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MWD

METROPOLITAN WATER DISTRICT OF SOUTHERN CALIFORNIA


ENGINEERING SERVICES SECTION

ELECTRICAL
DESIGN MANUAL

ESD-106 JANUARY 2006


TABLE OF CONTENTS MWD Electrical Design Manual

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CHAPTER TITLE PAGE

1 INTRODUCTION...................................................................... 1-1

1.1 OBJECTIVE................................................................... 1-1


1.2 RESPONSIBILITIES OF THE ELECTRICAL
DESIGNER.................................................................... 1-1
1.3 DESIGN TASKS ............................................................ 1-2
1.3.1 Study Phase ..................................................... 1-2
1.3.2 Preliminary Design Tasks ................................. 1-2
1.3.3 Final Design Tasks (30%)...................................1-2
1.3.4 Final Design Tasks (60%)...................................1-3
1.3.5 Final Design Tasks (90%)...................................1-3
1.3.6 Final Design Tasks (100%).................................1-4
1.4 DOCUMENT CONTROL ............................................... 1-4

2 PROJECT DESIGN ELEMENTS ............................................. 2-1

2.1 GENERAL APPROACH ................................................ 2-1


2.1.1 Design Criteria .................................................. 2-1
2.1.2 Drawings........................................................... 2-1
2.1.3 Specifications.................................................... 2-1
2.2 BASIC ELECTRICAL ENGINEERING FORMULAS ...... 2-2
2.2.1 List of Symbols ................................................. 2-2
2.2.2 Direct Current (dc) Formulas ............................ 2-2
2.2.3 Alternating Current (ac), Single Phase ............. 2-3
2.2.4 Alternating Current (ac), Three Phase .............. 2-3
2.2.5 Motors............................................................... 2-4
2.2.6 Power Factor Correction ................................... 2-4
2.3 DESIGN CALCULATIONS ............................................ 2-4
2.3.1 General ............................................................. 2-4
2.3.2 Load.................................................................. 2-5
2.3.3 Conductor Size, General ................................. 2-5
2.3.4 Conduit Size and Fill ......................................... 2-8
2.3.5 Motor Branch Circuit ......................................... 2-9
2.3.6 Power Factor Correction Capacitors................ 2-14
2.3.7 Transformer Primary and Secondary Conductors 2-17
2.3.8 Voltage Drop.................................................... 2-20
2.3.9 Short Circuit ..................................................... 2-23
2.3.10 Lighting ............................................................ 2-27

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2.3.11 Grounding ........................................................ 2-36


2.4 DRAWINGS.................................................................. 2-36
2.4.1 General ............................................................ 2-34
2.4.2 Organization .................................................... 2-34
2.4.3 Legend............................................................. 2-37
2.4.4 Abbreviations ................................................... 2-37
2.4.5 Site Plan(s) ...................................................... 2-37
2.4.6 One-Line Diagrams.......................................... 2-38
2.4.7 Floor Plans....................................................... 2-39
2.4.8 Grounding Plan................................................ 2-40
2.4.9 Equipment Elevations ...................................... 2-40
2.4.10 Control Schematic Diagrams ........................... 2-40
2.4.11 Installation Details.............................................2-40
2.4.12 Electrical Schedules .........................................2-40
2.5 PROJECT FILES .......................................................... 2-44

3 STANDARD ELECTRICAL DESIGN PROCEDURES............. 3-1

3.1 GENERAL APPROACH ................................................ 3-1


3.1.1 Types of Electrical Systems.............................. 3-1
3.1.2 References ....................................................... 3-1
3.1.3 Plant Distribution Systems ................................ 3-2
3.1.4 Voltage Considerations..................................... 3-7
3.1.5 Voltage Selection.............................................. 3-8
3.1.6 Voltage Rating ....................................................3-8
3.1.7 Protection/Coordination Philosophy .................. 3-8
3.1.8 Equipment Heat Dissipation Data ................... 3-13
3.2 LOCATING ELECTRICAL EQUIPMENT ..................... 3-13
3.2.1 Equipment Rooms and Buildings.................... 3-13
3.2.2 Equipment Enclosures .................................... 3-14
3.3 SWITCHGEAR ............................................................. 3-15
3.3.1 Low Voltage ..................................................... 3-15
3.3.2 Medium Voltage (4.16 kV through 13.8 kV) ..... 3-17
3.4 TRANSFORMERS........................................................ 3-17
3.4.1 Pad-Mounted ................................................... 3-18
3.4.2 Unit Substations............................................... 3-18
3.4.3 Equipment Selection........................................ 3-20
3.5 MOTOR CONTROL EQUIPMENT ............................... 3-20
3.5.1 Low Voltage ..................................................... 3-20
3.5.2 Medium Voltage............................................... 3-25
3.5.3 Adjustable Speed Drives.................................. 3-27
3.5.4 Power Factor Correction .................................. 3-32

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CHAPTER TITLE PAGE

3.5.5 Control Circuit Devices .................................... 3-32


3.6 MOTORS...................................................................... 3-33
3.6.1 Basic Motor Types ........................................... 3-33
3.6.2 Design Considerations..................................... 3-33
3.6.3 Low-Voltage Single-Phase Induction Motors ... 3-39
3.6.4 Low-Voltage Three-Phase Induction
Motors.............................................................. 3-39
3.6.5 Medium-Voltage Induction Motors ................... 3-39
3.6.6 Synchronous Motors........................................ 3-40
3.6.7 Direct Current Motors ...................................... 3-40
3.7 RACEWAY SYSTEMS ................................................. 3-41
3.7.1 Conduit System ............................................... 3-41
3.7.2 Conduit Identification ....................................... 3-42
3.7.3 Wireway ........................................................... 3-42
3.7.4 Cable Tray System .......................................... 3-42
3.7.5 Trench System................................................. 3-43
3.7.6 Ductbank System............................................. 3-43
3.8 CONDUCTORS ............................................................ 3-44
3.8.1 Low-Voltage Wiring
Systems (600 Volts and Below) ....................... 3-44
3.8.2 Medium and High Voltage Conductors
(Above 600 Volts) ............................................ 3-47
3.8.3 Splices and Terminations................................. 3-47
3.8.4 Conductor Identification ................................... 3-48
3.8.5 Conductor Installation ...................................... 3-48
3.9 JUNCTION BOXES AND PULL BOXES ...................... 3-49
3.9.1 Indoor Locations .............................................. 3-49
3.9.2 Outdoor Locations ........................................... 3-50
3.9.3 Corrosive Locations ......................................... 3-50
3.9.4 Hazardous Locations ....................................... 3-50
3.9.5 Terminal Junction Boxes.................................. 3-50
3.10 MANHOLES AND HANDHOLES.................................. 3-51
3.10.1 Handholes........................................................ 3-51
3.10.2 Manholes ......................................................... 3-52
3.11 LIGHTING SYSTEMS................................................... 3-52
3.11.1 General Illumination......................................... 3-53
3.11.2 Recommended Illumination Levels .................. 3-54
3.11.3 Lighting System Design ................................... 3-54
3.11.4 Luminaries ........................................................3-54
3.11.5 Emergency/Standby Lighting ........................... 3-57
3.11.6 Exit Signs......................................................... 3-58
3.11.7 Controls ........................................................... 3-58

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CHAPTER TITLE PAGE

3.12 LOW VOLTAGE POWER DISTRIBUTION................... 3-59


3.12.1 Voltage Selection............................................. 3-59
3.12.2 Panelboards..................................................... 3-59
3.12.3 Convenience Receptacles ............................... 3-60
3.12.4 Hazardous Area Receptacles .......................... 3-61
3.12.5 Power Receptacles.......................................... 3-61
3.13 GROUNDING ............................................................... 3-64
3.13.1 General ............................................................ 3-64
3.13.2 System Grounding ........................................... 3-64
3.13.3 Grounding Electrode Systems and
Grounding Grids .............................................. 3-65
3.13.4 Equipment Grounding...................................... 3-67
3.13.5 Instrumentation and Computer Grounding....... 3-67
3.13.6 Lightning Protection System Grounding .......... 3-67
3.14 EMERGENCY AND STANDBY POWER SYSTEMS.... 3-67
3.14.1 General ............................................................ 3-67
3.14.2 Emergency Power Systems............................. 3-68
3.14.3 Legally Required Standby Power System........ 3-68
3.14.4 Optional Standby Systems............................... 3-69
3.14.5 Engine Generators........................................... 3-69
3.14.6 Unit Equipment ................................................ 3-70
3.14.7 Computer Power Systems ............................... 3-71
3.15 SPECIAL SYSTEMS .................................................... 3-71
3.15.1 Plant Communication System.......................... 3-71
3.15.2 Fire Alarm System ........................................... 3-74
3.16 ELECTRICAL TESTING ............................................... 3-76
3.16.1 General Requirements..................................... 3-76
3.16.2 Plant Electrical System .................................... 3-77
3.16.3 Medium and Low Voltage Equipment .............. 3-78
3.16.4 Conductors ...................................................... 3-80
3.16.5 Emergency/Standby Generators...................... 3-80
3.16.6 Grounding ........................................................ 3-81

4 CONTROL SYSTEM DESIGN PROCEDURES ....................... 4-1

4.1 CONTROL PANELS ...................................................... 4-1


4.1.1 NEMA Standards .............................................. 4-1
4.1.2 Panel Design .................................................... 4-1
4.1.3 Indicating Devices............................................. 4-2
4.1.4 Switches, Pushbuttons, and Lights ................... 4-2
4.1.5 Annunciators..................................................... 4-3
4.1.6 Relays and Timers............................................ 4-4

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CHAPTER TITLE PAGE

4.1.7 Control Panel Layout ........................................ 4-5


4.1.8 Wiring and Terminations ................................... 4-6
4.1.9 Nameplates....................................................... 4-8
4.1.10 Installation......................................................... 4-8
4.1.11 Seismic Design Requirements.......................... 4-8
4.2 FIELD WIRING .............................................................. 4-9
4.2.1 Field Signal Wiring............................................ 4-9
4.2.2 Conduit ............................................................ 4-13
4.2.3 Spare Conductors............................................ 4-14
4.3 CONTROL DEVICE INTERFACING............................. 4-14
4.3.1 Remote Terminal Unit Outputs ........................ 4-15
4.3.2 Control Panels ................................................. 4-15
4.3.3 Status Monitoring............................................. 4-16
4.3.4 Signal Convertors ............................................ 4-17

APPENDIX TITLE PAGE

A REFERENCES ............................................................................ A-1


B ABBREVIATIONS........................................................................ B-1
C SAMPLE ELECTRICAL DESIGN CRITERIA MEMO .................. C-1
D ENCLOSURE TYPES ................................................................. D-1
E MOTOR ENCLOSURE TYPES ................................................... E-1
F MOTOR DESIGN TYPES.............................................................F-1
G MOTOR TORQUE DEFINITIONS ............................................... G-1
H STANDARD SPECIFICATIONS FOR THE IDENTIFICATION OF
ELECTRICAL CURRENT CARRYING CONDUCTORS.............. H-1

FIGURE TITLE PAGE

2-1 Relation Between kVA, kW, and kvar ....................................... 2-14


2-2 Impedance Diagram ................................................................. 2-23
2-3 Zonal Cavity Calculations ......................................................... 2-29
2-4 Calculation of Task Illumination ................................................ 2-32
2-5 Example Panel Drawing ........................................................... 2-40
3-1 Example Control Station Wiring................................................ 3-25
3-2 NEMA Configurations of General Purpose Nonlocking Plugs
and Receptacles....................................................................... 3-52
3-3 Additional NEMA Configurations .............................................. 3-53
4-1 Constant Speed Motor Control ................................................. 4-17
4-2 Reversing Motor Control........................................................... 4-18
4-3 Two-Speed Motor Control ........................................................ 4-19

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CHAPTER TITLE PAGE

4-4 Incremental Valve Control ........................................................ 4-20


4-5 Open/Close Valve Control, Electric Motor Applicator ............... 4-21
4-6 Open/Close Valve Control, Hydraulic/Pneumatic Operator ...... 4-22
4-7 Variable Speed Motor Control-Single Phase ..............................4-23
4-8 Variable Speed Motor Control-Three Phase...............................4-24
F-1 Examples of Power Feeder Cable Identification for
Water Treatment Plant Section ....................................................F-5
F-2 Examples of Control and Instrumentation Cable
Identification for Water Treatment Plant Section ..........................F-6
F-3 Cable Identification .......................................................................F-8
F-4 Identification for a Multi-Conductor Cable.....................................F-9
F-5 Identification for a Single-Conductor Cable ..................................F-9
F-6 Typical Box Identification............................................................F-11
F-7 Typical Duck Bank Identification.................................................F-12

TABLE TITLE PAGE

2-1 Motor Circuit Design Data--480 Volt, Three-Phase Motors ....... 2-12
2-2 480-Volt Lighting Transformer Circuit Design Chart (75o C) ...... 2-17
2-3 Three-Phase Line-to-Line Voltage Drop for 600 V Single-
Conductor Cable per 10,000 A-ft ............................................... 2-21
2-4 Coefficient of Utilization Zonal Cavity Method ........................... 2-27
2-5 Candlepower Distribution Curve ................................................ 2-31
3-1 Losses in Electrical Equipment................................................... 3-8
3-2 Recommended Illumination Levels............................................ 3-45
3-3 Requirements for Fire Alarm and Detection Devices................. 3-65
4-1 Annunciator Sequences ............................................................. 4-4
A Conductor Voltage Level Color Codes ....................................... F-7

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Chapter 1

INTRODUCTION MWD Electrical Design Manual

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1.1 OBJECTIVE
The objective of these electrical design standards is to provide a guide
that can be used for Metropolitan Water District of Southern California's
(Metropolitan) electrical practice. Anticipated users of this manual include
the engineer/designer with limited experience, management staff, and the
more experienced engineer/designer. The senior staff may find the
manual useful as a training tool for subordinates. The information
contained herein has been assembled from a number of sources; a list of
the readily available sources is contained in Appendix A, References.

These electrical design standards shall be used as the basis for all
designs prepared for Metropolitan. Outlined within these standards are
procedures for preparing design instructions, procedures for making most
of the calculations that will be required for a design, a data table that can
be used in making those calculations, drawing presentation formats,
standard legend items and abbreviations, descriptions of materials to be
used, and a number of informative memos. This information, used with
engineering judgment in conjunction with appropriate codes, national
standards, and other reference information, will provide electrical systems
that are safe and electrically suited for the intended application.

1.2 RESPONSIBILITIES OF THE ELECTRICAL DESIGNER


The electrical engineer/designer is responsible for all facets of a project
that are related to:

x Electrical energy for equipment located on the project site;

x Adequate illumination in all areas;

x Special electrical systems;

x Conduits and conductors for power distribution and


instrumentation and control (I&C) systems;

x Protective and safety alarm systems;

x Grounding and lightning protection systems;

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x Communication systems;

x Emergency power systems;

The engineer/designer must take an active role in consulting with other


members of the project team to identify the needs of his or her design and
the needs of other design groups.

1.3 Design Tasks


The following is a partial list of design tasks that the electrical engineer/
designer must assume responsibility for during the course of the design.
1.3.1 Study Phase

x Provide electrical support for preparation of draft study.


x Review electrical elements of project description in draft
study.

1.3.2 Preliminary Design Tasks

x Prepare the written electrical design criteria that are specific


to the needs of the project.
x Provide input to preparation of preliminary design report
(PDR).
x Define the method of electrical service. Contact the utility
that will serve the site to define the interface required
between the utility’s system and the site’s electrical
distribution system. Obtain a copy of the electrical rates that
will apply to the service.
x Identify and talk to the electrical inspection authority having
jurisdiction at the project site and obtain copies of any
special ordinances or codes that may apply to the electrical
design.
x Work with the process design staff and mechanical
engineers as well as other concerned design disciplines to
define the electrical load that will be required on the project
site and identify the electrical equipment.
x Develop a preliminary one-line diagram and written narrative
that describes the proposed electrical distribution system.
x Prepare a preliminary electrical site plan showing the
location of all major electrical equipment such as switchgear,
transformers, electrical ductbanks, etc.
x Perform preliminary calculations to size major electrical
equipment.
x Prepare a draft power system study.

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1.3.3 Final Design Tasks (30%)

x Update the electrical one-line diagram.


x Update the electrical site plan and sections.
x Update calculations for sizing of electrical equipment.
x Complete the power system study.
x Update the electrical equipment list
x Prepare draft electrical equipment specifications Table of
Contents.
x Prepare the electrical drawings required to define the
electrical system to be constructed (See paragraph 2.4,
Drawings).
x Prepare draft schedules for panelboards, lighting fixtures,
electrical boxes, manholes, conduit, cable,etc.

1.3.4 Final Design Tasks (60%)

x Update the electrical one-line diagram.


x Update the electrical site plan and sections.
x Complete and stamp all electrical calculations.
x Update the electrical drawings required to define the
electrical system to be constructed such as the power plan,
lighting plan, grounding plan, communication systems, fire
alarm systems, etc.
x Prepare the text electrical specifications required to define
the electrical system to be constructed (See paragraph
2.1.3, Specifications).
x Update all schedules for panelboards, lighting fixtures,
electrical boxes, manholes, conduit, cable, etc.
x Prepare draft control schematics and wiring diagrams.
x Review the Instrumentation and Control System Diagrams
(I&CS) to verify that all equipment on the project site that
must be interfaced with the electrical system has been
accounted for. In addition, the I&CSs should be consulted
when the control diagrams are being prepared because they
define the relationships that exist between the electrical
control equipment, the instrumentation system, and many of
the equipment items supplied in other divisions of the text
specifications.
x Prepare the ladder diagrams required for all panels that will
be provided by the I&C supplier. These ladder diagrams
should be used during the preparation of the process plans
to determine the conduit and conductor requirements of the
discrete control systems.

1.3.5 Final Design Tasks (90%)

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x Complete the electrical one-line diagram.


x Complete the electrical site plan and sections.
x Complete all electrical drawings required to define the
electrical system to be constructed such as the power plan,
lighting plan, grounding plan, communication systems, fire
alarm systems, etc.
x Complete all electrical equipment lists.
x Complete all text specifications for electrical equipment.
x Complete all control schematics and wiring diagrams.
x Complete all schedules.
x Complete the coordination of process control schematic
diagrams with Mechanical, I&C and SCADA design.
x Complete all protection relay settings.

1.3.6 Final Design Tasks (100%)

x Signoff of electrical plans and specifications.

1.4 DOCUMENT CONTROL


This manual is intended to be (1) the primary technical reference resource
for new employees in this discipline, and (2) the only reference guide for
engineering consultants who will augment Metropolitan engineering staff.

It is important that this manual be updated to keep it current and maintain


its usefulness. To propose changes to this manual, follow the change
control system procedure, located in ESD-171, Engineering Administration
Manual.

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Chapter 2

PROJECT DESIGN ELEMENTS MWD Electrical Design Manual

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2.1 GENERAL APPROACH


A design project can be broken down into a number of specific elements
that are prepared during several phases of the project. The two project
phases that are being covered by this design manual are the preliminary
design and final design phases. During the preliminary design phase, the
needs of the project must be evaluated, a preliminary one-line diagram
and electrical site plan prepared, the needs of the project outlined in a
brief report, and the design criteria for the project prepared. The electrical
drawings and text specifications are then prepared during final design
using the information prepared during preliminary design as a basis for
that design. All of the major decisions should be made during preliminary
design. Final design is an implementation of those decisions.

2.1.1 Design Criteria


The Electrical Design Criteria is a compilation of general information,
specific requirements that are applicable to the project, and design
instructions that shall be used by all of the design team members to
assure a complete and consistent product. An example Electrical Design
Criteria memo is presented in Appendix C.

2.1.2 Drawings
The purpose of a design is to develop a set of instructions and rules that a
contractor can use to bid the project and, if awarded the contract, build
what the designer had in mind. The drawings are a part of that installation
instruction set and describe the location and quantity of materials and
equipment needed for the project; the text specifications describe the type
and quality of materials and equipment and the quality of workmanship.
See paragraph 2.4, Drawings, for a description of the drawings to be
included in a construction package.

2.1.3 Specifications
The text specifications shall describe the materials to be furnished by the
contractor and the requirements for the products themselves, the
requirements for installing the products, and the quality control measures
that will be used to check the products and the execution of construction.
Moreover, the text specifications provide these descriptions in one place
for the general contractor's comprehension and use. As an electrical
engineer/designer, one may think that the electrical text specifications are
written for the electrical contractor, subcontractor, or equipment supplier,
but this is not the case. The text specifications are addressed to the
general contractor, who decides who shall do the work.

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2.1.3.1 Organization. The electrical text specifications will be


prepared in Construction Specifications Institute (CSI) narrative format in
the indicative mood. The standard electrical text specifications will consist
of sections organized as shown in Metropolitan's ESD-135, Standard
Specifications Sections Catalog.

2.1.3.2 Standard Specifications. The Standard Master Specifications


have been prepared to cover all normal projects that are expected to be
designed for or by Metropolitan. It is intended that the engineer will select
only those text specification sections that are applicable to the project and
then use those sections without changes.

2.1.3.3 Project Specifications. The engineer shall prepare project


specifications in the CSI narrative format for any additional requirements
not covered by the Standard Master Specifications. These specifications
shall also be prepared in the indicative mood. Only three parts will be
provided for in each technical section:

x Part 1--General;
x Part 2--Products;
x Part 3--Execution.

