ELECTRICAL CONCEPT NOTE

OSD FORMULATION FACILITY

National Pharmaceutical Industries DOC.NO.: NPI_SA_EL_CN_V.0 DCPL International

NATIONAL PHARMACEUTICAL INDUSTRIES

JEDDAH , KINGDOM OF SAUDI ARABIA

OSD FORMULATIONA FACILITY

AT
SAUDI ARABIA

ELECTRICAL CONCEPT NOTE

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National Pharmaceutical Industries DOC.NO.: NPI_SA_EL_CN_V.0 DCPL International

CONTENTS

S. No. Description Page No.

1. Project Information 2

2. Introduction 2

3. Design Basis 2

4. Scope of Work 2

5. Abbreviations used 2

6. Basic Design Philosophy for Electrical System Design 3

7. Proposed Distribution Scheme (Attached separately) 4

8. Load Assessment sheet (Attached separately) 4

9. Primary Power Distribution / Control /Operation system 4

10. Power Factor Compensation 5

11. Philosophy For Selection of Electrical Equipments- 6

HT Switchgear, Transformer, DG set, LT Panels, HT/LT Cables, UPS etc.

12. Illumination system 11

13. Power Outlets 13

14. Wiring/Cabling 13

15. Low Voltage System 13

16. Cable Trays & Cable Glands 16

17. Earthing and Lightening Protection System 16

18. Work Scope of Electrical Contractor 17

19. Tender Document 17

20. Detailed Drawings and Documents 18

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DOCUMENT REVISION HISTORY

Document name Revision Revision by Date Status note

NPI_SA_ EL_CN_V.0 0.0 B.Patel 15/09/2017 First release for comments

1. PROJECT INFORMATION

Owner- M/s National Pharmaceutical Industries

Project Title- OSD Formulation Facility

Project Location- M/s National Pharmaceutical Industries

At KAEC, Kingdom of Saudi Arabia

Engineering Consultant - M/s DCPL International.

2. INTRODUCTION

Description of document-
The purpose of this document is to specify the requirements and general scheme of Electrical system
for proposed Formulation facility. This document concludes design and distribution concept based
on the requirement of Process, HVAC, Utility equipments, Power & Lighting.

3. DESIGN BASIS

Electrical design criteria used in the design and detail engineering of Electrical System Design is
based on project’s present requirements, various codes and standards, good engineering practice
and local climatic conditions.

4. SCOPE OF WORK

Design of electrical distribution system for the proposed facility as per the standards which includes -
HT/LT distribution system, LT PCC, Distribution Panels, Power & Lighting DBs, Internal/External
Lighting Layouts, Power Layouts, Cable tray Routing, System Earthing, Low voltage (CCTV/
Networking/ Door Interlocking (Infra Red sensing device)/ Access control (Bio Metric type) / Digital
clock etc. system design, Equip. Specifications, BOQ, Cable Schedule, Tendering etc..

5. ABBREVIATIONS (list of abbreviations is too small. Many abbreviations are

missing. Highlighting them in red and underlining throughout the document.

HV - High Voltage
MV - Medium Voltage
LV - Low Voltage
PCC - Power Control Centre
DB - Distribution Board
LSDB - Lighting Sub Distribution Board
ELDB - Emergency Lighting Distribution Board
PSDB - Power Sub Distribution Board
UPSDB - UPS Fed Distribution Board
MLDB - Main Lighting Distribution Board
MPDB - Main Power Distribution Board
RTPFC - Real Time Power Factor Compensation /correction

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MFM - Multi Functional Meter

6. BASIC DESIGN PHILOSOPHY FOR ELECTRICAL SYSTEM DESIGN

6.1. Area Classification: Most of the plant area is classified as clean room type & shall be equipped
with clean room fixtures except few areas such as Admin/Store which will be equipped with Non
clean room fixtures. For Flame proof classified areas (Like: Granulation and Coating etc.), it shall
be equipped with Flameproof Fixtures &and other essentials.

6.2. Design Ambient / Service Condition: All electrical equipment shall be designed for tropical
climatic conditions. The ambient temperature and relative humidity to be considered for design of
electrical equipment shall be 50oC max. and 80% average respectively. All electrical equipment,
materials and installation shall be designed for suitable for operation under site conditions.

Electrical equipment intended for outdoor installation shall have minimum protection of IP 65 (in
accordance with SBC 401 standards). Electrical equipment intended for indoor installation shall
have minimum protection of IP 42 (in accordance with SBC 401 standards).

