or whether you are creating a detail from scratch. Every 1 to 2 weeks, the
detail coordinator shall send a copy of details being added to the project to each
electrical designer on the project.
DIVISION 11 SPECIFICATIONS
Division 11 specifications for equipment that requires electrical connections shall be
reviewed for electrical requirements by the electrical design engineer responsible for
the area where the equipment will be installed. In addition, the project lead electrical
engineer shall review each equipment specification before it is returned to the
Design Manager for processing. A list of Division 11 specifications will be prepared
that identifies which electrical design engineer is to review which sections.
DIVISION 16 SPECIFICATIONS
Refer to Metropolitan's ESD-135, Standard Specifications Sections Catalog for a list
of specifications necessary for this job. These specifications shall be developed by
the project lead electrical engineer with input from each electrical design engineer
where a specification affects an area they are designing. When developed, these
specifications shall be compatible in requirements to Metropolitan Standard
Specifications Sections Catalog.
x Circuit number;
x Raceway number;
x Raceway end points;
x Number, size, and type of conduits, e.g., 2-4 inch PVC;
x Circuits carried in the raceway.
x Cable number;
x Circuits carried in the cable.
What to include in circuit and raceway schedules. The following circuits and the
raceways containing them shall be identified and entered into the circuit and
raceway schedule:
x Circuits which leave a sheet (exception: circuits which leave one floor
plan to a second floor of the same building but do not leave the
building).
x Circuits which leave a facility, unless they do not leave the sheet, and
the routing between facilities is clear.
If a circuit is identified anywhere on its route, it shall be identified for its entire route.
All raceways containing that circuit shall also be identified unless the raceway
remains entirely within one facility. In such a case, that portion of the circuit may be
identified in the circuit schedule and the circuit will be identified as part of the
raceway fill on the drawings.
Information shall not be duplicated on the drawings and circuit and raceway
schedules. For anything appearing in the schedules, just give enough information
on the drawings to locate it in the schedules. This means that once the need to
identify a circuit has been established, the only information that needs to be put on
the drawings about that circuit is the circuit number and the raceways that contain it.
FAULT STUDIES
A preliminary fault study shall be completed for the entire plant as part of the PDR
but no later than the start of final design. The following assumptions shall be made:
x The standby engine generators shall not operate in parallel with the
utility source but the gas utilization generator shall.
x The maximum load operating on each 480-volt bus at each load center
shall be equal to 100 percent of the installed transformer capacity at
that load center.
The study shall show the load and fault duty on each bus and feeder overcurrent
device rated 460 volts or higher.
The final fault study shall be an update of the preliminary fault study.
The final load study shall show the load at each distribution assembly in the following
categories:
x HVAC;
x Process;
x Lighting;
x Other facility loads;
x Total.
Other categories may be added to the above, if required by the electric utility.
PROCESS CONSIDERATIONS
Hazardous Areas
The project lead electrical engineer shall review the various areas of the plant that
may contain hazardous concentrations of hazardous gases. Based on the
requirements of NFPA 820, a drawing shall be developed to deal with each area.
The areas that will be affected include enclosed areas, scum pits, and similar areas.
These are areas open to raw sewage or secondary influent (i.e., up to the aeration
basin), which shall be considered Hazardous Class I, Division I due to the presence
of methane and gasoline unless adequate ventilation is provided. In addition, the
digester gas compressor rooms shall also be classified as Class I, Division I areas.
Other areas may be classified hazardous as required by NFPA 820. Devices that
contain contacts located in hazardous areas shall generally be wired intrinsically
safe, except in Class I, Division II areas where hermetically sealed contacts may be
installed.
Reliability
This plant requires EPA Class I reliability. One utility source is available at the plant
and a standby generator shall also be provided. The plant shall be designed with
double-ended unit substations and MCCs in all facilities. Power for duplicate
equipment shall be put into different conduits so as to maintain the Class I reliability.
Redundancy of supply criteria shall comply with EPA Bulletin EPA 430-99-74-001
definitions for a Class I plant.
