Word 16-QSP-05-34 DESIGN GUIDE FOR PREPARATION OF ELECTRICAL LOAD LIST/ANALYSIS TT SOR | RST SSE RaB__|_MDM_ [ROP erm aie ~ wipe [ike ape Standard Number Re Ve DESIGN-GUIDE FOR PREPARATION neDonn i New Deli OF ELECTRICAL LOAD LIST/ ANALYSIS Sheet 1 of 8Word 1.0 PURPOSE 2.0 SCOPE 3.0 PROCEDURE a Triune Projects Pvt. Ltd. New Delhi DESIGN GUIDE FOR PREPARATION OF ELECTRICAL LOAD LIST/ANALYSIS. Standard Number_[R Fo 06-DG-001 Sheet 2 of 8 16.QSP.0534Word 1.0 2.0 3.0 31 [ie a ‘Triune Projects Pvt. Ltd. | DESIGN GUIDE FOR PREPARATION na New Delhi OF 16-QSP-05-34 PURPOSE ‘The purpose of this document is to lay down the guidelines for preparation of electrical load analysi SCOPE This document covers the following: a) Collection of input data b) Compilation of data in required format c) Estimation of maximum and peak electrical power demand for different buses of each switchboard d) Analysing the results for further use. PROCEDURE Collection of input data Input data for electrical load analysis are generally as follows: a) Absorbed power for various equipment and systems - Process equipment and systems like pumps, compressors, dehydrators, electric heat tracing - Utilities like cranes, elevators, hoists, HVAC, Firé Water Pumps - Instrumentation loads like field instruments, Fire & Gas system, panels - _Blectric motor operated valves - Cathodic protection system - Lighting fittings - Communication systems - Navigation Aids - Electric Switchgear Control b) Type of Duty ‘Type of duty determines how much capacity shall be kept in electrical system for given equipment. It depends on the duration of operation of equipment and is characterized by multiplying factor (MF). For the purpose of electrical load analysis, type of duty is considered to be of 3 types: - Continuous long duration operation; generally 100% load to be considered on electrical system (MF = 1) For mutually exclusive loads (where an equipment or group of equipment is operated only when another is shut| down), the MF for the larger one shall be taken as | ar + tor c.aeiler one it shali be t as U. Standard Number _[ Re 1 ELECTRICAL LOAD LIST/ANALYSIS ‘Sheet_3 of 8Word 16-QSP-05-34 + Standby Standby equipment is considered to be not operating when main equipment operates but when stand by equipment is to be operated for testing sometimes hence MF for standby loads is generally considered as 0.1. However Operation philosophy & design basis shall be referred to for considering the actual MF for standby Ioads. When main equipment has a different drive (like diesel engine or turbine, 100% load shall be considered on electrical system (MF = 1). = Intermittent Very short duration operation (like valves, flap gates etc); only partial load to be considered on electrical system. MF can be anything between 0 and 1 Generally, for intermittent loads MF is considered as 0.4 (40% load). This is generally followed by many engineering companies the world over. However for actual MF,, design basis shall be referred to. Notes: 1) Insome places the terms “diversity factor” or “coincidence factor” are used instead of “multiplying factor” 2) Some engineering companies follow the practice of determining MF as follows: MF = Average daily duration of operation in hours/24 For example, for a continuous duty pump running for an average of 8 hours per day, MF = 8/24 = 0.3 (only 30% load to be considered for electrical system sizing) In this case there is a possibility of electrical system being undersized. c) Rated power This is rated output of the equipment, which it is designed to produce at rated voltage and frequency, and can be expressed in kVA (for UPS, DC system, transformers etc.) or kW (for motors, heaters etc.). @)— Criticality Criticality determines how the given equipment shall be supplied with power. Based on criticality, loads are divided into 3 categories: Normal ‘These are process and utilities loads operated for normal production activity, and a temporary or prolonged shutdown of these does not pose any danger to safety of life or equipment. Th power supply for these loads is referred as “nonnal power”. ‘Standard Number ‘riune Projects Pvt. Ltd. | DESIGN GUIDE FOR PREPARATION New Delhi OF ee ELECTRICAL LOAD LIST/ANALYSIS Sheet 4 of 8Word 16.-Q5P-05-34 altemative source of power supply for these loads may be provided based on economic considerations (taking into account production loss). Emergency These loads are important for maintaining safety of plant and personnel, for starting normal sources of power, for operating fire fighting systems ,for restoring normal conditions and for normal shutdown. These loads shall be necessarily backed up by alternative source of power (emergency power), such as emergency generators. Most often, such loads are connected to an emergency switchboard, which is fed by a normal power source as well as an emergency source. Critical These loads are necessary for survival and communication, for evacuating and providing aid to personnel. These loads are generally supplied power from an uninterrupted AC or DC power source (AC UPS or DC system), which is supplied power from an emergency switchboard. Following loads are generally considered as critical loads: a) __Instrumentation/ F&G/ DCS Panels b) Switchgear Control ©) Critical lighting (escape lighting) e) Any other information This may include following information as to whether the equipment is a variable speed type, or whether the given load or group of loads is part of a single package, ete. This may not necessarily be available at the very beginning of the project and may not significantly affect load analysis, but it is important for producing other documents, like SLDs, MR’s and MTOs, Complete load list for all process and utilities loads shall be obtained indicating following details: a) Tag Number b) Service (Description) ©) Absorbed power (kW) d) Rated power (kW) e) Load Duty (Continuous/Standby/intermittent) f) — Criticality g) Any other information Notes: 1) Process/ utilities loads are generally normal or emegency loads. Fire fighting pumps, jockey and foam pumps are emergency load. b Standard Number _ ‘Triune Projects Pvt. Ltd. | DESIGN GUIDE FOR PREPARATION VY New Delhi OF Ce ELECTRICAL LOAD LIST/ANALYSIS. Sheet_5 of 8Word 3) 3.13 Notes: D 2) 3) 4) 3.1.6 31 16-Q5P.0534 Load list for Process and Utilities loads shall be obtained from Mechanical Deptt. Load list for fire fighting and safety loads shall be obtained from safety department Complete load list for all MOVs (motor operated valves) indicating following details: a) Tag Number b) Service (Description) ©) Rated power @)— Criticality ‘Absorbed load for MOVs may be considered to be equal to rated power (nameplate rating), since the total consumed load of MOVs is quite small in comparison with total electrical load. MOVs are always intermittent duty loads. Generally MOVs shall be considered as emergency loads, but. in case of a large number of them, connecting some of them to normal supply may be considered. Load list for MOVs is to be obtained from piping department. Complete load list for all instrument loads. Generally instrument loads are supplied from AC/DC UPS system. In such case, UPS KVA rating is to be treated as consumed load. Some instrument loads (instrument panels etc.) also require normal AC power, which is to be supplied from normal /emergency switchboard. This may be taken as continuous duty. Electrical loads Electrical loads like UPS, DC system, lighting etc. shall be estimated and included in electrical load analysis. Overall Single Line Diagram Overall SLD or at least a key SLD, if available, shall be referred to for the purpose of grouping of loads among various switchboards. Compilation of data Once all these input data are collected , these shall be compiled in the format 06-DF- 002A ‘Load List / Analysis’, First of all, differerit operational cases shall be identified as foll ‘Triune Projects Pvt. Ltd. | DESIGN GUIDE FOR PREPARATION New Delhi OF Standard Number 06-DG-001 ELECTRICAL LOAD LIST/ANALYSIS. ‘Sheet_6 of 816-QSP-05-34 Word Cases for power supply availability Cases for production For example, in an electrical system with 3 generators for normal power and one emergency generator, 4 different cases may be initially identified with respectively 3, 2 & I normal generators in. service, and with emergency generator in service. For identifying such cases, it is also necessary to coordinate with other disciplines to check the possibility of reduced production. It means that such identified cases should realistically exist. For each case, loads shall be grouped’ among various switchboard according to Overall SLD or Key SLD, arid within a switchboard, among various buses. The fields of Tag No. Service, Load duty, , absorbed power and rated power shall be filled as per load list inputs. Load factor shall be computed as ratio of absorbed power to rated power... Values of efficiency and power factor for motor drives shall be taken from motor catalogues / motor data sheets / Indian standards(in case the previous two are not available). For lighting loads, efficiency can be taken as 1.0 and power factor as 0.85. Demand on electrical system shall be calculated separately for continuous, intermittent and standby loads, as follows: Demand = Shaft power * multiplying factor Efficiency 3.3 Estimation of maximum and peak demand 33.1 After calculating demand for each individual equipment, total loads for each bus shall be calculated as follows: Maximum demand on bus = total continuous load + total intermittent load Peak demand on bus = Total continuos load + total intermittent load + total standby load 3.3.2 Care shall be taken to ensure that the maximum demand and peak demand on all buses of a switchboard are equal to the maximum possible extent. For this purpose, if required, loads shall be redistributed on different buses and result checked till the desired result is achieved. 