Chapter
Electrical
22
Electrical Plant Bulks
General Plant Electrical Bulks .......................................................... 22-3
Substation Electrical Plant Bulks ..................................................... 22-9
Schematic of Project Site Transmission Line Hook-Up .............. 22-13
Wire Sizes
US Country Base .............................................................................. 22-14
UK and JP Country Bases ................................................................ 22-14
Electrical Class/Division
NEC ................................................................................................... 22-15
IEC ................................................................................................... 22-16
G3 © ICARUS Corporation, 1998.
22-2 ICARUS Reference
© ICARUS Corporation, 1998. G3
Chapter 22: Electrical 22-3
Electrical Plant Bulks
Electrical plant bulks are divided into two categories, general and substation plant bulks. A description of each follows.
General Electrical Plant Bulks
General electrical plant bulks include cables, trays, grounding, lighting and tracing.
1
Description
Type
Electrical cable runs: wire, armored, multi-core
ELEC-CABLE
Material Selection:
ARMOR
W-C
W-NC
W-TR
M-C
M-NC
M-TR
LARM
- Armored multi-core cable
- Single wires in conduit, includes conduit
- Single wires in conduit (less conduit)
- Single wires in tray (less tray)
- Multi-core in conduit, includes conduit
- Multi-core in conduit (less conduit)
- Multi-core cable in tray (less tray)
- Lead covered armored cable
Voltage:
600
5000
15000
600
3300
11000
- 600 V at 60 HZ
- 5000 V at 60 HZ
- 15000 V at 60 HZ
- 600 V at 50 HZ
- 3300 V at 50 HZ
- 11000 at 50 HZ
Cable Size: Default: US: single wires in conduit, else multi-core cable in tray
without tray. See “Wire Sizes” later in this chapter.
Conduit Material: Default: *GALV*
GALV - Galvanized rigid steel conduit
EMT - Electrical mechanical tubing
AL
- Aluminum
PVC - PVC plastic conduit
PBON - PVC coated rigid steel (plasti-bond)
PVCA - PVC coated aluminum
FRE - Fiberglass
2
Rigid conduit, galvanized steel, couplings, fittings and seals
Material Selection: Default: *GALV*
GALV - Galvanized rigid steel conduit
EMT - Electrical mechanical tubing
AL
- Aluminum
PVC - PVC plastic conduit
PBON - PVC coated rigid steel (plasti-bond)
PVCA - PVC coated aluminum
FRE - Fiberglass
Diameter: Range: 0.5 - 6.0 INCHES [15 - 150 MM]
Number of Elbows: Default: *0*
No. of Fittings: Default: *0*
No. of Conduit Seals: Default: *0*
G3 © ICARUS Corporation, 1998.
CONDUIT
22-4 ICARUS Reference
Electrical Plant Bulks - General Electrical Plant Bulks continued
3
Description
Type
Electrical cable tray
ELEC-TRAY
Material Selection: *GALV*, FBRGL, SS, AL
No. of 90 DEG bends: *0*
Type: *L*, T, C, B
Width: Range: 6 - 36 INCHES [150 - 910 MM];
Default: *18* INCHES [*450* MM]
4
Electrical tracing of existing equipment
Electrical tracing of equipment; item of equipment and its insulation are assumed
specified elsewhere in the project.
EQPT-TRACE
Heating Cable Type: Use P series cable for process manten., A or P series cable
for ambient control.
3A - 3 W/FT [10 W/M] Chemelex BTV2-CT cable
5A - 5 W/FT [16 W/M] Chemelex BTV2-CT cable
8A - 8 W/FT [26 W/M] Chemelex BTV2-CT cable
10A - 10 W/FT [33 W/M] Chemelex BTV2-CT cable
5P - 5 W/FT [16 W/M] Chemelex XTV2-CT cable
10P - 10 W/FT [33 W/M] Chemelex XTV2-CT cable
15P - 15 W/FT [49 W/M] Chemelex XTV2-CT cable
20P - 20 W/FT [65 W/M] Chemelex XTV2-CT calbe
Distance to Panel: If the distance to the panel board is not specified, the system
defaults to the value defined for Area Electrical Specifications.
Thermostat Control: Default: *E-AMB*
E-AMB - Electric tracing/ambient temperature control
Single thermostat, control of electrical tracer based upon low
ambient temperature specified for General Area Specifications.