Interim. Until I&C tag numbers become available, utilization equipment will be
identified by the following format:
x FF-SS
Miscellaneous
Provide disconnects where required at process equipment, especially at
motor-operated valves. Work with the equipment specified to see if integral
disconnects are a standard option. Do not ask that they be specified unless they are
a standard option. Provide disconnect switches for all HVAC equipment that has
any integral controls (i.e., unit heaters, compressors, duct heaters, air handlers,
etc.).
480 Volts
208Y/120 Volts
Lighting, Receptacles,
and Miscellaneous Power 5LP1, 5LP2, 5LP3, etc.
Sequence numbers are required even if only one of a particular type of equipment is
in a particular facility. For TJBs only, the sequence number will be followed by "A"
for analog, "D" for discrete, or "P" for power.
Other equipment may be identified if identification is required for other purposes; for
example, junction boxes may need to be identified in order to homerun to them.
Major electrical equipment, i.e., MCCs, SWBDs, etc., shall be located on the site
plan and the 1"=20' scale area plans in addition to the facility and process electrical
plans.
x 480-volt motor control center main circuit breaker: 100 percent rated
molded case with solid state trips.
x 480-volt motor control center branch circuit breaker (other than com-
bination motor starters): molded case thermal magnetic.
Each circuit breaker that is located immediately downstream from the secondary
main on a 480Y/277-volt secondary transformer shall be equipped with ground fault
protection unless that circuit breaker is rated 200 amps or less. Each circuit breaker
protecting a motor of 100 horsepower or more shall be equipped with ground fault
protection. Ground fault protection on motors shall be instantaneous type and
ground fault protection on main breakers and feeder breakers shall be equipped with
time delay setting and restraint systems.
Motor control center type construction shall be used where multiple three-phase
motors are located in the same general area.
Each motor shall be provided with thermal overload protection in all ungrounded
phases. Controller-mounted thermal overload relays shall have external manual
reset.
All motor control circuits shall operate at 120 volts and shall be supplied by individual
control power transformers fused both in the primary and secondary sides.
Panelboards
A separate circuit breaker shall be provided for instruments that perform the same
function on parallel flow streams, such as DO meters, flow meters, etc. Instruments
of different types that are all associated with the same flow stream may be
connected to the same branch circuit to simplify the design. Where multiple
instruments are connected to a single-branch circuit, a toggle switch shall be
provided at each tap to allow each individual instrument to be disconnected from the
branch circuit.
A common branch circuit shall be provided for all valve and gate operators that are
associated with a single-flow stream.
Examples:
Branch circuits or feeders shall be identified on the drawings with the panelboard
and device protecting the individual circuit or feeder.
Panelboard schedules shall show the circuit description, protective device trip rating,
number of poles, rating of main lugs or main circuit breaker, neutral bus size, ground
bus size, and interrupting rating of breakers. Computer-generated panelboard
schedules shall be included in the drawings.
Convenience Receptacles
Duplex receptacles for general service shall be spaced not more than 40 feet apart
inside all process buildings and 75 feet apart in outside process areas and shall be
located on the surface of walls or columns. Receptacles in outdoor locations and
areas subject to washdown shall be weatherproof. Receptacles shall be located as
needed in commercial areas.
Ground Fault
Ground fault systems shall be zero sequence type. Coordination shall be obtained
by hard-wired trip restraints (about 2ms restraint). Facilities shall be provided for
testing the ground fault circuit by secondary current injection, with or without tripping
and for indicating the occurrence of a ground fault. Current and time trip levels shall
be adjustable. Ground fault shall be supplied external to the circuit breaker. Motor
ground fault shall be an instantaneous trip.
Power Factor
Power factor correction capacitors shall be applied to all motor starters for motors of
40 hp and larger. Capacitor banks shall generally be located on top of motor control
centers.
Raceways
Specific types of raceway shall be chosen for use in various locations in the facility
based on moisture, temperature, exposure to damage, corrosion, voltage, and cost.
Separate, concrete-encased, polyvinyl chloride (PVC) conduit, underground duct
bank shall be provided for the following systems:
Underground raceways that are not installed in a duct bank shall be direct-buried,
schedule 40 PVC conduit.