33.3 It is recommended that various loads of same group shall be distributed equally on different buses to the maximum possible extent. Standard Number ‘Triune Projects Pvt. Ltd. | DESIGN GUIDE FOR PREPARATION Y New Delhi OF 96-D6-001 ELECTRICAL LOAD LIST/ANALYSIS Sheet 7 of 8Word 334 32 A load summary shall be prepared indicating the maximum and peak demands on each switchboard bus. Analysis of results It should be checked that for each case studied under Electrical Load Analysis, the total power available shall be more than the maximum demand by a margin, specified in Electrical Design Basis document of the given project. In case nothing is specified in design basis , 10 % margin shall be taken. Also, the total power available for given case shall not be less than peak demand. Brief notes regarding different operational cases considered for load analysis and conclusion shall be included on the sheet for Notes. 16-5P-05-3A Vv Triune Projects Pvt. Ltd. New Dethi DESIGN GUIDE FOR PREPARATION OF ELECTRICAL LOAD LIST/ANALYSIS Standard Number_| Rev | 06-DG-001 i Sheet 8 of 816.0SP.05:3A. Word DESIGN GUIDE FOR CABLE SIZING 0 | SOOM | Fist fssue Most | KSO | ROR C ~) Prd Std. /D T Tre Projets Pvt.Ltd | DESIGN GUIDE FOR CABLE teDe-002 . Sheet ofWord 16.Q5P-0534 CONTENTS Lo PURPOSE 2.0 PROCEDURE 3.0 STEPS TO DO CABLE SIZING 4.0 APPENDIX-1 5.0 APPENDIX- IL Std. / Doc. Number Triune Projects Pvt. Ltd. DESIGN GUIDE FOR CABLE T New Deli SIZING O6-DG-002 Sheet? of U1Word 1.0 2.0 3.0 3.41 Tv 16-Q5P.05.38, PURPOSE The purpose of this document is to lay down the guidelines and design procedure for performing the cable sizing calculation . PROCEDURE The size of the cable is selected based on the following considerations. a) Short circuit withstand capacity (SC Ampacity). b) __Effective current carrying capacity (Thermal Ampacity). ©) Voltage drop during steady state operating conditions and motor start-up. Short circuit withstand capacity is to be checked for HT cables and for LT incomer feeders only.For LT breaker controlled motor feeders ,the cable impedance reduces short circuit current considerably,hence, short circuit withstand capacity is not required to be checked for the rated fault level of the LT motors. For HT feeders & LT incomer feeders ,the minimum cable size which satisfies the above three conditions is selected. For other LT feeders , minimum cable size which meets b) & c) is selected. STEPS FOR CABLE SIZING Following steps are to be followed to conclude proper techno-economical cable size for a consumer. Step-1 (Applicable for HT cables and LT incomer cables only) The cross sectional area where calculated shall not be less than the value determined by the following formula. S = K Where, S = Nominal cross sectional area of the conductor in mm? 1 = __ Value of fault current in Amperes, Fault clearing time in seconds (This is generally taken as 0.2 seconds for motor & transformer feeders,0.6 seconds for plant feeders, 1.0 seconds for incoming feeder.) K = _ Factor taking account of the resistivity, temperature co-efficient, heat capacity of the conductor material, initial and final temperature. Value of °K’ (as per BS 7671) shall be taken as 94 for XLPE insulated ‘Aluminium Cables , 143 for XLPE insulated copper cables and 76 for PVC insulated Aluminium cables. the application of the formula Lriune Projects Pvt. Ltd. | DESIGN GUIDE FOR CABLE New Delhi SIZING Sheet 3 of 11Word 32 33 a) Calculate load current for a consumer using following formulas @I= ___KW_____for3 ph AC loads (i) Tea= ~___KW______ for 1 Ph AC load 16-Q5P.05-34. Text higher standard cross section area shall be used. Short circuit duration for cables must be commensurate with the tripping time of the protective devices associated with the feeder. Step-2 - Effective Current Carrying Capacity (Thermal Ampacity) ‘The current carrying capacity of a cable corresponds to the maximum current that it can carry under specified conditions without the conductors exceeding the permissible limit of steady state temperature for the type of insulation concerned. Derating factor or correction factor (C) shall be applied where the installation conditions differ from those for which values of current carrying capacity are defined. Derating factors generally considered are as follows: a) In Ground Installation (direct burial) ic = CsXCgXCaxct Rating factor for variation in Ground temperature. Rating factor for Grouping of cables. Rating factor for Depth of laying. Rating factor for Thermal resistivity of soil. (ss ww 29 ee on b) Above Ground Installation Cc caXCg Where Ca = Rating factor for variation in Ambient air temperature. Cg =. Rating factor for Grouping of cables. ©) Values of different derating factors for calculating ‘C’ shall be taken as per manufacturer catalogues. The value of ‘C’ thus calculated is multiplied by the cable continuous current obtained from the standard tables gives the derated current carrying capacity of cable. 4) In case cables are laid partially in air and ground , take the lowest derating factor for calculation. ©) Prepare derated current rating chart for each size cable after multiplying the cable ampacity with the applicable derating factor ‘C’. Step-3 (Cable size according to load current) 13 * V* pf *efiin Vépfrefin Y L ‘Triune Projects Pvt. Ltd. | DESIGN GUIDE FOR CABLE 06-DG-002 ! New Delhi SIZING | ‘Sheet 4 of 11 |Word 16.0SP-05-34 (iii) loss Kw. for DC Veefin Where I = Load current of the electrical consumer ( in Amp) KW = Output kW (name plate) rating of the load . In case of battery charger maximurn| load considering normal load + boost charging to be considered -V__ = Line to line voltage in case of 3ph AC/ Line to phase in case of I ph AC/DC voltage in case of DC (in kV and name plate voltage rating of the consumer not the switchgear bus voltage) in kV pf = power factor in case of AC voltage at rated load effin = Efficiency (<1) of the equipment at rated load. b) Select the cable size from the calculated chart (cl 3.2 e) ©) Compare the cable size as per short circuit (step-I) and according to load Current (step-3). Select the higher cable size. 3.4 Step-4 Verification of cable size according to permissible voltage drop during steady state operating conditions & motor start up. a) For three phase circuits. % Voltage drop can be computed using the formula WVd = V3 *1*L * Rac * Cos@ +X * Sin@) * 100/ (N * V) Where, Vd = Voltage drop in percentage 2 Power factor angle as considered to calculate I. I Line current in Amps v System voltage in volts Rac = AC conductor resistance at maximum rated conductor temperature in ‘ohms per km.(70 deg C for PVC , 90 deg C for XLPE) x Reactance in ohms per km at rated frequency. ‘L = Cable length in km. N = Number of Runs( for star-delta feeder , minimum no. of runs is 2 ). b) For DC circuits : % Voltage drop can be computed using the formula’ %Vd = — (2*1* L* Rde* 100)/(N* V) Where, 1 = Line current in Amps V = _ System voltage in volts oe Std./Doe. Number | Rex | Y Triune Projects Pvt. Ltd. | DESIGN GUIDE FOR CABLE Ta New Delhi SIZING ees Te) “ Sheet 5 of 11Word = DC conductor resistance at maximum rated conductor temperature in nu ohm per km Cable length in km. ‘Number of Runs c) Forsingle phase AC circuits. %Vd = 2*1*L* (Rac * Cos + X * Sin@) * 100/(N* V) ‘Where Voltage.drop Power factor angle by which the current lags (or leads) the voltage. Line current in Amps System voltage in volts ‘AC conductor resistance at maximum rated conductor temperature in ‘ohms per km. Reactance in ohms per km at SO Hz Cable length in km, ‘Number of Runs Check the calculated voltage drop, for the selected cable as per step-3,if voltage drop voltage drop is higher than the permissible value , then calculate voltage drop with next higher cable size until the condition is satisfied. ‘A software program available for cable sizing of LT motor feeders shall be used by providing specific project requirements. 16.Q5P.05.3A, Vv Triune Projects Pvi. Ltd. New Delhi DESIGN GUIDE FOR CABLE SIZING Std. / Doc. Number 06-DG-002 Sheet 6 of 11Word 16.9SP.05.34, Derating factor due to variation in ambient temperature for cable laid in air Air Temp in Deg C as 20 [25 [30 [3s__ [40 45. LV cable PVC insulated Source: CCI Capital 133 [125 [116 [1.09 [1.00 | 0.90 HV cable XLPE insulated Source: Fort gloster 107 | Los [1.00 ) 095 Josr [086 | 0.82 Derating factor due to variation in ground temperature for cable laid in ground Ground Temp in Deg C 13__[20 [as [30 [35 [ao 45 LV cable PVC insulated 117 [112 [1.06 [100 [09s fos? [079 Source: CCI Capital | HV cable XLPE insulated os [700/096 [Oss [oa [Oss [Osi [076 Source: Fort gloster L Derating factor due to depth of laying in ground Depth of laying in mm [750 [ 900 | 1050 [1200 | 1500 | >1800 LV cable PVC insulated 3=25 [1.00 [0.99 [098 [0.97 | 096 | 0.95 Source: CCI mm2 25. [1.00 [098 [097 | 096 [094 | 093 300 mm2 5300 |T00 [097 [096 [095 [092 | 09T mm2 HV cable XLPE insulated Upto |= To [099 [058 [096 O95 Source: Fort gloster ky 2. [= - 100 [099 [097 | 096 33kv V Triume Projects Pvt.Ltd. | DE! New Delhi Number | Re Std. / Doo SIGN GUIDE FOR CABLE > 3 Sra 06-DG-002 0 Sheet 7 of 11Wor 16.95P-05-34 Derating factor due to variation in thermal resistivity of soil for cable laid in ground ‘Thermal resistivity of0ilin | 7 [ioe [a0 [150 [200 [250 300 Deg C-cmiw _| _| | - HV cable XLPE insulated T 1.20 Ll 1.00 [0.89 | 0.80 0.73 Source: Fort gloster | | - 7 Derating factor due to grouping of cables in ground HV cable XLPE insulated| Multicore [touching]0.79 [0.69 [0.62 [0.54 [oso | |oa6 [| | Source: Fort gloster jsingle 150mm [0.82 /0.72 [0.66 [0.59 |0.54 |- 0.51 layer gap (c- | lc) | [Multicore |touching|-|- 0.60. [051 |- |o43_|- | |— tier 150mm |- I~ 0.64 0.55 |- 0.46 |- | lzap (c~ le) - | ‘Single ltouching|0.78 [0.68 [0.61 |0.53 [0.48 |- 0.45, j lcore- [150mm |0.82[0.71 [0.65 [0.57 [0.53 |- 0.50 | refit |eap e- | jy | J Derating factor due to grouping of cables in air No. of Racks 1 3 6 ] No. of Cables per 2 3 6 9 2 3 6 9 2 3 6 9 rack 7 LV cable PVC Not available insulated jSource: : - HV cable paper [Multicore [0.84 [0.80 [0.75 [0.73 [0.78 |0.74 [0.70 [0.68 0.76 [0.72 [0.68 |0.66 insulated touching Source: CCI [Mcore with [0.98 [0.96 [0.93 |0.92 [0.94 /0.92 |0.89 [0.88 |0.93 0.87 |0.86 1d spacing |HV cable XLPE [Multi core- [0.84 [0.80 0.76 |0.73 [0.78 [0.74 [0.70 [0.68 |0.76 [0.72 [0.68 |0.66 insulated ltouching Source: Fort gloster [More with [0.98 [0.96 [0.93 [0.92 [0.94 0.92 |0.89 |0. 