Statutory requirement &IE Rules

Application on Electrical Equipment

Layout, Switchgear Room Layout,
Cable Tray/ Trench Layout,
Generator Isolated Phase Bus-duct.

Isolated Phase Busduct (IPBD)

Types of busducts
Busducts are designed considering the current and voltage requirement, short
circuit requirement, the availability of space and beauty aspects.
Broadly busducts are classified into Isolated Phase Busduct, Segregated Phase
Busduct, and Non-segregated Phase Busduct etc. Various types of busducts are
depicted in the following table:

Isolated
Phase
Busduct
(IPBD)
The Isolated Phase Busduct, most commonly used for large power

generating units and popularly known as Generator Busduct, serves

as interconnection between the generator and its associated Generator
Step Up Transformer, Unit Auxiliary Transformer, Start Up
Transformer and associated auxiliary equipments.
Isolated Phase Busduct is supplied for voltage class from 12 kV to 36
kV and rated currents up to 30,000A with natural cooling and up to
55,000A utilizing forced air cooling.
Isolated Phase Busduct complies with ANSI C37.23 and BIS-Design
Guide Isolated Phase Busduct 8084 standards.
Enclosures are all welded construction and can be supplied with dry
pressurized air, to maintain a moisture free environment, thereby
minimizing maintenance and stoppages of the plant and ensuring high
operational reliability and power supply.
The conductors and enclosures are manufactured from high
conductivity aluminium/copper alloy.

Isolated Phase Busduct (IPBD)

Depending upon the type of cooling, these busduct are categorized
Continuous Isolated Phase Busduct: Generally, continuous Isolated Phase
type arrangements shall be provided for generator busduct for current ratings of
5000A and above.
1.Natural Cooled: Isolated phase busduct up to unit capacity of 800 MW or
different rating up to 31,000 amps is feasible with natural cooling.
2 Forced Cooled: Higher rating of busduct beyond 800 MW unit capacity
requires higher enclosure size and sometimes this poses layout and other
constraints and hence are considered with forced cooling arrangement. Based on
the space constraints, some times even lower ratings are considered with forced
cooling arrangements.

Isolated Phase Busduct (IPBD)

From layout point of view, the generator busduct are categorized
Main Run: Isolated three phase busduct run from generator phase

terminals / phase segregated terminal adaptor box to the generator

transformer terminals is designed as Main Run busduct.
Delta Run: (for 3 x 1 Ph generator transformer wherever provided)
Isolated phase busduct which forms delta connection of the generator
transformers is designated as delta run busduct. It is tapped from the
three phase main run, and connects to the terminals of three single
phase generator transformers.
Tap-off Run: Isolated three phase busduct tapped from main run of the
isolated phase busduct and connects to the Unit Auxiliary transformer
terminals and other equipments such as LAVT/NG cubicle and
excitation transformer is generally known as Tap off Run of Isolated
Phase Busduct.

Isolated Phase Busduct (IPBD)

The Generator Busduct in thermal power plants provides connection
between Generator Transformer (GT), unit transformer other
associated equipments and the Generator.
The Generator Busduct is generally routed at a level higher than 6.0 m
(approx) from the ground inside Turbine Generator (TG) hall as well as
transformer yard to facilitate movement of other equipments. Necessary
insert plates in auxiliary columns in the TG sub-structure are provided
to fix the bus support structure. These insert plates are at a height
generally more than 5.0 m (Bottom of insert plates).
The location of the VT and SP cubicle is normally kept within 30m
from the Generator terminals considering the requirement of PD
measuring equipments as per international practice.

Isolated Phase Busduct (IPBD)

Design Criteria
The design of busduct is based on following factors:
The continuous current rating.
Short time current rating.
Maximum system voltage.
The maximum dynamic and transient forces.
Basic Insulation Level (BIL).
The dielectric requirement of the system.
Climatic conditions.

Isolated Phase Busduct (IPBD)

Selection Criteria
The shape and size of the bus bar/ enclosure is selected considering the
following aspects:

The current carrying capability.

The resistivity required for permissible thermal limits.
Forces between the different conductors in short circuit condition.
Skin effect.
Proximity effect.
Effect of solar radiation on temperature rise.
Seismic conditions.