The following general guidelines shall be used for raceway sizing, selection, and
installation:
x Conduit size shall be based on THWN insulation for sizes below No. 6
AWG, and THW insulation for all other wiring 600 volts and below.
x The minimum diameter of conduit in all areas shall be 3/4 inch.
x Exposed raceways shall be installed in process areas.
x Raceways in walls and ceilings in control rooms, offices, and all areas
Individual No. 14 AWG conductors shall be used for discrete control circuits, unless
it is practical to use multi-conductor cables to group control circuits.
Twisted-shielded pair control cable No. 16 AWG with an aluminum mylar tape shield
shall be used for analog signals. Multi-pair cables shall be used where grouping of
circuits is practical. Conductors above 600 volts shall be 19-strand copper with
ethylene-propylene polymer (EPR) insulation, copper tape shield and PVC outer
jacket.
Switchboards
Switchboards shall be similar to Square D Power Style with individually mounted,
molded case circuit breakers that have solid state trip elements. See the
manufacturers data contained hereinafter for additional information.
Grounding
Load centers shall be bonded to a grounding electrode, which may consist of a
building steel column that is bonded to the underground rebar or the nearest
available effectively grounded metal water pipe. In addition, ground rods shall be
driven outside the building to supplement the ground electrode.
Grounding electrodes of ground mats or embedded rods and cables shall have a
maximum resistance to ground of 1 ohm. A minimum of No. 2/0 insulated copper
cable shall be used for interconnecting ground rods and connection to equipment.
The parts of all electrical equipment, devices, panelboards, and metallic raceways
that do not carry current shall be connected to the ground conductors. The
transformer neutrals of wye-connected transformers shall be solidly grounded
through a grounding conductor connected to the grounding system.
A ground wire shall be installed in all raceways that contain power conductors at any
voltage.
Lighting
Lighting levels in all areas of the plant shall be calculated following the procedures
recommended in the Illumination Engineering Society (IES) handbook. In general,
the following minimum foot-candle level shall be provided:
Area Foot-Candle
Office 70
Process, inside 50
Process, outside 5
Storage, inside 10
Walkway 5
General site 1
The following general types of light service shall be used to provide the proposed
foot-candle levels:
AreaLight Service
Office Fluorescent
Process, inside to
12 feet mounting
height Fluorescent
Process, above
12 feet mounting High pressure sodium
height or metal halide
Storage, inside Fluorescent
Walkway, inside Fluorescent
Walkway, outside High pressure sodium
General site High pressure sodium
Transformers
Transformers to supply 208Y/120 volt requirements shall be dry type and suitable for
the area in which they are to be located. Transformers that include a small
panelboard in the same enclosure shall not be used, A small transformer with a
separate panelboard shall be used in every case.
Transformers to supply 480 volt 3-phase and 4160 volt 3-phase shall be of the pad
mount type where located outdoors and of the dry type where located indoors.
Miscellaneous Systems
Fire alarm systems shall be included in buildings as required by applicable codes.
INTERFACES
Facility
Each facility shall have designated interface points for connection with conductors
that leave the facility. For each facility, make a list showing where the interfaces are.
CALCULATIONS REQUIRED
Calculations shall be done in an orderly manner either on a desktop PC computer or
on computation paper. Each sheet shall have the date on which the computations
were made, the project number, and the designers name. All information used in the
preparation of the design shall be kept in a notebook with tabs to properly divide the
different items such as telco memos, comps, letters, equipment data sheets, etc.
Each computation shall clearly identify the facility for which the calculations are
being made and the type of computation that is being performed. Copies of all
calculations shall be sent to project lead electrical engineer as they are completed
for his review and filing. At the completion of the project, all pertinent information
shall be assembled in a single set of notebooks for inclusion in the project files.
The computations listed below are the minimum that need to be documented. All
calculations shall be reviewed before the related drawings are drafted.
Wire Sizing
Take into account wet/dry areas and ambient temperatures—see attached form for a
guide. Show wiring sizing for all services, feeders, and large branch circuits.
Calculations shall include a summary of all loads to be served where there is more
than one load. Calculations for feeders to panelboards shall reference the specific
panelboard being supplied and a copy of the panel schedule with all loads indicated
shall be included with the calculations.