2.2 BASIC ELECTRICAL ENGINEERING FORMULAS

2.2.1 List of Symbols

E = voltage (volts)
I = current (amps)
R = resistance (ohms)
X = reactance (ohms)
Z = impedance (ohms)
P = power (watts)
VA = voltampere
W = watt
ș = angle whose cosine is the power factor
ĭ = phase
Eff = efficiency

2.2.2 Direct Current (dc) Formulas


Basic formulas for dc current include:

Voltage (E) = Current (I) x Resistance (R) (Eq. 2-1)


Power (P) = E2/R = EI (Eq. 2-2)

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P = I2 x R (Eq. 2-3)

2.2.3 Alternating Current (ac), Single Phase

Basic formulas for ac current, single phase, include:

Voltage (E) = Current (I) x Impedance (Z) (Eq. 2-4)


Power factor (PF) = cosș (Eq. 2-5)
Apparent Power (VA) = E x I (Eq. 2-6)
Reactive Power (vars) = E x I x sinș (Eq. 2-7)
Real Power (Watts) = E x I x PF (Eq. 2-8)
ș = arctan (vars/Watts) (Eq. 2-9)
PF = Watts/(E x I) = Watts/VA (Eq. 2-10)

The voltage drop formula is:

Ed = 2 x (I x R x cosș) + (I x X x sinș) (Eq. 2-11)

where:

Ed = voltage drop in circuit


sin ș = load reactive factor
X = line reactance for one conductor, in ohms

2.2.4 Alternating Current (AC), Three Phase


Basic formulas for ac current, three phase, include:

Line Voltage (E) = 31/2 x Eĭ (Wye-connected) (Eq. 2-12)


Current (I) = 31/2 x Iĭ (Delta-connected) (Eq. 2-13)
Apparent Power (kVA) = (31/2 x E x I)/1000 (Eq. 2-14)
Real Power (kW) = kVA x cosș (Eq. 2-15)
Reactive Power (kvar) = kVA x sinș (Eq. 2-16)
ș = arctan (kvar/kW) (Eq. 2-17)
Power Factor (PF) = cosș = kW/kVA (Eq. 2-18)
PF = kW/((E x I x 31/2)/ 1000) (Eq. 2-19)

The voltage drop formula is:

Ed = 31/2 x (I x R x cosș + I x X x sinș) (Eq. 2-20)

where:

Ed = voltage drop in circuit


sinș = load reactive factor

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X = line reactance for one conductor in ohms


R = line resistance for one conductor in ohms

2.2.5 Motors
Motor (general) formulas include:

1 horsepower (hp) = 746 Watts (Eq. 2-21)


Torque (ft-lb) = (hp x 5250)/rpm (Eq. 2-22)
Fan hp = (cfm x Pressure)/(33,000 x Eff) (Eq. 2-23)
Pump hp = (gpm x Head x
Specific Gravity)/(3960 x Eff) (Eq. 2-24)

Motor (single phase) formula is:

Horsepower = (E x I x Eff x PF)/746 (Eq. 2-25)

Motor (three phase) formulas include:

Synchronous Speed: ns =
(120)(Frequency)/(# Poles) (Eq. 2-26)
Horsepower = (E x I x 31/2 x Eff x PF)/746 (Eq. 2-27)

2.2.6 Power Factor Correction


The size of the capacitor needed to increase the power factor from PF1 to
PF2 with the initial kVA given is:

kvar = kVA([1-(PF1)2]1/2 - PF1/PF2[1-(PF2)2]1/2) (Eq. 2-28)

2.3 DESIGN CALCULATIONS

2.3.1 General
Electrical calculations shall be made for all projects and filed in the project
notebook. They may be made either manually or by computer programs
approved by Metropolitan. As a minimum, the following types of
calculations shall be made where applicable and submitted to Metropolitan
for review:

x Load calculations;

x Conductor sizing;

x Conduit sizing;

x Motor branch circuit sizing;

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x Power factor improvement;

x Transformer primary and secondary circuit sizing;

x Voltage drop;

x Motor starting voltage dip;

x Short circuit analysis;

x Lighting levels;

x Grounding in substations.

Note: All references to the National Electrical code (NEC) for


calculations shown in this design manual are based on the 2005
Edition of the NEC.

If computer programs are used to make the calculations, the name and
version of the software, along with all input and output data, shall be
included in the submittal to Metropolitan. All calculations shall be certified
by the signature and stamp of a registered professional electrical
engineer.

2.3.2 Load
Load calculations shall be made using applicable sections of Articles 220,
430, and other sections of the NEC. The following load calculations will be
used for sizing:

x Feeder conductors and protective devices;


x Transformers;
x Panelboard and switchboard main busses;
x Motor control center components;
x Service entrance devices and conductors.

Load calculations must include all loads and should be made by summing
all of the loads, using appropriate diversity factors as allowed by NEC
Article 220, that are connected to each panelboard, switchboard, and
motor control center. The loads for each branch of the distribution system
can then be summed back to the service entrance equipment.

2.3.3 Conductor Size, General


Conductor sizes must be determined for general purpose branch circuit

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conductors and feeder conductors in accordance with the requirements of


NEC Article 220, the size of service entrance conductors as covered in
NEC Article 230, the size of motor branch circuit conductors as covered in
NEC Article 430, the size of air conditioning equipment branch circuit
conductors as covered in NEC Article 440, the size of generator
conductors as covered in NEC Article 445, the size of transformer primary
and secondary conductors as covered by NEC Article 450, and the size of
conductors to capacitors as covered in NEC Article 460. In this section we
will look at the general requirements for sizing conductors once the
calculated load current is known.

Paragraphs 210.19 and 215.2 of the NEC require that branch circuit and
feeder conductors have an ampacity not less than the load to be served.
NEC Paragraph 220.18 contains additional information relative to branch
circuit loads. Once branch circuit and feeder loads have been determined
using applicable sections of NEC Article 230 and other applicable articles,
conductor sizes shall then be determined using Tables 310.16 through
310.20 of the NEC for conductors zero through 2,000 volts and
Tables 310.67 through 310.86 of the NEC for conductors rated above
2,000 volts. The four examples presented below are based on the
ampacities presented in NEC Table 310.16 as modified by the applicable
correction factors for temperature and conduit fill.

2.3.3.1 Example No. 1. Conditions: Continuous load rated 37 amps


served by a conduit containing only the conductors for the load, running
through an area having an ambient temperature of 38o C. Conductors
shall be copper with type TW insulation.

Required ampacity per NEC Paragraphs 210.19 and 210.18:


Ampacity required = continuous load x 125%
= 37 x 1.25 or 46.25 amps

A No. 6 AWG copper conductor having an ampacity of 55 amps


would appear to be the correct choice.

Where the ambient temperatures exceed the 30o C ambient that


NEC Table 310.16 is based on, the allowable ampacity of the
conductor must be corrected using the correction factors at the
bottom of Table 310.16 as required by NEC Paragraph 310.10.

Corrected ampacity of No. 6 conductor = 55 x correction factor


(0.82)
or
Corrected ampacity = 55 x 0.82 = 45.1 amps

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Because an ampacity of 46.25 amps is required, this conductor


is not adequate and the next larger size (or a conductor with
different insulation) will need to be used.

2.3.3.2 Example No. 2. Conditions: The same load and ambient


temperature as above but with six phase conductors in the same conduit.
Assume that the conductors used above were No. 6 copper with RHW
insulation.

Corrected ampacity of No. 6 RHW = 65 x 0.88 = 57.2 amps

Where more than three current carrying conductors are


contained in the same raceway, the ampacity of the conductors
must also be derated by the ampacity adjustment factors
contained in NEC Table 310.15(B)(2)(a).

Corrected ampacity of No. 6 RHW conductor = 57.2 (ampacity


corrected for temperature) x 0.8 (ampacity adjustment factor) =
45.7amps

Because an ampacity of 46.25 amps is required, this conductor


size is not satisfactory for this application. A larger conductor or
a different configuration must be used.

2.3.3.3 Example No 3. Conditions: A feeder with 200 amps of


noncontinuous load and 65 amps of continuous load to be installed in
conduit in a wet area with an ambient temperature of 30o C or less.

Required ampacity per NEC Paragraph 215.2 =


noncontinuous load + 1.25 x continuous load
or 200 + 1.25 x 65 = 281.25 amps

The feeder overcurrent device would be sized at 300 amps


since that is the next largest standard rating (see Article 240 of
the NEC).

The conductor ampacity requirement can be met by either one


300 kCMIL conductor or two 1/0 conductors with RHW
insulation per phase. Because the ampacity of one 300 kCMIL
RHW conductor is only 285 amps, NEC Paragraph 240.4(B)
must be invoked.

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2.3.3.4 Example No. 4. Conditions: The same load as used in


example No. 3 but the conduit is to be installed in a dry area with an
ambient temperature of 38o C.

Required ampacity calculated above = 281.25 amps.

Ampacity of one 300 kCMIL RHH conductor is 320 in a dry


location.

Correction factor for 90o C conductors in a 38o C ambient =


0.91.

Corrected ampacity = 320 amps x 0.91 = 291.2 amps

The results are the same as for example No. 3, so NEC


Paragraph 240.4(B) must be invoked.

2.3.4 Conduit Size and Fill


Where conductors are installed in conduit, the conduit shall be sized in
accordance with Tables C.1 through C.12(A) in Annex C of the NEC, and
all associated notes. Following are two examples of how conduits can be
sized under different circumstances.

2.3.4.1 Example No. 1. Conditions: Three 4/0 AWG conductors with


RHH/RHW insulation installed in rigid steel conduit (no separate ground
conductor).

See NEC Table 3C.8 for conduit size required for three 4/0
AWG conductors with RHH/RHW insulation.

NEC Table 3C8 would allow three conductors to be installed in a


2-inch conduit.

2.3.4.2 Example No. 2. Conditions: Three No. 4/0 AWG phase


conductors, one No. 1/0 AWG neutral and one No. 2 AWG equipment
ground conductor to be installed in rigid steel conduit. Phase and neutral
conductor insulation will be RHH/RHW and the ground conductor will have
TW insulation.

Because NEC Table C.8 is for situations where all conductors in


a conduit are the same size, they cannot be used for this
example. Table 4 in Chapter 9 of the NEC, using appropriate
conduction areas from Table 5 in Chapter 9 of the NEC, must

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then be used.

Total conductor area:

Conductor size Area


4/0 RHH/RHW 0.4754
1/0 RHH/RHW 0.3039
# 2 TW 0.1333

Total Area = 3(0.4754) + 0.3039 + 0.1333 = 1.8634 sq.in.

Conduit size required:

Because more than two conductors that are not lead covered
are being installed, the column for 40 percent fill in Table 4 in
Chapter 9 of the NEC can be used.

Select conduit with a usable area greater than 1.8634 square


inches; therefore, conduit size = 2-1/2 inch (40 percent of total
area = 1. 946 sq.in.)

2.3.5 Motor Branch Circuit


NEC Article 430, Motors, Motor Circuits, and Controllers, covers the
provisions for motors, motor circuits, and controllers. NEC Article 430
includes tables for motor full-load currents, which are the minimum values
that can be used in determining sizes of motor branch circuits, motor
feeders, short circuit and overcurrent device sizes and settings, and
miscellaneous load calculations. Actual nameplate currents should be
used if they are known and must be used if they are larger than the
minimum. The full load current to be used for motors with speeds less
than 1,200 rpm should be obtained from the motor manufacturer. NEC
Article 440 contains special provisions that apply to the installation of air-
conditioning and refrigeration equipment and should be referred to for
these applications.

The following calculations and the accompanying table are based on the
applicable provisions of NEC Article 430 and are provided as a guide for
performing motor branch circuit and feeder calculations and for sizing
components for motor branch circuits as part of a design. The typical
calculations that are required are demonstrated by the following examples.

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2.3.5.1 Example No. 1. Conditions: Induction motor is rated 60 hp,


460 volts, three-phase, 1,800 rpm continuous, and will be powered by a
combination motor starter through a conduit system. All equipment and
the conduit system is located in areas with ambient temperatures of 30o C
or less.

In NEC Table 430.250, the motor full-load current that must be


used in the calculations is 77 amps. Using this value we can
size the motor branch circuit and ground fault protection device,
the branch circuit conductors, and the motor disconnecting
means.

Motor branch circuit and ground fault protection devices are to


be sized as outlined in Part IV of NEC Article 430 with maximum
settings as provided in NEC Table 430.52. Actual settings
should reflect the recommendation of the manufacturer of the
motor control equipment that will be provided.

For example, the following are General Electric's recommendations:

Device type Rating


Magnetic only circuit breaker 100 amp
Thermal magnetic breaker 125 amp
Time delay fuses 90 amp

Branch circuit conductors shall be sized in accordance with the


requirements of Part II of NEC Article 430. NEC Paragraph
430.22 requires that conductors supplying a motor must have
an ampacity not less than 125 percent of the full-load current of
the motor. A special exception is made for motors that are
operated intermittently for short periods of time.

Motor branch circuit ampacity shall be equal to or greater than:

77 amps x 1.25 = 96.25 amps

Conductor size to be No. 1 AWG copper with RHH insulation


No. 1 AWG = 110 amps at 60o C

Note: 60o C ampacity rating of conductors No. 1 AWG and smaller must
be used unless the engineer is sure that all terminals are rated for use at
75o C--see the Underwriters Laboratories, Inc. General Information
Directory for more details on this subject.

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Motor disconnecting means shall be sized in accordance with


the requirements of Part IX of NEC Article 430. The discon-
necting means for motor circuits rated 600 volts, nominal, or
less, shall have an ampere rating of at least 115 percent of the
full-load current rating of the motor.

Motor disconnecting means shall be sized greater than:

77 amps x 1.15 = 88.5


Disconnect to be rated 100 amps

See Table 2-1 for the conduit and conductor requirements for
motors typically found in design projects.

2.3.5.2 Example No. 2. Conditions: Determine the size of the feeder


conductors and thermal magnetic circuit breaker feeding a motor control
center that has a total connected motor load of 215 amps with the
uppermost 60-hp motor being the largest motor. In addition, there are
45 amps of continuous load and 65 amps of noncontinuous load.
Conductors shall be copper with type RHH/RHW insulation installed in an
area where the ambient temperature is less than 30o C. Assume all
motors are 460 Volt, 3 phase and 1800 rpm.

Motor feeder conductors shall be sized in accordance with applicable


portions of Part II of NEC Article 430 and feeder breakers shall be sized
in accordance with applicable portions of Part V of NEC Article 430.

NEC paragraph 430.24 requires that the conductors supplying the motor
control center have an ampacity not less than 125 percent of the full-load
current rating of the highest rated motor plus the sum of the full-load
current ratings of all other motors in the group, as determined by
Paragraph 430.6(A), plus the ampacity required for the other loads.

The required ampacity of the conductors shall be calculated as follows:

Total motor load + 25% of largest motor FLA + noncontinuous


load + 125% of continuous load

or 215 + (.25 x 77) + 65 + (1.25 x 45) = 355 amps

Conductors may be either one 500 kCMIL or two No. 3/0 AWG
per phase (one 500 kCMIL = 380 amps, two No. 3/0 =
400 amps).

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NEC Paragraph 430.62 covers the requirements for sizing the motor
feeder short-circuit and ground-vault protection.

NEC Paragraph 430.63 covers the requirements for sizing the feeder
protection when the feeder supplies a motor load and other power and
lighting loads.

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Table 2-1. Motor Circuit Design Data 480 Volt, Three-Phase Motors

Mcp Starter FLA Conduit Max.


HP FLA Conductor Size
Size Size *1.50 Size Dist.
1/2 3/M 1 1 1.25 3#12,1#12G 3/4” 5,333
3/4 3/M 1 1.4 1.75 3#12,1#12G 3/4” 3,810
1 3/M 1 1.8 2.25 3#12,1#12G 3/4” 2,963
1-1/2 7/M 1 2.6 3.25 3#12,1#12G 3/4” 2,051
2 7/M 1 3.4 4.25 3#12,1#12G 3/4” 1,569
3 7/M 1 4.8 6.00 3#12,1#12G 3/4” 1,111
5 15/M 1 7.6 9.50 3#12,1#12G 3/4” 701
7.5 15/M 1 11 13.75 3#12,1#12G 3/4” 485
10 30/M 1 14 17.50 3#12,1#12G 3/4” 381
15 30/M 2 21 26.25 3#10,1#10G 3/4” 403
20 50/M 2 27 33.75 3#8,1#10G 1” 485
25 50/M 2 34 42.50 3#6,1#10G 1-1/4” 580
30 100/M 3 40 50.00 3#6,1#10G 1-1/4” 493
40 100/M 3 52 65.00 3#4,1#8G 1-1/4” 577
50 100/M 3 65 81.25 3#3,1#6G 1/1/2” 554
60 250/M 4 77 96.25 3#1,1#6G 2” 719
75 250/M 4 96 120 3#1,1#6G 2” 577
100 250/M 4 124 155 3#2/0,1#12G 2” 611
125 250/M 5 156 195 3#3/0,1#12G 2-1/2” 577
150 300 5 180 225 3#4/0,1#12G 2-1/2” 615
200 400 5 240 300 3#350Kcm,1#3G 3” 600

Notes:1) Conductor ampacity is based on 60 C through size No. 1 AWG and


on 75 C above size No. 1 AWG.
2) Use thermal/magnetic circuit breakers in all autotransformer type
starters.
3) Conduit size is based on NEC Table 4 and 5, and areas are based
on conductor insulation Type RHH/RHW.
4) Conductor size is based on 125% of motor full load current.
5) Maximum distance is based on an allowed voltage drop of 3%.
These distances are calculated using Table 2-3 assuming copper
conductors in rigid metal conduit and a PF of 80%.
6) Ground conductor size (1#_G) shown in conductor size column is
based on NEC Table 250-95.

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For the above example, a 400-amp device would be selected.


For the 400-amp device to be used to protect the 500-kcm
conductors, NEC Paragraph 240.4(B) needs to be invoked.

2.3.6 Power Factor Correction Capacitors


Power factor correction capacitors are installed for either one of the
following reasons:

x To increase the measured power factor at the serving


utilities meter and reduce the power factor penalty being
imposed by the utility. Power factor correction for this
reason cannot be justified unless the serving utility actually
has a power factor penalty in their rate schedule.

x To release additional capacity in existing feeder conductors.

For example, a three-phase load of 200 kW would be equal to 301 amps


at 480 volts if the power factor were 80 percent, but would be only 254
amps if the power factor were raised to 95 percent. This would release 47
amps of capacity for additional loads.

Article 460 of the NEC covers the installation of capacitors on electric


circuits. In this section those calculations needed to determine the size of
the capacitor required and the size of conductors required to connect the
capacitors to their electric power supply will be discussed. Following are
several examples to illustrate the required calculations:

2.3.6.1 Example No. 1. Conditions: A load of 200 kVA exists at


480 volts with a power factor of 80 percent. Determine the amount of
capacitors required to improve the power factor to 95 percent.

Power factor = Real power (kW) y


Apparent power (kVA) (Eq. 2-29)

Figure 2-1 is provided to show the relation that exists between apparent
power, real power, and reactive power (kvar). By definition, the power
factor is the cosine of the angle that exists between the real power and
apparent power phasors.

The calculation to determine the amount of capacitance (measured in


kvar) shall be made as follows:

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RESULTANT REACTIVE
REAL POWER (KW)
POWER (kV AR)

T1

T2
RESULTANT POWER
SUPPLIED BY CAPACITATORS
APPARENT POWER (kV AR)
(kVA)

REQUIRED
REACTIVE POWER
(kV AR)

Figure 2-1. Relation Between kVA, kW, and kvar

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kvar @ initial power factor = [(kVA)2 - (kW)2 ]1/2 (Eq. 2-30)


or [(kVA)2 - (kVA X PF)2]1/2 (Eq. 2-31)

kvar = [(200kVA)2 - (160kW)2]1/2


kvar = (40,000 - 25,600)1/2 = 120 kvar

Because the real power of a load is not changed when the power factor is
improved, we can use the known real power and desired power factor to
calculate the new kvar value in the phasor triangle.

kvar @ 95% power factor = [( kW y PF)2 - (kW)2] 1/2 (Eq. 2-32)


kvar = [(160 y .95)2 - (160)2]1/2
kvar = (28,366 - 25,600)1/2 = 52.6
Required kvar for correction = 120 - 52.6 = 67.4 kvar

Similar calculations can be made to determine the size of the capacitor


required to improve the power factor of a single motor to a higher power
factor, but tables are available from capacitor manufacturers to simplify
the selection of these capacitors. Capacitors larger than the maximum
size recommended by motor manufacturers must not be installed.

2.3.6.2 Example No. 2. Conditions: Load is a 60-hp, 1,800-rpm motor


operating at 480 volts, three-phase. Capacitors rated 15 kvar at 480 volts
are being installed to improve the power factor. Determine the size of the
conductor needed to meet the requirements of the NEC.

NEC Paragraph 460.8 contains two criteria that must be met when sizing
branch circuit conductors to capacitors. First, the ampacity of the
conductors must be at least 135 percent of the rated current of the
capacitors. Second, if the capacitors are connected to a motor circuit, the
conductors to the capacitor shall have an ampacity not less than one third
of the ampacity of the motor branch circuit conductors.

Capacitor rated amps = 15 y (0.48 x 1.73) = 18

Branch circuit amps = 18 x 1.35 = 24.4 minimum

Motor branch circuit amps = 1.25 x 77 = 96.25

Need to use No. 1 AWG at 110 amps (60o C ampacity)

Capacitor branch circuit amps as one-third of motor branch


circuit conductor ampacity = 110 y 3 = 36.7 amps

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Therefore, the branch circuit conductors to the capacitor must


have an ampacity of 37 amps or greater.

Refer to the Industrial Power Systems Handbook by Beeman or Electrical


Systems Analysis and Design for Industrial Plants by Lazar for additional
formulas related to the application of capacitors on electrical systems.

2.3.7 Transformer Primary and Secondary Conductors


Article 450 of the NEC, Transformers and Transformer Vaults, covers the
installation of all transformers. Article 450 deals with transformers over
600 volts nominal and transformers 600 volts, nominal, and less. The
calculations most often made during an electrical system design are for a
transformer 600 volts, nominal, or less with both primary and secondary
protection.

The following calculations and Table 2-2 are based on the provisions of
NEC Paragraph 450.3(B). Primary conductors and feeder overcurrent and
ground fault protection devices (feeder breakers) are sized for the next
larger device above 150 percent of the transformer full-load amps to
minimize the possibility of the feeder breaker tripping on transformer
inrush (NEC would allow breaker to be sized up to 250 percent of primary
full load amps). The secondary conductors and secondary breaker are
sized at the standard rating that is nearest to 125 percent of the calculated
secondary full load current as required by the NEC. Note 1 to Table
450.3(B) of the NEC allows moving up to the next higher standard rating.
Following are two examples to show the calculations that are required for
three-phase and single-phase transformers.