Electrical Equipment Layout Criteria

Transformer Yard
Generator transformers, unit auxiliary transformers and station transformers
will be installed in transformer yard. Flexibility shall be kept for removal of
any transformer on rail track without affecting other transformer/equipment
and structure. Symmetry shall be maintained for transformer layouts to
achieve more or less identical arrangement for all units.
One main rail track parallel to A-row of powerhouse building shall be
provided. It will be interconnected with the rail track in unloading bay. From
main track, several branch tracks will be laid up to individual transformer
location. Jacking pads will be provided at each right-angled connection of rail
track right up to unloading bay.
Fire Baffle wall in between transformers shall be provided as per applicable
codes like TAC recommendations.
Each transformer shall have an individual soak pit complying is Code of
practice for installation of transformer and shall also meet the requirement of
IE rules.

Electrical Equipment Layout Criteria

In addition, for each 660 MW unit, there shall be a common oil pit to contain the oil of
largest transformer. The common oil pit will be closed type of water proof concrete
construction .The pit will be provided with 2X 100% sump pump such that each pump
can pump out emulsifier water and oil of largest transformer.Volume of the common oil
pit shall conform to relevant NFPA code.
In transformer yard area, cable shall be laid in RCC concrete trenches with RCC
covers.The main cable route coming from main plant building and crossing the
transformers yard shall be laid in overhead trestle/duct bank, Mininmum clear height of
trestle shall be 3M and for rail/road crossing, it shall be as per rail/road crossing norms.

GENERATOR

Generator shall be Installed in non-hazardous area and it should located close to their
associate step-up transformer so as to minimize the length of heavy current connection.
TRANSFORMER

Oil filled power transformer shall be installed outdoor in a fence-in area of the
substation. The fence shall have two lockable gates.
Each transformer shall have a minimum of 1M clear space all round.
With large transformer of 100MVA and above, a blast wall between transformer bay
shall be provided.

Electrical Equipment Layout Criteria

Transformer shall be mounted on a flat concrete base .Those of the non-sealed
type to be surrounded by a gravel filled or gravel covered oil catchment pit
which are sized to confirm the total oil content of the transformer. The
catchment pit should be connected to the following system :1. Oil water drain system .
2. Oilstorm water drain system through oil/ water separator system .
3. Pumping out by suction tanker.
Transformer shall be positioned and cover in a such a way as to minimise cable
crossing especially multiple single core cables are required.
Due account shall be taken to the magnetic field surrounding the transformer,
when positioning and sensitive electronic equipment and when designing any
adjacent metallic building. If necessay flux plot to obtained from the
manufacturer.

Electrical Equipment Layout Criteria

SWITCHGEAR
Switchgear should be installed when the switchgear civil and building work are
complete so as to minimise the ingress of dust and dirt during or after erection.
Switchgear foundation as per manufacturer drawing and shall be level within the
manufacturer specified tolerence.
Substation floor shall be smooth and level to permit the handling of equipment on roller.

Electrical Equipment Layout Criteria

Criteria of Oil Pit for Transformer

One separate common oil pit is required for Generator Transformer, Unit Transformers, and Station
Transformer. The criteria for sizing the Common Oil Pit shall be as follows:
The volume of new common oil pit will be 125% of the volume of oil of the transformer which
contains the largest volume of oil in transformers.
The oil pit will be closed type of water-proof concrete construction.
The oil pit will be connected to individual pit under each transformer and drain line of each
transformer will be at least 150 mm dia pipe with a minimum slope of 1:96 as per TAC Regulation.
Transformer fire/drainage of oil will be considered for only one transformer at a time.

Level of pit will be so selected that there would not be accumulation of oil/water/oil-water

mixture in the pit under each transformer.

Pit will be provided with 2 x 100% sump pump for common oil sump.
The location of sump pump over pit shall not be less than 15 M from nearest
transformer

Electrical Equipment Room Layout

Equipment layout
The layouts of the components shall be such as to facilitate the

interconnection shown in the single line diagram. The equipment arrangement

shall provide adequate access for operation, testing and maintenance.
Flexibility shall be kept for handling of equipment without obstruction during
erection and maintenance. Adequate handling facilities, space, door/rolling
shutter of adequate width and height shall be provided for this purpose.
Generally all electrical room shall be provided with 2 doors on opposite
sides. Doors shall be open able outwards to open space and shall be free of any
obstructions.
During design stage adequate space shall be provided for expansion of board
on either side to accommodate additional panels. Dummy panels wherever
required to avoid structural beams obstructing cable entry to panel shall be
provided.

