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CONTRACT NO : LC16104300 PROJECT NO: PCR049

PROJECT TITLE:-

EPIC FOR UPGRADING 500KVA EMERGENCY DG SET AT GD

STATION 'S', MESAIEED

DOCUMENT TITLE:

ADEQUACY REPORT FOR LV BREAKER SIZING

MAIN CONTRACTOR: DESIGN CONSULTANT:

P.O. Box: 22006

AlWaab City | Salwa Road | Doha | Qatar

0 10-03-2017 ISSUED FOR COMMENTS DS BR HT

Rev Date Description Prepared Checked Approved Approved

by by by by QP

Document No. PCR049-MGDS-2-12-0001 01 of 11 Rev.0

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REVISION RECORD

REV DATE DESCRIPTION

0 10-03-2017 ISSUED FOR COMMENTS

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CONTENTS Pag

DEFINITIONS.......................................................................................................................4

ABBREVIATION...................................................................................................................5

1 INTRODUCTION.....................................................................................................6

2 OBJECTIVE.............................................................................................................6

3 SCOPE DEFINITION...............................................................................................6
3.1 BACKGROUND......................................................................................................6
3.2 SCOPE....................................................................................................................7

4 BASIC DATA...........................................................................................................7
4.1 ENVIRONMENTAL CONDITIONS..........................................................................7
4.2 TAGGING SYSTEM................................................................................................8

5 CODES AND STANDARDS....................................................................................8

5.1 QP STANDARDS/SPECIFICATIONS.....................................................................8

6 DEFINATIONS.........................................................................................................9
6.1 CONSUMED LOAD (in KW)...................................................................................9
6.2 RATED POWER (in KW)........................................................................................9
6.3 CONTINUOUS LOADS.........................................................................................10
6.4 INTERMITTENT LOADS.......................................................................................10
6.5 STANDBY LOADS................................................................................................10

7 METHODOLOGY OF CALCULATION.................................................................10

1.1 SITE CONDITION..................................................................................................10

1.2 SELECTION CRITERIA........................................................................................10

8 ADEQUACY OF EXISTING DG INCOMER BREAKER.......................................11

1.3 BREAKER SIZING................................................................................................11

9 SUMMARY.............................................................................................................11

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DEFINITIONS
For the purposes of this report, the following definitions of terms and interpretations shall
apply regardless of and other meaning the words may have in other respects:

Shall The word "shall" is to be understood as mandatory.

Should The word "should" is to be understood as being strongly

Recommended

May The word "may" is used where alternatives are equally

acceptable

Must The word "must" is used where a provision is a statutory

Requirement

Client / Company Qatar Petroleum

Contractor Company / Firm or Party appointed by QP to perform the

works in accordance with this specification

Manufacturer The Party that manufactures, fabricates or produces

materials or products covered by this specification

Supplier Company / Firm or Party appointed by QP to supply

material, equipment or other products in accordance with
this specification

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ABBREVIATION
AC - Alternating Current
ACB - Air Circuit breaker
AWA - Aluminum Wire Armour
BP RP - British Petroleum Recommended Practices
BS - British Standard
CT - Current Transformer
CU - Copper
DEPM - Diesel Engine Prime Mover
DG - Diesel Generator
ES - Engineering Standard
EPIC - Engineering Procurement Installation and Commissioning
ESD - Emergency Shutdown System
FAT - Factory Acceptance Test
GCP - Generator Control Panel
IEC - International Electro-technical Commission
IET - Institute of Environmental Technology
IEEE - International Electrical Electronics Engineers
ISO - International Organization for Standardization
kVA - kilo Volt Ampere
LV - Low Voltage
OEM - Original Equipment Manufacturer
PLC - Programmable Logic Controller
PVC - Poly Vinyl Chloride
QDC - Qatar Design Consortium
QP - Qatar Petroleum
RMS - Root Mean Square
SB - Switchboard
TEFC - Totally Enclosed Fan Cooled
XLPE - Cross Linked Poly Ethylene

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1 INTRODUCTION
QATAR PETROLEUM (QP) has awarded contract to Petroserv Controls &
Communication for the project (Engineering Consultancy Services for Upgrading of
500kVA Emergency DG set at GD station S) under the contract no. LC16104300. Qatar
Design Consortium (QDC) is engineering design consultant to perform the detailed
design and engineering services for the contract.