6.3. Codes & Standards: Equipment, material and installation shall confirm to the latest edition of
relevant Saudi Arabia Standards, Saudi Arabia Electricity Act, Saudi Building Code Electrical
Requirement (SBC 401), TAC recommendations, Loss prevention Association of International
and National Code of practice for electrical installation.

Electrical systems design and installation shall be carried out in accordance with International
Electro technical commission and Saudi Arabia Standards, in particular:

 Saudi Arabia Act

 Saudi Arabia Rules
 Saudi Building Code Electrical Requirement (SBC 401)
 IEC code
 IEEE Code
 Classification of Hazardous Areas for Electrical Installations

6.4. Inspection & Testing: All equipment shall be inspected and routine tested as per relevant
Saudi Arabia Standards at the manufacturer’s works and type tested as per purchase order prior
to dispatch to site. After receipt on site, the equipment will be again inspected for any damage in
transit. After installation and before commissioning, pre-commissioning tests will be carried out.

6.5. Incoming Supply & Metering:

13.8KV/0.380KV Substation shall be considered. 13.8 KV supply is available from local network
of (SAEB). Supply is tapped from nearest overhead network to 4 pole structure for Proposed
Facility supply arrangement.

6.6. Sub Station:

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National Pharmaceutical Industries DOC.NO.: NPI_SA_EL_CN_V.0 DCPL International

Proposed 13.8/0.380KV, 3 phase, frequency 60Hz Oil Immersed Transformer’s (1600KVA

approx.) primary through underground HT cable. The Transformers shall be kept out door, near
the proposed Utility Block. The LT PCC shall be placed in LT Panel room inside the Utility Block.
Power distribution system shall be designed centralized for proposed facility.

6.7. Fault Levels At Various Voltage Levels: Following voltage levels and fault levels shall be
considered:

6.8. (did you consider the soil resistivity from the soil testing report? If not put a disclaimer
here)

Voltage Level Maximum Fault Level

a) 13.8 KV 32KA for 1 sec.

b) 380 V 50KA for 1 sec. at transformer sec.

7. PROPOSED DISTRIBUTION SCHEME- (SEPARATE SHEET ATTACHED)

8. LOAD ASSESSMENT SHEET- (SEPARATE SHEET ATTACHED)

The total connected load requirement for all facilities (Granulation, Coating & RMG) is estimated as
*** why is the load missingKW (Preliminary). This shall include the Machine process equipment
loads, HVAC loads, Utility Loads, Lighting loads and other misc. load for proposed facilities. Detailed
sheet is attached separately.

9. POWER DISTRIBUTION /OPERATION AND CONTROL SCHEME

9.1. The 13.8KV incoming supply from VCB Panel will feed the 1600kVA (approx.) Transformers.
The transformers shall be ONAN cooled. The transformer will have on load tap changer (OLTC).
The range of tap change shall be + 10% to - 10%. Thus 380V LT outgoing shall feed the LT
PCC Panel which shall be placed in LT panel room in Utility Block.

9.2. From LT PCC power will be distributed through XLPE insulated armored cables to the individual
blocks Main Panels, Chiller Panel, MLDB, Common Utility Panel (feeding common utility
equips.), Fire Panel etc. considering convenience of distribution and operation.

9.3. LT Supply from Transformer through bus bar shall be connect in LT PCC Panel.

9.4. Chiller Panel & Utility Panel shall be placed at Utility block portion. Chiller Panel shall feed to all
HVAC high side requirements like- Chillers and relevant pumps where as Utility Panel shall feed
to all utility equipments located in the building. The same panel shall have additional feeders for
miscellaneous outdoor requirements. E.g. Boiler house, ETP, Fuel Pumps, Bore well, Raw
Water Pumps etc.

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9.5. Individual block’s Main Panels will feed Process Panels and HVAC Panels, & PDB etc. Process
Panel in turn will distribute power locally to individual process equipments. MLDB shall feed
floor wise/ Area Wise Lighting Dist. Boards; whereas HVAC Panel shall feed HVAC units (Low
side) and PDB will feed Local PSDBs etc. These Panels shall be placed at convenient location
@ Technical area on service floors.

9.6. Proposed Single phase power sockets shall be powered through PSDBs for raw power and
UPSDBs for UPS connected power socket outlets. Three Phase power sockets outlets shall be
powered through PSDBs (3ø). These DBs shall be fed through the PDB Panel.

9.7. Proposed Lighting shall be powered through LSDBs for raw power connected Light fixture and
ELDBs for Inverter/UPS fed Light fixture and these Lighting DBs shall be fed through respective
block’s MLDBs/ PDBs.