E-PRO - Electric tracing/process temperature control
Multiple thermostated circuits, control of electrical tracer based upon
low ambient temperature specified for General Area Specifications.
5
Electrical tracing of existing piping run
Electrical tracing of piping; piping is assumed specified elsewhere. This item also
provides insulation of the same size, or one size larger than pipe diameter for pipe
diameters of 8 INCHES [200 MM] or smaller.
PIPE-TRACE
Traced Pipe Length: The pipe being traced is not included, but must be specified
elsewhere.
Traced Pipe Diameter: The pipe being traced is not included, but must be specified
elsewhere.
Maintenance Temp.: Process temperature to be maintained. Max: 250 DEG F
[120 DEG C] over ambient.
Thermostat Control: Default: *E-AMB*
E-AMB - Electric tracing/ambient temperature control
Single thermostat, control of electrical tracer based upon low
ambient temperature specified for General Area Specifications.
E-PRO - Electric tracing/process temperature control
Multiple thermostated circuits, control of electrical tracer based upon
low ambient temperature specified for General Area Specifications.
Distance to Panel: Distance -pipe to local panel, feeder run to individual tracers
determined by system.
Length: Total length of tracer segments, default based on pipe length and diameter.
© ICARUS Corporation, 1998. G3
Chapter 22: Electrical 22-5
Electrical Plant Bulks - General Electrical Plant Bulks continued
6
Description
Type
Ground grid
A system of buried cable and rods provide a grid work for grounding equipment, buildings
and structures.
GRND-GRID
Wire options: AWG (US only): 6, 2, 1/0, 2/0, 4/0; MM2: 16, 35, 50, 70, 95, 120.
Default: *2* AWG [*35* MM2]
Rod Types: *STD*, EL-L, EL-S.
Includes direct-buried grid cable brazed to each ground rod. The default rod type, STD,
includes manually-driven ¾ INCH x 10 FEET [3.05 METER] copper-clad ground rods
with studs, clamps, etc. The electrolytic rod types, EL-L (3 FEET vertical x 10 FEET
horizontal [0.91 x 3.05 METER]) and EL-S (straight 10 FEET length [3.05 M]), include
pipe with weep holes, electrolytic filling material, special conductive backfill material, and
protective cover.
If the number of ground rods is not specified, 4 rods are generated for the first 1-199
FEET [0.3-60.6 METER] of grid cable, then 1 rod for each 200 FEET [61 METER]
thereafter. For example, a 10 FEET [3.05 METER] length generates 4 rods, a 200 FEET
[61 METER] length generates 5, and 1,000 FEET [305 METER] generates 9.
Does not include trenching and backfill.
Ground Grid diagram and rod types:
G3 © ICARUS Corporation, 1998.
22-6 ICARUS Reference
Electrical Plant Bulks - General Electrical Plant Bulks continued
7
Description
Type
Area lighting: includes poles, lights and cable
Flood: 400 - 1000 W; Default: *400*
Other: 100 - 400 W; Default: *175*
AREA-LIGHT
Fixture Type: Default: Mercury vapor/explosion proof
FL1
FL2
FL1E
FL2E
MVPE
MVPV
MVCE
MVCV
MVF
SVPE
SVPV
SVCE
SVCV
SVF
INPE
INPV
INCE
INCV
MHV
- Fluorescent - 1 bulb
- Fluorescent - 2 bulbs
- Fluorescent - 1 bulb, explosion proof
- Fluorescent - 1 bulbs, explosion proof
- Mercury vapor/explosion proof
- Mercury vapor/vaportite
- Mercury vapor/ceiling/explosion proof
- Mercury vapor/ceiling vaportite
- Mercury vapor/flood
- Sodium vapor/explosion proof
- Sodium vapor/vaportite
- Sodium vapor/ceiling/explosion proof
- Sodium vapor/ceiling/vaportite
- Sodium vapor/flood
- Incandescent/explosion proof
- Incandescent/vaportite
- Incandescent/ceiling/explosion proof
- Incandescent/ceiling/vaportite
- Mercury halide flood
Length/Cable Runs: Cable run length from lighting panel.
Power per Light: Range: 100 - 1,000 W. Flood: Default: *400 W*, Min: 400 W;
Other: Default: 175 W; Max: 400 W.
Number of Poles: Default: *0*.
Pole Height: Default: *20* FEET [*6.0* M].
No. Basic Receptacle: Default: *0*.
No. Weld Receptacle: Default: *0*.