2 OBJECTIVE

The main objective of this document is to check adequacy of LV Breaker Sizing for
DG Incomer Breaker.

3 SCOPE DEFINITION
3.1 BACKGROUND
The Emergency switch board SSB-104 is now in excess of load, it would be more than
500kVA. Therefore, the existing 500kVA DG set needs to be upgraded to higher range of
DG capacity. Power supply to the existing switch board (S-SB-104) is fed from 500KVA
DG set in case of emergency power required. The existing DG set is skid mounting type;
Make: FG Wilson (Engineering) Ltd, the rating of the DG set is 500KVA or rated standby
power capacity of DG is 548 kVA (438kW).

Controller ACESS 4000 is provided for the protection of DG set. ACCESS 4000 controller
has a facility to operate the DG set in both Auto & Manual mode. The existing batteries:
2nos of 12V of capacity 200AH (Make: CAT; model: 1400 CCA) maintenance free with
auxiliary charger used for charging of batteries during DG off condition.

The power cables laid in existing cable trench from generator power panel to switch
board SWB-104. Adequacy of existing power cable needs to be checked for new
proposed DG set and the higher range of cable shall be replaced suitably, if the existing
cables are found inadequate.

The existing cable shall be 2Rx1Cx 630 Sq.mm per phase; Cu/XLPE/AWA/PVC cables
per phase & 1Rx1Cx 630Sq.mm for neutral; Cu/XLPE/AWA/PVC laid and these are
connected from DG power panel to the DG incomer ACB in the existing emergency
switch board SB-104.

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3.2 SCOPE

This document specification detailed about requirements for industrial type self-excited
power generators driven by diesel engine abbreviated DEPM (Diesel engine prime mover)
along with brushless excitation system, automatic voltage regulator, generator control panel,
generator breaker and associated accessories.

4 BASIC DATA
4.1 ENVIRONMENTAL CONDITIONS

A typical sulphurous coastal environment prevails with frequent sandstorms. The

atmosphere can be both salt and sand laden. Hydrogen sulphide (H2S) at corrosive
levels can be present in the atmosphere. The environmental data to be used is as follows:

4.1.1 Temperature & Pressure

Average Maximum Shade Temperature: 49 Deg C

Maximum Recorded Shade Temperature: 52 Deg C

Average Minimum Shade Temperature: 20 Deg C

Normal Winter Minimum Temperature: 12 Deg C

Minimum Winter Temperature 0 Deg C

Maximum Sun Radiation Temperature 84 Deg C

Average Barometric Pressure 0.98 / 1.01 Bar A

4.1.2 Relative Humidity

Absolute Maximum Humidity 100%

Absolute Minimum Humidity 0%

The highest average humidity occurs during the months of December and January. At the
time of maximum temperature the maximum relative humidity is 46%. Humidity in the
range of 100% at 27C is recorded previously. Moisture in the atmosphere occasionally
holds salts.

4.1.3 Rainfall
Average annual rainfall 80 mm

Maximum recorded annual rainfall 175 mm

Minimum recorded annual rainfall 13 mm

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4.1.4 Winds
Prevailing wind direction is from the North-West to North-North-West

Basic Wind Speed for Civil/ Structural 45m/Sec to BS CP3

for Design purpose wind direction shall be any direction.

4.1.5 Lightning
Thunderstorms and lighting occur at infrequent periods

4.1.6 Sandstorm
Severe sandstorms are common.

4.1.7 Earthquakes
Earthquakes do not occur and an earthquake zone rating is not applicable.

4.2 TAGGING SYSTEM

Dummy tags shall be used for the proposed equipment. A request for actual tags shall be
generated by EPIC contractor to QP during detail design phase as per QP
Engineering Standard QPR-DKN-05_Rev.02 (2012).

5 CODES AND STANDARDS

Reference has also been made in this specification to the latest edition of the following
codes standards and specifications.