2.3.7.1 Example No. 1. Conditions: Assume a 45-kVA 3-phase


transformer with a 480-volt primary and a 208Y/120-volt secondary.

Calculate primary full-load amps:


45 kVA y [(480 volts x 1.73) y 1000] = 54.2 amps

Calculate required feeder breaker and conductor ampacity:


54.2 amps x 1.5 = 81 amps

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Table 2-2. 480-Volt Lighting Transformer Circuit Design Chart (75q C)

Transformer Primary Circuit Secondary Circuit

KVA Phase Volts Amps Ckt. Amps Ckt. Conduit & Wire Ckt. Breaker Volts Amps Ckt. Amps Ckt. Conduit & Wire Ckt. Breaker

5 1 480 10 15.00 3/4" C-2# 12,1#8G 20A/2P 240 21 26.25 3/4" C-3# 10,1#8G 30A/2P

7.5 1 480 16 24.00 3/4" C-2# 10,1#8G 25A/2P 240 31 38.75 1" C-3# 8,1#8G 40A/2P

10 1 480 21 31.50 1" C-2# 8,1#8G 30A/2P 240 42 52.50 1 1/2" C-3# 6,1#8G 60A/2P
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15 1 480 31 46.50 1 1/4" C-2# 6,1#8G 50A/2P 240 63 78.75 1 1/2" C-3# 4,1#8G 80A/2P

25 1 480 52 78.00 1 1/4" C-2# 3,1#8G 80A/2P 240 104 130.00 2" C-3# 1,1#6G 150A/2P

37.5 1 480 78 117.00 1 1/2" C-2# 1,1#6G 125A/2P 240 156 175.00 2”6,3#3/0,1#4G 200A/2P

2-18
50 1 480 104 156.00 2" C-2#2/0,1#6G 175A/2P 240 208 260.00 2 1/2" C-3# 4/0,1#2G 250A/2P

9 3 480 11 16.50 3/4" C-3# 12,1#8G 20A/3P 208 25 31.25 1" C-4# 10,1#8G 35A/3P

15 3 480 18 27.00 3/4" C-3# 10,1#8G 30A/3P 208 42 52.50 1 1/2" C-4# 6,1#8G 60A/3P

30 3 480 36 54.00 1" C-3# 6,1#8G 60A/3P 208 83 103.75 1 1/2" C-4# 2,1#6G 110A/3P

45 3 480 54 81.00 1 1/2" C-3# 3,1#8G 90A/3P 208 125 156.25 2 1/2" C-4# 2/0,1#4G 175A/3P

75 3 480 90 135.00 2" C-3#1/0,1#6G 150A/3P 208 208 260.00 2 1/2" C-4# 4/0,1#2G 250A/3P

______________________________________________________________________________________________________________________________________________
Rules Used: 1) Feeder circuit breaker at next size larger than 1.5 times primary amps (NEC 450.3(b) allows up to 250% of primary amps).
2) Panel main breaker sized at next size larger than 1.25 times secondary amps. (NEC 450.3(B) allows up to next larger than 125% of sec. Amps)
3) All conductors No.1 AWG and smaller sized based on 60q C ampacities, larger conductor sizes based on 75q C ampacities. (Conductors sized per
NEC 240-4 including exceptions.
4) Minimum ground conductor sized at #8; Table 250.122 used for other primary side grounds and Table 250.66 used for secondary side grounds.
5) Conduit size based on NEC Chapter 9 Table 3C.
______________________________________________________________________________________________________________________________________________
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Use a 90-amp breaker and No. 3 AWG copper conductors*

Calculate secondary full-load amps:


45 kVA y [(208 volts x 1.73) y 1000] = 125.06 amps

Calculate required secondary breaker size and conductor


ampacity: 125.06 amps x 1.25 = 156.3 amps

Use a 150-amp breaker and No. 1/0 copper conductors*

Note: This selection limits the continuous load that can be


supplied by the transformer to 43.2 kVA ((80% x 208 volts x
150 amps x 1.73) y 1000).

The ground conductors for the above circuits shall be sized in


accordance with NEC Tables 250.66 and 250.122. The ground
conductor in the feeder to the primary shall be sized as an
equipment ground in accordance with NEC Table 250.122. The
grounding electrode conductor on the secondary of the trans-
former shall be sized as required by NEC Paragraph 250.30
using Table 250.66.

2.3.7.2 Example No. 2. Conditions: Assume a 25-kVA single-phase


transformer with a 480-volt primary and a 120/240-volt secondary.

Calculate primary full-load amps:


25 kVA y (480 volts y 1000) = 52.1 amps

Calculate required feeder breaker size and conductor ampacity:


52.1 amps x 1.5 = 78.1 amps

Use an 80-amp breaker and No. 3 AWG copper conductors*

Calculate secondary full-load amps:


25 kVA y (240 volts y 1000) = 104.2 amps

Calculate required secondary breaker size and conductor ampacity:

104.2 amps x 1.25 = 130 amps

*
Conductor sizes for examples No. 1 and No. 2 are based on the use of 60q C wire for sizes Nos.
14 through 1 AWG and 75q C wire for sizes No. 1/0 and larger as required by the General
Information Directory 1988, published by Underwriters Lab, Inc., because many items of
equipment are still not rated with 75q C terminals in these sizes.

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Use a 125-amp breaker and No. 1 AWG copper conductors*.

2.3.8 Voltage Drop

2.3.8.1 Feeder and Branch Circuits.


Fine-print note No. 4 to NEC Paragraph 210.19 says that branch circuit
conductors must be sized so that voltage drop on the branch circuit does
not exceed 3 percent. Furthermore, it states that the total voltage drop on
feeder conductors plus branch circuit conductors must not exceed
5 percent. Fine-print note No. 2 to NEC Paragraph 215.2(A) would allow
the voltage drop on a feeder to be 3 percent as long as the total voltage
drop to the load is 5 percent or less.

Steady-state voltage drops are caused by current flowing through an


impedance. To calculate steady-state voltage drop, the circuit impedance,
circuit current, and power factor of that current relative to some voltage
must be known. Rigorous methods of calculating voltage drop can be
very involved and complicated and for purposes of ordinary use in
designing power circuits for industrial projects, approximate methods are
generally satisfactory. IEEE Standard 141 (Red Book) gives the
approximate formula for voltage drop as:

V = IR cos ș + IX sin ș (Eq. 2-33)

where:

V = voltage drop in circuit, line to neutral


I = current flowing in conductor
R = line resistance for one conductor in ohms
X = line reactance for one conductor in ohms
ș = angle whose cosine is the load power factor
cos ș = load power factor in decimals
sin ș = load reactive factor in decimals

The voltage drop calculated using this formula must be multiplied by 2 for
single-phase circuits and 1.73 for three-phase circuits.

Calculations using the above formula are not required for most designs

*
Conductor sizes for examples No. 1 and No. 2 are based on the use of 60q C wire for sizes Nos.
14 through 1 AWG and 75q C wire for sizes No. 1/0 and larger as required by the General
Information Directory 1988, published by Underwriters Lab, Inc., because many items of
equipment are still not rated with 75q C terminals in these sizes.

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because the results obtained using published tables give satisfactory


results. The following calculations were made using Table 2-3 which is a
reproduction of Table 3-12 of IEEE STD 141-1993 and the procedure for
making the calculations that accompanies Table 3-12. Similar results can
be obtained using published tables and graphs available in other reference
books and manufacturer's catalogs.

2.3.8.2 Example. Condition: No. 1 AWG copper conductors feeding a


motor rated 60 hp (77 amps full-load), three-phase, 460 volts through rigid
metal conduit with a circuit length of 520 feet. Assume that the motor
power factor is 85 percent.

Calculate voltage drop on a three-phase circuit from Table 2-3.


The factor for No. 1 AWG copper conductors in magnetic
conduit at 85 percent PF = 2.7 (need to interpolate between 0.8
and 0.9 PF)

Voltage drop = ((520 ft x 77 amps) y 10000)


x 2.7 volts drop = 10.8 volts

Calculate percent voltage drop by dividing the calculated volts


drop by the system voltage and then multiplying by 100:
(10.8 volts y 480 volts) x 100 = 2.25 % drop

Factors are provided at the bottom of Table 2-3 and are to be used to
convert the calculated voltage drop to single-phase line-to-line and single-
phase line-to-neutral values.

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Table 2-3. Three-phase line-to-line voltage drop for 600 V single-conductor cable
Per 10 000 A-ft (60q C conductor temperature, 60 Hz)

Wire size (AWG or kemil)

ESD-106
Load Power
factor
Lagging 1000 900 800 750 700 600 500 400 350 300 250 4/0 3/0 2/0 1/0 1 2 4 6 8* 10* 12* 14*
Section 1: Copper conductors in magnetic conduit
1.00 0.28 0.31 0.34 0.35 0.37 0.42 0.50 0.60 0.68 0.78 0.92 1.1 1.4 1.7 2.1 2.6 3.4 5.3 8.4 13 21 33 53
0.95 0.50 0.52 0.55 0.57 0.59 0.64 0.71 0.81 0.88 1.0 1.1 1.3 1.5 1.9 2.3 2.8 3.5 5.3 8.2 13 20 32 50
0.90 0.57 0.59 0.62 0.64 0.66 0.71 0.78 0.88 0.95 1.1 1.2 1.3 1.6 1.9 2.3 2.8 3.4 5.2 8.0 12 19 30 48
0.80 0.66 0.68 0.71 0.73 0.74 0.80 0.85 0.95 1.0 1.1 1.2 1.4 1.6 1.9 2.3 2.6 3.2 4.8 7.3 11 17 27 43
0.70 0.71 0.73 0.76 0.78 0.80 0.83 0.88 0.97 1.0 1.1 1.2 1.3 1.5 1.8 2.1 2.5 3.0 4.4 6.6 9.9 15 24 38

Section 2: Copper conductors in nonmagnetic conduit


1.00 0.23 0.26 0.28 0.29 0.33 0.38 0.45 0.55 0.62 0.73 0.88 1.0 1.3 1.6 2.1 2.6 3.3 5.3 8.4 13 21 33 53
PROJECT DESIGN ELEMENTS

0.95 0.40 0.43 0.45 0.47 0.50 0.54 0.62 0.71 0.80 0.92 1.0 1.1 1.5 1.8 2.2 2.7 3.4 5.3 8.2 13 20 32 50
0.90 0.47 0.48 0.52 0.54 0.55 0.59 0.68 0.76 0.85 0.95 1.1 1.1 1.5 1.8 2.2 2.7 3.3 5.1 7.9 12 19 30 48
0.80 0.54 0.55 0.57 0.59 0.62 0.66 0.73 0.81 0.88 0.97 1.1 1.1 1.4 1.7 2.1 2.5 3.1 4.7 7.2 11 17 27 43
0.70 0.57 0.59 0.62 0.64 0.66 0.69 0.74 0.83 0.88 0.97 1.1 1.1 1.4 1.6 2.0 2.4 2.8 4.3 6.4 9.7 15 24 38

Section 3: Aluminum conductors in magnetic conduit


1.00 0.42 0.45 0.49 0.52 0.55 0.63 0.74 0.91 1.0 1.2 1.4 1.7 2.1 2.6 3.3 4.2 5.2 8.4 13 21 33 52 --
0.95 0.62 0.65 0.70 0.73 0.76 0.83 0.94 1.1 1.2 1.4 1.6 1.8 2.3 2.7 3.4 4.2 5.3 8.2 13 20 32 50 --
0.90 0.69 0.72 0.76 0.79 0.82 0.88 0.99 1.2 1.3 1.4 1.6 1.9 2.3 2.7 3.4 4.1 5.1 7.9 12 19 30 48 --
0.80 0.76 0.80 0.83 0.85 0.88 0.95 1.0 1.2 1.3 1.4 1.6 1.8 2.2 2.6 3.2 3.9 4.7 7.3 11 17 27 43 --
0.70 0.80 0.83 0.87 0.89 0.92 0.98 1.1 1.2 1.3 1.4 1.6 1.7 2.1 2.4 2.9 3.6 4.3 6.5 10 15 24 37 --

2-22
Section 4: Aluminum conductors in nonmagnetic conduit
1.00 0.36 0.39 0.44 0.47 0.51 0.59 0.70 0.88 1.0 1.2 1.4 1.7 2.1 2.6 3.3 4.2 5.2 8.4 13 21 33 52 --
0.95 0.52 0.56 0.60 0.63 0.67 0.74 0.85 1.0 1.1 1.3 1.5 1.8 2.2 2.7 3.4 4.2 5.2 8.2 13 20 32 50 --
0.90 0.57 0.61 0.65 0.68 0.71 0.79 0.89 1.1 1.2 1.3 1.5 1.8 2.2 2.6 3.3 4.1 5.0 7.9 12 19 30 48 --
0.80 0.63 0.66 0.71 0.7 0.76 0.83 0.92 1.1 1.2 1.3 1.5 1.7 2.1 2.5 3.1 3.8 4.6 7.2 11 17 27 42 --
0.70 0.66 0.69 0.73 0.75 0.78 0.83 0.92 1.1 1.1 1.3 1.4 1.6 1.7 2.3 2.8 3.4 4.2 6.4 9.9 15 24 37 --

*Solid conductor. Other conductors are standard.

To convert voltage drop to Multiply by


Single-phase, three-wire, line-to-line 1.15
Single-phase, three-wire, line-to-neutral 0.577
Three-phase, line-to-neutral 0.577

Reproduced from IEEE Std 141-1993, IEEE Recommended Practice for Electric Power
Distribution for Industrial Plants, © 1994, by the Institute of Electrical and Electronics
Engineers, Inc., with the permission of the IEEE.
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PROJECT DESIGN ELEMENTS MWD Electrical Design Manual

2.3.8.3 Motor Starting. The calculations required to determine the


voltage drop on an electrical system because of motor starting are too
complex to be covered in this design guide. The Industrial Power Systems
Handbook by Beeman and Electrical Systems Analysis and Design for
Industrial Plants by Lazar both have very complete sections on this
subject. These calculations are often done as part of a short circuit
analysis using a computer program such as ETAP, because they are very
complex and are based on much of the same information required to do
the short circuit analysis. These calculations should be made based on
the largest motor at each load center to determine if the voltage drop on
motor starting is of such magnitude that it will cause adverse impacts on
other equipment in the system. For instance, a 20 percent voltage dip
could cause control relays to drop out since many of these are only
designed to operate at voltage levels 10 percent below rated voltage.

2.3.9 Short Circuit


The proper selection of protective devices and coordination of their trip
settings is based on short circuit calculations. The calculations required to
complete a detailed short circuit analysis are very complex and beyond
the scope of this design guide. The Industrial Power Systems Handbook
by Beeman, Electrical Systems Analysis and Design for Industrial Plants
by Lazar, the IEEE Std 141-1993, and many other references contain
detailed procedures for performing short circuit analysis.

In those situations where an approximate value of short circuit current is


needed for preliminary design purposes, the following abbreviated method
can be used to determine a very conservative value. In every situation
where this method is used, a detailed calculation, either made by hand or
using an approved computer program, shall be made during final design.

Calculations to determine an approximate value of symmetrical short


circuit current in a power distribution system are shown in the following
example:

2.3.9.1 Example. Conditions: The load will be served by a 1,500-kVA


transformer at 480 volts three-phase through a single motor control
center. The fault current available from the utility on the source side of the
transformer is unknown, the transformer impedance is assumed to be
5.75 percent (based on published data), and the motor load on the
transformer is approximately 75 percent of the rating of the transformer.

The current flowing during a fault at any point in an electrical


system is limited by the impedance of the circuits and equip-
ment from the source or sources to the point where the fault has

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occurred. For these simplified calculations we will assume that


the only sources are the transformer and the motors connected
to the system. Figure 2-2 shows that the motors are connected
in parallel with the transformer as impedance with an infinite bus
as the source of the fault current.

The basic formula used to calculate short circuit currents is:

Short circuit current = volts y total impedance


(ohm's law) (Eq. 2-34)

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A point-to-point calculation of short circuit current available at any point


can be made using this formula and it is the basic formula used in the per-
unit method to calculate short circuit current values in electric power
circuits. The reactance of the utility system must be assumed to be zero
and the following simplification can be made to determine short circuit
current let-through by a transformer:

Approximate transformer per-unit Z = (%Z)(base kVA) y [(100)


(transformer kVA)] (Eq. 2-35)

If we let base kVA = transformer kVA, then:

per-unit Z of the transformer = %Z / 100 (Eq. 2-36)

The basic formula for calculating short circuit current when the per-unit
method is used is:

Is.c. rms sym = base kVA y (1.73 x kV x (per-unit Z of the


transformer)) (Eq. 2-37)

Because we have let base kVA = transformer kVA and transformer kVA y
(1.73 x kV) = Transformer load current for three phase transformers, we
can simplify the above formula to:

Is.c. rms sym = Transformer FLA y (%Z y 100) (Eq. 2-38)

Transformer FLA = 1,500 kVA y (0.48 x 1.73) or FLA = 1,806.4


amps (Eq. 2-39)

The resulting short circuit current let through by the transformer in our
example would be:

Is.c.rms sym = 1806.4 y (5.32* y 100)


or Is.c. rms sym = 33,914 amps

*.Note: Published transformer impedances are subject to a ±7.5 percent tolerance. To be


conservative in these calculations, the lower limit of 5.32 percent (5.75 - (0.075 x 5.75)) has been
used.

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The motor contribution to a fault by a single or group of low-voltage


induction motors can be taken as approximately four times the motor full-
load current since the reactance of a low-voltage induction motor,
including the leads, is approximately 25 percent. A point-to-point
calculation made as above for a transformer would result in a multiplier of
4.

Motor load of 75 percent of transformer rating was


given; therefore, motor FLA would be 1,806 x .75 =
1,355 amps.

Is.c. rms sym = 1,355 x 4 = 5,420 amps

The total short circuit current available at the point of the fault
would be the total of the contribution from the transformer plus
the contribution for the motor load

or total Is.c. rms sym = 33,914 + 5,420


or 39,334 amps rms sym

Because neither the serving utilities' source impedance nor the imped-
ances of the interconnecting conductors and equipment are included in
this calculation, this value can be very conservative and must be used
carefully.

2.3.10 Lighting
Lighting calculations shall be made using the recommended procedures
established by the Illuminating Engineering Society and outlined in the IES
Lighting Handbook. Two methods are available for calculating the lighting
levels in a space. The first is the lumen or zonal cavity method and the
second is the point-by-point method. The zonal cavity method is used to
calculate the average footcandle level within the space and the point-by-
point method is used to predict the illumination for a specific visual task.
The following examples are provided to demonstrate these two calculation
methods.

2.3.10.1 Example No. 1--Lumen or Zonal Cavity Method. Conditions:


Design a lighting system for a room 15 feet x 25 feet having an 11-foot
ceiling that will be used for general office work. The ceiling will be lay-in
ceiling tile and the walls will be painted an off-white. The luminaries will be
cleaned regularly and lamps will be group-replaced when the first failures
start to occur.

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Basic equations:

Footcandles = total lumens striking area


square feet of area (Eq. 2-40)

Footcandles = lamps x lumens per lamp x CU x LLF


area (Eq. 2-41)

where:

CU = coefficient of utilization
LLF = light loss factor, which is made up of a number of
factors. The ones to be included in most calculations
are the LLD, LDD, and RSD
LLD = lamp lumen depreciation
LDD = luminaire dirt depreciation
RSD = room surface depreciation

The coefficient of utilization (CU) of a luminaire is calculated by the zonal


cavity method and is a measure of how a specific luminaire distributes
light into a given room. The CU takes into account luminaire efficiency,
candlepower distribution of the luminaire, room size and shape, mounting
height, and surface reflectances. The CU for a specific luminaire must be
obtained from the manufacturer's catalog.

To determine the CU for a specific application, several values must be


determined.

x Effective floor cavity reflectance;


x Effective ceiling cavity reflectance;
x Wall reflectance;
x RCR or room cavity ratio.

Most CU tables are based on a floor cavity ratio (pfc) of 20, so that figure
will be used for this example (Table 2-4).

If the suspension length of the luminaire below the ceiling is zero, which it
is for this example, the ceiling cavity ratio is equal to the ceiling
reflectance. If the luminaire is suspended, a ceiling cavity ratio must be
calculated before the effective ceiling cavity reflectance can be
determined. Reflectance values for various surfaces are available in the
IES Lighting Handbook. For this example, 70 percent will be used.

The wall reflectance of materials can again be obtained from the IES

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Lighting Handbook. For this example, 70 percent will be used.

The room cavity ratio (RCR) must be calculated and it is equal to 2.5 times
the area of the walls divided by the area of the work place.

RCR = (2.5) (room height - work plane height) x perimeter of


walls y area (Eq. 2-42)

The work plane height is the level at which most tasks will be performed
and is assumed to be 30 inches for this example.

RCR = (2.5) (11-2.5) (2 (15+25)) = 4.53


(15) (25)

Table 2-3. Coefficient of Utilization Zonal Cavity Method


4-Lamp
pfc 20
pcc 80 70 50
pw 70 50 30 70 50 30 50 30
RCR
0 76 76 76 74 74 74 70 70
1 70 68 66 69 66 64 64 62
2 65 61 57 64 60 56 58 55
3 60 55 50 59 54 50 52 49
4 56 49 45 55 49 44 47 43
5 51 44 39 50 44 39 42 38
6 48 40 35 46 39 35 38 34
7 44 36 31 43 36 31 35 30
8 40 32 27 40 32 27 31 27
9 37 29 24 36 29 24 28 24
10 35 26 21 34 26 21 25 21
Test No. 7834 S/MH = 1.3.
For 2-lamp: multiply above C.U.s by 1.16.
For 3-lamp: multiply above C.U.s by 1.09.