Wiring System: Default: *3 wire system*
2 - 2 conductor system
3 - 3 conductor system
4 - 4 conductor system
Wiring Size: Default: US: *12 AWG*, else: 2.5 MM2.
14- 14 AWG - US only
12- 12 AWG - US only
10- 10 AWG - US only
1.5 - 1.5 MM2 - other bases
2.5 - 2.5 MM2 - other bases
4
- 4 MM2 - other bases
Wire Placement: Default: *ABOVE*
ABOVE - Above-grade
BURIED - Buried
Wire Type:
ARMOR
W-C
W-NC
W-TR
M-C
M-NC
M-TR
- Armored multi-core cable
- Single wires in conduit, includes conduit
- Single wires in conduit (less conduit)
- Single wires in tray (less tray)
- Multi-core in conduit, includes conduit
- Multi-core in conduit (less conduit)
- Multi-core cable in tray (less tray)
Support type: *PENDT*, BRAKT, STAND, POLE.
© ICARUS Corporation, 1998. G3
Chapter 22: Electrical 22-7
Electrical Plant Bulks - General Electrical Plant Bulks continued
Description
8
Electrical control cable runs (LV)
Type
CTRL-CABLE
Material Selection:
ARMOR
W-C
W-NC
W-TR
M-C
M-NC
M-TR
LARM
- Armored multi-core cable
- Single wires in conduit, includes conduit
- Single wires in conduit (less conduit)
- Single wires in tray (less tray)
- Multi-core in conduit, includes conduit
- Multi-core in conduit (less conduit)
- Multi-core cable in tray (less tray)
- Lead covered armored cable
No. of Conductors: Range: 3 - 37
Conduit Material: Default: *GALV*
GALV - Galvanized rigid steel conduit
EMT - Electrical mechanical tubing
AL
- Aluminum
PVC
- PVC plastic conduit
PBON - PVC coated rigid steel (plasti-bond)
PVCA - PVC coated aluminum
FRE - Fiberglass
Cable Size: *14*, 12, 10 AWG; *1.5*, 2.5, 4.0 MM2.
9
Group of anodes in deep well
A group of anodes in a deep well with connecting leads to an adjacent junction box.
DEEP-ANODE
Capacity: Based on five amps per anode.
Depth: Depth should be based on the local soil conditions. The depth is 100 FEET
[30 M] plus 7 FEET [2 M] per anode (5 amps per anode).
Well Casing Symbol: Default: *NONE*
NONE - No well casing
CASED - Cased well
10
Individual galvanic anode
An individual galvanic anode for road crossings, etc.
GALV-ANODE
Length/Cable Runs: Default: *40* FEET [*12* M]
11
Group of anodes in shallow surface bed
A shallow surface anode bed consisting of anodes with underground leads to an
adjacent junction box.
Type of Anode:
A
B
C
D
- Drilled hole, native backfill
- Drilled hole, coke breeze backfill
- Trench, coke breeze backfill
- Trench, native backfill
No. Anodes per Bed: *10*
Spacing: Anode spacing is the center-to-center distance.
Default: *8* FEET [*2.5* M]
G3 © ICARUS Corporation, 1998.
SURF-ANODE
22-8 ICARUS Reference
Electrical Plant Bulks - General Electrical Plant Bulks continued
Description
Type
12
Potential measurement test station
Enter number of test stations per location.
POT-TEST
13
Transformer/rectifier
480 V/60 HZ [415 V/50 HZ] 3 phase input
D.C. Output: 50 V/50 A or 100 V/100 A
RECTIFIER
Power pole line must be specified separately.
Current: Range: 50 - 100 A
Length/Cable Runs: Default: *500* FEET [*150* M]
14
Solar panel with storage batteries
Solar panels, adjacent storage batteries, control center, supporting structure, fencing
and cable to a junction box.
SOLAR-PANL
Length/Cable Runs: Default: *500* FEET [*150* M]
15
Emergency light with battery
Provides short-term, local lighting for personnel in case of an electric power failure.
Indoor, general-purpose type includes selection of light types, 6V battery, batteryrecharger, power cable with plug for local outlet, and mounting bracket.
EMER-LIGHT
Type: HEPS, HEPR, LEPS, LEPR, STDS, STDR
Number of bulbs: *1*, 2
16
Underground cable duct
Type: *TILE*, ENVEL, CONC, PRCST
CABLE DUCT
© ICARUS Corporation, 1998. G3
Chapter 22: Electrical 22-9
Substation Electrical Plant Bulks
Substation electrical plant bulks include transformers, breakers, transmission lines and bus.