5.1 QP STANDARDS/SPECIFICATIONS

QP STANDARDS

ES.2.03.0001 Electrical Engineering Philosophy, Rev B

ES.2.06.0001 Electrical Installation Recommended Practices, Rev A

ES.2.14.0002 Diesel Engine Driven Generator, Rev A

E.S.2.14.0098 Electrical Requirement for package equipment

E.S.2.14.0015 Low Voltage Switchgear and Control gear for use indoor

E.S.2.14.0035 Low Voltage cage induction Motors.

ES.2.14.0070 Electrical Power Control Cables and Cable glands, Rev A

ES.2.14.0074 Electrical Bulk Materials

ES.2.18.0001 Safety Instructions Electrical General, Rev 1

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ES.2.03.0001 Electrical Engineering Philosophy, Rev B

INTERNATIONAL STANDARDS

IEC 60034 Rotating Electrical Machines

IEEE 141 Electrical power distribution for Industrial plants.

Low-voltage electrical installations - Part 5-52: Selection and
IEC 60364
erection of electrical equipment - Wiring systems
IEC 60439 Low Voltage switchgear and control Assemblies.

IEC-60947 LV Motor Starters

IEC-60227 PVC cables of rated voltages up to including 450/750V.

BS 7671 Requirements for Electrical Installations, IET Wiring Regulations

BS 6883 Cable selection and sizing

BS 6121 Cable Glands.

Guide for measuring earth resistivity, ground impedance and
IEEE 81
earth surface potentials for ground system.
IEC 60529/ BS 60592 Degrees of protection provided by enclosures (IP Code)

IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres.

IEC-60885 Electric test methods for Electric cables.

6 DEFINATIONS
The following items defined below are for general information and better understanding of Load
Schedule

6.1 CONSUMED LOAD (in KW)

This is the design power requirement of the driven equipment at design point, in kilowatt. The
design power requirement is the power drawn by the equipment when the plant is operating at the
design capacity under normal operating condition.

6.2 RATED POWER (in KW)

The rated power is the rated kilowatt indicated on the name plate of the equipment.

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6.3 CONTINUOUS LOADS

All the loads, which may be running continuously in normal operating conditions like motors,
lighting loads, UPS and battery charger loads etc.

6.4 INTERMITTENT LOADS

All the loads which are required for intermediate operations like Hoist, Motor operated Valves etc.

6.5 STANDBY LOADS

All loads which are required to be operated only in the event of failure of normal operating loads
and during shutdown of plant like spare motors, receptacle outlets, welding outlets etc.

7 METHODOLOGY OF CALCULATION

1.1 SITE CONDITION

Facility Location GD STATION 'S', MESAIEED

Temperature (Ambient) 45 C
Max. Temperature (Ambient) 52 C
Humidity 65-100%
Rainfall 175mm(max)-13mm(min)/annum
Wind & Storms 45 m/s

1.2 SELECTION CRITERIA

Breaker sizing is based on the following criteria:

Continuous Current Rating
Maximum interrupting capacity
In regards to continuous current rating, ACB are rated in amperes at a specific
ambient temperature. The interrupting rating is generally accepted as the highest
amount of fault current. The breaker can interrupt without causing system failure to it.
The calculation for breaker sizing is given in Section 5.3.

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8 ADEQUACY OF EXISTING DG INCOMER BREAKER

Rating of existing DG incomer ACB : 1600 Amps

Peak Load of emergency switch board : 511KVA
Rated current of the System = 711 A
Considering 25% Margin on System :711* 1.25
(Refer QP Electrical Engineering Philosophy- Rev-B)
Full Load Current after 25% Margin = 888A

Conclusion:
Looking into the above, the existing DG incomer ACB (1600A) is adequate to carry
the rated full load current of 1000KVA DG set.

1.3 BREAKER SIZING

Calculations are carried out using the formulae as:

Load details:

Peak Load of Emergency switch board : 511KVA

Determine current rating:

IfL : kVA / (1.732 x Supply voltage)

: (511) / (1.732 x 0.415)

= 711 A

Full Load current after considering 25% Margin= 711 x 1.25

= 888A

9 SUMMARY

Referring to the above sizing calculation result, selection of breaker size (1600A) is
adequate for 1000kVA DG set.

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