Electrical Equipment Room Layout

Minimum Clearance between adjacent panels in a row shall be less then 200

mm . This clearance shall also be guided by equipment handling space where

applicable and space required for movement of personnel.
Clearances in between adjacent panels in a row or from the side wall/door
shall be so decided that handling of shipping section of any board is not
obstructed.
Separate battery room shall be provided for each 100% capacity battery for
unit and station.
Floor of battery rooms shall be with acid proof tiles.
Minimum clearance of 800mm shall be kept between each rows of battery.
Each battery room shall be provided with exhaust fan of adequate capacity
and also wash basin.
Switch rooms in indoor substations shall be single storey.

Electrical Equipment Room Layout

HV switchgear at voltage above 20kv should be located in a separate room. An

equipment access door should lead to directly to the outside from each
switchroom and internal personnel doors may connect adjacent rooms. All
access doors shall be fitted with emergency exit light.
There shall be at least space for two additional panel for future extension at
each end of each switchgear.
If electrical equipment is installed on the roof of the substation e.g. air
conditioning compressor/condenser, a cage ladder shall be provided leading
from an entrance platform to the roof.
In the cable vault underneath the substation, cable tray/racks shall be installed
for all cables to the LV switchgear and for all interconnecting auxiliary cables
between switchgear, panels, etc. For the power cables to the HV switchgear
vertical cable supports should be installed.

Electrical Equipment Room Layout

All the cable entry holes in the substation floor or walls shall be suitable
sealed. Where such cable entry holes are required to be gas tight and/or fire
resistant, multi-cable transits blocks shall be installed, or silicone foam, weakmix concrete(in floors only) or a chemical compound with subliming heat
resistant and fire retardant properties may be used.
Instrumentation and control system interface panels should be located in the
same switchroom as the associated switchboard.
When air conditioning is provided to cool and dry the substation air in relation
to the outside air, provisions shall be made to avoid warm, humid outside air
entering directly on to electrical equipment, causing condensation.
A smoke detection system compising very early smoke detection apparatus
(VSEDA) should be installed in substations. A common alarm shall be routed
from each substation direct to the plants central fire and gas alarm system, i.e.
independent of the substation alarm annunciator.
One hand-held extinguisher shall be provided near each door. No fixed or
automatic firefighting facilities shall be provided.

Switchgear in plant rooms

plant room is a room in a building other than a substation. E.g. an

administration building, workshop, etc., which contains service plant and
equipment for that building, e.g. HVAC plant.

In general only LV switchboards and, where required, associated indoor

transformers shall be installed in these rooms, but subject to the following
additional requirements.
The switchboards shall be installed back to the wall with at least 1.5m free
space in front for safe operational and maintenance access.
Service lines, e.g. fuel, water and airlines, shall not be routed over the
switchgear, and fuel and water lines should be positioned at least 2m clear
of it.

Battery Installation and Battery Rooms

For vented batteries a separate battery room shall be provided in the

substation and have an access door from within the substation.

For valve-regulated batteries of any capacity, do not require a separate battery
room.
The battery room shall be designed to contain the battery banks only. The size
of the room shall be adequate to allow access to at least three sides of each
battery bank for maintenance purpose.
All batttery rooms shall be provided with one equipment access door, and
large rooms, exceeding 6m length, shall also be provided with a personnel
access door. A water tap, eye-wash basin, sink and drain shall be installed in
the room.

Battery Installation and Battery Rooms

All non-current carrying metalwork in the room, e.g. cable tray, battery stands,

etc., shall be bonded to earth. All metalwork shall be protected against

corrosion.
Exhaust fan motors shall have type of protection e or d, gas group C,
exhausting to the outside of the battery room.
The luminaires and convenience outlets shall be suitable for Zone 1, gas group
C.
Batteries installed outside battery rooms should be installed in cabinets. These
cabinets shall be naturally ventilated and either house the battery alone or the
battery in combination with the associated battery charger.