9.8. The PSDB’s, LSDB’s, ELDB’s & UPSDB’s shall be installed at Technical area to supply power to
sockets.

9.9. Provision for Separate UPS systems (For Lighting & Power) will be kept for equipment s under
Low Current category and other specified equipments. It is suggested for the following
equipment’s:

o For critical production equipment having separate UPS to be considered for

equipments.
o For critical HVAC system, like: Class B AHUs, QC Micro labs AHUs, RLAF, All LAF
related to Class A, etc. Why do you want AHUs on UPS?
o BMS/IT/Security/Communication systems
o QC/ Lab Instruments having separate UPS.
o Emergency Lighting to be considered on separate UPS.
(This list should be made and confirmed from Client)

10. POWER FACTOR COMPENSATION DEVICES

Power factor of the electrical system shall be improved by incorporating power factor improvement
capacitors on 380 V bus of LV switchgear at load centre i.e in LT Panel Room, such that overall
system PF shall not be less than 0.99 lag.
One Real Time power factor controller panel shall be provided in LT Panel room for total load on the
transformer. The Real Time power Factor controller (RTPFC) panel shall constantly monitor the power
factor of distribution system and based on that feedback, cyclically select capacitor units to be
switched ON/OFF so as a result, the power factor is controlled within preset range.

PF improvement capacitors shall be complete with discharge resistors. Each bank shall comprise of
suitable combination of capacitors of different size. Number of banks shall be decided as per design.

transformer lagging power factor compensating capacitor shall be tapped on busbar before power
factor correction feedback CT and shall be ON permanently.

We can also considered additional capacitor bank for PF correction for Utility Panel which is having
maximum electrical load.

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11. PHILOSOPHY FOR SELECTION OF ELECTRICAL EQUIPMENT :

11.1.HT Switchgear:

11.1.1. 13.8KV HT Switchgear shall be in accordance with specification. Minimum Rating for
HT Panel shall be 800 Amp for 13.8 KV System. It shall be Indoor, fully draw out type
with natural air-cooled design, with degree of enclosure protection of IP55 and shall
be in accordance of standards.

11.1.2. Switchgear, bus bar, CT shall be designed for minimum 32kA fault level for 1 sec. The
current transformers and potential transformers shall be of epoxy resin cast type. CT
secondary shall be rated for 5A continuous current ratings of the breakers shall be
decided based on the application requirement and after considering appropriate de-
rating factors on account of site ambient and panel mounting conditions.

11.1.3. Breaker shall be provided with draw out type on line PT. All bus sections shall be
provided with draw out type bus PTs. All PTs shall be provided with primary and
secondary fuses.

11.1.4. The circuit breaker shall be provided with trip coil and suitable trip circuit supervision
relay and other necessary Numerical protection relays. Control voltage for circuit
breakers shall be 110 V DC supply. 110 V DC supply shall be provided through a
power pack.

11.1.5. Provision of power and control cables entries shall be from bottom.

11.1.6. Internal control wiring shall be carried out with 1.5 mm2 stranded copper conductor
1.1 KV FRLS grade PVC insulated flexible wires. However, CT circuit wiring shall be
carried out with 2.5 mm2 stranded FRLS copper conductor flexible wires.

11.1.7. Suitable extension facility on switchgear shall be provided for addition of switchgear
panels at a later date.

11.2.Transformer:

11.2.1. 1600kVA (approx.). ONAN transformer will be installed outdoor near Utility Block.

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National Pharmaceutical Industries DOC.NO.: NPI_SA_EL_CN_V.0 DCPL International

11.2.2. Voltage ratio of the transformers shall be 13800/380 volts. The transformer
vector group shall be Dyn11. Transformer loading should not exceed more than 90%
of rated capacity.

11.2.3. Transformer shall be provided with ON circuit taps in the range of +10% to -10%.
There will be motorized tap changer on the H.T. winding controlled by automatic
voltage regulator to maintain constant voltage in specified range of variation. The taps
will be in the range of 1.25% voltage steps.

11.2.4. For transformer’s protection necessary protection relays shall be provided in

respective 13.8 KV switchgear. Additionally provisions for protection against winding
temperature high, oil temperature high, any internal fault conditions (Buchholz Relay),
oil level low is made.