88 [0.93 [0.90 |0.87 |0.86 1d spacing Score trefoil [0.98 [0.96 |- I~ 0.94 |0.92 |- I~ 10.93 |0.90 |- I~ with 2a spacing | Std. / Doc. Number mee a . ns oe V ‘Triune Projects Pvt. Ltd. | DESIGN GUIDE FOR CABLE neve New Delhi SIZING Sheet 8 of 11Word 16.95P.05.34, APPENDIX-II SAMPLE OF HT CABLE SIZING CALCULATION INCOMER FEEDER From : Switch Board At Tps To: HT Switchgear RMS Symmetrical short circuit current = 40 KA (asstimed) Operating time of the Protection device for Fault current = 0.6 sec. (assumed) Minimum live Aluminum conductor section in order to allow for max. S.C. current = 40000 * SQRT(0.6)/94= 329.61 mm? Min. Cable size =1- 3Cx 400mm? Full load current =300A Cable Data Considered : Cable size considered 3C x 400 mm? (XLPE + AD Cable resistance = 0.102 YKM Cable reactance Cable Ampacity Derating factor Derated cable ampacity No. of cable runs selected no selected. Cable length = 80m. % Voltage drop =1.732 * 300 * 0.08 * (0.102 * 0.8 + 0.091 * 0.6) * 100/(1* 6600) = 0.395% (LESS THAN 3% ACCEPTABLE) Hence 1 Nos. of 3C x 400 mm? cable is acceptable. MOTOR FEEDER From: HT Switchboard To: HT Motor RMS Symmetrical short circuit current = 40 KA (assumed) I Triune Projects Pvt. Ltd. | DESIGN GUIDE FOR CABLE \ New Delhi SIZING 06-DG-002 ‘Sheet 9 of 11Word Fault clearing time Min, conductor Size Min. Cable size Cable Length Load (as per load list) Power factor / Efficiency Full load current Derating factor Cable Data Considered Cable size considered Cable resistance Cable reactance Cable Ampacity Cable derated current Min. no. of cable runs required No. of cable runs selected % Voltage drop (during running condition) = 0.197% Locked rotor cunient = 6 * 100.475 Starting power factor = 0.25 (Assumed) % Voltage drop (during starting condition)= 0.849 % Hence 1 No. of 3C x 240 mm’ cable is sufficient. = 1,732 * 602.85 * 0.40 * (0.161 * 0.25 + 0.097 *0.968) * 100/(1* 6600) (LESS THAN 5 % ACCEPTABLE) 16.98.0534. =0.2 sec. (assumed) 0000 * SQRT(0.2/94 90.30 mm? =1- 3Cx 240mm? 0.40 KM (assumed) 951 KW 0.90 / 0.92 951/(1.732*6.6*0.90*0.92) 100.475 A = 0.58 (from manufacturer catalogue) 3C x 240 mm? (XLPE + Al) 0.161 WKM = 0.097 KM 385A = 385 *0,58=223.3 A 100.475/223.3 = 0.449 NOS. 1 = 1.732 * 100.475 * 0.40 * (0.161 * 0.9 + 0.097 * 0.436) * 100/(1* 6600) (LESS THAN 3% ACCEPTABLE) = 602.85 A Vv Triune Projects Pvt. Ltd. New Delhi DESIGN GUIDE FOR CABLE SIZING Std. / Doc. Number ‘Sheet 10 of U1Word 16-08P-05-34 SAMPLE OF LT CABLE SIZING CALCULATION MOTOR FEEDER From PCC To Cooling Tower Fan Cable Length .425 KM (assumed) Load (as per load list) 60K W (assumed) Power factor / Efficiency 0.85/0.95 Full load current = 160/(1.732*0.415*0.85*0.95) = 275.665 A Derating factor = 0.54 (from manufacturer catalogue) Cable Data Considered : = 3C x 300 SQ.MM.PVC + AL) 0.1230Q/KM. Cable size considered Cable resistance Cable reactance 0.079 O/KM Cable Ampacity 305A Derated cable ampacity = 305 * 0.54 = 164.7 A Min, no. of cable runs required = 275.665 / 164.7 = 1.674 NOS. No. of cable runs selected =2 % Voltage drop = 1.732 * 275.665* 0.425 *(0.1234 0.85+ 0.079 * 0.526) *100 12 415) (during running condition) =3.572% (LESS THAN 5.5 % ACCEPTABLE) Locked rotor current =5.5*275.665 = 1516.1575A Starting power factor = 0.25 (Assumed) % Voltage drop= 1.732 * 1516.1575 * 0.425 (0.123 * 0.25 + 0.079 *0.97) * 100/(2* 415) (during starting condition)= 14.44% (LESS THAN 15 % ACCEPTABLE) Hence 2 Nos. of 3C x 300 mm’ cable is sufficient. T ‘Triune Projects Pve. Ltd. | DESIGN GUIDE FOR CABLE fone New Delhi SIZING | aaWord 16.QSP.0534 LIGHTING CALCULATIONS DESIGN GUIDE FOR 0 9711702 First Issue VY [Rev Date | Triane Projects Pvt. Ltd. New Delhi Description _ DESIGN GUIDE FOR LIGHTING CALCULATIONS ee Sheet 1 of 10Word 16.95P-05-34 CONTENTS 1.0 INTENT 2.0 PARAMETERS 3.0. STEPS FOR INDOOR LIGHTING CALCULATION EXAMPLE 4.0 STEPS FOR OUTDOOR LIGHTING CALCULATION EXAMPLE 5.0 ANNEXURE- 60 ANNEXURE-IL 7.0 ANNEXUREMIL 8.0 ANNEXURE-IV 9.0 ANNEXURE-V Standard Number [3 VY in ee Dea LIGHTING CALCULATIONS Cee Sheet 2 of 10Word 16-QSP-05-38 Tux level required can be taken from IS standard / contract specifications. Minimum recommended values are given for various types of industrial area at Annexure-II enclosed for ready reference. Lumen output of fixture is also fixed based on the type of Lamp being used ic. fluorescent, HPMV, HPSV ete. A) Maintenance factor: - This depends on the two factors. 1) Lumen output of lamps generally go down with the increase in number of burning hours. Generally by the end of the life at least 10% to 15% reduction has been noted. 2) Cleanliness of the fixture and Lamp, as there can be dust deposit on the Lamps/Glass cover if not cleaned which also reduces lumen output. Generally in indoor area this also can be considered as 5% to 10% and for outdoor area 15% to 20%. Hence in general practice maintenance factor considering the above is taken as follows: = i) ForindoorArea - «= 0.8 ii) For OutdoorArea - 0.7 B) Coefficient of Utilization (COU) This factor depends on types of fixture, mounting, height, colour and cleanliness of walls and ceiling, In fact this factor gives the indication — how much of the lux output of the Lamp is being utilized effectively. Various Lamp manufacturers give this in tabular form for different type of fixtures co-relating room. index and reflection co-efficient. This means we have to find out room index and reflection coefficient to get the value of Co-efficient of Utilization (COU). ©) Room Index:- This is based on the length, Breadth and height of the fixture from plane where the Lux level is to be calculated. Room Index= LxB Hx(L+B) D) Reflection coefficient: ~ Normally ceiling, sidewalls & floor reflects the light falling on them from fixture & that’s why a newly painted room appears brighter than old painted. Considering the various types of walls, ceiling etc. following Reflection Coefficient has been under normal practice. 7 05 For newly painted ceiling in white For newly painted walls in whit Floor/ working plane = 0.2 Considering the above room index and reflection coefficient, Coefficient of Utilization (COU) can be taken from the supplier's data bank. — Stand: jumbe. ue ‘Triune Projects Pvt. Ltd. DESIGN GUIDE FOR ~ | New Dethi LIGHTING CALCULATIONS Cand | Sheet 4 of 10 :Word 1.0 2.0 21 22 23 24 25 2.6 27 28 3.0 16.9SP-053A PURPOSE The purpose of the document is to lay down the guidelines and design procedure for doing Indoor & Outdoor Lighting Calculation. PARAMETERS Use the most efficient luminaries (ie. Lumens/watt) To avoid glare and best utilization of fixture, mounting height as recommended in Annexure-I must be maintained. Minimum Lux Level for various areas if not provided in the contract should be taken from Annexure-II which is as recommended in IS. Emergency Lighting fed from DG Set or UPS shall be about 25% of the total lights or as per customer’s specific requirements. Panic or Critical Lights (Battery Backed) shall be provided at convenient locations in plant S/S, Control Rooms etc. for safe evacuation of operation personals. This should have a minimum back up time of 60 minutes. Aviation Lighting as per the aviation rule of the country of installation shall be provided wherever required. In India generally all structures of height 30 Muss. and above are be provided with aviation lights. It is recommended to inform DGCA before such installation (to know about the density of air traffic in that area) HPSV Lamps not to be used in the areas where colour differentiation is needed and is not to be provided in hazatdous area i.;e. Zone-1 & 2. HPMV & HPSV Lamps take 4 to 5 minutes to glow when switched ‘ON’. Hence provide some GLS or Fluorescent fixtures also along with these fittings. STEPS FOR INDOOR LIGHTING CALCULATIONS An indoor area is defined as an area covered by four sidewalls and ceiling. While calculating the minimum number of fixture required for a given lux level following formula is applied. Minimum number of fixture required= __ L_x B x Lux Level Required (Lumen Output of Fixture x MF x COU) Where L_ - Length of the area in meters B_ - Breath of the area in meters ME - maintenance factor COU - Coefficient of Utilization (COU) for the lighting fixtures used. VY Standard Number Triune Projects Pvt. Ltd. DESIGN GUIDE FOR New Dethi LIGHTING CALCULATIONS 06-DG-003 ze Sheet 3 of 10Word VY ‘Triune Projects Pvt. Ltd. 16-Q8P-05-34 EXAMPLE Calculate the number of ceiling mounted fixtures required in a room of 12 M x 6 M with mounting height of fixture above working plane as 2.5 M. The room is reasonably clean a Lux level of 300 Lux is required. Room Index 2x6 == 2=16 2.5(12+6) 45 Consider reflection coefficient 70% 30% 10% From the supplier data the value of COU shall be 0.496 (See Attached Table) No. of fixture = 12x 6x 300 = 1.15 (2.x 2440) x 0.8 x 0.496 Minimum no. of 2 x 36W, Mirror Optics Fluorescent Fixture required are 11.15. However, this can be increased to 12 for properly placing the fixture symmetrically in the room. The layout could be as given in Annexure-III enclosed. STEPS FOR OUTDOOR LIGHTING CALCULATION In outdoor area there are no walls, ceiling or other objects to reflect the light. Hence only the direct lumens coming to the place where lux level has to be find out from various fixtures stalled around is calculated and sum of all these values will give us the illumination level of the point. For calculating the light intensity at a point for out door area we have to finalize the following things. i) Type of fixtures to be used ii) Mounting height of the fixtures iii) Polar curve of the