Package Substation

Package substation shall be supplied as complete factory assembled and tested

transportable units.
HV switchgear, transformers and LV switchgear shall be located in separate
compartments.. Sufficient space shall be available in the compartment to terminate
cables and to operate the switchgear safety.
Each compartment shall be provided with luminaries and convenience outlets of the
weatherproof, industrial type.
Heating, ventilation and /or air conditioning provisions shall be made in the substation

Cable Tray/Trench Layout

Cabling System

Cable routing will be done on unit basis as far as possible.

Cables will generally be laid on cable trays either in concrete trenches or overhead supported
from building steel/structures. Cables shall be run in concrete trenches in those electrical
rooms at ground level, which are without any spreader room below.
In indoor pumps, mechanical equipment areas overhead cable trays shall generally be used
Local concrete trenches shall be used outdoor within switchyard bays for cable routing. In
boiler area, trench will be avoided as far as practicable. The cable racks shall be supported
from Boiler structure in vertical configuration with suitable cover to avoid deposition of coal
dust as far as practicable.
The cable laying in pump rooms shall be through overhead trays. The laying of cables
towards motors / equipment to be through embedded conduits.
Cable should not be routed below oil pipes and in the vicinity of steam pipes.
.Cable length increase exceed commercially available cable drum length. Cable joint shall be
recorded and then location marked

Cable Tray/Trench Layout

For inter plant connections, the cables shall be routed through an overhead cable bridge
pipe cum cable bridge. For isolated but long outdoor cable route with very few cables,
the cables may be directly buried subject to the approval of the Owner.
For underground crossing of railways, road etc. additional protection shall be provided in
the form of hume pipe or concrete encased rigid steel conduits (duct bank).
A.C. and D.C. circuit will not be run in same cable.
Cables for redundant equipment system shall be run in separate trays, as far as possible.
Erection of cabling work shall be executed keeping in view all necessities and
requirements of fire fighting codes for Generating Stations having an adverse industrial
environment.
Cable bending for LV cable shall be 8D and HV cable 20D for single core cable and
12D for multicore cable.
When measurement for cables and wires are proposed, the length measured accordance
with the layout and drawings and shall be increase by 5% of the total length.\
HV& LV single core cables shall be laid trfoil group with 150mm clear space between
trefoil.
On tray or rack HV cable shall be segrgated from the LV cables.

Cable Tray/Trench Layout

Cable and cable support shall not be fixed directly of indirectly to plant, equipment of
process pipes which may require removal or replacement.
Cable racks or trays shall be bonded and connected to the common earth grid.
No sub zero level vault/trench shall be provided below control building/ switchroom in
the main plant building areas.
Cable entry from outdoor underground/ cable route to the building if any shall be above
the finished floor level of the building.
As a standard load carrying cables shall be laid in the single layer formation and shall only
laid in double layer with client approval.
Cable Installation shall be carried out as per IS:1255.
Cable shall be laid on the cable tray strictly in line with cable schedule.
Power & control cables shall be laid on separate tiers. In horizontal tray stacks, HT (11kv)
cables shall be laid on topmost tier and cable of subsequent lower voltage grades on lower
tiers of trays. Single core cable in trefoil formation shall be laid with a distance of four
times the diameter of cable between trefoil center lines and clamped at every two meter.

Cable Installation

Cable shall be laid on the cable tray strictly in line with cable schedule.
Power & control cables shall be laid on separate tiers. In horizontal tray stacks, HT (11kv)
cables shall be laid on topmost tier and cable of subsequent lower voltage grades on lower
tiers of trays. Single core cable in trefoil formation shall be laid with a distance of four
times the diameter of cable between trefoil center lines and clamped at every two meter.
Bending radii for cables shall be as per manufacturers recommendation and IS 1255
Where Cable cross roads/rails tracks, cable shall be laid in hume pipe/PVC pipe.
Joints less than 250meter run of cable shall not be permitted.
Control cable termination inside equipment enclosure shall have suffcient lengths so that
shifting of termination in terminal blocks can be done without requiring any jointing.
Separation- At least 300mm clearance shall be provided between HT power and LT power
cables. LT power and LT control/ instrumentation cables.
All cables associated with the one unit shall be segregated from cables of other units.