11.2.5. Transformer shall be provided with standard accessories like conservator, Buchholz
relay, marshalling box, OTI, WTI, magnetic oil level gauge, silica gel breather,
explosion vent, drain valves, grounding lugs, jacking pads, filter valves, disconnecting
chamber, cable end boxes, radiators with shut off valves, lifting lugs, bi-directional
rollers, oil surge relay for OLTC etc.

11.2.6. Cable box on HT side shall be detachable type complete with disconnecting chamber;
LT side shall be suitable disconnecting chamber for Bus Duct.

11.2.7. Detailed features of transformer shall be given in the technical specification .

11.3.Power Control Centre-

11.3.1. LT PCCs shall be indoor type of metal clad construction, partly draw out type having
self-aligning type auxiliary contacts for circuit breakers and draw out modules. All Air
Circuit Breaker modules shall be draw out type; other feeders like MCCBs shall be
fixed type. The LT PCC shall be located in LT room proposed in Utility Block.

11.3.2. Dual power supply shall be provided to LT PCC Panel which shall provide continuous
supply to electrical loads of the proposed facility.

11.3.3. Air circuit breakers of incoming transformer shall be with current display feature,
within built microprocessor based overload, short circuit, earth fault release and
should be communication (RS 485 port to be considered) with EMS (energy
monitoring system). In addition shunt trip coil and closing coil shall be provided.

11.3.4. TPNE (three phases – neutral earth) Bus bars and air circuit breakers shall have
short circuit withstand capacity of 50/65 KA for 1-second duration.

11.3.5. All the Incomer and outgoing switchgears should be 4P.

11.3.6. For all incomers shall be having Load Manager with Demand shall be provided. For
other feeders digital MFM shall be provided. And all the meters of LT PCC Panels
shall be having comm. port – RS 485.

11.3.7. Cable shall be laid from LT PCC Panel to individual block’s Main Panels, the LT PCC
shall be located in LT room proposed in Utility Block.

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11.3.8. 20% spare feeders/modules shall be provided on the switchboard with at least one
spare feeder module of each rating and type.

11.3.9. Control supply voltage for various starter modules shall be 220V AC. For control
supply separate control bus shall be provided in the panel and control voltage for
individual module shall be tapped from control bus. Individual module, DP MCB is to
be provided which can be accessed only after opening the module door. This MCB
will isolate the control supply of individual module whenever required. The control bus
will be tapped from any one phase and neutral of the main bus bar.

11.3.10. All cable entries to Panels shall have provision of top/bottom as specified on SLD.

11.3.11. Heavy Duty Exhaust System will be considered for each Vertical Busbar
section/Alley and ACB feeders/compartments above 1000A rating.

11.3.12. Max height of LT PCC panel shall be 2375 mm. and operating height shall be
2000mm.

11.3.13. Suitable extension facility on switchgear shall be provided for addition of

switchgear panels at a later date.

11.4.Power Distribution Panels-

11.4.1. Distribution Panels shall be indoor type, sheet steel enclosed, compartmentalized,
single front. The modules shall be non-draw out type for outgoing feeders and draw
out for incoming/outgoing feeders if it is ACB.

11.4.2. TPNE (three phase – neutral – earth) Bus bars and air circuit breakers shall have
50/35/25kA short circuit withstand capacity for 1-second duration.

11.4.3. Each Distribution Panels shall be provided with 100% rated Incomer. Incomer shall be
MCCB up to 630A rating and above the same shall be ACB.

11.4.4. All MCCBs of 250A and above shall be of Microprocessor Based with Overload, Short
Circuit and Earth Fault Protection. There should be fault indication and fault
differentiation between S/C & E/F.

11.4.5. MCCBs up to 200A shall be with Thermal release.

11.4.6. All switchgears incoming and outgoing shall be 4P.

11.4.7. Distribution Panel shall house DOL starters for motors rated up to 7.5 KW OR Star
Delta starters for all motors rated above 7.5 KW. For individual motor starter module,
MPCB/MCCB/Contactors/Relay etc. as per manufacturer’s Type-2 coordination chart.

11.4.8. Motor starters rated up to 7.5 KW shall not be provided with ammeter. Motor starter
modules rated 10 KW and above shall be provided with CT + Ammeter for current
indication. Each starter module shall be provided with ON, OFF push buttons in
addition to ON, OFF and TRIP indication lamps with MPD protection device instead of
thermal over load.

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11.4.9. Motor Starters rated above 30kW shall be fed from the Panel means of MCCB +
VFD/Star Delta as per requirement.