From the table of coefficients of utilization, the resultant coefficient of


utilization must be interpolated between 0.55 and 0.50.

The resultant CU = 0.523

Before the calculation to determine the number of lamps required can be

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performed, there are still several decisions that must be made.

x Type of lamp to be used; this affects lumens per lamp.


Assume 3150.

x Lamps per luminaire; this affects the coefficient of utilization,


which was calculated. For this calculation, assume four,
which is the basis of the CU table.

x LLD must be determined.

x LDD must be determined.

x RSD must be determined.

x Footcandle level desired must be determined.

Values for LLD, LDD, RSD, and a number of other factors that cause light
loss in the space can be found in the IES Lighting Handbook but for most
calculations dealing with lighting in noncritical areas all of these factors
can be combined into a single factor, which is often referred to as the light
loss factor (LLF). For this calculation, an LLF of 0.75 has been assumed.

Footcandle levels are recommended for a number of applications in the


IES Lighting Handbook. The recommended level for general office work
falls between 50 and 150 footcandles depending on the level of difficulty of
the task. For this calculation, the level required is assumed to be
100 footcandles.

Put all of the numbers into a basic equation (Eq. 2-41) and solve it for the
number of lamps required:

100 = lamps x 3150 x 0.523 x 0.75


15 x 25

No lamps = 30.4

At four lamps/fixture = 7.6 fixtures

Figure 2-3, Zonal Cavity Calculations, provides a form to be used in


making lighting calculation. It, or something similar, shall be used to
document all calculations.

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Project Name: _____________________________________________________________________________

Date: _______________ Room Name: __________________ Reviewed By: _________________________

A. ROOM DATA B. CAVITY DATA C. FIXTURE DATA


Room 1. Length ft Room 9. Height ft 17. Mft.
dimen. 2. Width ft Cavity 10. Ratio 18. Cat. No. etc.
3. Floor area sq ft Ceiling 11. Height ft
4. Ceiling ht. ft Cavity 12. Ratio 19. Lamps per fixture
Surface 5. Ceiling % 13. Eff. Reflectance % 20. Lumens per fixture
Reflect. 6. Wall % Floor 14. Height ft 21. Coeff. Of util (cu)
7. Floor % Cavity 15. Ratio 22. Light loss factor
8. Fixture mounting ht. 16. Eff reflectance % (LLF)
D. FOOTCANDLES E. CALCULATING CAVITY RATIOS
No. of fixtures required to
5 x cavity height x (length + width)
produce a give number of
Cavity ratio =
footcandles Length x width
23. Desired lighting level fc ROOM:
24. No. of tootcandles produced 27. 5 x line 9 x (line 1 + line 2) = 5 x __x (__ + __) = __
line 1 x line 2 __ x __
by a given no. of fixtures
Option A 25. Fixtures fc CEILING:
Option B 26. Fixtures fc 28. 5 x line 11 x (line 1 + line 2) = 5 x __x (__ + __) = __
line 1 x line 2 __ x __
FLOOR:
29. 5 x line 14 x (line 1 + line 2) = 5 x __x (__ + __) = __
line 1 x line 2 __ x __
F. CALCULATING NUMBER OF FIXTURES
Floor are x desired footcandles
30. No. fixtures =
lamps per fixture x lumens per lamp x coeff. Of utilization x light loss factor
31. No. of fixtures = 5 x line 14 x (line 1 + line 2) = 5 x __x (__ + __) = __
line 1 x line 2 __ x __
G. CALCULATING FOOTCANDLES
32. Footcandles = no. of fixture x lamps per fixture x lumens per lamp x
Coeff. Of utilization x maintenance factor
floor area
33. Option A Line 25 x line 19 x line 21 x line 22 = ___ x __x __ x __ = __
line 3 __ x __
34. Option B Line 26 x line 19 x line 21 x line 22 = ___ x __x ___ x ___ = __
line 3 __ x __

Figure 2-3. Zonal Cavity Calculations

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The next task is to lay out the luminaries in the room to determine if they
will fit in a logical arrangement. Since the luminaries are being installed in
a lay-in ceiling, spacing can only be in multiples of 2 feet.

For this example, installation of eight luminaries would require two rows of
four luminaries each.

Spacing across room = 15 y 2 or 8 feet

Between rows and (15 - 8) y 2 or 3.5 feet between wall and


closest luminaire (all dimensions are to centerline)

Spacing length of room = 25 y 4 or 6 feet

Between luminaries in the row and (25 - (3 x 6)) y 2 or 3.5 feet


from the wall to the end luminaries

The footcandle level that results from the number of luminaries to be


installed should then be checked:

Footcandles = (8 x 4) x 3150 x 0.523 x 35 = 105.4


(15) (25)

The maximum spacing of the luminaries shall also be checked against the
mounting height above the work plane (S/MH ratio) to determine if it is
within the ratio of the luminaire being used.

8 ft spacing y 8.5 ft mounting height = 0.94

This is well within the 1.3 S/MH ratio of the luminaire used in the example.

If the luminaries required could not have been fit into the space in a
reasonable layout, or the footcandle levels that resulted from the selected
layout were not acceptable, or the S/MH ratio calculated was not less than
that of the luminaire being used, then the layout would need to be revised
using a luminaire with a different number of lamps or different
characteristics.

The footcandle level calculated tells us the quantity of light that reaches
the work surface. Other factors that affect visual comfort and ability to see
include direct glare, indirect glare, reflected glare, and veiling reflections.
In areas where seeing tasks are critical, these must also be evaluated.

See the IES Lighting Handbook and other lighting design and application

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guides for additional information on these subjects.

2.3.10.2 Example No. 2--Point-by-Point Calculation. Conditions:


Referring to the luminaire layout for Example No. 1, calculate the
footcandle level on a desk located at point No. 1. For this calculation, use
the candlepower distribution table (Table 2-4) and assume that no light is
reflected from the end wall.

Point-to-point calculations are typically used to determine the footcandle


level, either horizontal or vertical, on a specific task location from a point
source or multiple point sources of light. Illumination on the task is
inversely proportional to the square of the distance from the source of
illumination.

Table 2-4. Candlepower Distribution Curve


4-Lamp
Angle End 45o Cross
0 3429 3429 3429
5 3396 3401 3460
15 3293 3328 3401
25 3061 3133 3245
35 2649 2814 2906
45 1982 2051 2188
55 1229 1110 1247
65 681 425 662
75 314 218 306
85 94 90 78

Basic equations:

Footcandles (horizontal plane) Fc(h) =

candlepower x cos ș
distance2 (Eq. 2-43)

Footcandles (vertical plane) Fc(v) =

candlepower x sin ș
distance 2 (Eq. 2-44)
where:

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Candlepower (CP) = the candlepower of the source in the


direction of the ray

Cos ș = height above task (H) y actual distance


from task (D)

Sin ș = horizontal distance from task (R) y D

Using the above data, calculate the horizontal footcandles on the work
surface 4 feet horizontal from the luminaire. (Figure 2-4)

H
8.5 FT

ACTUAL DISTANCE OF
LIGHT SOURCE FROM
TASK POINT

VERTICAL HEIGHT
OF LIGHT SOURCE
FROM WORK SURFACE

WORK SURFACE

R
4 FT

HORIZONTAL DISTANCE
OF LIGHT SOURCE
FROM TASK POINT

Figure 2-4. Calculation for Task Illumination

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D = (H2 + R2)½ = (8.52 + 42)½ = 9.4

Cos ș = H y D = 8.5 y 9.4 = 0.904

ș = Arc cos 0.094 = 25.3o

Use candlepower from Table 2-5 at 25o = 3245

Fc(h) = (3245 x 0.904) y 9.42 = 33.2 fc

To determine the total footcandles on the task, the same calculation must
be made for each luminaire that could contribute to the illumination level.
All of the contributions would then be totaled.

Contribution from the luminaire on the opposite side of the point will be the
same as calculated above. The next pair of luminaries are close enough
that their contribution must also be checked.

Calculate footcandles contributed by one luminaire horizontal


distance F = (42 + 62)½ = 7.2 ft

D = (8.52 + 7.22)½ = 11.14 ft

Cos ș = 8.5 y 11.14 = 0.763

ș = arc cos 0.763 = 40.27o

Use value for candlepower at 45o with respect to the luminaire and
interpolate between 35o and 45o values (Table 2-5).

Use 2420 for candlepower.

Fc = (2420 x 0.763) y (11.14)2 = 14.88 fc

The footcandle level on the task is the sum of the contributions from the
four closest luminaries.

Fc total = (33.2 x 2) + (14.88 x 2) = 96.16 fc

The IES Lighting Handbook contains a table to simplify these calculations.


If you know the mounting height above the work plane and the horizontal
distance from the task, the table provides the angle to be used to enter the
candlepower distribution table and a multiplier to be used with the
resultant candlepower to calculate footcandle contribution on the task by

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the luminaire.

This method is seldom used within a building except where a single


workstation may exist within a larger space where a lower average level of
illumination is required and a higher level is required at the workstation.
This procedure is often used with outdoor lighting systems to determine
the lighting levels on parking lots and roadways. It is the basis used by
luminaire manufacturers in their computer programs for laying out area
and roadway lighting systems.

As previously shown in Figure 2-3, a form can be used in making these


calculations. This form shall be used with data provided by the
manufacturer of the lighting equipment being specified to determine the
lighting levels, in footcandles, for the spaces being illuminated.

2.3.11 Grounding
Grounding system calculations shall be made for substation and other
areas where step potential will be of concern. The subject is too complex
for presentation in this design guide. Grounding system calculations shall
be in accordance with applicable sections of ANSI/IEEE Standard 80.

2.4 DRAWINGS

2.4.1 General
The purpose of a design is to develop a set of instructions and rules
whereby a contractor can bid the project and, if awarded the contract,
build what the designer had in mind. The drawings are a part of that
instruction set and describe the location and quantity of materials and
equipment needed for the project; the text specifications describe the type
and quality of materials and equipment and the quality of workmanship.

2.4.2 Organization
The drawings are generally divided into the following groups and appear in
the order shown below:

x Electrical Legend and Abbreviations;


x Site Plan(s);
x One-Line Diagrams(s);
x Facility Lighting Plan;
x Facility Power Plan;
x Facility Grounding Plan (if needed);
x Equipment Elevations;
x Control Schematic Diagrams;
x Connection Diagrams;

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x Installation Details;
x Electrical Schedules.

A general description of each group or kind of drawings is given on the


following pages.

2.4.3 Legend
The legend is a list of the symbols to be used on the design drawings.
Generally, they are based on the standard legend symbols contained in
NEMA, ICS, and ANSI Standard Y32. Where a design requires the use of
a symbol that is not present on the legend, the symbol shall be added to
the legend if it is used on more than one sheet of the design. If it is used
on only one sheet, it may be described on that sheet. The standard
legend symbols shall be used wherever practical to reduce confusion and
time spent on inventing unnecessary new symbols.

2.4.4 Abbreviations
The abbreviations used on the electrical drawings shall be listed on the
electrical legend sheet to minimize possible confusion with similar
abbreviations that are used on the sheets prepared by other disciplines.
All abbreviations used on the drawings shall be included in the
abbreviations list. Unless a word is used often, it should not be abbrevi-
ated.

2.4.5 Site Plan(s)


The electrical drawings usually include a plan view of the overall project
site that typically shows the following data: relative location of buildings
and structures, exterior raceways and circuits, locations of manholes and
handholes, exterior lighting, and references to the drawings for buildings
and structures that need to be shown in more detail. Often, the large size
of a site requires a scale so small that additional site plans at a larger
scale are required to show the detail required for the design. The single
site plan shall always be provided, but when the scale of the overall site
plan is less than 1 inch = 40 feet, detailed site plans at a larger scale shall
also be provided. The detailed site plans should always be at the same
scale used for process equipment layout if possible; that is, 1 inch = 20
feet or larger. The detailed site plans should be used to show all
equipment wiring and general lighting and the overall site plan should be
used to highlight the locations of switchgear, motor control centers,
transformers, and the ductbank system, including all manhole and
handhole locations. The overall site plan can also be used as a key to the
detailed site plans and detailed plans for buildings and structures.

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2.4.6 One-Line Diagrams


One-line or single-line diagrams are a symbolic representation of the
major electrical components of the electrical system of the project and
their interconnection. All applicable information shall be included on one-
line diagrams as follows.

x Power sources, including voltage and available short circuit


currents;

x Power ratings, voltages, impedances, connections, and


grounding methods of all transformers;

x Protective relay types and sensing connections;

x Frame rating, trip rating, and special features of over-current


and short circuit protection devices;

x Size and type of motor control devices;

x Voltage, enclosure, short circuit, and main bus ampacity


ratings of switchgear assemblies, switchboards, motor
control centers, and distribution panelboards;

x Instrumentation, including instrument transformers, in-


strument switches, voltmeter, and ammeter, with appropriate
ratios and ranges;

x Type and location of surge arresters and capacitors;

x Identification of all loads;

x Identification of all distribution system equipment;

x Key interlock systems;

x Motor sizes;

x Generator--size, voltage, phase, and power factor;

x Function lines to show interaction between components in


the system such as protective device trip functions and
restraints.

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When the electrical distribution system is too large to be shown on a


single drawing, the major components and feeders shall be shown on a
single drawing. Additional one-line diagrams shall be provided for
individual motor control centers as required to show all the loads supplied
from them.

2.4.7 Floor Plans


Two types of building floor plans are used to depict the electrical
requirements for buildings and enclosed structures: the facility lighting
plan and the facility power plan. Although the entire electrical design can
be shown on a single drawing when facility lighting and power
requirements are minimal, separating of floor plans by the kind of work
involved is often a preferred method of design that makes the floor plans
less crowded and easier to read.

The electrical facility power plans show the general location of equipment
to be wired and connected under the electrical specifications, and show
the necessary conductors and raceways associated with the work. For
facilityexpansions, the power plan shall show the interface with existing
facility power system. Symbols used on the drawings are usually not to
scale but, by definition, tell the contractor how a particular device is to be
connected to the electrical system.

Conductor and conduit requirements, definitions, and "homerun"


designations are shown on electrical drawings. In some cases the
conductor and conduit requirements are called out by the symbol used, in
other cases the specific requirements are shown on the drawings, and in
still other cases a code is used. The code definition can be either a small
circuit callout list located on the drawing or a more complete circuit and
raceway schedule for the entire project. The circuit codes and circuit
names must be developed for each specific project.

Lighting, general purpose outlets, special system equipment, connections


to HVAC equipment, and miscellaneous power requirements that are
directly related to the building or structure are shown on the facility
drawings. Luminaire types are identified and located, general purpose
outlets are located, special purpose outlets and power connections are
located and identified, and all conduit and conductor requirements
associated with the above-named equipment is shown. All panelboards
and equipment from which the above luminaire, outlets, and power
connections receive their power supply shall be shown on the drawings, or
the drawings that show them must be referenced.

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2.4.8 Grounding Plan


The grounding Plan should be a separate and complete group of
drawings. The set of drawings should show the below-grade grounding
such as the ground grid including locations of all ground rods. If the
grounding plan is for a facility expansion where electrical service will be
provided by the existing facility, show the interconnection of the facility
expansion ground grid with the existing facility ground grid. The above-
grade grounding should be shown in plan form, indicating which steel
columns, fence or specific equipment require bonding. The type of
grounding connection welded type for below-grade and above-grade or
bolted type of above-grade shall be shown using appropriate symbols as
defined in the legend sheet.

2.4.9 Equipment Elevations


Two-dimensional drawings of control pads, switchboards and motor
control centers, secondary unit substations and switchgear shall show the
arrangement of components of the assemblies. The elevation drawings
are usually nonscale drawings. However, their intent is to determine
general space requirements for the assembly so they need to be laid out
using the dimensions of the equipment being specified. The front
elevations typically show main service and feeder circuit protective
devices, metering, branch circuit protective devices and controllers,
terminal board compartments, and future designated space requirements.

2.4. 10 Control Schematic Diagrams


The purpose of the electrical control schematic diagram is to illustrate
schematically for the equipment supplier and contractor how a system is
controlled. The control schematic diagrams contained in the electrical
drawing set are for I&C panels, motor starters, contactors, etc., that are to
be installed as part of the I&C and electrical systems. Each control
schematic diagram shall show all devices that are to be located on the
panel starter or contactor and all field-installed devices. Control logic that
is provided in a remotely located control panel supplied with equipment
shall be shown as a terminal connection. All interfaces with remote
equipment shall be clearly shown using appropriate symbols and clearly
identified so that the contractor can easily make the interconnections in
the field.

2.4.11 Control Panel Drawings. Control panel drawings provide the


following information to the contractor:

x Panel size;
x Major panel components and their layout;

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x Panel installation.

The following format and content guidelines shall be followed in preparing


control panel drawings:

x Show full views of the front of the panel. (Partial views may
be used for details.)

x Show front and side views as a minimum. Show further


views as needed.

x Show smaller panels (wall mount) as manufactured item


(e.g., Hoffman or equal).

x Show only outlines of instruments and devices. Show future


instruments and controls in phantom.

x Show overall panel dimensions (H,W,D). Dimension the


location of only critical components. Use drawing scale for
location of other components.

x Show conduit and tube entry points.

x Show the mounting of the panel (installation detail).


Preferred mounting of freestanding panel is 3-1/2-inch-thick
concrete pad secured with anchor bolts and holddown clips.

x Show location key plans for each panel and include the
sheet number of the mechanical plan where the panel is
located, building and room names where the panel is
located, title (e.g., LP-XXX LOCATION PLAN), scale
(1s=100c or 1s=50c), panel name (e.g., LP-XX), and north
arrow.

x Note any special features on the drawing (e.g., special


enclosure).

x Include schedules for panel face mounted devices and


annunciators. Include device number (as noted on panel
drawing), tag number, and nameplate or service legend
inscription in the schedules. Annunciator schedules shall
include point location (row-column), alarm tag number, and
annunciator window inscription.

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Refer to Figure 2-5 for an example of a panel drawing.

2.4. 12 Installation Details


Installation details illustrate specific requirements that an
engineer/designer has in mind for construction, installation, or connection
of equipment and/or materials that are better shown by a drawing than by
wordy specifications. Many installation details are provided in the
standard drawing package and should be used whenever possible. If the
engineer/designer encounters a unique situation that requires a special
detail, he or she shall prepare a new detail using materials that are
equivalent to those used in the standard detail and then have the detail
reviewed for constructability and compatibility of materials. Thedetails to
be used shall always be referenced on the plan drawings by either notes
or symbols. Details should, where possible, include notes to indicate the
area and/or circumstances where they apply.

2.4. 13 Electrical Schedules. The electrical drawing package usually


includes some electrical material or equipment listings in schedule format.
Typical schedules provided are:

x Lighting fixture schedule;


x Distribution panel schedules;
x Conduit and cable schedules;
x Special electrical device schedules;
x Pull box and junction box schedule.

On small projects, separate drawings for the schedules may not be


required. They shall be located throughout the drawing set where they are
required. On very large projects, it is better to include all of the schedules
as a supplement to the specifications so they can be found and handled
more easily. The use and presentation of schedules shall be reviewed for
each project. There is no single correct way to prepare and present them.

2.5 PROJECT FILES


Each engineer/designer shall keep a project file that contains all
information received and/or originated by the individual during the
performance of his or her duties on the project. The project file shall
contain a copy of the project instructions and all addenda to it, telephone
conversation record of all phone conversations, copies of all written
correspondence and memorandums, field notes, and copies of all design
calculation prepared as required by paragraph 2.3, Design Calculations.
The project files shall be kept in a notebook with identified divider tabs.

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At the completion of the project, each individual shall purge the file of the
project instructions and other memos that were originated by other team
members and submit the purged project files to the project manager for
inclusion in the overall project file. Any memos, instruction sets, and
similar items prepared by the individual shall be left in his or her project file
so that originals of all material prepared or used on the project are
contained within the overall project files.

24” 8”

FULL LENGTH 1
PIANO TYPE 2
HINGE 3 6 9

4 7 10

5 8 11

12 15 18

13 16 19
30”

14 17 20
21 24 27
22 24 25
23 24 29

30

31

32

33

FRONT SIDE
SCALE 1 ½“ = 1’-0” SCALE 1 ½“ = 1’-0”

Figure 2-5. Example Panel Drawing

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Chapter 3

STANDARD ELECTRICAL
DESIGN PROCEDURES MWD Electrical Design Manual

ŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮŮ

Note: All references to the National Electrical Code (NEC) are based on
the 2005 Edition of the NEC.

3.1 GENERAL APPROACH


Because no single electrical system is adaptable to all projects, the
specific requirements of each project must be analyzed and the electrical
system designed to meet those needs. Any approach to providing the
required design shall include several considerations that will affect the
overall design. First, safety of personnel and preservation of property are
important factors in the design of electrical systems. Second, reliability
and continuity of service is of utmost importance.

This chapter discusses many of the basic decisions that shall be made
during a design, identifies reference sources that shall be used to help
make those decisions, and outlines the materials that shall be used in
implementing those decisions.

3.1.1 Types of Electrical Systems


Electric power is distributed through a network of conductors and electric
circuit protective and control equipment from its source of supply in the
serving utility to the utilization equipment located on the premises. This
assembly of conductors and equipment is called the electrical distribution
system and is the main subject of this design guide; other subjects
covered include motor controls, lighting, and special systems such as
telephone, paging, and fire alarm.

3.1.2 References
There have been a number of codes, standards, and handbooks prepared
on the basic subjects covered by this design guide. A brief list of some of
the more applicable references, many of which have been used in the
preparation of this design guide are contained in Appendix A. The latest
edition of each of these references shall be used.

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3.1.3 Plant Distribution Systems


A variety of basic circuit arrangements is available for industrial plant
power distribution. Selection of the best system or combination of systems
will depend upon the needs of the plant process. In general, system costs
increase with system reliability if component quality is equal.

The first step is the analysis of the plant process to determine its reliability
need and potential losses and costs in the event of power interruption.
Some plant processes are minimally affected by interruption. Other plant
processes may sustain long-term damage or experience excessive cost
by even a brief interruption, therefore, a more complex system with an
alternate power source for critical loads may be justified.