Primary and secondary feeders to/from dry type transformers shall be sized in
accordance with the attached transformer table and the proper sized main breaker
shall be shown in the panelboard that is served from the transformer.
Voltage Drop
Prepare steady-state voltage drop calculations for all heavily loaded and/or long
branch circuits and feeders using the attached "Voltage Drop Calculation Data."
Base calculations for motor circuits on an 80 percent power factor. Motor starting
voltage drop calculations shall be shown for all motors that exceed 20 percent of the
rating of the serving transformer.
Steady state voltage drop shall be limited to the values listed in the Design Criteria
with not more than 2 percent drop on feeder. Motor starting voltage drop shall be
limited to 20 percent.
Branch Circuits
Connected load and NEC requirements shall be used for sizing branch circuit
breakers and conductors.
A minimum wire size of No. 12 AWG copper shall be used for lighting and receptacle
branch circuits. No. 10 AWG shall be used where the first convenience receptacle is
more than 75 feet from the panelboard.
In general, 120 volt lighting branch circuit load shall be used for up to 1800
voltamps.
120 volt lighting loads shall be connected to circuits separate from receptacles
except in storage rooms where the lights may be connected to receptacle circuits or
vice versa.
Branch circuit shall be limited to five duplex receptacles in process areas and six
duplex receptacles in office areas. Special areas may require further reduction in
number of receptacles per circuit.
Conduit Size
Calculations shall be included for sizing of all conduits that are not covered by the
table of conduit sizes included hereinafter. Conduit fill shall not exceed that allowed
by the NEC when all conductors, including the ground conductor, are included in the
calculation assuming that ground conductors have TW insulation and phase
conductors have THW insulation.
Lighting
Calculations may be in any form. For small areas, a statement that "so many" lights
of "such" a size will do the job, and is all that is required. For larger areas, use the
"Zonal Cavity Calculations" form attached. The foot-candle level resulting from the
actual fixtures to be installed shall be documented.
NEMA Type 1, General Purpose. Enclosures intended for indoor use primarily to
provide a degree of protection against limited amounts of falling dirt.
NEMA Type 2, Dripproof. Enclosures intended for indoor use primarily to provide a
degree of protection against limited amounts of failing water and dirt. Enclosures have
provisions for drainage. If provision is made for the entrance of conduit at the top, it
consists of a conduit hub or equivalent.
NEMA Type 3, Dusttight, Raintight, and Sleet- (Ice-) Resistant. Enclosures intended for
outdoor use primarily to provide a degree of protection against rain, sleet, windblown
dust and damage from external ice formation. Enclosures have conduit hubs or
equivalent provision for watertight connection at the conduit entrance.
NEMA Type 3R, Rainproof and Sleet- (Ice-) Resistant. Enclosures intended for outdoor
use primarily to provide a degree of protection against rain, sleet, and damage from
external ice formation.
NEMA Type 3S, Dusttight, Raintight, and Sleetproof (Iceproof) Enclosures intended for
outdoor use primarily to provide a degree of protection against rain, sleet, windblown
dust and to provide for operation of external mechanisms when ice laden. Enclosures
have conduit hubs or equivalent provision for watertight connection at the conduit
entrance, mounting means external to the equipment cavity, and provision for locking.
NEMA Type 4X, Watertight, Dusttight, Sleet- and Corrosion Resistant: Same provisions
as Type 4 enclosure, and in addition, are corrosion-resistant.
NEMA Type 6P, Submersible, Watertight, Dusttight, and Sleet- (Ice-) Resistant. Same
provisions as Type 6 enclosure except for protection against entry of water during
prolonged submersion at a limited depth.
NEMA Type 10. Nonventilated enclosures constructed for mine use and designed to
meet the requirements of the Mine Safety and Health Administration.
NEMA Type 12, Industrial Use, Dusttight, and Driptight. Enclosures intended for indoor
use to protect the enclosed equipment against fibers, flyings, lint, dust, and external
condensation of noncorrosive liquids. Enclosures have no holes, conduit knockouts or
conduits openings, except that oiltight or dusttight mechanisms may be mounted
through holes in the enclosure when provided with oil-resistant gaskets.