11.4.10. All CTs and PTs shall be Resin cast type. Secondary of all CTs shall be rated for
5A.

11.4.11. Each Panel’s incomer shall have Multi Function meter with Communication port.

11.4.12. Internal wiring of Distribution Panel modules shall be carried out using 1.5 mm2;
copper conductor PVC insulated flexible wires. For CT wiring conductor size shall
be 2.5 mm2 copper.

11.4.13. All cable entries to Panels shall have provision of top/bottom as specified on
particular SLDs.

11.4.14. 20% spare modules of each rating shall be provided on Panel with at least one
spare module of each rating and type.

11.4.15. Current density for Copper bus bar shall be considered 1.2 A/mm².

11.4.16. Tinned copper earth bus shall run all along the panel for panel earthing.

11.4.17. Wall mounting type Lighting and small power distribution boards shall be located in
Panel room, strategic location, Technical area or inside Block. The distribution
switchboards shall be in accordance with specification. The distribution
switchboards shall be suitable for indoor having IP-42 protection.

11.4.18. Suitable extension facility on switchgear shall be provided for addition of switchgear
panels at a later date.

11.4.19. Maximum height of Distribution Panels shall be 2.2 Mtr. And operating height shall
be 1.8 Mtr.

11.5.DBs configuration shall be as under –

11.5.1. Lighting DBs – Incomer – TPN MCB, Sub Incomer DP RCCB (100mA), Outgoings
10/16 Amp SP MCBs.

11.5.2. Raw Power DBs- Incomer-TPN MCB, Sub Incomer DP RCCB (100mA), Outgoings
10/16 Amp SP MCBs.

11.5.3. UPS Power connected DBs- Incomer -2P/4P RCCB (30mA), Outgoings 10 Amp SP
MCBs for Lighting Purpose and 10/16 Amp SP MCB for Power socket outlet purpose.

11.6.AC Uninterruptible Power Supply (UPS) System-

AC UPS systems shall be in accordance with specification. On line three phase input – three
phase output Centralized AC UPS system to provide continuous power supplies to the
following systems shall be considered:

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National Pharmaceutical Industries DOC.NO.: NPI_SA_EL_CN_V.0 DCPL International

 PC/LAN System
 Access Control System (Bio Metric type)
 AV System
 CCTV System
 Door Interlock (Infra Red type sensing device)
 Digital Clock (with real time and date)
 Critical Production Equipments
 Specified QC / Lab Instruments (Dedicated UPS shall be provided for all QC instruments
as reqd.)

11.7.UPS System

UPS systems shall be in accordance with specification as an option to control Emergency

lighting system of the facility. Single phase input- single phase output UPS shall be
considered for Emergency Lighting system.

Static type UPS shall be considered for Injectable critical equipments.

The UPS systems shall be designed for uninterrupted power supply for 30 minutes in case of
power failure.

11.8.HT/LT Cables Selection-

Selection of cables shall be done on the basis of the following guidelines:

11.8.1. HT Cable- Cu XLPE insulated Ar. unearthed FRLS Grade cable shall be suitable for
system.

11.8.2. All power cables shall be of copper multi strength armored conductor XLPE insulated,
1.1 KV FRLS grade, XLPE insulated type. Low voltage power cables 1.5 mm² and
less size shall have PVC insulation. (SBC / IEC standard)

11.8.3. All control circuits cables shall be of stranded copper conductor, with minimum
conductor size of 1.5 mm2, 1.1 KV FRLS grade, PVC insulated type.

11.8.4. Cables sizing shall be done based on continuous current rating of equipment and
after applying de-rating factors on environmental and laying conditions. Incomer cable
to 13.8KV switchgear shall be sized considering load and fault current.

11.8.5. Voltage drops in various cables are restricted to the following limits while sizing the
cables:

i) Between 13.8 KV receiving point & 3% of 13.8 KV

Transformer.

ii) Between 415 V switchgear terminals 2% of rated voltage

(LT PCC to PDB, MCC)

iii) Under full load running 3% of rated voltage

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iv) Under starting 15% of rated voltage

iv) Lighting main circuits (up to LSDB) 2% of rated voltage

v) Lighting sub circuits 2% of rated voltage

11.8.6. Short circuit withstand capacities of various cables shall be as under:

Sr. no. Description S/C Current Value & Its duration

i) 13.8KV incoming cables : 32 KA for 1 second

ii) 13.8 KV outgoing cables to : 32 KA for 1 second

Transformer

iii) 380 V cable between LT PCC : 50 KA for 1 second

outgoing ACB/MCCB and Incomer to
MCC / Power Distribution Boards

iv) 380 V Cable between MCC / Power : 50/35/25kA (As per Calculation)
Distribution Boards and motors /
Power Sub Distribution Board