fixture for a particular supplier. Polar curve is a curve given by the Lamp manufacturer for each type fixture used for outdoor area. The curve indicates total lumen out put from the fixture from 0° to 90° from centre of the fixture in all direction. Generally the value of lumen is given in candlepower or candlepower per K” lumens. Hence it is’ essential to read the polar curve properly and find out the value of lumen output of the fixture at the angle required Lux level at a given point from a particular fixture can be calculated as follows: DESIGN GUIDE FOR New Dethi LIGHTING CALCULATIONS Sheet 5 of 10Word 16-QSP-053A Fixture D 5 PI (Point where lux level required) Lux level at point P1 = Output of fixture at angle @ x (Cos 6)° x M.F # From above it is evident that apart from height, value of angle 0 as to be calculated. For this the horizontal distance DP1 has to be known. Maintenance factor M.F. is taken as 0.7 for outdoor as explained. Tan 0 = DPI Hence find the value of 8 AD And then value of Cos @ and put the values in the formulae as given above to obtain the Lux level at point P1. If there are more fixtures around P1, similar calculation can be done and all values added to get the actual Lux level EXAMPLE In the above figure take the following values and calculate: Fixture ~ 250 W HPMV well glass fixture Mounting height H = 4 M Horizontal Distance B = 3 M Hence Tan 0 .75, 8 = 36.86" Cos 6 = 0.8 Value of lumen out put at 36.86°. ‘Now from Polar Curve (See attached polar curve in Annexure V) Intensity of the fixture at 36.86° is 200 ed/kim x 25 klm = 5000 ed. Lux Level at Point P1 = 5000x. (9.8) x07 4 = 112 Lux Standard Number_[i_ ‘Triune Projects Pvt. Ltd. DESIGN GUIDE FOR 16 D6-003 | Y New Delhi LIGHTING CALCULATIONS, z Sheet 6 of 10Word 16.Q5P-05.34 Ss $$ rrr Similar calculations are done for all fixtures around P1 to come to final result. It may be noted that when a Lux Level is recommended for an area it is the average Lux Level. There has to be maximum and minimum Lux Level in the area depending upon the mounting position of the fixture. It is recommended that the ratio of maximum to minimum should not be more than 2 ie. for an area with an average Lux of 50, the maximum and minimum Lux Level should be say 70/35 or 60/30 and not the 70/20 or 60/15 as the situation would stress the eyes. Standard Number __| Re ‘Triune Projects Pvt. Ltd. DESIGN GUIDE FOR New Delhi LIGHTING CALCULATIONS ce 1 ‘Sheet 7 of 10 jWord 16.5P-05-38 ANNEXURE -I Mounting Height Recommended 1, Incandescent Lamp Fixture upto 200 W . Fluorescent Lamp Fixture - 20/40 W 3. Meroury Vapour = 80/125 W - 250W - 400W 4, Sodium Vapour - 10W - 150 W = 250W 2.5m 3.5m 6.0m - 3.5m Y ‘Triune Projects Pvt. Ltd. New Delhi Standard Number DESIGN GUIDE FOR LIGHTING CALCULATIONS 06-DG-003 ‘Sheet 8 of 10Word 16.QSP-0538 ANNEXURE - II ILLUMINATION LEVELS & TYPE OF FIXTURES Minimum illumination levels and type of fixtures to be used for various areas shall be as follows “SL. NO. 1. ii ii iii iii iv = AREA ROADS Plant Roads Security Roads YARD Marshalling yard Loading/ Unloading areas Open areas PLANTS Operating Platforms ~ Safe area - Hazardous areas Non-operating platform/general process areas & walk ways = Safe areas ~ Hazardous area Compressor House - Safe area ~ Hazardous area Turbine Hall - Safe Area - Hazardous area D.G Set room Pump house/ Pump bay LUX TYPE OF FIXTURES 20 | 1S0W HPSV street lighting fixtures 20 | 70/150W HPSV street lighting fixture 12 | 150/250W HPSY flood light 15 | 150/250W HPSV flood light 3 150/250W HPSV flood light 100 | 80/i25W HPMV well glass 100 | 80/125W HPMV well glass 50 | 80/125W HPMV well glass, 2 x 40 W fluorescent 50 | 80/125W HPMV well glass. 150 | 125w/2s0W/400W HPMV well glass 125W/250W/400W HPMV well glass 100 | 125W/2S0W HPMV High Bay 100 | 125W/250W HPMV Well Glass 150 | 125W/250W HPMV High Bay 150 | 125W/250W HPMV High Bay Projects Pvt. Ltd. New Dethi DESIGN GUIDE FOR LIGHTING CALCULATIONS Stangard Number 06-DG-003 ‘Sheet 9 of 10Word 16.Q5P-05-34 ae ee LUX ‘TYPE OF FIXTURES vii Product Handling - Silo 25 400 W HPSV high bay = Conveyors 70 | 18W LPSV street light - Bagging 150 | 2.x 40W fluorescent dust & corrosion proof ~ Transfer tower 100 | 2x 40W fluorescent dust & corrosion | proof - Empty bag storage |60 | 125W HPSV high bay - Filled bag storage 60 | 125W HPSV high bay ~ Loading platforms | 150 | 2x 40W fluorescent dust & corrosion proof viii Top of cooling towers ~ Safe areas 50 80W/ 125W HPMV well glass - Hazardous area 50. 80W/ 125W HPMV well glass | ix Boiler gallery 50 160W MLL well glass 4 Sub-Stations | Switch room | - Front of panel 200 2x 40W industrial fluorescent | - Back of panel 100 2x 40W industrial fluorescent ~ Battery room 70 | 2x 40W corrosion proof fluorescent ~ Transformer room, cable room | 70 2x 40W industrial fluorescent = Outdoor/ transformer bay 70 | 128W/ 250W HPMV street lighting fixtures 5 Control Rooms ~ Front of Panel 400 2 x 40W = recessed mounting decorative fluorescent ~ Back of Panel 200 ]2 x 40W recessed mounting decorative fluorescent 6 Offices 300 2 x 40W recessed mounting decorative fluorescent 7 Stores, bath room 100 | 2x 40W industrial fluorescent 8 Stair cases ~ Safe areas 100 2 x 40W industrial fluorescent ~ Hazardous area 100 | 80W HPMV well glass 9 Panic Lighting : 60W incandescent well glass 10 Naphtha, fuel oil, diesel oil | 100 80W/ 12W HPMV well glass flame storage _ proof. - Standard Number Triune Projects Pvt. Ltd. DESIGN GUIDE FOR Y New Delhi LIGHTING CALCULATIONS ee Sheet 10 of 10“we ee ewe wer we ewe weuvuvwws Anne xoRE~DD Ansexcke iB HEVISIUN ; 00 01. OF ISSUL : aryute fuetnatre: ANTT GLARE HIRROR OPTICS FTL LUMINAIRE Report: P0222002/36H CREDZAHSB Nane..7 SH 23 APR 1993 Type. eres tases go tk BEAM FM Ho. of Lanps....t -H]: 48 Length.fam)l: 1240 Lane flux...(igl: 2440 Tilt angle.("}: 0 Width. -fmnl: 265 Mutput ratio.[Z]: 58.9 Dianeter..(mel: 0 Herght-tnal: 75 UTILIZATION FACTORS ptt 70 70 70 5a 80 50 30 30 Y rGwall) | 50 30 10 50 306 10 30 “10 tooo + vork) F 10 YO 19 YO 10 19 10 10% poe Roomindex | Utilszatien factors for cerling mounted luacnaires 1 : t ‘ t 1 t : 1 Shot ean 4 t ' #3 L 1 1 38 : ' 1 3 ‘ 1 1 i 1 2S 1 49 86 4a 4B azo 1 152 48: ar 51 aS ot 1 1 85 $2. so 54 ae ot 1 1 b Shoe Sr se stot 1 t Se 5? 55. 8? 53 t 1 t.59 5a 7: 58 Sa 1 1 1 60 59° Se 89 555 eeeild 1 720 20 70 $0 SO $0 30 30 te 0 r(wall) $0 30° 1G $0 30 19 30 10 took rGiork) 1 10 10 10 to 1g to 100 Leet t : t t 1 t { Ronmindes | Util:iztion factors for suspended mounted luminaires 1 pe 4 t t i ‘ ‘ 1 t t ' 1 1 1 i t 1 i t t 1 ( [ ' ! t t t : ' ' i i I ' 1 ' Crompton Greaves Ltd. Lighting Uivisien Ur. L. Moses Road Horli. Bombay 4U00tr Talenhane: Vetex: O11-71708 Tax: aga 2975.my . ie? (Compl Genes REVISION + 60 OT. CF ISSUE + 01/01/98 Report: POAIAGO!/250K5/ Luminarre: SODIUM HIGHBAY LUMINEIRE (NARROW? unt Type. SHB2STH Lame. wn 28 Ju! 1929 No. of Lanps. Pover..- Length.innl Lane flux... 9 jilt angie.f" Hidtn. (on! 6 Gutout ratio.(Zd: 79.0 Oraneter-.{mm}: 490 Height.fmni: 656 I rteeapt 2 20 7 $0 $¢ $0 90 30 ' Por Gall) | 50 30 10 50 38 10 3 10 ip tuork? | 10 10 1G 10 1010 ' { Roominaex | Utriization factors for Ie I 1 1 1 162 $8. $6 6S $8 S56. 57 55 1 64 61 58 63 60 58 60 58 1 PBA BN 6 63 61 s2 60 1 i 1 68 66 63 67 55 S82 6a GF 70 67 65 63 66 64 §5 69 7) 68 66°70 667 «665 BHA 1 72-69 67 71 «68 66 67 65 1 fi 2. 2. 3. ay 5 Crampton Greaves Ltd. Lighting Division Dr. £. Hoses Road Norli, Bonbay S0U0!¢ Telephone: 494 5621/8908/5983 Foiess O1e71900 Fax: a$@ 2925 THIS DATA ALSO SUITABLE FOR SHST125IH 7 . . va. BeerAnnexure ~ Bb (Compt Creme REVISION + 00 DT. DF ISSUE: CL II¥s Luminaire: BIGHBAY LUFINAIPS - VETREGUS CKIBE> Repart: PQ41aN02/255.5/ Type. SHBCS Hy Nane.-: VAM Lane ic ill: 30° RATS Mese Lane Date..: 0% Nov 19¢! 4 Pouers....-lWlz 282 | Lanett. 4 25000 Trit angie! 1: "0 Wades. ¢ 69.3 Dianeter..iaal: 930 Height 63 IN IN cd/klm £. Hoses Road Cromoton Greaves itd. Ligh ohn 7irag 5 ng Divibion Ore sTeohone! 490 563" 7600/5989 Telex! Pag DATA ALSO SUITABLE FO SHSIT2SIN/V 480 £4 Ack16-8P-05.38 DESIGN GUIDE FOR LIGHTNING PROTECTION CALCULATIONS Word 0 [31712702 First Issue RAB__|_MDM ROR je aD 3c ___Deseription | Pepa. chied Tare? | DESIGN GUIDE FOR Triune Projects Pvt. Ltd. | WY sew en: Sid. Doe. Number_| kj LIGHTNING PROTECTION 06-DG-004 ( CALCULATIONS ‘Sheet 1 of 7Word CONTENTS 16.08P-05.34, 1.0 PURPOSE 2.0 REFERENCE DOCUMENTS 3.0 NEED FOR LIGHTNING PROTECTION 4.0 CALCULATION 5.0 RECOMMENDED PRACTICES FOR LIGHTNING PROTECTION 6.0 PRACTICAL EXAMPLE DESIGN GUIDE FOR Std. /Doc. Number_|} Triune Projects Pvt. Ltd. New Delhi LIGHTNING PROTECTION 06-DG-004 CALCULATIONS ‘Sheet 2 of 7Word 1.0 2.0 3.0 4.0 Tv: 16-QSP-05-34 PURPOSE ‘The purpose of this document is to lay down the guidelines and design procedure for doing lightning protection calculation. The calculations are done for estimating the following: a) To find out whether lightning protection system is necessary b) To estimate the number of horizontal conductor, down conductor, air terminations and earth connections. REFERENCE DOCUMENTS The code prevailing in the country of instailation/ specified in the contract document has to be followed for lightning protection. This design guide is prepared for Indian installations and accordingly IS 2309 : 1989 & OISD -180 is referred for calculations. 