1
Description
Type
Bus duct
BUS-DUCT
Continuous Current: Max: 3,000 A
Voltage:
*600*
5000
15000
600
3300
11000
- 600 V at 60 HZ.
- 5000 V at 60 HZ.
- 15000 V at 60 HZ.
- 600 V at 50 HZ.
- 3300 V at 50 HZ.
- 11000 V at 50 HZ.
Number of Elbows: Default: 1 per 20 FEET [6 M]
Termination Type: *NONE*
NONE - No terminations
TRANS - Transformer termination only
SWGR - Switchgear termination only
BOTH - Switchgear and transformer termination
2
Electrical transformer: 1 or 2 tap
TRANSFORM
Rated load: Range: 10 - 100,000 KVA
Type: *DRY*, OIL
3
Oil circuit breakers
OIL-C-BRKR
Rated voltage: Range: 11 - 400 KV
Continuous Current: Max: 5 KA
4
Disconnect switches
DISCNCT-SW
Voltage: Range: 4 - 230 KV
5
Overhead transmission line: cables, structures, guys, grounds
See “Schematic of Project Site Transmission Line Hook-Up,” page 22-13.
POLE-LINE
Wire size: See “Wire Sizes” later in this chapter.
6
Steel for substation structure
G3 © ICARUS Corporation, 1998.
SUBSTN-STL
22-10 ICARUS Reference
Electrical Plant Bulks - Substation Electrical Plant Bulks continued
7
Description
Type
Circuit breakers: main, feeder, tie-breakers
BREAKER
Continuous Current: Max: 3,000 A
Voltage: through the maximum HV.
Interrupt Capacity: LV: 25 - 70 MVA; MV: 250 - 350 MVA;
HV: 500 - 1000 MVA
Breaker type: Defualt: *FEED*
FEED - Feeder breaker
MAIN - Main breaker
TIE - Tie breaker
Type: *AIR*, SF6, VAC
8
Motor control center
Floor-mounted assemblies of one or more enclosed vertical sections principally
containing combination motor control/overload protection units (starters).
MCC
Range: LV: 0.5 - 400 HP [0.33 - 300 KW]
MV: 200 - 1000 HP [150 - 3000 KW]
Voltage: LV or MV
Type: *S*, I
The MCCs described below are intended for inside use (i.e., are not for outside
use local to the motors). They are unaffected by the electrical class/zone
specifications covered later in this chapter. The “intelligent” MCCs provide more
sophisticated electronic control and communication to a control center. The cost
for upstream items are not included (e.g., supply bus duct/cable; switchgear
[feeder breakers, metering, substation disconnect switch, main breaker]; and
substation transformer).
There are two types of MCC available in the system (see diagram below)- those
which supply electric motors driven at low voltage (MCC-LV: COA 733) and
those driven at mid-voltage (MCC-MV: COA 744). The MCC-LV may contain
starters for motors and as well as circuit breakers for other small electrical loads
(LIGHTING TRANS. BRKR- to supply panelboards feeding lights, electric
tracing, control center hardware). The MCC-MV contains only starters for
motors.
The MCC-LV is a 12-NEMA space cabinet; the MCC-MV is a 3-NEMA space
cabinet. This item is specified by the HP [KW] rating of the motor being
supplied- this permits the system to select an appropriately sized starter (see table
below). The resulting cost includes both the cost of the starter as well as the cost
for the fraction of the cabinet occupied by the starter. For example, assume that
you specify a 20 HP [15 KW] rating- the reported cost for the MCC-LV is the
cost of the 3-space starter plus three-twelfths of the whole cost of the cabinet.
Specifying four such items would, in effect, completely account for the cost of
one 12-space MCC-LV containing four 3-space starters.