12. ILLUMINATION SYSTEM

For proper and safe operation of plant, a complete and adequate lighting illumination shall be
provided as under:

Illumination Level
Area (Lux)

i) Manufacturing, Process, packing : 400-500

ii) Aisles, Corridors in manufacturing Areas : 250

iii) Offices : 250-300

iv) Utility / Technical Areas : 200

vii Laboratories /QC/QA : 400-500

viii) Inspection : NLT 500

ix) External Lighting : 15-20

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Adequate lighting (approx. 5-10%) in entire plant shall be provided from emergency AC source.
The emergency lights shall be identical to normal lights in those areas, but they shall be
connected through centralized UPS systems located at strategic locations. Such that in case of
power failure there will not be complete blackout in areas to avoid accidents.

12.1. In Clean Room areas – In Main Process Area Clean Room Fixtures with SS304 shall be
top open able & other area shall be Bottom Cover- with LED lamps will be used. (Bottom
open able light fixture to be consider where at no space between walkable ceiling and
Main ceiling).

12.2. Lighting fixtures for general area will be operable from the bottom (Surface / recess
mounted) with LED lamps.

12.3. Medium Bay / High Bay type 80W or 100W or 150W LED luminaries shall be used in
appropriate non hazardous locations such as warehouses, workshops, Utility area etc. And
LED type Industrial fixtures shall be used for Tech. Areas.

12.4. In hazardous classified Clean room areas (Coating, Solvent Rooms) light fixtures (suitable
for 2X20W or 2X30W LED lamps) will be flame proof type.

12.5. Suitable Nos. of Sodium Vapor Lighting Fixtures shall be used in specified areas for light
sensitive products. The room lux level to be minimum 90 to be considered.

12.6. In addition to normal plant lighting, Solar or normal LED street lighting shall be provided on
street lighting poles.

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13. POWER OUTLETS:

13.1. For general areas switches/socket outlets and other devices will have Poly carbonate
front cover plate.

13.2. In hazardous classified areas Power outlets (Industrial) will be flame proof type as per
standards.

13.3. In Clean room areas switches/socket outlets and other devices will be with SS 304 cover
Plate type as per standards.

13.4. Equip. Up 7.5KW shall be fed through the dedicated 3-Phase Industrial Sockets or
through SS Pendant.

13.5. The cable tray will be installed above modular false ceiling and below the RCC slab for
taking connection to various equipment in clean rooms throughu common SS pendant or
an individual SS pendant from false ceiling up to the point of connection on individual
equipment.

13.6. The electrical connection for light switches and power switch sockets to be installed on
modular wall panels will be taken from cable trays throughu conduits provided in modular
partition wall panels as per design and connected to individual connections.

14. WIRING/CABLING:

The points and circuit wiring in the Non flameproof area shall be provided with PVC FRLS grade
Copper flexible cable in recessed/surface Heavy duty PVC FRLS conduit. The wiring/cabling
installations shall confirm to IS latest addition.

In Flameproof areas point wiring and circuit wiring shall be done by Cu. Ar. Cable using double
compression glands.

For Equipments 1.1KV Grade XLPE insulated Cu. Ar. Cable shall be provided.

15. LOW VOLTAGE SYSTEM:

Low Voltage System concludes Data Point, Voice Point, CCTV, Access Control, Door
Interlocking, Digital clock, Attendance Recording, PAS, FAS etc.

Occupancy sensor to be considered in the Admin area, to considering energy conservation of

lighting load.

15.1. Data and Voice System:

 Data system for the computers shall be provided as per the requirement.

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 Data Cable shall be CAT6/ CAT6A (U/FTP Cable , up to 650 MHz )

 Data Cable with Conduits and data I/Os and Face plate for Computer Network,
Loaded Patch panel, Network Rack, Patch cord, Network switch, LIU shall be
designed.

 Voice point shall be provided as per the requirement.

 Telephone Cable shall be CAT6/ CAT6A (U/UTP Cable , up to 450 MHz )

 Telephone cable shall be distributed to all areas through a net-work of cables in PVC
conduit.

 Multi-core telephone cables shall be provided between the EPABX and individual
floor/block Network rack.

15.2. Door Interlocking System:-

To control more than one door such that only one door can open at a time and all doors
controlled through a central monitor having emergency defeat facility.

Door Interlock system is used to prevent the simultaneous Opening of Airlock /Change
room doors. The system thus aids in minimizing the microbial, particulate contamination
and also the disturbance of Area Conditions.