NEMA Type 13, Oiltight and Dusttight. Nonventilated enclosures intended for indoor
use primarily to house control-circuit devices such as limit switches, foot switches,
pushbutton, selector switches, and pilot lights and to protect these devices against lint
and dust, seepage, external condensation, and spraying of water, oil, or coolant. All
conduit openings have provisions for oiltight conduit entry.
OPEN MACHINE: ventilation openings permit passage of external cooling air over and
around the winding of the machine
GUARDED MACHINE: all openings giving direct access to live metal or rotating parts
are limited in size by structural parts or by screens, baffles, grilles, expanded
metal, or other means to prevent accidental contact with hazardous parts.
OPEN PIPE VENTILATED MACHINE: openings for the admission of the ventilation are
so arranged that inlet ducts or pipes can be connected to them. Machine shall
be self-ventilated or force-ventilated, external from and not a part of the
machine.
WEATHER PROTECTED MACHINE TYPE II: ventilation passages at both intake and
discharge are arranged so that high velocity air and airborne particles blown
into the machine by storms or high winds can be discharged without entering
the internal ventilating passages.
The polyphase induction motor shall be of either the squirrel-cage or the wound-rotor
type. The squirrel-cage induction motor has been classified by National Electrical
Manufacturers Association (NEMA) Tests and Performance-AC (MG1-1987) according
to the following designs.
Design A motors are usually used for applications where extremely high efficiency and
extremely high full-load speed are required. Therefore, Design A motors tend to be
special motors.
Design B motors are the standard general-purpose motors used where low locked-rotor
current and moderate locked-rotor torque are required along with high full-load speed
and efficiency.
The following figure shows typical speed-torque curves of NEMA design-class squirrel
cage motors.
Full load torque – Torque necessary to produce rated horsepower at full-load speed.
Locked-rotor (starting) torque – Minimum torque which the motor will develop at rest
for all angular positions of the rotor, with rated voltage applied at rated frequency.
Pull-up torque – Minimum torque developed by the motor during the period of
acceleration from rest to the speed at which breakdown torque occurs. For motors
which do not have a definite breakdown torque, the pull-up torque is the minimum
torque developed up to rated speed.
Breakdown torque – Maximum torque which the motor will develop with rated voltage
applied at rated frequency, without an abrupt drop in speed.
Pull-out torque (synchronous motor) – Maximum sustained torque which the motor
will develop at synchronous speed with rated voltage applied at rated frequency and
with normal excitation.
Pull-in torque (synchronous motor) – Maximum constant torque under which the
motor will pull its connected inertia load into synchronism, at rated voltage and
frequency, when its field excitation is applied.
CABLE IDENTIFICATION
Conductor and multiconductor cables should be identified at each end of the installed
cable. Cable tags and fastening devices shall be made of nonconductive materials.
Cable tab marking should be permanent type and waterproof. The cable number should
be show on single-line diagrams, wiring diagrams, wire list, instrument-loop diagrams,
and panel-wiring diagrams. The cable number should be constructed as follows:
ELECTRICAL BRANCH
HYDRO PLANT DESIGN SECTION
STANDARD SPECIFICATION
FOR THE IDENTIFICATION OF
ELECTRICAL CURRENT
1.0 SCOPE:
This standard provides the means of identifying electrical current
Carrying conductors on single line diagrams, wiring diagrams, wire lists.
Instrument loop diagrams, and internal/external panel diagrams. Also
provided is the installation requirements for cable identification tags.
2.00 DEFINITIONS:
Cable: A current carrying conductor/ conductors enclosed in an insulating
sheath and bound by an outer jacket of insulating material.
Conductor: A single current carrying material enclosed by an insulating jacket.
3.21 EXCEPTIONS:
I. where taping or shielding is required the tag shall be placed as close
to the termination point as physically possible.
3.32 All conductor voltage levels shall be identified by the following color
code in Table-A.
TABLE - A
BACKGROUND CHARACTER
VOLTAGE LEVEL
COLOR COLOR
X XX X X X
XXXXXX
1MH123
TYPICAL MANHOLE IDENTIFICATION
1MHH123
1TB123
X X X X X X
COLUMNS 01 TO 99
01 02 03 04 05