3.1.3.1 Simple Radial System


Figure 3-1 shows a simple radial system where the distribution is at the
utilization voltage. It is the simplest and lowest cost way of distribution
power. A single primary service and distribution transformer supply all the
feeders. This system is satisfactory for small industrial installations where
process allows sufficient down time for adequate maintenance and the
plant can be supplied by a single transformer.

3.1.3.2 Expanded Radial System


Figure 3-2 shows an expanded radial system. The advantage of a simple
radial system may be applied to larger loads by using an expended radial
primary distribution system to supply a number of unit substations located
near the load, which in turn supply the load through radial secondary
systems. This system provides better voltage conditions, lower system
losses, less expensive installation cost than using relatively long, high-
amperage, low-voltage feeder circuits.

3.1.3.3 Primary Selective System


If pairs of substations are connected through a secondary tie circuit
breaker, the result is a secondary selective system (see Figure 3.3). Each
unit substation is connected to two separate primary feeders through
switching equipment to provide a normal and an alternate source. Upon
failure of the normal source, the distribution transformer is switched to the
alternate source. Switching can be either manual or automatic, but there
will be an interruption until load is transferred to the alternate source. Cost
is somewhat higher because of duplication of primary cable and
switchgear.

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3.1.3.4 Secondary Selective System (Double-Ended Substation with


Single Tie)
If pairs of substation are connected through a secondary tie circuit
breaker, the result is a secondary selective system (See Figure 3.4).
Under normal conditions, the system operates as two separate radial
systems with the secondary bus-tie circuit breaker normally open. A key
interlock system is used to prevent parallel operation of the transformers.
Maintenance of primary feeders, transformer, and main secondary
disconnection means is possible with only momentary power interruption.
If the primary feeder or transformer fails, supply is maintained through the
secondary tie circuit breaker. To allow for this condition, the following
should be considered:

x Oversizing both transformers so that one transformer can


carry the total load
x Providing forced-air cooling to the transformer in service for
the emergency period
x Shedding nonessential load for the emergency period
x Using the temporary overload capacity in the transformer
and accepting the loss of transformer life.

The double-ended substation with single tie configuration is the preferred


method of power distribution in the Metropolitan’s water treatment plants.
Primary power is distributed at 4160 volts to the substation and secondary
power is distributed at 480 volts from the substation to motor control
centers and switchboards.

3.1.3.5 Secondary Selective System (Individual Substations with


Interconnecting Ties)
Figure 3-5 shows modified secondary selective system with only one
transformer in each secondary substation. Adjacent substations are
interconnected in pairs by normally low-voltage tie circuit. When the
primary feeder or transformer supplying one secondary substation bus is
out of service, essential loads on that substation bus can be supplied over
the tie circuit. Operation of the system is somewhat complicated if the two
substations are separated by distance. A key interlock system would be
required to avoid typing two substations together while they are both
energized.

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BUS DUCT

PANEL

FIGURE 3-1 SIMPLE RADIAL SYSTEM

FIGURE 3-2 EXPANDED RADIAL SYSTEM


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FIGURE 3-3 PRIMARY SELECTIVE SYSTEM

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SECONDARY
UNIT
SUBSTATION

FIGURE 3-4 SECONDARY SELECTIVE SYSTEM


(DOUBLE-ENDED SUBSTATION WITH SINGLE TIE)

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SECONDARY SECONDARY
UNIT UNIT
SUBSTATION SUBSTATION

FIGURE 3-5 SECONDARY SELECTIVE SYSTEM


(INDIVIDUAL SUBSTATIONS WITH INTERCONNECTING TIES)

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3.1.4 Voltage Considerations
ANSI/IEEE Std 141 refers to ANSI C84.1 for nominal standard system
voltages and their associated tolerances. The standard defines three
voltage classes:

x Low voltages are used to supply utilization equipment and


are 1,000 volts and less.
x Medium voltages are used as primary distribution voltages
to supply stepdown transformers to low-voltage systems
and are greater than 1,000 volts but less than
100,000 volts. Medium voltages of 13,800 volts and less
are also used to supply utilization equipment such as large
motors.
x High voltages are used to transmit large amounts of
electrical power between transmission substations, and are
higher than 100,000 volts.

The nominal voltage of the systems covered by this design guide will be in
either the low or medium voltage class. Table 3-1, Standard Nominal
System Voltages and Voltage Ranges in Chapter 3 of ANSI/IEEE Std 141-
1993 lists the standard and nonstandard nominal system voltages within
all three of the voltage classes. The table uses a system voltage
nomenclature that describes how the nominal voltage is supplied.

A single-number, single-phase voltage, such as 120 volts, indicates a two-


wire single-phase system where the voltage indicated is the nominal
voltage between the two wires.

A single-number, three-phase voltage, such as 480 volts, indicates a


three-wire, three-phase system where the voltage designates the nominal
voltage between any two phase wires.

A two-voltage designation where the smaller number is first, such as


120/240, indicates a single-phase three-wire voltage in which the nominal
voltage between phase conductors is 240 volts and the nominal voltage
between either phase conductor and neutral is 120 volts.

If the two numbers are reversed with a Y between, such as


480Y/277 volts, a three-phase four-wire system supplied by a wye
connected transformer is indicated. The first number indicates the
nominal phase-to-phase voltage and the second number indicates the
nominal phase-to-neutral voltage.

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3.1.5 Voltage Selection


The preferred utilization voltage for industrial plants is 480Y/277 volts,
three-phase, four-wire. Three-phase loads can then be supplied at 480
volts with single-phase loads such as high bay lights supplied at 277
volts. Small dry-type transformers rated 480-120/240 or 208Y/120 are
then provided to supply 120-volt lighting and convenience receptacles.
The three-phase 208Y/120 volt utilization voltage is preferred except
where only very small loads are involved because it also allows small
three-phase loads to be supplied and it balances the loads on the
480Y/277 volt system. Where double-ended unit substations with tie
breakers are used, loads shall not be connected phase-to-neutral on the
480-volt system to simplify the ground fault protection scheme. Where
individual loads of 500 kVA or more must be supplied, 4,160 volts should
be considered for the utilization voltage for this equipment.

Power distribution voltage within a plant site is often dependent on the


supply voltage available from the serving utility. In a case where the load
on the plant site is small and located in a concentrated area, service from
the utility at 480Y/277 volts shall be specified. Larger sites where the
loads are spread out and a number of unit substations will be required
shall be supplied at a higher voltage. If there are large motors that could
be supplied at a higher voltage, the distribution voltage shall be selected
to supply the large motors without additional transformation. This would
make 4,160 volts three-phase the preferred distribution voltage unless
very large motors are involved.

3.1.6 Voltage Rating


Most electrical utilization equipment has a nameplate voltage that matches
the nominal supply voltage for which the equipment is designed. Motors
are the exception. Motors designed for connection to a 480-volt three-
phase system are rated 460 volts three-phase. Similar differences are
found in the ratings for motors designed for operation on 120-volt,
208-volt, 240-volt, and 4,160-volt systems. See Table 3-7 in Chapter 3 of
ANSI/IEEE Std 141-1993 for the nameplate voltages of motors as
specified in NEMA MG1. Table 3-8 in Chapter 3 of ANSI/IEEE Std 141-
1993 also contains information on the effect of voltage variations on the
operation of motors and other equipment.

3.1.7 Protection/Coordination Philosophy


The primary objectives of electrical system protection and coordination are
to prevent injury to personnel, to minimize damage to the system
components, and to limit the duration of outages that result from the
operation of the system protective devices. Protection of personnel and
equipment shall be given first consideration and then coordination of
devices within the system to limit the extent of service interruptions.

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3.1.7.1 Protection Equipment. The electrical system components


shall be protected against overcurrent, phase to phase faults, and phase
to ground faults. There are two basic types of equipment available to
perform these protection functions: the fuse and the circuit breaker. There
are a variety of devices that fall within these two broad categories, and in
this design guide we will only review a few of them.

A. Fuses. A fuse may be defined as a device that protects a


circuit by fusing open its current-responsive element when an
overcurrent or short circuit passes through it. It combines both
the direct sensing and interrupting elements in one self-con-
tained device. A fuse is also direct-acting in that it responds to
a combination of magnitude and duration of circuit current
flowing through it, it is single phase, it is nonresettable, and it is
not capable of being used to interrupt a circuit during normal
operation. It must be used in conjunction with a switch for
normal circuit interruption.

B. Low Voltage Circuit Breakers. The NEC defines a circuit


breaker as a "device designed to open and close a circuit by
nonautomatic means and to open the circuit automatically on a
predetermined overcurrent without injury to itself when properly
applied within its rating." Low voltage circuit breakers have
contacts to interrupt the circuit that are isolated from the thermal
or solid state elements, which determine that an overcurrent
condition has occurred. Low voltage circuit breakers are
divided into two basic classes and three types.

1. Classifications:
a. Low-voltage power circuit breakers
b. Molded-case circuit breakers
2. Types:
a. Low-voltage power circuit breakers (LVPCBs)
b. Molded-case circuit breakers (MCCBs)
c. Insulated-case circuit breakers (ICCBs)

Low-voltage power circuit breakers are open-construction


assemblies on metal frames with all parts designed for
accessible maintenance, repair and ease of replacement. They
are intended for service in switchgear compartments or other
enclosures of dead-front construction. Tripping units are
electromagnetic overcurrent direct-acting type or solid-state
type. Solid-state trip units are preferred because of the wide
range of adjustments through use of interchangeable trip rating
plugs, tripping selectively and accurately.

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Molded-case circuit breakers are switching devices and


automatic protective devices assembled in an integral housing
of insulating material. These breakers are generally capable of
clearing a fault more rapidly than power circuit breakers and are
available in the following general types:

x Thermal magnetic—employs thermal tripping for overloads


and instantaneous magnetic tripping for short circuits
x Magnetic—employs only instantaneous magnetic tripping
where only short-circuit interruption is required
x Integrally fused—combines regular thermal magnetic
protection against overloads and lower value short-circuit
faults with current-limiting fuses responding to higher short-
circuit currents.
x Current-limiting—provides high interruption rating
protection, plus it limits let-through current and emergency
to a value significantly lower than the corresponding value
for a conventional molded-case circuit breaker.

Molded-case circuit breakers are generally not designed to be


maintained in the field as such are sealed to prevent tampering.

Insulated-case circuit breakers utilize characteristics of design


from both power and molded-case types. The frame size of this
type of breakers I larger than the same size for molded-case
breakers. The trip unit can be interchanged, and the breaker
can be designed to fix-mounting as well as with drawout
configuration. The interruption duty of this type of breaker can
be faster than that of molded-case breakers but not fast enough
to be a current limiting type. Insulated-case circuit breakers are
partially field-maintainable.

C. Medium Voltage Circuit Breakers. Circuit breakers for 5- and


15-kV systems are available in either of two types of
construction. The air magnetic contactor type has been the
standard of the industry for a number of years. Recent changes
in technology have resulted in the manufacture of vacuum and
SF6 interrupter circuit breakers. Vacuum interrupter circuit
breakers are currently the standard for 5- and 15-kV class circuit
breakers. They are integrated with protective relays as may be
required for the application, and are installed in switchgear
assemblies. They are available in 1,200-, 2,000-, and
3,000-ampere ratings at both 5- and 15-kV.

3.1.7.2 Application.

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Circuit breakers shall be used to provide overcurrent and short circuit
protection on the 4.16-kV distribution systems in water treatment plants
and as primary protection for medium voltage transformers. Circuit
breakers shall also be used on the load side of all transformers. Fuses
shall be used in combination with circuit breakers where current limiting
protection is required.

A. Low Voltage Systems. Protection for low voltage systems


shall be provided by the use of a combination of low voltage
circuit breakers.

x Motor branch circuit breakers installed as part of a


combination motor starter shall be magnetic-only type.

x Motor branch circuit breakers installed as part of a reduced


voltage starter or to feed an adjustable frequency drive unit
shall be thermal magnetic type. Provide adjustable magnetic
trip units for all sizes for which they are available.

x Branch and feeder circuit breakers 225 amps and smaller


shall be thermal magnetic type. Adjustable magnetic trips
shall be specified for all frame sizes where they are
available.

x Larger branch circuit breakers shall also be the thermal


magnetic type with adjustable magnetic trip units.

x Feeder circuit breakers from 225 amps through 800 amps


shall be molded case with solid state trip units.

x Feeder circuit breakers larger than 800 amps shall be


molded case with solid state trip units and 100 percent load
rating.

x Transformer secondary and service entrance circuit breakers


600 amps and less with no subfeed breakers rated 225
amps or more shall be molded case thermal magnetic type
with adjustable magnetic trip units.

x Transformer secondary and service entrance circuit breakers


rated 400 or 600 amps with subfeed breakers rated 225
amps or more and all similar breakers larger than 600 amps
shall be low voltage power circuit breakers with solid state
trip units. Breakers 1,000 amps and larger shall also be
100 percent load rated.

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x Secondary unit substation main and feeder circuit breakers
800 amp frame and larger shall be insulated case circuit
breakers with solid state trip devices.

x Low voltage motor control center main circuit breakers shall


be insulated case circuit breakers with solid state trip
devices.

B. Low Voltage Ground Fault Protection. Ground fault


protection shall be provided on all transformer secondary and
service entrance breakers rated 600 amperes or more, all
feeder breakers rated 400 amps or more that are downstream of
a circuit breaker equipped with ground fault protection. Ground
fault protection on transformer secondary and service entrance
circuit breakers and feeder breakers shall have adjustable time
delays and shall be zone selective interlocked to minimize
outage to the zone nearest the ground fault.

C. Medium Voltage Systems. Protection for medium voltage


systems shall be specified to be metal clad switchgear with
vacuum interrupter type circuit breakers. All medium voltage
main and feeder circuit breakers shall be equipped with time
and instantaneous phase overcurrent and time and
instantaneous ground overcurrent as a minimum. Motor branch
circuits shall have thermal overload relays with instantaneous
overcurrent trip attachments, undervoltage and phase sequence
relay, and overcurrent ground relay with instantaneous trip
attachments as a minimum. This protection for motor branch
circuits may be provided by a solid state motor protection
module that also incorporates optional modules to monitor
motor and bearing temperature.

3.1.7.3 Coordination. Coordination is the selecting or setting, or both,


of protective devices to minimize the portion of a power distribution system
that is affected by a fault within the system. Although maximum effort
needs to be made to select and set protection equipment to provide
coordination, protection of personnel, and minimization of equipment
damage must be considered first.

Safety of life is always the most important consideration. The system shall
preserve the safety of the general public and be capable of safe operation
by plant personnel. The second consideration should be the preservation
of property. Next, the need for reliability must be balanced against the
cost of providing the electrical system that provides the level of reliability
desired. If the impact of a short outage has little affect on the cost of plant
operation, additional expense to provide a fully coordinated system is

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probably not justified. Should a short outage adversely affect the cost of
plant operation, then the additional expense of a fully coordinated system
may be justified. The cost/benefit ratio of each situation shall be reviewed
and an economic balance struck.

3.1.8 Equipment Heat Dissipation Data


Heat is generated in electrical equipment due to the electrical losses that
occur within the equipment. An estimate of the electrical losses shall be
developed and added to the cooling requirements of the space where the
electrical equipment is installed. Table 10-1, Range of Losses in Power
System Equipment, in Chapter 10 of ANSI/IEEE Std 141-1993 contains a
list of energy losses for a number of types of electrical equipment.
Table 3-1 shows energy losses for the equipment that will be most often
found in water treatment facilities.

3.2 LOCATING ELECTRICAL EQUIPMENT


Electrical equipment is designed for a variety of environmental conditions,
and it is important that the equipment selected be suitable for the location
where it is to be installed. Both the basic design of the equipment and the
requirements of the NEC shall be taken into account when locating
electrical equipment.

3.2.1 Equipment Rooms and Buildings


Article 110 of the NEC contains a number of specific requirements that
pertain to the location of electrical equipment. NEC Table 110.26(A)(1)
defines the working space required in front of equipment rated 600 volts
and less. NEC Table 110.34(A) defines the working space required in
front of equipment rated above 600 volts. Note that these are minimums
and do not provide comfortable working space.

Table 3-1 Losses in Electrical equipment

Percent Energy Loss


Component
(full load)
Medium voltage switchgear 0.005-0.02
Transformers 0.4-1.90
Medium voltage starters 0.02-0.15
Low voltage switchgear 0.13-0.34
Low voltage motor control 0.01-0.40
Cable 1.00-4.00
Motors
x 1-10 hp 14.0-35.0

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x 10-200 hp 6.00-12.00
x 200-1,500 hp 4.00-7.00
Static variable speed drives 6.00-15.00
Note: Use high end of range except when more accurate data are known
or provided.

NEC Article 408 contains additional requirements that pertain to the


location of switchboards and panelboards.
NEC Article 450 contains a number of specific requirements that are
applicable to the installation of different types of transformers. It also
contains specific requirements for construction of transformer vaults.

Major electrical equipment such as transformers, switchgear assemblies,


switchboards, and motor control centers shall be installed in dedicated
rooms or buildings. Smaller equipment such as individual motor starters
and panelboards shall be installed in mechanical spaces that are
ventilated and dry. All equipment rated above 600 volts, except pad-
mounted transformers and metal enclosed outdoor switchgear
assemblies, shall be located in dedicated spaces that are only accessible
to qualified persons. Rooms containing motor control centers should be
ventilated, not air conditioned, so that the ambient temperatures around
both the motors and their controllers are similar.

3.2.2 Equipment Enclosures


Electrical equipment enclosures shall be designed for the conditions that
they will be subject to when installed. ANSI/NEMA 250 defines the types
of enclosures and the conditions for which those enclosures were
designed. The most often used NEMA enclosure types are as follows:

x NEMA Type 1;
x NEMA Type 3R;
x NEMA Types 4 and 4X;
x NEMA Type 7, Class I, Group A, B, C, or D;
x NEMA Type 12.

See Chapter 16 of the Switchgear and Control Handbook for a complete


list of the NEMA enclosure types and their intended uses. Appendix D
also describes each NEMA enclosure type.

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3.2.2.1 Indoor Locations. Enclosures installed indoors in dry indus-


trial type areas shall be NEMA 12. NEMA 1 enclosures may be used in
electrical rooms, offices, and laboratory areas where flying dust and debris
would not be present. NEMA 4 enclosures shall be installed in indoor
damp and wet areas that do not have corrosive atmospheres. Where
corrosive atmospheres are also anticipated, 316 stainless steel or
reinforced fiberglass NEMA 4X enclosures shall be installed.

3.2.2.2 Outdoor Locations. Enclosures installed outdoors must be


designed to meet a number of conditions. If the atmospheric conditions
are not known, 316 stainless steel or reinforced fiberglass NEMA 4X
enclosures shall be installed. If it is known that no corrosive atmospheric
conditions can be expected, then NEMA 3R or NEMA 4 enclosures could
be used. NEMA 4 enclosures shall be used in process areas where
washdown of the area can be expected, and NEMA 3R can be used for
disconnect switches and similar equipment where it is located away from
process equipment.

3.2.2.3 Hazardous Locations. Equipment enclosures in hazardous


locations shall be classified for use in the hazardous classification that
applies. NEMA 7 enclosures for use in Class I Group A, B, C, and D
locations (gaseous hazards) and NEMA 9 for Class II Groups E, F, and G
locations (explosive amounts of dust) are the two most often needed.

3.3 SWITCHGEAR
Switchgear is a general term covering switching and interrupting devices
alone or in combination with other associated control, metering, protective,
and regulating equipment. A power switchgear assembly consists of a
complete assembly of one or more of the above-noted devices and main
bus conductors, interconnecting wiring, accessories, supporting
structures, and enclosures. Both medium voltage and low voltage
enclosed switchgear will be reviewed in this design guide. See
Chapter 10 of ANSI/IEEE Std 141-1993 and ANSI/IEEE C37.20-1,
C37.20-2, C37.20-3, and C37.100 for additional information on
switchgear.

3.3.1 Low Voltage


Two types of low voltage enclosed switchgear are used in power
distribution systems: the metal-enclosed low voltage power circuit
switchgear, and the power switchboard.

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3.3.1.1 Metal-Enclosed Switchgear. Metal-enclosed low voltage


power circuit switchgear is constructed in accordance with ANSI C37.20-1
and meets the requirements of UL Standard 1558. It features individually
mounted air break power circuit breakers in drawout construction. Power
circuit breakers both with and without current limiting fuses are available.
Circuit breakers are equipped with solid-state tripping systems and offer a
wide range of adjustability. See additional requirements defined in
Metropolitan's Standard Specifications Sections Catalog.

Metal-enclosed low voltage power circuit switchgear shall be used where


the available fault current exceeds 50,000 amps symmetrical at 480 volts
or 65,000 amps symmetrical at 208 or 240 volts.

3.3.1.2 Power Switchboards. Power switchboards are available in


either group-mounted or individually mounted configurations. The group-
mounted configuration is normally used for small boards and in
commercial construction. Both types are constructed in accordance with
applicable provisions of UL 891 and NEMA PB-2.

The main circuit protective devices in group-mounted switchboards are


either fixed or drawout-mounted, but the branch devices are all fixed-
mounted. The main device is either a molded case circuit breaker, a
molded case circuit breaker with solid state trip units, an air break power
circuit breaker, or a bolted pressure switch. The branch devices are either
molded case circuit breakers with or without solid state trip units, or fused
switches. The standard short circuit rating for group mounted
switchboards is 50,000 amps RMS symmetrical, but higher ratings are
available. See Metropolitan's Standard Specifications Sections Catalog
for more detailed requirements of this equipment.

Both the main and feeder circuit protective devices shall be drawout type
in individually mounted configurations. Circuit protective devices shall be
applied in a manner consistent with applicable portions of Section 3.1.6,
Protection and Coordination Philosophy. The standard short circuit rating
for switchboards with individually mounted drawout circuit breakers is
50,000 amps RMS symmetrical, but higher ratings are available. See
Metropolitan's Standard Specifications Sections Catalog for more
complete and detailed requirements for this equipment.