 Combined/room wise door interlock system shall be provided along with the access
control and biometric access control system to be used.

 The Door Interlock System comprises of Door Controller, Door Stations,

Electromagnetic Locks, Door Position Indicators base on Infra Red sensing device
and Power supply unit.

 The Door Controller monitors the status of the Doors and controls the locking and
release sequence of the Doors.

 The user can request for release of the door by pressing the emergency push button.

 The Door Emergency Station is provided to override the Interlock logic and release all
the doors and allow free passage during an Emergency event.

 All service entry door will have access control system.

15.3. IP based CCTV Surveillance System:-

Our Concept covers the CCTV system consists of IP based cameras connected with
centralize monitoring / NVR system through CAT6/ CAT-6A cable.

Requirements associated with regards to CCTV shall be established, IP based cameras

and associated equipments like NVR system etc. will be provided to cover internal
footprints of the general areas. Control and monitoring equipment will be provided
together with remote connection facilities.

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 CCTV cameras shall be located at the convenient/required locations i.e. All process
area/Passages/Stores/Work stations and at entrance of each block etc.

 CCTV Camera shall be IP based Dome type, fixed type, PTZ type, motion base type,
360 degree rotate type, etc. as per applicable.
 All Camera shall have separate UPS power socket outlets.

 The system shall be comprised Cameras, PoE Switches, Data Cable, Network video
recorder, TV Monitor etc.

 All the cameras shall be connected through Data point to Network switch to NVR and
the unit shall record all the cameras full scale images for 180 Days recording storage
facility.

 Control monitors shall be in Low Voltage room.

 Emergency door will have motion sensing based camera system and rest it is fixed
type. Also all process rooms, service area and engineering department will have fixed
type camera system.

 Outer side will have PTZ type camera system.

 Security gate 1 & 2 will have 360 degree rotate type camera system.- To check and
consider accordingly.

15.4. Access Control System (Card Reader):-

Access control shall be provided at the main access points (of specified areas) to restrict
and monitor personnel flow into and out of the room to allow only authorized staff entry to
the restricted areas through thumb print or any other matrix. The systems will have the
facility to monitor and record personnel access and egress from the Room. The unit shall
be mounted near the controlled door and shall require single phase control. The control
wiring to be hooked to the electrical lock of door which is to be controlled and having
networking inter connectivity.

15.5. Public Address System (PAS):

Public address system will be provided in admin, Stores, Corridors/Passages, Canteen,

Service floors etc.

There will be one microphone station near security office, from which announcements
can be made to reach whole plant. The speakers will be looped zone wise and with a
selector switch the required zones or all zones can be selected. The same system can be
used as music system if required.

15.6. Fire Alarm System:

The Fire alarm system with multi criteria detectors will be provided. The detectors will be
provided in AC duct also in case any smoke is detected in the duct the AHU will be
switched off. This output can be linked with FA System to give alarm. The FA system will

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be addressable type and exact location of detector device operation will be known in
panel room. Optical multi criteria detectors, intrinsically safe flame proof detectors in
Flame proof areas and Hooters /Strobes, Fire Alarm control panel, Manual call points,
Control Modules, Monitor Modules and Isolator Modules etc will be provided in the area at
certain intervals depending on the layout of the area.

Fire detection & alarm system has been considered in all classified areas, Technical
and general areas.
The zoning shall be carried out based on all areas for easy location of fault in display
panel

The multi criteria detectors will be ceiling mounted, hooters and MCP will be mounted on
wall and will be concealed.

In Security Room, LCD display will be used to indicate exact location where the alarm is
activated so that the Security/Fire Officer can immediately proceed to the exact point of
fire where it is detected.

16. CABLE TRAYS & CABLE GLANDS

16.1. Cable Trays shall be of SS304 or Hot Dipped G.I. (80 micron thickness) Perforated or
ladder type construction for power cables & Control cables. Standard tray widths shall be
750 & 1000mm for ladder type trays and 100, 150, 300 & 400, 600 & 1000MM for G.I.
perforated with 100/50/25mm of collar. Thickness of material shall be 2.5/3 mm.

16.2. Standard tray length shall be 3 m and trays shall be supported at every 1.5 m interval.

16.3. Cable glands shall be made of Nickel-plated brass, single compression type. However
flame proofs terminations shall be with double compression type flame proof glands.

16.4. Minimum distance of 400mm shall be maintained between Low voltage cable Tray
(Instruments control supply) and Power Cable tray. (Both are separate cable tray to avoid
the harmonics distortion and data corruption).