1S 2309: 1989 Protection of Buildings & Allied Structures against Lightning. — Code of Practice OISD 180 Lightning Protection NEED FOR LIGHTNING PROTECTION A number of factors should be taken into consideration when deciding whether or not lightning protection devices for any structure is required. The major factors to be considered are as follows : a) The frequency and severity of thunderstorms b) Personnel hazards ©) Inherent self protection of equipment d) Value of its contents or consequential effects and nature of its construction. ©) Height of the structure( in the case of composite structures , the overall height). f) Location of the structure. g) Possible operating loss caused by plant shutdowns if lightning caused a fire or explosion. hh). Use to which the structure is put. CALCULATION Calculation method is based on IS-2309. | | | DESIGN GUIDE FOR lume Projects Prt Ltd. | LIGHTNING PROTECTION 06-DG-004 few Delhi CALCULATIONS 1. Sheet 3 of 7 i:Word 44 5.0 5.1 16.Q5P-05.38 ‘Overall Assessment of Risk Collection area Ng Number of flashes to ground per km” per year P = Probable no of strikes L Length of building w Width of building H Height of building Overall assessment of risk is calculated by equation P=Ac X Ng X 10° Ngis calculated from map listed in IS-2309 (Refer clause no. 8.1.2) Weighting factor:~ Weighting factors denote a relative degree of importance of risk. The following weighing factors are to be considered. (Refer Table 1A to Table 1E of IS 2309:1989 Rev.2) A- Use of structure B - Type of construction C-- Contents of consequential effects D - Degree of isolation E- Type of country. Overall risk factor = Px AxBxCxDxE ‘The acceptable risk figure has been indicated in 1$:2309 as 10° i.e, 1 in 100000 per year (Ref 8.1.3 of IS 2309:1989 Rev.2). For P< 10° lightning protection is not required. However, for P> 10° lightning protection shalll be provided. However , for hazardous areas lightning protection is essential considering the serious consequences of fire / damage due to lightning strokes and shall be provided irrespective of the value of risk factor. RECOMMENDED PRACTICES FOR LIGHTNING PROTECTION Estimation of Down Conductor a) The number and spacing of down conductors on large structures in safe area shall largely depend upon the size and shape of the building and upon aesthetic considerations. The no. of down conductors may however be decided on the following considerations. 1. Structures having base area not exceeding 100 m? need have only one down conductor only if the height of termination provides sufficient protection. However it is advisable to have at least two down conductors. 2, For structures having a base area exceeding 100 m’ , the number of down conductors should be atleast the smaller of the following: Vv ‘Triune Projects Pvt. Ltd. |. 1GHTNING PROTECTION DESIGN GUIDE FOR Std./ Doc. Number New Delhi CALCULATIONS Sheet 4 of 7Word 16-Q5P-05-34 * One for the first 100 m* plus one more for every additional 300 m?, or a part thereof’, in excess of the first 100 m’. * One for every 20 m of perimeter for structures upto 20 m of height) and every 10 m of perimeter for structures above 20 m height. b) Minimum size of down conductor of copper, Aluminum or galvanized steel strip as recommended in IS-2309 is 60 mm2 i.e a strip of 20 x 3 or rod of 10 mm dia ( As per OISD minimum size shall be 25 x 3 mm Gl strip) . The zinc coating of galvanized steel strip shall be 610 gm /sq.m. c) The horizontal conductors mesh on the building roof in safe area shall not be greater than 20 m x 10 m network whereas for hazardous areas , the mesh size shall be 10 m x 5 mor smaller , according to the risk involved. 4) For full metallic structure no horizontal or down conductors are required as the structure itself acts as a down conductor. However the base of the structure must be connected to earth pits at number of points depending upon the area or perimeter of the structure, €) Properly designed / constructed gas tight storage tanks do not require any special lightning protection provided it is properly earthed and bonded. However, tanks with floating roof will need special protection as per OISD. f) Metallic structures like flood light towers may not have any lightning conductors if the electrical continuity of all the members are maintained. The earth connection shall be welded or rigidly bolted to the bottom of the structure 300 mm above floor level. 2) Metal pipes leading rain water from the roof of a building to the ground may be connected to the down conductors but shall not replace them. h) Sharp bends , kinks and joints in the down conductor shall be avoided as far. as possible 52 Air Terminations Air termination networks may consist of vertical or horizontal conductors or combination of both. No part of the roof should be more than 9 mtr. from the nearest horizontal protective conductor. Vertical air terminations shall be used for very high structures with small base areas e.g non- conducting chimneys etc. Minimum 2 nos vertical terminations shall be provided for chimneys, All the vertical air terminations provided on the same structure shall be interconnected. Where a structure has two elevations ; out of which lower is projecting outside and the higher elevation does not protect the lower elevation , separate network shall be provided for lower elevation & both networks shall be interconnected. ; ; DESIGN GUIDE FOR umber W Triune Projects Fv. Lid. LIGHTNING PROTECTION oeee “eres CALCULATIONS |Word 53 6.0 16.Q5P.0534. Earth Termination Network ‘An earth electrode (As per IS 3043) shall be connected to each down. conductor and all earth electrodes shall be interconnected through underground strip. Each of these earth should have a resistance not exceeding the product given by 10 ohm multiplied by the number of earth electrodes to be provided. The whole of the lightning protective system including any ring earth should have combined resistance to earth not exceeding 10 ohm without taking account of any bonding. PRACTICAL EXAMPLE : Control Room Building ( GS-1), ONGC , Gandhar Length = 24 m Width = 15.5 m Height = 5 m Flashes / km? /year = Ng = 1 Collection Area Ac= (Lx W) + 2(L x H) + 2(W x H) + 0H” 24 x 15.5) + 2(24 x 5) + 2(15.5x 5) + Ox 5x5 72 +240 + 155 + 78.57 45.57 m> Ac Probability of being struck , P= Ac x Ng x 10° times per year = 845.57 x 1x.10% 345.57 x 10° 8456 x 10° Applying the weighting factors : A=07 B=0.4 1.0 D=10 03 The overall multiplying factor = A x B x C x Dx E = 0.084 0.8456 x 0.084 x 10° Therefore , the overall risk factor = 7.103 x 10° Since overall probable risk exceeds the acceptable risk of P = 10° per year . So protection is necessary. _ DESIGN GUIDE FOR {Doc. Number_j 7 4 Triune Projects Pvt.Ltd. | L]GHTNING PROTECTION 06-DG-004 ' New Delhi CALCULATIONS | Tin min) oO 1 59 60 Step-5 Calculation For Battery Sizing The following factors are to be considered for battery sizing: - a) b) d Performance factor This factor is considered to estimate the performance of the battery at a discharge rate other than the nominal rate. The performance factor is defined as the ratio of the amperes that can be drawn from the battery for ‘t’ minutes to the rated capacity (AH),.for a particular end cell voltage. Performance factor = Amperes ( in ‘t’ minutes) / (Rated AH) ‘Temperature Correction Factor : This factor is considered to take care of the variations in performance of the battery at different temperatures. While high temperature results in higher performance, lower than nominal temperature (27°C) lead to lower performance due to sluggish chemical activities. The performance factor is divided by the temperature correction factor to obtain the corrected performance factor. Aging factor ‘The performance of a battery comes down with the time of usage. The battery reaches the end of its useful life when it fails to deliver 80% of its rated capacity. In order to deliver its rated capacity even at the end of the estimated life of the battery, a correction factor of 1.25 (= 1 /0.8 ) is taken as aging factor. However, customer’s design basis shall also be referred for any specific requirements regarding aging factor. ‘Spare capacity factor A spare capacity factor shall be considered to take care of any future additional load. Customer’s design basis shall be referred for any customer requirements regarding spare capacity. In the absence of any specific customer requirements, a spare capacity factor of 1.2 ( 20% additional capacity } can be considered. VY Siand ca Nurnver Sviune Projects Pvt. Ltd, | DESIGN GUIDE FOR RATTERY ; New Dethi & CHARGER SIZING O5-DG-605 i! SenateWord, 35.2 i) ii) iii) iv) vi) vii) viii) » x) 16-Q5P 05-3 ‘ion of Ampere Hour requirement for the first minute Total time duration = 1 min The 1" minute load current is obtained from calculation in clause 3.4.1 above The end cell voltage is obtained in clause 3.4 above. For the value of end cell voltage, the performance factor corresponding to the value of load current shall be obtained from manufacturer's data. Typically for an end cell voltage of 1.14 volts per cell, corresponding to a load of 212A for | min, the performance factor = 212 / 145 = 1.46 Let the minimum ambient temperature = t® C. Corresponding to the minimum ambient temperature, the temperature correction factor is obtained from manufacturer's data. Typically for a minimum ambient temperature of 10° C, the temperature correction factor is 1.11 ‘The performance factor is divided by the temperature correction factor to obtain the corrected performance factor Corrected performance factor = (Performance factor ) / (Temperature correction factor ) Here in our case, the corrected performance factor = 1.46 / 1.11 = 1.31 ‘Ampere Hour Opening Balance = 0 Ampere ‘Hour Capacity Required for the 1*-minute shall be calculated from the formula mentioned below. ‘AH capacity required = ( Load current ) / (Corrected Performance Factor ) ‘Ampere Hour Capacity Drained shall be calculated from the formula mentioned below: - ‘AH capacity drained = (Load Current ) * (Time Duration in mins) / ( 60 ) ‘AH Balance = AH Required - AH Drained AH to be added = AH Required - AH Opening Balance.” For the Ist minute, AH Opening Balance = 0 Therefore AH to be added = AH Required Calculation of Ampere Hour Requirement from the first minute to the 60th minute Total time duration = 58 min AH Opening Balance = AH balance at the end of Ist minute obtained from calculation in clause 3.5.1 x) above. The value of end cell voltage is the same as obtained in clause 3.5.1 above. Y ‘Triune Projects Pvt. Ltd. | DESIGN GUIDE FOR BATTERY (ears Standard Number New Delhi & CHARGER SIZING ‘Sheet 8 of 1116.95°-05:38 Ti) The Toad current drawn from the battery during this time duration is the total continuous load current. The value of continuous load current is obtained from calculation in clause 3.4.2 above. iii) For the value of end cell voltage, the performance factor corresponding to the value of load current, shall be obtained from manufacturer's data. For the determination of performance factor, even through the actual time duration is 58 min, the time duration shall be considered as 60 min. From the attached manufacturer’s data, for an end cell voltage of 1.14 Volts per cell, corresponding to load current of 129A for 60 min, Performance factor = 129/285 =0.45 iv) The value of temperature correction factor is obtained in clause 3.5.1 x) above. v) The performance factor is divided by the temperature correction factor to obtain the corrected performance factor. In this case, corrected performance factor = 0.45 / 1.11 = 0.4 vi) AH Capacity required shall be calculated from the formula mentioned in clause 3.5.1 viii) above. vii) AHI capacity drained shall be calculated from formula mentioned in clause 3.5.1 ix) above. viii) AH Balance = AH required — AH drained. ix) AH to be added = AH required ~ AH opening Balance. ‘AH opening balance is already obtained in 3.5.2 ii) above. 