Switchboards with group-mounted circuit protective devices shall be used


where the main bus rating is 800 amps or less, the fault current available
is less than 50,000 amps RMS symmetrical, and the feeder and/or branch
circuit protective devices are all 225 amps or less. Where the main bus
rating must be greater than 800 amps and feeder breakers of 400 amps or
larger are required, switchboards with individually mounted circuit

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protective devices shall be used if the fault current available is
50,000 amps RMS symmetrical or less. Where higher fault currents are
available, metal-enclosed low voltage power circuit switchgear shall be
used.

3.3.2 Medium Voltage (4.16 kV through 13.8 kV)


Two types of medium voltage switchgear are available: metal-clad
switchgear and load interrupter switchgear. Both are available for either
indoor or outdoor installation. Metropolitan standard is metal-clad
switchgear with vacuum circuit breakers.

3.3.2.1 Metal-Clad Switchgear. Metal-clad switchgear shall be an


assembly of drawout vacuum circuit breakers, auxiliary equipment,
metering equipment, and insulated copper bus bars enclosed in a rigid
metal assembly and constructed in accordance with ANSI C37.20.2. Each
compartment in the assembly shall be isolated from all other
compartments by grounded metal barriers.

The circuit breakers shall be horizontal drawout type on rails. The


breakers shall be operated by a motor-charged, spring-stored energy
mechanism. The mechanism shall be front accessible and will be charged
normally by a universal electric motor and in an emergency by a manual
handle. Each circuit breaker shall contain three vacuum interrupters
separately mounted. The detailed requirements for metal-clad switchgear
shall be as specified in Metropolitan's Standard Specifications Sections
Catalog.

Metal-clad switchgear shall be provided as the service entrance


equipment for all medium voltage distribution systems that require more
than one main device and more than two feeder devices downstream of
each main device. Metal-clad switchgear shall also be provided where
large motors are served directly from the medium voltage distribution
system.

3.4 TRANSFORMERS
Unit substations and pad-mounted transformers are both available to
transform medium voltage primary power to lower utilization voltages. The
lower voltage may be either a low voltage class such as 480 volts or a
medium voltage class such as 4,160 volts. There are several basic
differences between these transformer types that must be kept in mind
when selecting one for an application.

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3.4.1 Pad-Mounted
Pad-mounted transformers are intended for use with underground power
distribution systems. They offer flexibility and provide a pleasing
installation. Their tamperproof construction allows installation in locations
accessible to the general public without the need for protective fencing or
vaults. They are oil-filled and are not suitable for indoor installation.

Compartmental type pad-mounted transformers are designed for the


underground entrance of primary and secondary conductors. Provisions
are available for live or dead front primary termination on radial or loop
feed systems. Secondary connections are spade terminals mounted to
the tank wall.

Three-phase pad-mounted transformers are available from 45 kVA to


5,000 kVA. They are constructed for a 65o C rise over a 30o C ambient
and have no provisions for increasing overload capability.

3.4.2 Unit Substations


A unit substation consists of a substation type transformer designed for
close coupling to a primary switch or switchgear assembly, and a
secondary switchgear assembly. Each of the three parts need to be
looked at individually because there are several options available for
each. The substation transformer may be installed along or with either the
primary or secondary switchgear assembly where proper bushings and
terminal cabinets are provided and where the switching and protection
functions are provided by remotely located equipment.

3.4.2.1 Primary Switch. Several options are offered for the primary
switch of a unit substation. A metal-clad nonfused interrupter switch shall
be provided where transformer protection is provided elsewhere. Should
transformer protection be required, a metal-clad vacuum circuit breaker
shall be bolted to the high voltage flange of the transformer. Should a
loop feed or primary selective switching be required, a metal-clad
switchgear assembly shall be bolted to the high voltage throat of the
transformer to provide both transformer protection and flexibility in the
distribution system.

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3.4.2.2 Transformer Section. The transformer section shall be either


liquid-filled, dry type, or cast coil type. Selection of the transformer must
be made based on where the transformer is to be installed and the
expected overload requirements.

A. Liquid-Filled Transformers. Transformers are available from


225 to 5,000 kVA with a variety of high and low voltage
windings. Several types of insulating liquid or fluid are available
and NEC Article 450 Section II contains special provisions that
cover the use of different liquids or fluids in different locations.

The standard load rating for liquid-filled transformers is at a


65o C rise. Liquid-filled transformers are available with a
55/65o C rating, which increases the nominal rating of the
transformer at a 65o C rise by 12-1/2 percent. In addition, the
overload capability of liquid-filled transformers can be increased
by the addition of fans. The self-cooled rating of transformers
from 225 to 2,000 kVA can be increased by 15 percent and the
self-cooled rating of transformers from 2,500 to 5,000 kVA can
be increased by 25 percent.

B. Dry-Type Transformers. Dry-type transformers are available


in either ventilated or nonventilated construction for both indoor
and outdoor applications. The standard load rating for a dry-
type transformer is at a 115o C rise over a 40o C ambient.
These transformers are capable of carrying a 15 percent
overload continuously without exceeding the 150o C enclosure
temperature. They are also available with an 80o C rise over a
40o C ambient capable of carrying a 30 percent overload
continuously without exceeding 150o C in the transformer
enclosure. Dry type transformers are available in sizes from
225 to 2500 kVA self-cooled ratings, and the self-cooled rating
can be increased 33-1/3 percent for short-term load peaks with
the addition of fans. The standard basic impulse level (BIL) for
dry type transformers is typically less than the standard for (BIL)
liquid-filled transformers and needs to be kept in mind when
selecting transformers.

3.4.2.3 Secondary Switchgear Assembly. Several options are


available for the equipment to be located on the secondary of a unit
substation. They range from an air terminal cabinet for termination of
either a bus duct or cables to a metal-enclosed low-voltage power circuit
switchgear. The circuit protective devices used shall be dependent upon
the needs of the system.

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3.4.3 Equipment Selection


Unit substations are Metropolitan standard. Pad-mounted transformers
shall only be used where transformer requirements are so small that unit
substations are not available.

3.5 MOTOR CONTROL EQUIPMENT


Motor control equipment is a general term that covers a range of voltage
and horsepower ratings and innumerable combinations of equipment
arrangements and operational functions. All such equipment is designed
and produced in accordance with NEMA Standards Publication Industrial
and Control Systems. In addition to ac motor starters, this section
includes discussions of adjustable speed controllers, DC motor controls,
and power factor improvement. Section 10.6 of ANSI/IEEE Std 141-1993
identifies a number of factors that must be kept in mind when selecting the
controller for a motor.

3.5.1 Low Voltage


In ac motor control, contactors are normally used for controlling the power
supply to the motor. The contactor, when applied in conjunction with a
thermal overload heater block, is called a starter. The starter is then
applied in combination with either a magnetic-only circuit breaker or a
thermal magnetic circuit breaker, and is called a combination motor
starter. The thermal overload heater block provides overload protection,
and the circuit breaker provides short circuit protection. The standards for
magnetic controllers rated 115 through 575 volts are summarized in
ANSI/NEMA ICS2. Motor starters for Metropolitan projects shall be sized
as shown in Table 2-1 for 480-volt three-phase motors. Starters for
motors operating at other voltages shall be sized in accordance with
appropriate NEMA standards.

There are several types of low-voltage motor starters available. Following


is a list of the more commonly used types and a brief description of each.
A more complete description can be found in either ANSI/IEEE Std 141-
1993 or the Switchgear and Control Handbook.

x Manual motor starter. A manual starter is a manually


operated switch that is rated for control of induction loads
and includes thermal overload protection. The manual
starter may not provide undervoltage protection.

x Magnetic, nonreversing motor starter. Provides full-


voltage starting for motors that must be started frequently
and are suitable for use with remote control devices such as
pushbuttons, selector switches, or similar pilot devices. The
magnetic, nonreversing motor starter provides overload

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protection and can also provide undervoltage protection if
momentary contact controls are provided.

x Magnetic, reversing motor starter. Control is provided by


two contactors wired so that reversing the phases provides
the reversing function. In all other respects, control is the
same as for magnetic, nonreversing motor starters.
Mechanical and electrical interlocks are provided to prevent
momentary short circuiting when changing directions.

x Combination motor starter. Either a nonreversing or


reversing magnetic starter can be provided in combination
with a nonfused disconnect switch, a fused switch, or a
circuit breaker. The resulting assemblies are then called
nonfused nonreversing (or reversing) combination motor
starter; fused nonreversing (or reversing) combination motor
starter; or circuit breaker type nonreversing (or reversing)
motor starter. The control functions are as described above,
with the addition of a disconnect function and short circuit
protection in the case of the fused and circuit breaker type
starters.

x Reduced voltage starters. Reduced voltage motor starters


include the basic components of a combination motor starter
with a means to reduce the inrush current to the motor to
some level below that which would be expected should full
voltage be applied.

Reduced voltage starters shall be provided for all motors


50 hp and larger when installed as part of a retrofit, unless
motor starting voltage drop calculations are made that show
that the voltage dip that would result from full voltage starting
is less than 20 percent.

Reduced voltage starters shall be provided for all motors


100 hp or larger when installed as part of new construction,
unless motor starting voltage drop calculations are made
that show that the voltage dip that would result from full
voltage starting is less than 20 percent.

Following are the four types of reduced voltage starters that


are available from most manufacturers:

- Autotransformer type (both open transition and


closed transition). An autotransformer is used to
reduce the voltage being applied to the motor windings.

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The starting torque will vary almost directly with the
variation in motor current. To minimize the short
duration, high inrush current that occurs during an open
transition, the closed transition connection momentarily
uses the autotransformer as a series reactor to minimize
the current surge. The autotransformer type reduced
voltage starter offers the highest starting torque in foot
pound of torque per kVA of inrush. It is a good choice for
reduced voltage starting of high inertia loads, but is also
the most expensive reduced voltage type starter.

- Primary resistor or reactor-type reduced voltage


starter. The motor inrush current is limited by the value
of resistance or reactance placed in the primary circuit.
Because starting torque is a function of the square of the
voltage, if the voltage applied to the motor is only
50 percent of rated voltage, the starting torque will be
reduced to only 25 percent of normal starting torque.
This type of starter shall only be used with low inertia
loads where the low starting torque provided is sufficient
for the connected load. This type of starter provides the
smoothest acceleration of the load possible and is usually
the least expensive.

- Part-winding motor starter. This requires a special


motor that is wired for part-winding starting and two
magnetic motor starters. It shall only be used on light or
low inertia loads. It is fourth in terms of smooth
acceleration of the load.

- Wye-delta type motor starter. This type of motor


starter initially energizes the motor windings in a wye
configuration and then transitions (either open transition
or closed transition are available) when the load
approaches full speed. Because wye-delta starters only
provide 33 percent of normal starting torque, this method
shall only be used where the drive equipment can be
started unloaded. This installation requires a special
motor, and both ends of each motor winding shall be
brought back to the motor starter. This type of reduced
voltage starter is especially useful for long acceleration
type applications such as centrifuges. Table 10-17,
Comparison of Different Reduced Voltage Starters, in
Chapter 10 of ANSI/IEEE 141-1993 shows a comparison
of the operating characteristics of different reduced
voltage starters.

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x Solid-state motor starters. Solid-state motor starters can


control the starting cycle and provide reduced voltage
starting for conventional ac motors. The solid-state
electronics provide a smooth and adjustable acceleration
rate for motor starting that limits inrush current surges and
reduces sudden torque surges to the motor. Solid-state
motor starters shall be considered where smooth
acceleration is a must and where maximum limitation of
inrush current must be achieved.

Reduced voltage auto transformer-type starters shall be specified unless


special starting requirements exist. Review special starting requirements
with Metropolitan before selection of alternate equipment is made.

The branch circuit device provided in a combination motor starter shall be


selected with care. If an upstream device provides the necessary short
circuit protection, then a simple disconnect switch may be sufficient. In
motor control center applications, the branch circuit device must provide
both the disconnect function and the short circuit protection for the branch
circuit.

Short circuit protection shall be provided by circuit breakers except that


properly sized fuses shall be used in combination with them where current
limiting protection is required. Two types of circuit breakers are available
for motor branch circuit protection and each functions differently. When a
branch circuit device is used in combination with a motor starter it may be
selected to provide both overcurrent and short circuit protection, or only
short circuit protection.

The two types of circuit breakers used in low voltage motor control,
magnetic-only and thermal magnetic, are discussed below.

x Magnetic-only circuit breakers (MCP) are the type most often


used in combination motor starters. They can only be used
in combination with a motor starter because they do not
provide any overcurrent protection. The NEC allows MCPs
to be sized up to 700 percent of motor full-load ampere
(FLA) and set up to 1,300 percent of motor FLA. In most
situations, the selection of the proper MCP shall be left to the
motor starter manufacturer and it should be sized so that its
range of adjustment allows it to be set between 7 and 13
times motor FLA. MCPs are less expensive than thermal
magnetic circuit breakers and clear short circuit currents
faster. For motors 50 hp and larger, they may provide less
protection than a properly sized thermal magnetic circuit

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breaker.

x Thermal magnetic circuit breakers are also used as motor


branch circuit protection. They provide both short circuit and
overcurrent protection. Depending on the type of motor
being protected, the NEC allows thermal magnetic circuit
breakers to be sized at as much as 250 percent of motor
FLA. Thermal magnetic breakers 70 amps and larger with
an adjustable magnetic trip unit can be sized such that the
magnetic trip assembly provides adequate short circuit
protection for the motor branch circuit. Smaller breakers
with only fixed magnetic trip units cannot be sized small
enough so that the instantaneous trip point is between 7 and
13 times motor FLA and will not be tripped by motor running
current.

Where the convenience of a circuit breaker is desired but the available


fault current exceeds the rating of a motor starter with a magnetic-only
circuit breaker, a current limiter shall be added to the breaker to increase
the rating of the assembly. A current limiter is similar in construction and
characteristics to a current limiting fuse.

Because circuit breakers offer more convenience, tripping of all three


phases, and adequate motor protection if properly selected, they shall be
used for motor branch circuit protection unless a special condition exists.
Combination motor starters for 480-volt applications shall be provided with
magnetic-only circuit breakers (MCPs). MCPs shall be sized in
accordance with Table 2-1.

3.5.1.1 Motor Control Center. Except in those situations where only a


couple motor starters are required, low voltage combination motor starters
shall be grouped in motor control centers (MCC). "Motor control center" is
a term that generally refers to a collection of motor control equipment and
circuit breakers assembled in a series of steel-clad enclosures. Each
circuit breaker and combination motor starter is individually enclosed in a
compartment separated from other compartments by metal barriers.

Motor control centers are available in a variety of enclosure types. The


NEMA 1 enclosure is the most common, but NEMA 1 gasketed and
NEMA 12 types are offered for those times when a greater degree of
exclusion of dust is required. NEMA 3 and NEMA 3R enclosures can be
purchased for outdoor installation.

Several types of motor control centers can be purchased. They are


defined as Class I Type A, Type B, and Type C; and Class II, which is
furnished in Type B and Type C only. The class and type define the type

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of wiring to be provided within the MCC. See Chapter 23 of the
Switchgear and Control Handbook or a manufacturer's descriptive
literature for a complete description of the requirements of each.

Class I Type B wiring shall be specified for all motor control centers unless
significant amounts of wiring are required between control units, and then
Class II Type B wiring shall be specified.

Motor control centers shall be specified with sufficient ampacity in the


main bus to carry the connected load, including known future loads, and
have 20 percent spare capacity. Where this criteria results in a main bus
with an ampacity greater than 1,000 amps, the selection shall be reviewed
with Metropolitan.

The short circuit rating of the motor control center shall be greater than the
fault current available at the line side terminals of the MCC plus the motor
contribution, as required by NEMA ICS 2-322. The short circuit rating of
an MCC is equal to the interrupting capacity of the lowest rated device in
the assembly. Circuit breaker type combination motor starters are UL
listed for 22,000 amps interrupting capacity (AIC). Higher short circuit
ratings are available by the substitution of high interrupting circuit breakers
or the addition of current limiters. Where fault currents above
22,000 amps symmetrical are available, circuit breakers with current
limiters or current limiting circuit breakers shall be specified.

3.5.1.2 Control Power Transformers. Control power transformers


(CPTs) shall be provided in all motor starters to provide 120-volt control
circuit power. CPTs shall be provided with two primary fuses, one on
each side of the transformer, and one secondary fuse on the ungrounded
side of the transformer. CPTs shall be sized to carry at least 150 percent
of the total connected load of the control circuit. CPTs shall not be smaller
than 100 VA.

3.5.2 Medium Voltage


The protection of an ac motor is a function of its type, size, speed, voltage
rating, application, location, and type of service. Medium voltage motor
control equipment (controllers) are rated for use on systems from
2,300 volts to 4,800 volts. Above 4,800 volts, metal-clad switchgear
equipment must be used.

Medium voltage motors shall be controlled by medium voltage motor


starters that are specifically designed for the type of motor to be controlled
and that have a horsepower rating equal to or greater than the rating of
the motor. Motor starters shall be NEMA Class E-2 as described in
ANSI/NEMA ICS2.

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Each motor starter shall consist of current limiting power fuses, a
contactor, instrument and control power transformers, instrumentation,
and appropriate protective relay functions for the type of motor being
supplied. Two types of contactors are available, vacuum and air break;
the vacuum contactor type shall be selected. Motor protection is
discussed in detail in ANSI/IEEE Std 242. In addition, manufacturers of
medium voltage motor control equipment offer recommendations. The
protective, metering, and control functions shall be provided by using a
multipurpose microprocessor-based module such as the GE Multilin 469,
Areva MiCom P243, or equal.

Each starter shall be completely self-contained, prewired with all


components in place. Where multiple starters are required in a single
location, an assembly of medium voltage motor starters with a common
supply bus, grounded metal barriers, and drawout mounting assemblies
for each motor starter shall be provided. See the Standard Specifications
Sections Catalog for more detailed requirements for medium voltage
motor control equipment.
3.5.3 Adjustable Speed Drives
The advancements in semiconductor devices have enhanced the design
and application of solid-state drives for DC and AC motors’ speed controls.
Semiconductor devices like diodes, thyristores, transistors, gate-turn-off
switches (TGOs) and insulated bipolar gate transistors (IGBTs) are
available with high current-carrying capacity. Microprocessor-based control
systems provide reliable and highly accurate speed control.

3.5.3.1 DC devices
DC motors have been the prime choice for speed control based on their
adaptability to wide ranges of speed-serving duties of small to several
thousand horsepower mechanical demands. Varying the armature voltage
or field current can change a DC motor’s speed.

3.5.3.2 AC Drives
Advances in solid-state electronics have resulted in AC drives that have
high reliability and low maintenance. AC drives, which are commonly called
inverters, are designed to operate standard squirrel cage induction motors.
The basic drive consists of an inverter which converts the 60 Hz incoming
power to a variable frequency and variable voltage.

3.5.3.3 Types of AC Drives


The major types of AC drives in use today are as follows:

A) Voltage Source Inverter (VSI). The design of VSI utilizes


thyristors in the converter section and thyristors, GTOs, and
transistors in the inverter section. The output voltage is
controlled as six-step and is pulse-width modulated (PWM).

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B) Current Source Inverters (CSI). The design of CSI is based on


controlling motor current for the voltage frequency requirement.
In the case of circuit design, the inductance of the motor plays a
major part. This design can accommodate the motor to be
driven at higher than the rated horsepower.

C) Pulse Width Modulated (PWM) Inverter. The design of PWM


does not change the amplitude of the controlled variable to the
motor (typically voltage). They change the rms value by turning
the controlled value on and off at a relatively high frequency
while varying the pulse width. The switching frequency
(commonly referred to as the “carrier frequency”) will determine
the audible motor noise resulting from motor lamination
excitation as well as how closely the PWM controller
approximates a pure sine wave.

D) Load Commutated Inverter (LCI). Unlike the first three drives


which use forced commutation to turn the inverter on and off,
the LCI drive uses the emf generated at the motor armature
terminals to commute the thyristor inverter. The LCI drive is
typically used on large horsepower synchronous motors.

3.5.3.4 Drive Power Ratings


Drive controls are rated to provide a defined amount of current for
continuous operation at a defined maximum ambient temperature.
Controls re generally identified as one of two basic types.

A) Variable torque. A variable torque control rated with a 1- minute


overload capability of typically 110 percent to 125 percent of
nameplate continuous rated current which is typically sufficient
for variable torque loads.
B) Constant torque. A constant torque control is typically rated with
a 1-minute overload capability of 150 percent of the nameplate
continuous rated current.

3.5.3.5 Control Methods

A) Volts per Hertz. In V/Hz control the volts to hertz ratio is


maintained at a user programmable value ove rthe operating
frequency range. It is generally applied where fast response to
torque and speed commands is not required. A control using the
V/Hz technique is particularly useful where multiple motors are
connected to a single control.

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B) Vector Control. A squirrel-cage motor is singly excited machine
fed by connection to its stator windings, unlike a DC motor that
is doubly excited through its armature and field windings. An AC
vector control decouples the magnetizing flux producing current
and the torque producing current to control them separately.
This gives the ASD excellent steady state and dynamic
performance. Very accurate speed and torque control can both
be achieved.

x Direct Vector Control - A direct field oriented control scheme


is one that directly regulates the motor flux vector in order to
produce controllable motor torque. Such a scheme employs
Hall effect transducers or air-gap flux sensing windings for
the measurement of the motor air-gap flux with the
necessary modifications to approximate the rotor flux. The
rotor flux would then be used as the feedback in the direct
vector control regulator.
x Indirect Vector Control - An indirect field oriented control
scheme is one that interprets the motor flux vector from
other parameters, such as speed or current. The two types
of indirect vector drive control schemes used today are
closed-loop or feedback vector control (which requires a
speed feed back sensor to provide rotor position feedback)
and open loop or sensorless vector (SV) control (monitors
motor current instead of using a speed feedback sensor). A
closed loop vector drive provides precise speed control and
maximum torque from zero speed to base speed. An open
loop vector drive does not have as wide a speed range as a
closed loop vector drive and cannot produce holding torque
at zero speed.