Cable Installation

Minimum number of spare cores required to be left for interconnection in control cables
shall be as follows:
2C,3C----NIL
5C ----1
7C-10C2
14C and above---3

Cable Tray/Trench Layout

Cable Routing
Interplant cable routing will be on overhead cable trays on pipe cum cable

trestle or only cable trestle. Supporting of inter plant cable trays from building
structure shall be avoided as far as possible.
Space for accommodating additional cable trays, which may come in future,
shall be provided in the cable route.

Fire Sealing System

All openings in the floor and wall for cable access shall be sealed after
installation of the cable system with non inflammable materials. Thickness of
such materials shall be equal to the thickness of floor/wall. Sealing work shall be
carried out with approved sealing compound having fire withstand capability for
atleast one hour.

IE Rules

Chapter I (Ru )--- Preliminary

Chapter II (Rule4-10)----- Inspector
Chapter III(Rule11-28)---- Licence
Chapter IV(Rule 29-46)---- General safety requirements
Chapter V ( Rule 47-59) -----General condition of supply and use of energy
Chapter VI ( Rule 60-62)-----Electric supply lines system and apparatus for low and
medium voltage.
Chapter VII ( Rule 63-73)-----Electric supply lines system and apparatus for high and
EHV .
Chapter VIII ( Rule 73-93)----Overhead lines under ground cables and Generating
Station.
Chapter IX( Rule 94-108)------Additional rules for electric traction
Chapter X ( Rule 109-132)------Additional precaution to be adopted in mines and oil field
Chapter XI ( Rule 133-143)------ Misc.

IE Rules

Rule No. 64
The following minimum safety working clearance shall be maintained for the bare conductor
or live point of any apparatus outdoor substation.
12kv-2.6meter
36kv-2.8meter
245kv- 4.3meter
420kv -6.4meter
800kv- 10.3 meter
Where transformer are used, suitable provision shall be made either by connecting with earth a
point of the circuit at lowest voltage.
A substation or switch station with apparatus having more than 2000litres of oil, shall not be
located in the basement where proper oil draining arrangement cannot be provided.
Where substation or switchstation with apparatus having more than 2000litres of oil is
installed whether indoor/outdoor, the baffle wall (4 hours fire rating) shall be provided
between apparatus.
Provision shall be made for suitable oil soakpit and where use of more than 9000litres of oil in
any one oil tank.Provision shall be made for drainge away or removal of any oil which may
leak or escape from the tank.

IE Rules
Special precaution shall be taken to prevent the spread of oil fire resulting from

the ignition of the oil from any cause and adequate provision shall be made for
extinguish any fire which may occur.
Spare oil shall not be stored in any such substation.
Only dry type transformer shall be used for installation inside the residential /
commercial buildings.
Transformer shall be protected by an automatic high velocity water spray
system or CO2.
Rule 67
All non current Carrying metal parts associated with HV/ EHV installation shall
be effectively earthed to ground system or mat which will
Limit the touch and step potential to tolerable value.
Limit the ground potential rise to tolerable values so as to prevent danger due
to transfer of potential through ground, earth wire, cable sheath, pipelines etc.
Maintain the resistance of the earth connection to such as value to make
operation of the protective devices effectively.

IE Rules

In case of star connected system with earth neutral or delta connected system
with earthed artificial neutral point.
The neutral point of transformer and generator shall be earth by connecting it
to earth system as define in rule (61). All electrical equipment shall be earthed
atleast from two distinct location.
Earth leakage protection device shall be provided below 5kw load.
In case of appreciable harmonics current flowing in the neutral connection so
as to cause interference with communication circuit, the generator or
transformer neutral shall be earthed through suitable impedance.
In case of delta connection system the neutral point shall be obtained by the
inserting grounding transformer and current limiting resistance,

IS: 1255 Installation of Power Cable upto

33Kv Rating
Guidelines for selection and planning of cable Installation.
Length of cable route
Route and Indicator
Soil condition
Nature of soil
Chemical action
System voltage

Earthing system
Load condition Normal cont./ short duration/ intermittent
Permissible voltage drop
Short circuit data
Installation condition
Economic condition
Data cable joint and termination
Drum length

IS: 1255 Installation of Power Cable upto

33Kv Rating
METHODS OF CABLES LAYING AND INSTALLATION
The conventional methods of cables laying and installation are:

a) Laying direct in ground

b) Drawing in ducts
c) Laying on racks in air

d) Laying on racks inside a cable tunnel

e) Laying along buildings or structures .