353 \mpere Hour Requirement for the 60" minute culation i) Total time duration = 1 min ii) AH Opening Balance = AH Balance at the end of 58 minute as obtained from calculation in clause 3.5.2 x) above. iii) The value of end cell voltage is same as obtained in clause 3.5.1 above. iv) The value of current drawn from the battery during this period is obtained in clause 3.4.3 above. v) The value of performance factor shall be obtained by the method shown in clause 3.5.2 v) above. vi) The value of temperature correction factor is already obtained in clause 3.5.1 v) above. vii) The value of corrected performance factor is obtained by the method shown in clause 3.5.2vii) above. Word Sheet 9 of 11 T ‘Triune Projects Pst. Ltd. | ‘SIGN GUIDE FOR BATTERY New Dethi i & CHARGER SIZINGWord 3.5.4 4.0 41 42 16.95P-05-34 viity AH capacity required shall be calculated trom The formula mentioned in clause 3.5. viii) above. ix) AH capacity drained shall be calculated from formula mentioned in clause 3.5.1 ix) above, x) AH Balance = AH required — AH drained xi) AFlto be added = AH Required ~ AH Opening Balance ‘AH Opening Balance is already obtained in clause 3.5.3 ii) above. Calculation of Battery AH capacity Minimum AH capacity required = ( AH to be added for 1* minute ) + (AH to be added from 1* minute to 60" minute ) + (AH to be added for 60" minute ) Aging Factor = 1.25 or as specified in customer’s design basis Spare Capacity Factor = 1.2 or as specified in customer’s design basis Hence battery AH capacity required = ( Minimum AH Capacity ) * (Aging factor ) * ( Spate Capacity Factor ) The nearest battery AH capacity as per manufacturer's rating shall-be selected. For example, if the calculated value of AH Capacity is 645 AH & the nearest rating as per manufacturer is 690 AH, then 690 AH shall be selected. STEPS FOR BATTERY CHARGER SIZING STEPS FOR BATTERY CHARGER SIZING ‘The customer’s design basis shall be referred for any customer requirements regarding battery charger sizing. In the absence of any specific customer requirements, the method mentioned below shall be followed: - Sizing Of Boost Charger: 15 * 0.14 * AH rating of battery (For lead acid battery ) = 1.15 * 0.2 * AH rating of battery (For Nickel Cadmium Battery ) ‘AH capacity of battery is obtained from calculation in clause 3.5.4 above. Battery Boost Charger Current Rating = Sizing Of Float Charger Battery Float Charger Current Rating = 1.15 * Average DC load + float charge current ‘Average DC load = (Area under the battery duty cycle curve ) / ( Battery duty cycle duration ) VY ‘Triune Projects Pvt. Ltd. | DESIGN GUIDE FOR BATTERY Standard Number New Delhi & CHARGER SIZING O6-DG-008 Sheet 10 of 11Word 43 5.0 V 16.90.0535, Tn this case, Average DC load = (1/60) * { (Total 1* minute load current )* | + (Total continuous load current ) * 58 + (Total 60" minute load current ) * 1 } Float charger Current = ( Float Charge factor ) * ( Battery AH Capacity ) The value of float charge factor shall be obtained from battery charger manufacturer. However, for preliminary battery charger sizing calculation it can be assumed as 0.01 ( 1 % max.) battery AH capacity. However, the same shall be checked & confirmed with charger manufacture, Selection Of Battery Charger Current Rating The battery charger current rating shall be selected based on Boost charge current or float charge current, whichever is higher, A spare capacity factor, on the basis of customer design basis, shall be considered for future use. In the absence of any specific customer requirements, a spare capacity factor of 1.25 (25 % spare capacity) can be considered. Battery Charger rating = (Float charge currént or Boost charge current whichever is higher ) * (Spare capacity factor ) List Of Attachments Attachment 1 — Sample Battery & Charger sizing calculation Triune Projects Pvt. Led, New Dethi TERY 06-DG-005 ‘Sheet 11 of 11Attachment 1 for Doc. No. 06-DG-006, Rev. 0 BATTERY SIZING CALCULATION Assumptions = Following have been considered for calculating battery size. oi Performance factor (PF) of battery for | minute 10a 740 [See Note p Performance factor (PF)of battery for 6 minute load 0.40 |See Note 3 B) FTemperature correction factor (TF) = 20% |See Note 1 i) [Aging factor (AF) = 25% 5) Spare capacity factor (SF) = 20% 7 z z a 5 z 7 3 Opening | Current | Duration AHDrain | 5244 | Al Balance| At to be Balance | 1 Ping | PF |eyaeyreo| Resuired| Gry sy] added (at 1a) ©) 0 205 7 qa0_[ 338 | 145.00 | _vae2 | 148,00. qa1ge [11266 040 | 108.27 | 280.00] 171.73] 138.38 tira [M5 1 140 [2.42 | 103.67 | 169.32 | 0.00 [Total AH (TAR) = 283.38 Considering all factors (temperature correction, aging & spare capacity factors) Battery AH capacity = TAH"(1+TF)*(I+AF)*(1+SF) = 283 38°4.2°1.25°1.2 = 510.09 AH BATTERY CHARGER SIZING CALCULATION Battery capacity = BC1 = 510 AH Battery boost charging current = BC1"1.15°0.14 = 8212 A Charger current based on DC load (Average) + Float charging current =1.15%((2031)+(112°58)+(145°1)/60 + 0.01°8C1 136.28 A Battory charger tobe sized based on Battery boost charging current or average DC load plus battery float charging current whichever is higher. Hence, charger to be sized for 136.28 A Charger capacity considering 25% spare capacity for future use is 170.35 A Charger selected= 220 V, 175A Note: 1 if temperature correction factor (TF) is available as per manufacturer data the same shall be applied to the performance factor (PF) to obtain corrected PF before calcul- -ating battery capacity. Otherwise TF may be applied after battery sizing is done. 2 Relevant manufacturer's data to be obtained from the Supplier before the calculation Is performed 3 Performance factor assumend in this example, the same shall be obtained/confirmed by battery manufacturer.Word 16-05P.05:34 GENERATOR SIZING CALCULATION DESIGN GUIDE FOR 0 [rane [Fist ise Rev. Date Deseriptic j.Rev. | Date | cep OED pion Triune Projects Pvt, Ltd, | DESIGN GUIDE FOR DG \ New Delhi SIZING CALCULATION | Sheet 1 of 1040 5.0 Word CONTENTS 1.0 PURPOSE os 2.0 | STEPS TO BE FOLLOWED 3.0 ELABORATED CALCULATION STEPS ELABORATED SELECTION STEPS CONCLUSION Enclosure APPENDIX- A sessses (4 pages) ‘Standard Number Triune Projects Pvt. Ltd. DESIGN GUIDE FOR T New Delhi LIGHTING CALCULATIONS 06-DG-008 ‘Sheet 2 of 10 16-058.05Word 1.0 2.0 16-QSP-05.38 PURPOSE The purpose of the document is to lay down the guidelines for preliminary Sizing of Generator Set to float the inquiry or to design the electrical system at early phase of a project. It is imperative to check the rating as well as suitability of generator with respect to supplier offer keeping in mind the state of art modern technology is available for governor, AVR and exciter control system. It’s not only necessary to cross check only with generator supplier but also technology adopted by the supplier of non-linear equipments like UPS, VED, soft-starter etc. STEPS TO BE FOLLOWED Following steps are elaborated in forthcoming calculation to achieve a most suitable rating of generator. 2.1 CALCULATION STEPS: Step-CO) Estimate the peak load requirement and overall power factor of plant to be catered by Generator. This exercise is not covered under the scope of generator sizing and not elaborated further as the same is part of load analysis. Step-Cl) Segregate the load at different categories Step-C2) Calculate the effective load on generator applying. suitable multiplying factor on different categories of load. Apply suitable design/future margin 20 to 30% to get the’ generator rating by empirical formula . G Step-C3) Check the step-C2 rating with overload capacity of generator wrt largest starting load and increase the generator rating if condition not fulfilled Step-C4) Check the step loading capability of generator calculated in step-C3 and increase the generator rating if condition not fulfilled Step-C5) Check the step-C4 rating wrt the allowable voltage dip during starting of largest motor or a group of motor started same time and apply correction if required or select the proper type of reduced voltage motor starting to gain desired target. CAUTION: Further to_calculation it is imperative to analysis the behavior of ‘Starting load and response/ capability curve of both engine & generator on case to case basis. Step-C6) Select the suitable generator rating according to market availability and % margin, if necessary, applied on rating achieved in step-C3 22 SELECTION STEPS: Step-S1) Determine the type of generator rating required/applicable for the project Step-S2) Determine the type of governor, AVR, exciter necessary for the project Step-$3) List down critical parameters, which is to be crosschecked during further course of engineeri ” ° Fl »iaidard Number Projects 2V¢, Ltd. DESIGN GUIDE FOR PO coca - | piGRTTNG CALCULATIONS Ct ed _ New Delhi | | Sheet 3 of 10Word 16.Q5P-05-34 3.0 ELABORATED CALCULATION STEPS, 3.1 STEP-C1:SEGREATION OF LOADS: 3.L.1 It is important to gather a reasonably accurate load schedule as soon as possible for determining generator rating as well as overall system design. If all the load equipment information is not available early in project, estimates and assumptions will have to be made for the first sizing calculations and the same must be iterated as more accurate information becomes available progressively. 