3.5.3.6 Line Harmonic Currents


Nonlinear loads like adjustable speed drive create line harmonics when
connected to the AC power distribution system. These harmonic currents
are the result of non-sinusoidal current, which is a characteristic of all
adjustable speed drives using diodes or silicon controlled rectifiers (CSRs)
on the input. The drive input current is composed of the fundamental
sinosoudial current and currents at frequencies higher than the
fundamental frequency. These harmonic currents contribute to the volt-
ampere losses:

A) Possible interference with communication equipment


B) Possible overheating of transformers and other branch circuit
equipment
C) Possible increased heating in motors connected acress-the-line
due to copper and iron losses

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D) Possible resonance with power factor capacitors

The AC input line harmonic current magnitudes vary with the design of the
drive. The power distribution system impedance at the installation and the
drive input design determines the actual magnitude of th eline harmonic
currents.

Harmonic distortion levels as stated in IEEE 519 apply at the Point of


Common Coupling (PCC) between the utility system and multiple users.
The harmonic voltage and current distortion values at the PCC may be
reduced through several methods that include:

A) Design Techniques

x Power System Design - decreasing the drive system load, as


percentage of the total power distribution network load will
improve harmonic voltage distortion conditions.
x DC Link Choke/Inductor - an inherent design feature within
some controls, provides a minimum level of harmonic
reduction by changing the rate of rise of the input current.

B) Line Impedance

x AC line reactor - based upon the percent of line impedance,


provides lower amplitude of harmonic currents by slowing
down the rate of rise of input current pulses, similar DC link
choke.
x Drive Isolation Transformer - provides similar performance to
an AC line reactor with the additional power quality benefit of
being able to adjust the voltage magnitude.

C) Multi-Pulse Methods/Converter Design Topologies

x Phase multiplication - involves the use of a phase-shifting


transformer for feeding multi-pulse control inputs. By shifting
the phase relationship to various 6-pulse controls, the net
effect in the power system is to create a 12-pulse circuit with
cancellation of the 5th and 7th characteristic harmonics.
However, this method is most effective when the motor loads
are equal size and load.
x 12-Pulse Rectifier - a control that utilizes a dual 6-pulse
rectifier network with a phase shifting transformer for proper
commutation of the dual bridges. The net effect is
cancellation of the 5th, 7th, and 19th characteristic harmonics.

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x 18-Pulse Rectifier - a control that utilizes three 6-pulse
rectifier networks with a pulse shifting transformer for proper
communication. This results in an improved waveform,
cancellation of lower order 5th, 11th, 13th, 23rd, 25th, 29th, and
31st characteristic harmonics.
x Active Rectifier Input - a control that incorporates gate
controlled power semiconductors in the input rectifier stage
to shape the input current waveform, to a sinusoidal
waveform symmetrical to the voltage. This method of
harmonic abatement is the most complex. A microprocessor
controller is required for gate control of the input power
semiconductors.

D) Harmonic Filters

x Shunt filters – passive filters that are properly designed and


for the 5th, 7th, and 13th harmonics can effectively reduce the
harmonic currents in a power distribution system.
x Series filters – these filters consist of a parallel LC circuit
tuned to resonate a specific frequency, similar to a shut filter.
The series reactor acts to de-tune other power distribution
system harmonics form being trapped by the passive filter.
x Harmonic injection – adaptive compensators are designed to
constantly monitor the AC line current to the drive by
injecting a current equal in frequency/magnitude and 180
degrees out phase to the distorted current.
x Active Filters – designed primarily for multiple non-linear
harmonic loads, monitoring dynamic load conditions and
switching necessary VAR compensation.

3.5.3.7 Drive Application Information


Complete application information is critical to the proper selection and
installation of an ASD system. The specifications for an ASDsystem
should include:

A) Horsepower and torque requirements at various speeds


B) Speed range of the load and motor
C) Motor voltage
D) Incoming power, voltage dips and derivations, frequently
derivation, and regulating
E) Dynamic response (Wk2) to the motor shaft, including
acceleration and deacceleration time
F) Ride-through requirements and response to momentary
interruption
G) For large motors with high-speed operation, mechanical
resonance effects of gears, couplings, and flywheels

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H) Starting and stopping cycles for emergency-management
applications
I) General description of the type of application including the
environment in which the ASD system components must
operate
J) A description of additional functionality that may be met with the
motor and drive only (motor temperature monitoring, ability to
bypass the drive if necessary, special sequencing circuits or
analog input speed reference signals to control the ASD
system)
K) Harmonic current and its effect on a plant’s power distribution
apparatus, especially to microprocessor-based equipment and
electronically sensitive instruments
L) Harmonic current’s effect on mechanical output, such as torque
and pulsation
M) Regeneration applications

3.5.4 Power Factor Correction


Power factor improvement shall be provided only when the electric utility
rates include a penalty for low power factor and the projected power factor
of the facility will be less than the minimum allowed within the rate. Power
factor improvement shall be provided by installing capacitors on the larger
motors (25 hp and larger), which are powered by full voltage starters. The
capacitors shall be sized in accordance with the procedures provided in
Section 2.3, Design Calculation, in this design guide, and shall not be
larger than the maximum size recommended by the motor manufacturer.
The capacitors shall be connected between the motor starter contacts and
the overload relays so that overload relay heaters can be sized in accor-
dance with motor nameplate currents.

3.5.5 Control Circuit Devices


This section covers a broad range of devices that are found in motor
control circuits. All control circuit devices shall meet the requirements of
applicable NEMA ICS 2-125 Standards. Devices that contain contacts
and are used in 120-volt control circuits shall have contacts with the
designation A300 or A600. Only devices with contacts having the
designation A600 shall be used where the control circuit voltage will be
greater than 120 volts. Contacts with these designations are capable of
carrying 10 amperes continuously, making a circuit requiring 7,200 volt-
amperes and breaking a circuit carrying 720 volt-amperes. Devices
covered by this rating include momentary and maintained contact
pushbuttons and control switches; push-to-test pilot lights; limit switches;
snap action switches in temperature, pressure, and similar switches; and
control relays.

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All pushbuttons, selector switches, and pilot lights shall be heavy duty oil-
tight or corrosion resistant type. Standard duty type shall not be used. In
addition, all snap action switches and control relays shall be of the quick-
make quick-break type.

Every motor control circuit shall contain a control switch or START/STOP


pushbutton station in series with the main contactor coil to allow manual
control of the drive motor. The use of two-wire and three-wire control
stations is illustrated in Figure 3-6. Where the drive motor is remote from
the motor starter location, the control switch or pushbuttons shall be
located near the motor in either a local control panel or as a locally
mounted control station. The primary function of this control device is to
provide a local override of all other control devices that may exist in the
control circuit.

3.6 MOTORS
The subject of motors is a very broad topic and will not be dealt with in any
detail in this section. The text Motor Applications and Maintenance
Handbook is an excellent reference on the subject and should be reviewed
for specific questions that are not addressed in this manual. In addition,
NEMA standard MG 1 Motors and Generators covers the construction and
testing of all types of motors and should be consulted for the general
standards of the industry.

3.6.1 Basic Motor Types


There are three basic types of motors that will be discussed in more detail
in this section; the induction motor, the synchronous motor, and the dc
motor. Most motors used within a water treatment facility will be induction
motors and will fall into one of the following classifications: low-voltage
single-phase, low-voltage three-phase, or medium-voltage three-phase.

3.6.2 Design Considerations


There are a number of things that must be taken into consideration when
specifying a motor for a specific application. Most important are the
torque characteristics of the motor, its operating speed, thermal protection,
and the environmental protection provided by the enclosure and the
insulation system.

3.6.2.1 Motor Torque. Torque is the force that tends to produce a


turning motion in an electrical motor. Torque is expressed in terms of
force and distance to represent the turning moment. There are a number
of types of torque that are defined in the Motor Application and
Maintenance Handbook, but only the basic ones will be defined here. See
Appendix G for a typical motor torque curve and associated definitions.

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Figure 3-6. Example Control Station Wiring

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x Locked Rotor Torque. This is the minimum torque devel-


oped by the motor at all angular positions of the rotor at the
instant of rated-power application to the motor primary wind-
ing circuit. This torque is sometimes referred to as the
breakaway starting torque.

x Full-Load Torque. This is the torque necessary to produce


rated speed with rated-power input.

x Breakdown Torque. This is sometimes referred to as maxi-


mum torque and is the maximum torque developed at rated-
power input without an abrupt change in speed.

x Accelerating Torque. This is the torque developed with


rated-power input during the period from standstill to full
rated speed. It is the positive torque available beyond the
requirements of the load.

The torque capabilities of the motor being proposed must be compared


against the torque requirements of the load to verify that the motor is
capable of operating the load. This is typically done by plotting the torque
curve of the motor and the load torque on the same graph from zero
speed to synchronous speed of the motor.

3.6.2.2 Duty Classification. Motors are classified for continuous,


intermittent, or varying duty depending on their ability to drive a load:

x Continuous duty refers to a load that demands operation at a


substantially constant load for an indefinitely long time. Most
motor applications in water treatment and pumping plants
will be continuous duty.

x Intermittent duty refers to a load that demands operation for


alternate intervals of load and rest or load and no-load,
where each interval has a specific duration. Few intermittent
loads occur in water treatment and pumping plants.

x Varying duty refers to a load that demands operation at


loads and for intervals of time both of which may be subject
to wide variations. Most motor applications in water
treatment and pumping plants that are not continuous duty
shall be varying duty.

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3.6.2.3 Motor Speed. Motor speed is designated in terms of revolu-


tions per minute (rpm), and for synchronous and induction motors is
directly related to the frequency of the power source. Following are
several definitions that need to be kept in mind:

x Full-load speed is the rated speed at which rated full-load


torque is delivered with rated-power input.

x Constant speed indicates that the normal operating speed is


constant, or practically constant, for a specified range of
torque.

x Synchronous speed indicates that the motor speed is in


synchronism with the frequency of the power supply. For ac
motors, synchronous speed shall be found by using the
following formula:

Synchronous speed = 120 x frequency (Hz)


(rpm) no. of poles in motor (Eq. 3-1)

x Slip speed is the difference between synchronous speed and


actual rotor speed.

x Adjustable speed indicates that the speed may be varied


gradually over a considerable range, but remains practically
unaffected by load at each adjustment.

Since the number of poles in a motor is in pairs and the synchronous


speed of an ac motor is directly related to the number of poles in the
motor, the motor speeds available are very limited. The synchronous
motor speeds (rpm) at 60 Hz are as follows:

3,600 1,800 1,200 900 720 600


514 450 400 360 327 300
277 257 240 225

Motors are specified in terms of full-load speed, where full-load speed is


the synchronous speed minus the slip speed, which will vary between
0.5 and 5 percent, depending on motor design, at full load. This term only
applies to induction motors because synchronous motors operate at
synchronous speed. With the introduction of adjustable-frequency
controllers, it is now possible to continuously adjust the speed of ac
motors because the frequency can be continuously varied.

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A single motor can be operated at up to four different constant speeds
depending on the design of the motor. A single-winding induction motor
can be wound such that it can be operated at either of two speeds by
reconnecting the windings within the motor. The low speed must be one-
half of the high speed. A two-winding motor can be constructed to operate
at any of the normally available speeds, and the low speed does not need
to be one-half of the high speed. Therefore, a single motor designed with
two sets of windings, each designed for two-speed operation, would allow
four operating speeds. Since a two-speed single-winding and a two-speed
two-winding motor require different controllers, the type of motor to be
specified shall be coordinated with the controller to be provided.

3.6.2.4 Motor Thermal Protection. Thermal protection must be


provided to prevent uneconomical and excessive rates of electrical
insulation system deterioration caused by excessive temperatures.
Severe overheating may result in immediate motor burnout. There are a
number of causes of motor heating but the ones most often encountered
include: sustained overload, low or unbalanced supply voltage, high
ambient temperature, loss of ventilation, failure of electrical elements, and
failure of mechanical components.

Several methods can be employed to protect a motor against thermal


damage. In some cases, it is best to provide a combination of elements to
provide protection against several possible causes. In every case,
thermal overload protection needs to be included as part of the motor
controller and, where high ambient temperatures are anticipated, an
insulation system with a higher temperature rating should be specified.
Integral overheating protection shall be provided for all motors 100 hp and
larger, all motors that are driven by an adjustable-frequency drive system
(AFD), and most motors that are located in wet wells or other locations
where continuous cooling cannot be assured.

Integral thermostat devices are adequate for small motors but larger
motors shall be protected by thermistors or resistance temperature
devices (RTDs). Thermistors should be used for motors 100 hp and larger
at 480 volts with RTDs being used for all medium-voltage motors.

The need for special protection schemes needs to be evaluated for each
of the other possible causes of motor overheating. The larger the motor,
the higher the operating voltage. The more critical the drive, the more
likely that special protection shall be provided.

3.6.2.5 Motor Enclosures. Different types of motor enclosures are


offered that provide varying degrees of physical protection from the
elements for a motor (see Appendix E). Following is a brief list of those
enclosures most often needed in a water treatment plant:

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x Drip-Proof Enclosure. This is an open enclosure with


ventilating openings constructed so as to prevent drops of
liquid or solid particles that fall on the machine from an angle
of 15o or less from the vertical from entering the machine.

x Weather-Protected Type I Enclosure. This is an open


enclosure with ventilating passages constructed and
arranged to minimize contact of rain, snow, and airborne
particles with live and rotating parts.

x Totally Enclosed Fan-Cooled Enclosure. This is designed


to prevent free exchange of air between the inside and
outside of the enclosure and includes an integral fan external
to the enclosure to provide cooling.

x Totally Enclosed Nonventilated Enclosure. This is de-


signed to prevent free exchange of air between the inside
and outside of the enclosure and includes no external
provisions for cooling the enclosed parts. The motor is
cooled by heat radiating from the surface to the surrounding
atmosphere.

Motors larger than 5 hp that are located in indoor dry areas may be
specified to have drip-proof enclosures. Totally enclosed fan-cooled
enclosures shall be specified for motors smaller than 5 hp in all locations
and for larger motors located outdoors and in wet areas, except for the
following two exceptions. Very small motors may also be specified to
have totally enclosed nonventilated enclosures when these are the
standard of the manufacturer supplying the equipment. Motors 200 hp
and larger that are installed outdoors shall be specified to have weather-
protected Type I enclosures. All motors to be located outdoors and in wet
and/or corrosive indoor locations shall be specified to have sealed winding
insulation.

3.6.3 Low-Voltage Single-Phase Induction Motors


Single-phase motors shall be specified for nonessential process loads less
than 3/4 hp and in heating and ventilating (HVAC) system equipment
where they are the standard of the manufacturer. Single-phase motors
shall be equipped with some type of starting device to cause motor
rotation. Because this starting device often includes a centrifugal switch
and a capacitor, which can be points of failure, use of this motor is limited.

Single-phase motors are available for operation at 115 volts, 208 volts, or
230 volts single-phase, which will allow their connection to most low-
voltage systems.

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3.6.4 Low-Voltage Three-Phase Induction Motors


Three-phase induction motors shall be specified for most low-voltage
process applications. Apart from the motor controller, three-phase
induction motors do not require any type of auxiliary equipment to facilitate
starting, and therefore they offer the highest reliability available. Low-
voltage three-phase motors are available from 1/4 to 600 hp but shall not
be specified above 200 hp except in special situations. Voltage selection
for motors larger than 200 hp shall be reviewed with Metropolitan.

Low-voltage three-phase induction motors are classified by NEMA in


accordance with five design types (Appendix F). The design types are A,
B, C, D, and F, and the main difference between them is their torque
characteristics. Design B motors shall be specified unless the load being
driven has special torque requirements and a special motor is required.

These motors are capable of being driven as either constant-speed


motors by a full- voltage or reduced-voltage motor controller, or at
adjustable speed by a speed-control system. An adjustable-frequency-
controlled speed drive system can be used to operate a normal induction
motor, whereas a wound-rotor motor is required if a wound-rotor motor
controller is to be used. Except where special circumstances require
otherwise, adjustable-speed motors shall be three-phase induction type
with pulse width modulated (PWM) adjustable-frequency controllers.
Motors specified for operation with adjustable-frequency controllers shall
be sized so that the driven load does not exceed 87 percent of the
nameplate rating of the motor.

3.6.5 Medium-Voltage Induction Motors


Medium-voltage induction motors shall be used for all applications where
the motor size exceeds 200 hp. Medium-voltage motors may be used for
smaller motors if medium-voltage motor control was provided for the
existing motors to be replaced. There are some situations where
synchronous motors should be selected; these applications are covered
under paragraph 3.6.6, Synchronous Motors.

All medium-voltage motors shall include integral overheating protection


provided by resistance temperature devices (RTDs) embedded in the coils
of the motor and in the bearing housings. A multichannel system shall be
provided to monitor the temperature at each RTD location. A contact
operation shall be provided to STOP the motor should the temperature at
any location exceed a preset value.

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3.6.6 Synchronous Motors


Synchronous motors are similar in construction to induction motors and
require similar type controls except that, since they need to be separately
excited, the control equipment is much more complex. Synchronous
motors are available from fractional horsepower to many thousands of
horsepower. They are typically used where large loads are operated
continuously and power factor improvement is required because they can
be a source of VARs when they are overexcited. There are few
applications in a water treatment plant that justify the added expense of a
synchronous motor and its associated controls; each potential application
needs to be reviewed carefully.

The synchronous motor needs to be protected for the same conditions


that apply to a large induction motor. In addition, due to the
characteristics of the synchronous motor, there are a number of additional
types of protection required. These include pull-out protection, loss-of-
field protection, starting winding protection, and incomplete sequence
protection. The details of these types of protection are covered by several
of the reference texts.

3.6.7 Direct Current Motors


There are a number of applications for dc motors in a water treatment
plant. These motors offer a wide speed range with essentially stepless
variation in speed setting. They are capable of being accelerated and
decelerated quickly and result in very accurate speed control when set.
With their associated controllers, dc motors shall be specified to drive
chemical feed pumps where precise control is required.

Dc motors shall be powered from the low-voltage ac power system using


DC-SCR drive units. Units 5 hp and less shall be supplied power at either
120 or 240 volts single phase.

3.7 RACEWAY SYSTEMS


A raceway system shall be installed to provide protection for conductors
for power, control, and instrumentation circuit conductors. Raceway
systems can take a number of forms, but in a water treatment facility the
forms most likely to be found include conduit systems, wireways, cable
trays, underground trenches, and underground duct systems. The guide
specifications cover the products to be used in each system and the
installation of that material. This section describes when to use the
different systems, the design criteria to be used in sizing the components
of each system, and identifies many of the applicable sections of the NEC.

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3.7.1 Conduit System


The raceway most often used to protect conductors is the conduit.
Conduit is available in a number of materials, but the ones most often
used are Schedule 40 PVC, galvanized rigid steel conduit (GRS), PVC-
coated galvanized rigid steel conduit, electrical metallic tubing (EMT), and
liquid-tight flexible metal conduit (flex). Schedule 80 PVC and flexible
metal conduit (not liquid-tight) are also used for some applications.

The conduit type to be used in each situation shall be determined based


on the conditions expected on the project. GRS and PVC-coated GRS
offer superior physical protection and should be selected for those
applications where physical damage can be expected. PVC-coated GRS
and Schedule 40 PVC conduit offer resistance to corrosion and shall be
selected where corrosive conditions can be expected. The properties of
these conduits shall be considered in combination when selecting the
conduit to be used for such applications as turning up out of a corrosive
soil or passing through the interface between concrete and either the soil
or a wet condition exposed to the air. In both of these situations, the
superior properties of PVC-coated GRS make it the preferred choice.

The galvanized coating of EMT resists corrosion well but the walls are so
thin that it does not resist physical damage well. EMT shall be used in dry
areas above ceilings and concealed in walls for lighting, receptacle, and
HVAC circuits.

Schedule 40 PVC shall be used where conduits are to be installed


underground, either direct buried or concrete encased, because of their
superior resistance to corrosion. Schedule 40 PVC shall also be installed
abovegrade where a corrosive environment is anticipated, such as in a
chemical room, and where the conduit can be protected from physical
damage.

Articles 344, 350, 352, 353, and 358 of the NEC contain additional
information pertaining to the installation of conduit systems and shall be
consulted during design.

3.7.2 Conduit Identification


Conduit numbers shall be assigned to conduits. The conduit number shall
be shown on equipment layout drawings, electrical conduit layout
drawings, wiring diagrams, and conduit schedules. The conduit number
shall be composed of the equipment number of the serviced equipment,
plus a sequentially assigned number.

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3.7.3 Wireway
Wireways with conduit nipples shall be used to interconnect electrical
equipment where there will be a number of separate enclosures located
close to each other. The wireway provides an ideal pathway between the
enclosures, it provides space for tapping of conductors, if necessary, and
it makes grouping of conductors from the various enclosures into conduits
leaving the area very easy. Article 376 of the NEC contains additional
information pertaining to the application of wireway and shall be consulted
during design.

3.7.4 Cable Tray System


The cable tray system is an ideal raceway system for use where frequent
changes in the conductor or cable systems are expected. They have
limited use in a water treatment plant where changes occur only
infrequently. There are a number of rules in the NEC which must be kept
in mind should the engineer choose to use a cable tray system.

Article 392 of the NEC covers the installation of cable tray systems and
the installation of conductors and cables in them. Single conductors shall
be No. 1/0 AWG or larger and labeled for installation in a cable tray. All
multiconductor cables shall also be tray cable (TC) rated to be installed in
a cable tray system.

In water treatment plants, cable tray systems shall be used in electrical


rooms to provide convenient routing of feeder conductors between major
equipment items and between the electrical room and the control room to
route control and instrumentation cable.

Ladder or ventilated/trough cable trays without covers permit the


maximum free flow of air across cables and shall be used to route power
and control cables.