16.5. In process area for the equipment above 7.5KW as far as possible the cables shall be
dropped through SS Pendant of 25mm/50mm/75mm dia. From the technical areas to
near/on the power supply point of the machine through the opening in the ceiling. These
openings will be properly sealed.

17. EARTHING & LIGHTNING PROTECTION SYSTEM

17.1. Earthing system shall be designed as per IEEE80 or SBC 401 and other statutory
regulations.
17.2. Material of earthing conductor in plant area shall be chemical base earthing. All earth
electrodes shall be interconnected using G.I. conductor.
17.3. Power system earthing and equipment body earthing bonding shall be achieved by a
common system. All units shall be bonded together to form a single continuous earthing
system expect electronics earthing.
17.4. Earthing conductors shall be sized to carry fault current of respective systems for 1
second duration for all the areas.
17.5. Earthing Pits shall be Plate Type or Chemical type with suitable (Cu/ GI) electrode.

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17.6. Each earth pit shall have disconnecting/testing facility to check the loop resistance.
17.7. All electrical equipment such as transformers, switchgear, motors and motor controllers
connected to systems at 380 Volts and higher are to be connected to earth system
through minimum of two paths. Neutrals of transformers and D.G. set Alternator shall be
directly earthed through a conductor of appropriate size at two separate Earth pits. For
transformer and D.G. neutral earthing copper earth electrodes and copper strips earth
conductor will be used.
17.8. 1 No. earthing strip shall be installed in all cable trays. This earthing conductor is to be
connected to the tray at every 20 m.
17.9. Dedicated earthing pits for Lightning protection system with ESE Air Terminal (Confirms to
NFC 17-102) shall be designed in accordance with IEC.
17.10. The lightning protection system shall comprise air terminations, mounting structure, Down
Conductor, Discharge Counter, Test Terminal etc and earth electrodes.
17.11. Dedicated earthing pits for safeguard against static charges will be provided as per IS
provision. All equipment likely to generate static charges will be grounded individually with
earthing grid.
17.12. Die electrical floor to be considered in the FLP area.
17.13. All Earthing Pit shall be loop or connected with common grid Earthing Network through
Earthing Strip.

18. WORK SCOPE OF CONTRACTOR

The installation of the electrical system and equipment shall be given on contract. The supply of
following main electrical equipment by client -

 HT Panel
 Transformer
 D.G. Sets
 HT/LT Cables
 LT Panels
 Lighting Fixtures
 UPS

Work scope of Electrical Contractor will be to install above free issue material including
loading /unloading of above such electrical equipments. Supply and installation of other electrical
items like distribution boards, cable glands, Domestic and Clean room area modular switch /
Sockets outlets , Industrial socket outlets, Wiring/cabling material including conduit and conduit
accessories, Earthing system material, Cable tray & Cover, Safety items, sand for cable
bedding and cover, cable tiles, trench markers, installation of internal/external lighting fixtures ,
Street lighting poles, all hardware and consumable for free issue material as well as own supply
material etc. in scope of Electrical contractor including consumable materials and their
installation like fixing hardware, steelwork for site fabricated supports.

19. TENDER & PROCUREMENT SCOPE

Detailed Tender Document with essential commercial terms & conditions, conditions of contract,
technical specifications for supply items and electrification work, applicable standards, approved
make list, BOQ and drawings shall be prepared and floated to recommended/ mutually selected
bidders.

Confirm this procurement philosophy from client.

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Following high cost items will be procured directly from OEM:

 HT Panel-
 Transformer–.
 D.G. Sets-.
 HT/LT Cables –.
 LT Panels –
 Safe area Lighting Fixtures –
 Hazardous area lighting fixtures-.
 UPS –.

Procurement shall be in scope of installation contractor:

 Cable Trays-
 G.I. /Cu. Earthing-
 Lightening Arrestor-
 Industrial Sockets –
 Modular Switches / sockets –
 Wires

20. DETAILED DRAWINGS AND DOCUMENTS

Based on the approval on this document, Tender document, BOQ, Technical specs of major
equipments and execution Drawings shall be prepared.

Following shall be provided along with the Electrical tender during the detailed engineering.

 Tender Document with General information, Conditions of contract, Description /

scope of work.
 Technical specifications
 Bill of quantities
 Relevant tender drawings
 List of approved makes

Detailed coordinated drawings required for the successful completion of the electrical
works / CRP installation shall be provided at the time of execution.

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