Choice of System

The choice of any of the systems given under above depends on the actual installation
conditions, initial cost of laying, maintenance and repair charges, desired ease in
replacement of any cable or adding new cables. The relative meri.ts and demerits of the
above systems are summarized in Appendix B if IS 1255

IS: 1255 Installation of Power Cable upto

33Kv Rating
Laying Direct in Ground
This method involves dig'ging a trench in the ground and laying cable(s) on a bedding of
minimum 75 mm sand at the bottom of the trench, and covering it with additional riddled
sailor sand of minimum 75 mm and protecting it by means of tiles, bricks or slabs (see
Fig. 2). In IS 1255
Depth -The desired minimum depth of laying from ground surface to the top of cable is as
follows:
High voltage cables, 3.3 kV to 11 kV rating 0.9m
High voltage cables, 22 kV, 33 kV rating 1.05 m
Low voltage and control cables 0.75 m
Cables at road crossings 1.00 m
Cables at railway level crossings (measured 1.00 m from bottom of sleepers to the
top of pipe)

Clearances -The desired minimum clearances are as follows:

Power cable to power cable Clearance not necessary; however, larger the clearance, better
would be current carrying capacity
Power cable to control cables 0.2m
Power cable to communication cable 0.3m
Power cable to gas/water main 0.3 m

IS: 1255 Installation of Power Cable upto

33Kv Rating
The power cable should not be laid above the telecommunication cable, to avoid danger to life
of the person, digging to attend to the fault in the telecommunication cable.
For identification of power cables, the cable protective cover, such as bricks or RCC slabs
may be suitably marked by words 'power cable'
While laying power cables, the likly interference to existing telecommunication cables should
be avoided by referring to and coordinating with the appropriate telecommunication
authorities.
Cables Laid Across Roads, Railway Tracks and Water Pipe Lines
Steel, cast iron, plastics, cement or earthenware ducts, or cable ducting blocks should be used
where cables cross the roads and railway tracks. Spare ducts for future extensions should
be provided, Spare duct runs should be sealed off. Buried ducts or ducting blocks should
project into footpath or up to the edge of road, where there is no footpath, to permit
smooth entry of cable without undue bending.
The duct/pipe joints should be covered by collars to prevent settlement of in between pipes. It
may be desirable to leave a pilot wire inside the ducts.
The diameter of the cable conduit or pipe or duct should be at least 1.5 times the outer
diameter of cable. The ducts/pipes should be mechanically strong to withstand forces due
to heavy traffic when they are laid across road/railway tracks.

IS: 1255 Installation of Power Cable upto

33Kv Rating

Single-core cables should not be laid individually in steel ducts but instead, all
three cables of the same system should be laid in one duct.
Cable Over Bridges -On bridges, the cables
Laying on Racks in Air
6.5.1 Inside buildings, industrial plants, generating stations, substations and
tunnels, cables are generally installed on racks fixed to the walls or supported
from ceiling. Racks may be ladder or perforated type and may be either
fabricated at the site or pre-fabricated.
Considerable economy can be achieved using standard factory made racks. The
necessary size of the racks and associated structure has to be worked out takjng
into consideration the cable grouping and permissible bending radii.
The vertical distance between the two racks should be minimum 0.3 m and the
clearance between the first cable and the wall (if racks are mounted on wall)
should be 25 mm. The width of the rack should not exceed 0.75 m in order to
facilitate installation of cables.

IS: 1255 Installation of Power Cable upto

33Kv Rating
The cables are laid directly on the trays with or without spacers. Each tray

should preferably contain only one layer of cables. Stacking cables one above
other in 2 or 3 layers on one rack or tray reduces their current carrying
capacity to a very great extent. More than one tier trays are permissible if the
cables present cannot be accommodated in a single tray.
Ungalvanized steel work of cable rackingltrays should be painted with a coat.
of primer and thereafter finished with suitable anticorrosive paint.
Only single-core cables laid on horizontal racks need be clamped at suitable
intervals. Multi-core cables need not be clamped.
The distance between the vertical clamps should not be more than 2 m.