3.12 After arriving load list. of generator it is necessary to segregate the loads in different application categories as listed below Category-1) ser loads like lighting, heating etc in kW (KW!) and its overall pF I Category-2) Running highest motor or @ group of motor to be started at a time or sam of auto accelerated motor loads input power at running condition whichever is higher in kW (KW) and its other parameters like pf (PF, Starting current times (P), Starting pf (PF*) and Starting time (€@) based on load type Category-3) Running motor loads except VFD & soft started, input power in kW (KW") and its overall pf (PF) Category'4) | UPS rating input power in kW (KW * and its overall pf (PF*) Category-5) VED drives input power rating in kW (KW"), not the connected motor name plate rating, and its overall pf (PF") Category-6) ‘Soft started motor input power rating in kW (KW), and its overall pf er) 3.2 STEP-C2:EFFECTIVE LOAD TO GENERATOR 3.2.1 Itis important to note that generator rating is not necessarily to be just sum of the loads if some non-linear loads present. Conventionally that may be taken care by margin factor but to determine a cost effective as well as project required rating of generator, effective loads on generator must be calculated properly to avoid generator oversizing CAUTION: Due to high cost of complete_generator package including driver and its auxiliaries, a single kW increase in rating ‘may cause commercial impact substantially. Further there is_no_mandatory rule to keep margin unless specific requirement of Client or depending on inaccuracy of data according to project phase. 3.2.2 EBffective load to generator to be calculated as below based on load segregation done in clause 3.1.2 Load to generator (KW electrical) shall be sum of loads with correction factor for non- linear loads, so that additional heating due to third harmonic generated by these non- linear loads can be taken care. Generation of third harmonic mainly depend on conversion technology adopted and correction factor accordingly differs. CAUTION: KW electrical determines the rating of generator not the ‘rating of driver. KW mechanical to be calculated separately to determine the rating of driver based on KWe.. Standard Number__| Triune Projects Pvt. Ltd. DESIGN GUIDE FOR New Delhi LIGHTING CALCULATIONS ee Sheet 4 of 10Word 3.3 Triune Projects Pvt. Ltd. DESIGN GUIDE FO? New Delhi LIGHTING CALCULATIONS 16-Q5P-05-34, KWe= KW'+ KW+ KW" +N"* KW! +N KW FN@ KW Where KW* Explained in clause 3.1.2 nN" 1.25 * 1.4 for 1 phase & 6 pulse UPS = 1.25* 1.15 for 6 pulse with input filters or 12 pulse ups Factor 1.25 is considered to take the battery charging after drain out with supplying connected loads. N’ = 2.0 without PWM VFD_ = 1.4 with PWM VED Nt 1.15 for without bypass contactor after start 1.0 for with bypass contactor after start 3.23 Though not necessary but better to calculate the overall power factor of total load as, below to calculate effective KVA rating peel = KW! + KW! + KW" +KW" +KW' + KW! (KW "PF + (KW'/PP) + (KW "/PF*) + (KWPF*) + (KWPF) + (KWIPF) 3.24 In ease someone wants to avoid/skip the caleulations/verifications further or to estimate the generator rating instantly based on load analysis following empirical formula may be used subject to generator catering also linear loads, KWe = (KW! +N'* KW! + KW" +N"* KW" +N" KW" + N'* KW!) #12 (margin) % margin could be 30% in case load data are preliminary. ‘And. check the step loading/transient voltage dip as per following empirical relationship KWe > Biggest motor starting KVA * 0.8 * generator pf (0.8) Where N’=2.0 for DOL starting 1.0 for reduced starting STEP-C3:OVERLOAD CAPACITY 3.3.1 Generator is normally capable to deliver 150% to 300% of overload capacity for short time ranging from 10 sec to 15 sec. In case generator manufacturer is predetermined, its better to get this overload capacity factor from manufacturer specific data sheet. 3.3.2 Considering. starting load, short time totals kVA load rating to be calculated as below without considering correction factors for non-linear loads. KVA short time= KVAs = (KW! /PE'}+ (KW! *1'*K'/PF) + (KW "/PF®) + (KW"/PF*) + (KW/PF?) + (KWIPF) Where Kr to be selected from below table for reduced voltage starting Type of % voltage ‘% full voltage | Factor K" starting applied torque ‘Auto 80 & 064 transformer 65 4 0.42 50 25 0.25 Series reactor 80 64 0.80 65 2 [0.65 30 25 0.50 Staridelta 33 0.33 — ‘Wound rotor 100 60 | motor If there are groups of motors to be started at a time and starting current times differs each other, then individual motor starting KVA must be calculated, Standard Namber 06-DG-008 i ‘Sheet 5 of 10Word Y 333 16.98P-05:34 Tn case of Firewater pump connected to generator, voltage dip of 15% only to be considered during starting as per NEC. Even if firewater pump starter is fitted with reduced voltage starting, DOL to be considered for generator sizing keeping in view criticality of fire water pump, CAUTION: Overloading to be checked with respect to short time KVA ratin, 334 ‘not the short time KW rating as during starting KW short time is low due to low starting power factor where as line current still continues to 5 times of full load current at 80% of motor speed ‘even though power factor increased to nearly 0.7 to 0.8 However, if no data is available on overload capacity, K"™ =1.5 could be considered and suitability to be checked ic. KVAs KW'*I'*K" * Xd"(100~1) PF > Motor starting KVA_* Xd"(100-1) ‘Min Gen KVA= Motor starting KVA * 0.92 ‘Min Gen KVA= Motor starting KVA * 1.30 Min Gen KVA= Motor starting KVA * 0.80 Min Gen KVA= Motor starting KVA * 1.13, Min Gen KVA= Motor starting KVA * 0.64 Min Gen KVA= Motor starting KVA * 0.90 Standard Number DESIGN GUIDE FOR LIGHTING CALCULATIONS 06-DG-/ 18 ‘Sheet 7 of 10Word, 16.Q8P.05:38 3.6 STEP-C6:GENERATOR RATING 3.6.1 3.62 3.63 3.64 3.65 After exercising all above five steps Generator rating. shall be maximum rating out of calculation from step-C2 to C5 Generator electrical KW (KWe) caeauss ~ Generator KVA electrical (KVAe) * 0.8 , as 0.8 pfis considered forall type of generator Suitable design/future margin, normally 10 to 30%, to be applied on above calculated ‘KWe rating and round off to nearest rating available in market. i.e, KWerieges “rounded off acc to market of (KWe sauines * design/future margin factor) Engine i.e, mechanical kW (KW) siesed = KWe seers / efficiency of engine In case there are major loads are non linear type and correction factor considered is more than 1.15 to calculate effective load on generator in step-C2, during calculation of KWm the extra margin considered on generator can be eliminated (minused) from KW as the third harmonic effect on generator does not imply to increase the engine kW rating other than 1.15 correction factor. 40 ELABORATED SELECTION STEPS 4.1 STEP-S1:GENERATOR RATING TYPE 4.1.1 Only power rating of generator is not sufficient to select the proper model. Type of ‘generator rating type ( STANDBY/PRIME/CONTINUOUS) as explained below is also to be determined as applicable for a project 412 STANDBY POWER RATING: Standby power rating is applicable to emergency power applications where power is supplied for the duration of normal power interruption. No sustained overload is applicable for this rating. This rating is applicable.to variable load with average load factor of 80% of the standby rating for a maximum 200 hours bperation per year and a maximum of 25 hours per year at 100% of its standby rating. In case requirement exceeds more than operations as specified, prime rating to be selected ZBIT goo XTi ee ET; =200 hours per year ETi (at 110% of prime rating) = not allowed Ti (at 100% of prime rating) = 25 hours per year ‘Where P is the power and T is corresponding time cycle 4.13. PRIME POWER RATING :Prime power rating is applicable when supplying power in lieu of utility power. The number of operations per year is unlimited for variable load ‘applications but is limited to for constant load applications 41.3.1 Unlimited Running time fer: Unlimited no. of operations but average load factor should not exceed 70% of the prime rating. 