- Continued -
© ICARUS Corporation, 1998. G3
Chapter 22: Electrical 22-11
Electrical Plant Bulks - Substation Electrical Plant Bulks continued
Description
Type
Motor Size
Voltage
Starter Size (spaces)
< = 10 HP
[< = 7.5 KW]
LV
2
20–50 HP
[15–37.4 KW]
LV
3 (lighting transformer breaker)
60-100 HP
[44.7-75 KW]
LV
5
125-200 HP
[95-150 KW]
LV
6
250-400 HP
[180-300 KW]
LV
9
200-400 HP
[150-300 KW]
MV
1
MV
3
450-4,000 HP [335-3,150 KW]
Medium Voltage (MV) and Low Voltage (LV) Motor Control Centers
(MCC):
9
Switch board
SWITCH-BRD
Continuous current: 600-4000 A
Voltage: 3-13.8 KV
Interrupt capacity: *25*-40 KA
Type: VCB, VCS1, VCS2, VCS3
10
AC/DC Transformer
AC-DC-TRAN
Rating: 30-300 ampere-hours
11
Package transformer with panel
Rated load: 50-800 KVA
Primary voltage: 3000-13800 V
No. of phases: 1 or *3*
G3 © ICARUS Corporation, 1998.
PKG-TRANSF
22-12 ICARUS Reference
Electrical Plant Bulks - Substation Electrical Plant Bulks continued
13
Description
Type
Emergency diesel generator
EM-PWR-SET
Rated power: 5 - 1500 KVA
14
Uninterrupted power supply
UPS
Rated load: 2-300 KVA.
Type: *STD*, MULT.
15
Power factor connection capacitor
PF-CORRECT
Capacity: 24-2500 KVAR.
Voltage: LV, MV.
© ICARUS Corporation, 1998. G3
Chapter 22: Electrical 22-13
Schematic of Project Site Transmission Line Hook-Up*
Power from National
or Local Power
Supply Grid
Overhead Transmission Line
* not to scale
G3 © ICARUS Corporation, 1998.
Steel for
Substation
Structure
Oil Circuit
Breaker
Power to Main
and Unit
Substations
22-14 ICARUS Reference
Wire Sizes
Wire sizes must be chosen from one of the following tables:
US Country Base
US Country Base or AWG Wire Units
Wire Size Symbols (gauge sizes)
LV
MV
HV
14
12
10
8
6
4
2
1
1/0
2/0
4/0
250
350
500
750
............. (AWG) .............
1000
1250
1500
1750
2000
..... (KCMIL) .....
UK and JP Country Bases
UK and JP Country Base or MM2 Wire Units
Wire Size Symbols (MM2 sizes)
LV
MV
HV
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
............................... (MM2) .................................
© ICARUS Corporation, 1998. G3
Chapter 22: Electrical 22-15
Electrical Class/Division
National Electrical Code (NEC).
Electrical
Class and Division
Symbol
Cable Type
Single Core
or
Multi-Core
Wire
In Tray
Single Core
or
Multi-Core
Wire
In Conduit
Armored
Cable
Flammable Gasses or Vapors
11
Highly inflammable gasses and/or
vapors. Hazardous atmospheres
exist continuously or can occur
during course of normal operation
for this area. Explosion-proof.
—
+
—
12
Flammable liquids are handled
and processed in this area,
but they are normally confined.
—
+
+
Combustible Dust
21
Dust is suspended in air
continuously or during course of
normal operation for this area.
—
+
—
22
Suspension of dust is not likely
in this area, but deposits of dust
can occur and be ignited by sparks.
—
+
+
Combustible Fibers or Particles
31
Locations exist in this area in
which ignitable fibers are
handled or used.
—
+
+
32
Locations exist in this area in which
easily ignitable fibers are stored.
—
+
+
+
+
+
General Purpose
GP
Non-hazardous conditions.
+
Indicates cable type consistent with electrical class and division.
—
Indicates cable type inconsistent with electrical class and division.
G3 © ICARUS Corporation, 1998.
22-16 ICARUS Reference
International Electrical Code (IEC).
Electrical Zone
Cable Type
Single Core
or
Multi-Core
Wire
In Tray
Single Core
or
Multi-Core
Wire
In Conduit
Armored
Cable
0
Explosive gas/air mixture is constantly
present or is present for long periods.
—
+
+
1
Explosive gas/air mixture is likely to
occur under normal operating conditions.
—
+
+
2
Explosive gas/air mixture is unlikely to
occur under normal operating conditions.
If it does occur, it will be of short duration.
+
+
+
GP
Non-hazardous conditions.
+
+
+
+
Indicates cable type consistent with electrical class and division.
—
Indicates cable type inconsistent with electrical class and division, WARNing message will be
issued in the SCAN report.
© ICARUS Corporation, 1998. G3
Chapter 22: Electrical 22-17
G3 © ICARUS Corporation, 1998.