10% overload for 1 hour on every 12 hours operations but not exceed 25 hours per year is applicable EPITI _ 99, STi 70% ‘XTi =unlimited hours ‘ETi (at 110% of prime rating) = 25 hours per year | Standard Number | ¥ Triuge Projects Pvi Ltd, | __ DESIGN GUIDE FOR ye o-n8 New Delhi LIGHTING CALCULATIONS Sheet 8 of 10Word VW ETi (at 100% of prime rating) = 500 hours per year Where F is the power and T is corresponding time cycle 4.13.2 Limited running time prime power: Prime power is available for a limited number of annual operating hours in costant load applications Any application requiring more than 750 hours of operation per year at the prime power rating should use the base load power rating HL ET; =750 hours ETi (at 110% of prime rating) = not allowed ETi( at 100% of prime rating) = 750 hours per year Where P is the power and T is corresponding time cycle 4.14 BASE LOAD OR CONTINUOUS POWER RATING: The continuous power rating is applicable for supplying power continuously to a load up to 100% of the base rating for unlimited hours. No sustained overloading is applicable at this rating, zpiti _ Et = 100% ZT; = unlimited ETi(at 110% of prime rating) = not allowed ETi (at 100% of prime rating) = Unlimited ‘Where P is the power and 1 is corresponding time cycle 4.1.5 Typically. prime rating = 90% of standby rating Continuous or base load rating = 70% of standby rating 4.1.6 For voltage selection of generator, generally medium voltage generator is recommended when LY generator current exceeds 2000Amp 4.2 STEP-S2:TYPE OF CONTROLS 42.1 Generators are available with with two types of excitation system Self excited & separately excited and behaviour of both as below Self excited: Higher voltage dips, collapsing field, single phase average sensing, lower tolerance for non-liner load, lesser capable motor starter ‘Seperately excited: Lower volaige dips, sustained fault current, three phase RMS sensing, better non-linearity immunity, better motor starter 1 case largest motor rating is very large compare to generator rating, separately excited generator is recommended to overcome the voltage dip. 4.2.2 Further time constant of exciter and rate of voltage change (volts/sec) of AVR are considerable factor to determine the time to recover rated voltage during transient voltage dip 423 There are broadly two types of governor, mechanical & electronic type. Due to fast response of electronic governor, step load is allowed more for electronic governor ‘compare to mechanical load. In above calculations, electronic governor is considered as, default. If engine is fitted with mechanical governor, allowable step load to be checked with engine capability curve “Standard Number _[ Rev. ; DESIGN GUIDE FOR STING CALCULATIONS Cat Sheet 9 of 10 Triune Projects New DelhiWord 16.05P-05.34, 5.0 VY 43 STEP-S3:CRITICAL PARAMETERS 43.1. Following critical parameters should be checked during further further course of engineering and/or after receiving offer from generator vendor. 432 Load Calculation ‘© Cross checking with lad analysis report ‘© Type of control and correction factor envisaged for non linear loads # Sequence of load start-up 433. Design parameters Overload capacity of generator ‘© Allowable step load for engine ‘+ sub transient reactance of generator 434 Control system ‘© Governor type (mechanical or electronic) «Excitation type (self or separately) © AVR details, © Time constant of exciter {© Mode of operation (droop method and/or isochronous method) 435 Characteristic curve «Capability curve ie. load verses % voltage dip = Recovery voltage curve i. transient load verses voltage dip + Overload capability curve CONCLUSION 5.1 After selecting generator and engine rating, all assumptions and considerations must be cross checked with power generation package vendor. 52. Incase generator and engine vendor are not same, compatibility of selected governor type with 'AVR and excitation system is necessarily to be verified with past executed projects. 53 Atypical calculation according to this guide line is enclosed in Appendix-A ‘Triune Projects Pvt. Ltd. New Delhi LIGHTING CALCULATIONS Standard Number DESIGN GUIDE FOR 06-DG-008 ‘Sheet 10 of 10)APPENDIX - A TO “DESIGN GUIDE FOR GENERATOR SIZING CALCULATION TYPICAL CALCULATION.02 [STEP-CT: LOAD SEGREATION (ALL ARE INPUT POWER] RAF [LIGHTINGIHEATING LOAD ew 700) 0a. Ta IHIGHEST MOTOR LOAD(STARDELTALKWS= 760 0.85 | 1882 ISTARTINGAMPIPF [P= 6 0.25 REDUCED VOLTAGE STARTING FACTOR. 033 RUNNING MOTOR LOAD lew" 500 083 | 6024 [UPS LOAD (12 PULSE) ws 40 08, 500 [UBS LOAD (6 PULSE) 5 08. 83. VED ORIVES LOAD (WITH PH 30 0.82 366 [VED DRIVES LOAD (WITHOUT PMA), 10 or 143 [SOFT STARTED MOTOR LOAD 35, or 50.0 [(wrTHOUT BYPASS CONTACTOR) TOTAL. aT Tos |STEPoE EFFECTVE TORDTOCENERATOR Rives 100+ 160+500 +125 TSAO TIS TASTE GODOT ISS 9285 KW Peness — gg0/ 1058 ast Kvae= KWelPR™ 17 KA, TO AVOID FURTHER CALCULATION, GENERATOR RATINGS ‘KWe= (100 + 1° 160 + 500 + 1.25" 1.18"40 + 1.257 1.4°5 + 1.4°30+ 2.0" 10+ 1,15" 35)°12 16 KW AND Kie> 160°3*0:39°0 80.80.85, > 299 30, as above relationship is fullfilled 1114 1.0. 1100KW is OK [STEP-G3: EFFECTIVE LOAD TO GENERATOR TKVAS= T0010 9>160°6"0 5310,85°50010 BSA 8-510 BIO. BE TOOT =SSIOT 1260 KVA sav, Koma 18 80, kvaerreet 41745 1675 KVA [AS KVAs < KVAe*K™™™ THEN KVAe NOT TO BE CORRECTED KyAe(correctod in stop-C3) a a7 KA STEPGH STEP LOADING FOLLOWING RELATIONSHIP TO GE CHECKED. Kent KOBE PE < __KVAe (corrected in step-C3) * 0.8 °0.4 seorer0.as0 25085, < irosos 2 < 258 [AS ABOVE RELATIONSHIP IS FULLFILLED, SO NO NEED TO CORRECT KVAe KovAe (corrected in siep-C4)=KVAe (corrected in tep-C3)= 4117 KVA TRANSIENT VOLTAGE DIP lsav, Target vd= 20% xd'= 02 S0,Va= 6% [AS TARGET Vi IS MORE, NO NEED TO INCREASE THE GENERATOR CAPACITY [STEP-C6: GENERATOR RATING GENERATOR RATING REQUIRED AS PER ABOVE STEPS C2 TO C5 1417 KVA GENERATOR KWe cacione= 4 KW ‘SELECTED GENERATOR RATING KWe yas WITH 10% MARGIN 983 KW = 1000 Kw JQ0UENGINE EFFN. KW. ENGINE CAPACITY KW sanoIX-A TO“DESIGN GUIDE FOR GENERATOR SIZING CALCULATION APPEND) TYPICAL CALCULATION03 [STEP-C1: LOAD SEGREATION ALL ARE INPUT POW! Kur LIGHTINGIHEATING LOAD io _JPF= 28 1 HIGHEST MOTOR LOAD(DOL) et 160__|PF*. 0.85 188.2 [STARTING AMPIPE = 6 [pr [025 [REDUCED VOLTAGE STARTING FACTOR ___[K" 1 RUNNING MOTOR LOAD. KW": 300 PFS aa | aoa [UPS LOAD (12 PULSE) Ka 40 [PR 08 50.0 [UBS LOAD (6 PULSE) ia 0 [prs 08: 0.0 IVD DRIVES LOAD (WITH PNW) [KIN 0 |PR= 0.82 0.0 IVEO DRIVES LOAD (WITHOUT PHAW)_[KIN' opr o7 0.0 [SOFT STARTED MOTOR LOAD [WE oP o7 0.0 THOUT BYPASS CONTACTOR) TOTAL woo ez [STED-Cz: EFFECTIVE LOAD TO GENERATOR, TOO 160+ 500+ 125° TIS ATT TIES OT TP OPED OT TITS a7 KW KW Pres 900/961 0841 Kwerre" 973 KYA Kv ‘TO AVOID FURTHER CALCULATION, GENERATOR RATING= 100 » 2° 160 + 500 +1.25°1.15"40 + 12571404 1.470+20°0+ 1.15" O12 73 KW AND KWe> 160°6"0.8°0.810.85 > 13 $0, 3 above relationship is fullfilled 1173 1.0. 1200KW is OK [STEPS EFFECTIVE LOAD T0 GENERATOR. sav, TKVAS= T0010 9+100°6° 110. 8550070 BS-AOO ETO BOO BE-OO.T OUT = 1853 KVA Kote 18 80, KvaerKowet kVA [AS KVAs > KVAe"K™*"™™ THEN KVAe TO BE CORRECTED TO KvAo(corrected in step-3)= kvasienn 3262___KVA [STEPER ‘STEPLOADING FOLLOWING RELATIONSHIP TO BE CHECKED KW! KSPR < _KVAe (comected in step-C3) "0.8 0.4 160°6°1"0.2510.85, < — 1ero.804 262 < 408 'AS ABOVE RELATIONSHIP IS FULLFILLED, SO NO NEED TO CORRECT KViAe KvAe (camected in siep-C4)=KVAe (comected in step-C3) 4262 KVA, [STEPCS: “TRANSIENT VOLTAGE DIF say, [STEP-TE: AS TARGET Vi IS MORE, NO NEED TO INCREASE THE GENERATOR CAPACITY 5" GENERATOR RATING GENERATOR RATING REQUIRED AS PER ABOVE STEPS C2 TO.C5 = 1262 KVA GENERATOR KWe exit 1010 KW ‘SELECTED GENERATOR RATING KWe jageng WITH 103% MARCI 41 KW ~ 1100 KW OOENGINE EFS ENGINE CAPACITY KW ws.[APPENDIX -A TO "DESIGN GUIDE FOR GENERATOR SIZING CALCULATION TYPICAL CALCULATION [STEP-Ci: LOAD SEGREATION (ALL ARE INPUT POWER] REF ILIGHTINGIHEATING LOAD, w= 700) 08. 1 IHIGHEST MOTOR LOAD(OOL) lewF= 110 _|PF: Das | 1294 [STARTING AMPIPE___|P= 6 ee 0.25 [REDUCED VOLTAGE STARTING FACTOR | 1 + [RUNNING MOTOR LOAD, 500_ [PF o83 | e028 |UPS LOAD (12 PULSE) 0 08 500 [UPS LOAD (6 PULSE) 5 08 63. [VED DRIVES LOAD (Wit pu) | 30 82 366 [VED DRIVES LOAD (WITHOUT PH) 10 oF 143 ISOFT STARTED MOTOR LOAD 35. OF 500 [WITHOUT BYPASS CONTACTOR) [oral wo] 1000, [STEP-Cz: EFFECTIVE LOAD TO GENERATOR. Wie= 100+ 110+ 500+ 125" TIS ADP TIS TPES TOOT DO TOF TTS OS 8785 KW Pre: 930/ 1000 = 0890 KvAe= KWelPE"™= 1058 KVA 30+ 2.0°10+1.4535)41.2 TO AVOIO FURTHER Soca aN Hes (100 2" 140 + 506+ 1.28 1.15" 40 + 44 105 KW 4 AND kwe> 11980 80.8085 # *, > 497 & 4 soon shove inondtip mfp 1186: FoowW is OK . ISTEP-G3: EFFECTIVE LOAD TO GENERATOR TKVAS= 10010. 9610 WO 85-EDUI0 B40 BAO BT GOO BLOM 77ST cme ee ae 1508 KA, [AS KVAs > KVAe"K™**™™ THEN KVAe TO BE CORRECTED TO KvAo(corrected in step-C3)= vast 5 4098 KVA [STEP-Ca: STEP LOADING FOLLOWING RELATION SHIP TO BE CHECKED KW KP RPE < _KVAe (comectedin stop-C3)*0.8°0.4 110°61"0.2500.85, < — 1096'08°04 194 < 351 |AS ABOVE RELATIONSHIP IS FULFILLED, SO NO NEED TO CORRECT KVAe he Vie (cottected in tep-Ca)=KVAe (corrected in step-C3)= 1098 KVA [STEP-CS" TRANSIENT VOLTAGE DIF Jsav, Target Vé= 20% AS TARGET Vi IS MORE, NO NEED TO INCREASE THE GENERATOR CAPACITY, [STEP-GB”GENERATOR RATING GENERATOR RATING REQUIRED AS PER ABOVE STEPS C2 TO C5 = 1098 KVA GENERATOR KWVe caatt™ 378 KW ‘SELECTED GENERATOR RATING KW saeaneWITH 10% MARGIN= 965 KW = 1000 KW 1Q0UIENGINE EFEN. KW ENGINE CAPACITY Kim. CALOT 4APPENDIX - A TO “DESIGN GUIDE FOR GENERATOR SIZING CALCULATION TYPICAL CALCULATION-04 STEP-CT LOAD. FON ALL ARE INPUT POWER LIGHTING/HEATING LOAD. Kv [a9 [HIGHEST MOTOR LOAD(DOL) Kw 0.85, [STARTING AMPIPE [i= 025, [REDUCED VOLTAGE STARTING FACTOR 1 |RUNNING MOTOR LOAD 100 8s 1205 [UPS LOAD (12 PULSE} 40, 08 500 [UPS LOAD (6 PULSE) 0 08 00 IVED DRIVES LOAD (WITH PMV) 0 0.82, 0.0 [VED DRIVES LOAD (WITHOUT PMV) 0 o7 0.0 [SOFT STARTED MOTOR LOAD 0 oF 0.0 |(WITHOUT BYPASS CONTACTOR) TOTAL 3 36 [STEP-Cz:_EFFE TOAD TO GENERATOR 25+ 170+ 1007 125° 118 40+ 1S TROT TH OTZO OA TINO 3525 KW KV Proms 935/308 ogat kvae= KWelPFo™ 419 KA ‘TO AVOID FURTHER CALCULATION, GENERATOR RATING= KWe= (25 +2"170 + 100 + 1.257 1.15"40 +1.25°1.4°0+1.4"0+20°0 + 1.15" O}"12 627 KW AND KWe> 170°6°0.8°0.8/0.85 > 768 ‘So, as above relationship is not fullfilled 768 i.e. 800KW is SELECTED [STEP-C3._EFFECTIVE LOAD TO GENERATOR KVAS= 26/0. 941 70°E°110 85+ TOOTS AO BvOTO BORE 1398 kVA say, KS 2 TOOT 80, KvAerk™moe = 4192 = 838 VA [AS KVAs > KVAo"K*™"*" THEN KVAe TO BE CORRECTED TO KVAe(cortected in stop-C3) KVASIe™ 99 kVA [STEP-C#STEPLOADING CY FOLLOWING RELATIONSHIP TO BE CHECKED Kut PEPPY <__KVAe (corrected in step-C3) “0.8 *0.4 ie 170°6"170.2510.85 < essr0sr04 300 < 224 ‘AS ABOVE RELATIONSHIP IS NOT FULLFILLED, SO KVAe TO BE CORRECTED he. KAe (corrected in step-Ca)=200(0.8°0, 938 KVA, [STEP-C5_TRANSIENT VOLTAC Jsay, Target Vd= 20% xd"= 02 S0,Vd= 20% AS TARGET Va IS SAME, NO NEED TO INCREASE THE GENERATOR CAPACITY STEP-C5_ GENERATOR RATING GENERATOR RATING REQUIRED AS PER ABOVE STEPS C2 TO.C5 = 938 KVA, GENERATOR KWe ceva 750 KW ‘SELECTED GENERATOR RATING KWo ceases WITH 10% MARGI 825 KW ~ BBO KW ENGINE CAPACITY KW ssc BSOIENGINE EFFN, KW.