Solid bottom steel cable trays with steel covers provide EMI/RFI shielding
protection for sensitive circuits and shall be used to route instrumentation
cables.

3.7.5 Trench System


The trench system offers an alternative to an above ground cable tray
system or a duct bank system in substation and switching station yards
where a large number of conductors and cables must be routed around
the yard. The trench system may be either precast concrete sections or
cast in place. A variety of trench widths and depths are available and the
precast type are available with a broad range of options and accessories.
Barriers shall be provided to separate conductors and cables of different
systems that are routed through the same trenches.

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Trench systems shall be open bottom with a crushed rock fill to provide
drainage and cable and conductor support. The trench shall be covered
by removable fiberglass reinforced concrete panels. Special sections shall
be provided where equipment will be expected to cross the trench system
that are designed to carry traffic loads and meet the requirements of
applicable portions of AASHTO H-20.

3.7.6 Ductbank System


A ductbank system consists of a number of handholes and/or manholes
interconnected by red concrete encased buried conduits. The conduits
are grouped together and routed along a single corridor to minimize the
space required for them.

Ductbanks shall be constructed using Schedule 40 PVC conduit with


appropriate spacers to maintain the NEC required spacing. Separate
ducts shall be installed for low-voltage (600-volt and less), medium-
voltage, control, instrumentation, and communication cables.

Communication duct shall have a separate handhole. High voltage duct


shall have a separate manhole. Low-voltage, power, control, and
instrumentation cables that run in the same manhole or handhole shall be
provided with barrier in accordance with NEC.

The largest ducts shall be installed at the bottom of each ductbank with all
of the spare ducts being provided at the top of the ductbank. Even though
different sizes of ducts may be required by the conductors and cables to
be installed, the number of sizes being installed shall be kept to a
minimum. Each row in the ductbank shall be the same size throughout its
width and the minimum size conduit to be installed shall be 1 inch.

3.8 CONDUCTORS
All conductors, regardless of use, shall be copper and shall be stranded.
This section will cover both low-voltage, including conductors and cables
for instrumentation and control systems, and medium-voltage wiring
systems and their related appurtenances.

3.8.1 Low-Voltage Wiring Systems (600 Volts and Below)


Low-voltage wiring systems shall generally consist of insulated copper
conductors installed in an approved raceway system. The minimum size
conductor to be used for power and lighting systems shall be No. 12
AWG. Conductors used for control circuits shall be No. 14 AWG
minimum, but larger conductors may be used where control circuits are
long.

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3.8.1.1 Power Conductors and Cables. Conductors used for feeders


and branch circuits to process equipment shall be insulated with a cross-
linked, thermosetting, polyethylene insulation and shall be UL type RHH-
RHW-USE. Conductors used for lighting and receptacle branch circuits
shall be PVC insulated, shall have a nylon jacket, and shall be UL Type
XHHW.

Where conductors for power circuits are to be installed in cable trays, they
shall be UL-listed as suitable for that use. The NEC does not allow single
conductors smaller than No. 1/0 AWG to be installed in cable trays.
Smaller feeder and branch circuit conductors to be installed in cable tray
shall be multiconductor power cable rated type TC.

Low-voltage conductors shall be sized in accordance with the require-


ments of NEC Table 310-16, as described in paragraph 2.3, Design
Calculations. Conductor ampacities used in the calculations shall be
based on the appropriate temperature rating for the conductor and
corrected for the ambient temperature that can be expected and for the
conduit fill conditions. Because many terminals used in equipment for
conductors No. 1 AWG and smaller are not UL-listed for applications
above 60o C, conductors No. 1 and smaller shall be sized using their
60o C ampacities. Where derating factors are used in the calculations for
sizing these conductors, either 75 or 90o C ampacities, whichever is
appropriate for the application, may be used in the calculation as long as
the resulting ampacity calculated is equal to or less than the listed
ampacity at 60o C.

Terminals for larger conductors are rated for use with conductors rated
75o C. The 90o C ampacities of conductors larger than No. 1 can be used
in determining the size of the conductor to be used, if:

x The conductors (conduit) are being installed in a dry area;

x Derating is required due to high ambient temperatures or if


the number of conductors being installed in the conduit
exceeds three;
o
x The resulting ampacity calculated does not exceed the 75 C
rating of the conductor.

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3.8.1.2 Control Conductors and Cables. The minimum size conduc-


tor to be used for control circuit shall be No. 14 AWG. No. 12 AWG
conductors shall be used for long circuits where additional physical
strength is required. The conductors shall be PVC insulated, shall have a
nylon jacket, and shall be UL type THWN/THHN/MTW. Where multiple
control conductors are required between two panels or terminal junction
boxes, a multiconductor control cable shall be installed. Multiconductor
control cables shall be constructed using UL type THWN/THHN/MTW
single conductors bound together in a single assembly with a PVC jacket.
The assembly shall be manufactured in accordance with UL 1277 and
shall be UL and NEC Type TC suitable for cable tray installation.
Individual conductors of multiconductor control cable assemblies shall be
color coded in accordance with Method 1, Table K-2 of ICEA 5-66-524.

Control conductors may be installed with motor branch circuit conductors


where control devices are located at or near the motor. Individual
conductors shall be installed with branch circuit conductors No. 4 AWG
and smaller, and multiconductor cables shall be installed where the branch
circuit conductors are No. 2 AWG or larger. Where the branch circuit
conductors are larger than No. 4/0 or parallel conductors are used, control
conductors shall be installed in a separate raceway.

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3.8.1.3 Instrumentation Cables.
The minimum size conductor to be used for analog signal circuits and
other low voltage discrete dc circuits shall be No. 18 AWG. These
conductors shall be installed as twisted shielded pairs (TSPs) and/or triads
(TSTs) as may be required for the installation. A TSP shall consist of two
No. 18 or larger stranded copper conductors with PVC insulation and a
bare copper drain wire twisted together within a conducting shield and a
flame retardant jacket. A TST shall be similar except that it shall contain
three No. 18 or larger insulated stranded conductors. Instrumentation
cables are available with both 300-volt and 600-volt insulation. Cables
with 600-volt insulation shall be used wherever they will be installed in
equipment that contains circuits that operate at above 120 volts to
ground. Cables with 300-volt insulation may be used wherever physical
separation will be maintained from conductors that operate at above
120 volts to ground. See the specifications for the details of construction
of the instrumentation cables to be used.

A TSP shall be installed from each field-located device to the associated


control room-located instrument, panel, or remote terminal unit without the
use of intermediate terminal junction boxes, wherever possible. The
exception to this is where multiple instruments (more than five) are located
close to each other, and then a local terminal junction box shall be
installed to gather the single TSPs together into a multipair cable. The
multipair cable shall be constructed of multiple, individually jacketed,
twisted shielded pair conductors cabled together within an overall shield
and jacket.

Where a large number of 24-volt discrete signals have been brought


together in a terminal junction box and need to be connected to the
terminals of a distributed control system or similar input/output assemble
for a programmable logic controller (PLC), a multipair unshielded cable
may be used.

All instrument cables shall be terminated with locking forked tongue lugs
on numbered screw type terminal blocks. Terminal blocks shall be
constructed of UL- recognized component plastic, phenolic, and have
nickel-plated brass, binder head type screws.

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3.8.2 Medium and High Voltage Conductors (Above 600 Volts)


Two types of insulation must be considered when specifying medium- and
high- voltage conductors. They are the cross-linked polyethylene (XLPE)
and thermosetting ethylene-propylene rubber (EPR) compounds.
Although both insulations have similar properties and ratings, EPR is less
subject to treeing in the presence of water. Therefore, all medium- and
high-voltage conductors shall be shielded, shall have EPR insulation, and
shall have a PVC or neoprene jacket. Conductors with insulation rated
133 percent shall be used on ungrounded and resistance grounded
medium-voltage systems. Conductors with insulation rated 100 percent
may be used on systems that are solidly grounded. See the specifications
for the details of medium-voltage conductor construction.

The ampacity tables of Article 310 of the NEC shall be used in selecting
conductor sizes for medium- and high-voltage circuits but the Engineer
must not forget the effects of short circuit currents on these conductors.
The application of each medium- and high-voltage conductor shall be
reviewed with respect to allowable short circuit current for the conductor
size required and allowable temperature rise of the insulation before the
short circuit protective device trips. Chapter 12, Cable Systems, of IEEE
Standard 141-1993 should be consulted for additional information on this
subject. In addition, several manufacturers have published data and
graphs that are useful in selecting conductors that are properly sized for
applications where fault currents are high.

3.8.3 Splices and Terminations


As a general rule, no conductor, regardless of voltage, shall be spliced,
but there are certain situations where splices and terminations will be
required. This section deals with the splicing and termination of low-
voltage and medium-voltage insulated conductors.

Low-voltage power conductors in lighting and receptacle circuits may be


spliced using UL-listed insulated, twist-on spring connectors (wirenuts).
Splices in conductors to process equipments, control elements, and
instruments shall be made with approved compression type connectors.
Final terminations at motors and similar equipment where removal of the
equipment for maintenance can be expected shall be made with approved
bolted connection. All splices and termination shall be insulated using
heat-shrinkable sleeves that provide an insulation level at least equal to
that of the conductor.

Splices shall not be tolerated in control and instrumentation circuit


conductors. Where splices are required, they shall be made on terminal
strips in a junction box (terminal junction box). Control conductors and
cables shall be terminated at box lug type terminal blocks rated 600 volts

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as specified in Section 16050, Basic Materials and Methods, of
Metropolitan's Standard Specifications Sections Catalog. Instrumentation
conductors and cables shall be terminated using locking forked tongue
lugs and screw type terminals as previously mentioned in this chapter and
as specified in Section 16120, Conductors, of the specifications.

Splices shall only be allowed in medium-voltage conductors where existing


conductors must be extended and terminals are not available for the
extension. Such splices shall be made inside of manholes or above
ground pedestals using premolded deadbreak elbow and modular splice
assemblies of ethylene-propylene-terpolymer (EPDM).

Terminations located indoors and in motor termination boxes shall be of


the factory premolded EPDM type. Terminations in pad-mounted
transformers shall be of the premolded EPDM loadbreak elbow type. All
other terminations of medium-voltage conductors shall be made using
factory premolded and skirted EPDM type or preassembled slip-on type
terminators. See Metropolitan specification Section 16120, Conductors,
for additional information about splices and terminators for medium-
voltage conductors.

3.8.4 Conductor Identification


All conductors on each project shall be identified by a system of unique
numbers. Circuit numbers shall be keyed to the equipment to which the
conductors are connected. Each conductor shall be identified at each
termination point and at all accessible locations, such as handholes,
manholes, pullboxes, etc. The conductor number shall be shown on
wiring diagrams, wire lists, instrument loop diagrams, and panel wiring
diagrams. Conductors shall be identified by approved conductor and
cable tags. See Metropolitan specification Section 16120, Conductors,
and Appendix H for additional information on the conductor identification
system and a material specification for the tags.

3.8.5 Conductor Installation


Conductors and cable shall only be installed in conduits and ducts that are
properly sized, properly installed, and free from debris. Installation of
large conductors and cables in long conduit or duct runs, or in conduit or
duct run with multiple bend, need to be reviewed carefully to verify that
they can be safely installed without damage to them. Pulling tension
calculations and jam ratio calculations should be performed to determine if
additional pull points or larger conduits are required.

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3.9 JUNCTION BOXES AND PULL BOXES


Junction boxes and pull boxes shall be provided to facilitate the
combination of multiple circuits into a single conduit and the pulling of
conductors and cables. They shall be sized as necessary to
accommodate the conductors and cables being installed and shall be con-
structed of a material suitable for the environment where they will be
located. Section 16050, Basic Materials and Methods, of Metropolitan's
Standard Specifications Sections Catalog covers the basic materials that
are available for use. Two sizes of boxes are discussed in this section:
device boxes (small boxes) used as junction and pull boxes, and boxes
that must be larger than device boxes. Junction boxes shall be shown on
the drawings as required in the conduit system to group conductors,
terminate cables, etc. Pull boxes may or may not be shown depending on
the needs of the project. Even if pull boxes are not shown, the
specifications require the contractor to install them to limit the number of
bends in a conduit section to not more than three 90o equivalent bends.

3.9.1 Indoor Locations


Indoor locations can have environments that vary anywhere from dry to
wet and can include corrosive as well as hazardous atmospheres.
Corrosive and hazardous atmospheres will be discussed later in this
section.

The boxes used in indoor locations must be able to withstand the physical
abuse they are likely to receive, stand up to the environment, and keep
water out of the raceway system.

Boxes used in dry areas may be manufactured of either sheet steel or cast
metal. Small boxes that may be subject to physical damage shall be
manufactured of cast metal, whereas larger boxes in such locations shall
be manufactured of sheet steel. Small boxes located 4 feet above
finished floor in lighting, and receptacle circuits and concealed boxes in all
raceways, shall be constructed of sheet steel.

Small boxes to be installed in damp or wet locations shall be cast metal.


Larger boxes may be either cast metal, epoxy-coated sheet metal with
stainless steel hardware and neoprene gaskets, stainless steel, or
gasketed reinforced fiber glass with stainless steel hardware rated
NEMA 4.

Cast metal conduit fittings may be used as junction boxes in both dry and
wet areas if the box contains no splices; large device boxes shall be used
wherever splices are necessary.

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3.9.2 Outdoor Locations


Boxes to be installed in outdoor locations that have noncorrosive
atmospheres shall be installed using the same criteria as for indoor wet
areas. Boxes shall be installed in such a way as to protect them from
physical abuse either by locating them out of harm's way or installing them
behind a removable barrier. Concrete pull boxes shall be installed in
underground runs of conduits where the number of conduits passing
through them do not justify installation of a handhole or manhole.

3.9.3 Corrosive Locations


Boxes to be installed in corrosive locations shall be rated NEMA 4X and
shall be manufactured of a material suitable for the corrosive
environment. These boxes should be located away from corrosive
materials as much as possible. Acceptable materials include 316 SST,
reinforced fiberglass, and PVC. PVC may only be used in the smaller
sizes.

3.9.4 Hazardous Locations


Boxes to be installed in hazardous locations shall be UL-listed for use in
an area with the hazard classification that exists if a standard exists.
Where a standard does not exist, the boxes shall be designed to meet the
requirements of NEMA 7 as a minimum.

3.9.5 Terminal Junction Boxes


The term "terminal junction box" (TJB) shall be a term applied to junction
boxes that contain terminal strips for the termination of either control
conductors, small power conductors, or instrumentation cables. They
shall be constructed using a junction or pullbox that is suitable for the area
where it is to be installed and contains terminal strips that are suitable for
the conductors to be terminated. See Section 16050, Basic Materials and
Methods, of Metropolitan's Standard Specifications Sections Catalog for
additional requirements for TJBs.

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3.10 MANHOLES AND HANDHOLES


Manholes and handholes are similar in construction except for their size,
but are used for different purposes. Handholes are smaller and are used
as pull points and locations to redirect circuits in low-voltage and
communication ductbank systems where it is reasonable to work with the
conductors from above ground. Manholes are much larger and are used
as pull points and places to redirect circuits in medium- voltage ductbanks
and in low-voltage ductbanks where the conductors are too large to work
from above the ground. Manholes are constructed with enough depth to
allow a worker to climb down into it. Since a worker must be able to move
within the manhole without contacting the low- and medium-voltage
conductors that pass through it, the horizontal dimensions of the manhole
must also be larger than that of a handhole.

3.10.1 Handholes
Handholes shall be precast concrete, shall contain blockouts or knockouts
on all four sides, and shall have a square or rectangular opening in the
cover. The opening in the cover shall be equipped with a hinged cover
that is suitable for the location where the handhole is to be installed.
Handholes that will be installed in driveways, parking areas, or other areas
where vehicle travel can be expected shall be equipped with covers that
are rated for AASHTO H-20 loading. Handholes in other areas may have
covers with a lower loading class.

Handholes that are smaller than 4 feet by 4 feet by 4 feet need not be
equipped with cable racks and insulators, but the contractor shall be
required to provide adequate support for all conductors and cable to keep
them from laying on the floor of the handhole.

Handholes to be installed in areas with high groundwater shall be


equipped with a single drain opening that can be either plugged or
plumbed to a drain. When trying to keep the inside of the handhole dry,
remember the buoyant effect that can result. It is often better to leave the
opening open and allow the water level in the handhole to rise and fall with
the groundwater level. In areas where groundwater is not a problem,
similar handholes can be used, or handholes with no bottom are also
acceptable.

Handholes shall be installed in low voltage and communication system


ductbank at all 90o bends, adjacent to every building and/or structure
where large numbers of ducts enter the ductbank system, and as
necessary to limit pulling tension required for installation of conductors
and cable to within safe limits.

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3.10.2 Manholes
Manholes shall be precast concrete, shall contain blockouts or knockouts
on all four sides, and shall have a round opening in the top. The opening
in the top shall be equipped with a cast metal cover that is suitable for
AASHTO H-20 loading. The manhole shall be a minimum height of
6-1/2 feet clear inside so that a person can stand full erect within the
manhole.

Manholes shall be equipped with heavy duty inserts and cable racks to
provide support for conductors and cables that pass through them. All
conductors and cables shall be trained around the perimeter of the
manhole and shall be tied into place with suitable wire ties or similar
banding material.

Manholes shall be equipped with a depressed area for installation of a


portable sump pump. Remember, in high groundwater areas the
buoyancy of the manhole may be sufficient to lift it out of the ground;
therefore, it may be necessary to provide a drain in the bottom of the
manhole to allow the level of the water in the manhole to rise and fall with
the groundwater level.

Manholes shall be used in all medium-voltage ductbank systems and in


low-voltage ductbank systems where the size of the conductors makes it
impossible to work with them from above the ground. They shall be
installed at all 90o bends and as necessary to limit the pulling tension
required for conductor or cable installation to within safe limits. Should
handhole or manhole spacings greater than 300 feet be desired or 90o
bends be necessary, pulling tension calculations shall be performed.

3.11 LIGHTING SYSTEMS


In this section, three different lighting systems are discussed. The first
provides general illumination for visual tasks that are necessary in and
around a facility, the second is an emergency/standby system to provide
minimum illumination of means of egress so that safe exit from an area is
possible should normal power fail, and the third is exit signing. All three
lighting systems are not always necessary; building codes and common
sense dictate when the second and third types of systems are necessary.

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3.11.1 General Illumination


Lighting for general illumination can be provided by a variety of sources
depending on the visual tasks that are anticipated, the lighting levels
required, the mounting height of the luminaires, and the frequency of use
of the lighting system. Illumination should be provided by the source that
provides the highest light output (lumens) per watt of input power
(efficacy) that can be used, providing reasonable color rendition for the
visual tasks in the area. Fluorescent lamps shall be the preferred source
in indoor locations, and high-pressure sodium (HPS) lamps shall be the
preferred source in outdoor and high bay indoor locations.

Fluorescent lamps are available in several types and each has very
specific characteristics. Because of their long life expectancy, the
fluorescent lamps most often used are the 48-inch, 40-watt (34-watt
energy saver) preheat rapid start; the 96-inch, 75-watt (60-watt energy
saver) slim line; and the 96-inch, 110-watt (95-watt energy saver) high
output lamps. They are available in several color classifications, but the
only ones that will be considered here are the cool white and warm white
classifications.

Although warm white lamps produce a higher light output, cool white
lamps are recommended for most applications because they provide truer
color rendition and thus better visibility. Warm white may be selected for
industrial type applications where color rendition is not important.

HPS lamps are available in a number wattages and are suitable for
burning in any position. Even though their color rendition is not equivalent
to that of fluorescents, their increased efficacy (lumens per watt) and their
longer life make them the best choice for outdoor and hard to relamp
indoor areas. One characteristic of all high- intensity discharge lamps
(mercury vapor, HPS, and metal halide) is that they require a warm-up
and restrike time, they are not immediately on as is a fluorescent or
incandescent lamp. The warm-up time for a HPS can be as much as 3 to
4 minutes, during which time the light output is greatly reduced. The
restrike time for a HPS is usually 1 minute or less. Where immediate light
output is necessary on re-energization, an auxiliary quartz lamp can be
provided by some luminaire manufacturers.

Other lamps that may be used include the incandescent, the mercury
vapor, and the metal halide or multivapor lamps. The incandescent has
very low efficacy and short life, but it is on immediately when energized
and is very low cost. It has applications in out-of-the-way places that are
not visited frequently, and where low temperatures or hazardous
environments make the selection of other sources difficult. Mercury vapor
and metal halide could be applied in the same areas where HPSs have

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been recommended. Each has advantages and disadvantages, which will
not be discussed here. When used, incandescent lamps shall be
extended service, inside frosted type unless clear lamps are required to
meet specific design requirements.

3.11.2 Recommended Illumination Levels


The Illuminating Engineering Society (IES) has published a handbook that
contains recommended illumination levels for nearly all situations.
Table 3-2 is based on the recommendations of IES but is abbreviated
because of the need to use more general area classifications that can be
applied to a water treatment plant or pump station.

Footcandle levels recommended are only approximate, and judgment


must be exercised when selecting appropriate levels and making the
calculations. In some instances the lighting level indicated only applies to
a small portion of a room or area, and it may be best to provide task
lighting (Figure 2-4) at the higher level and use a lower level for the rest of
the area.

3.11.3 Lighting System Design


The design of lighting systems for Metropolitan’s water treatment plants,
pump stations, and administration and maintenance buildings shall be in
accordance with California Code of Regulations, Title 24, State Building
Code. The Code provides performance and perspective compliance
approaches for achieving energy efficiency in building lighting systems.

3.11.4 Luminaires
There are too many companies that manufacture luminaires to list them or
the types of luminaire that they manufacture. In this section, some of the
general types of luminaires available will be discussed and
recommendations for their use will be made.

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Table 3-2. Recommended Illumination Levels


Task/Area Footcandles
Office/Lab Areas
General 50
Close Work 100
Control Room 50
Process Areas 30
Storage Areas/Active 20
Storage Areas/Inactive 10
Outdoor Areas
Filters 5
Pump Stations 10
Storage Areas 5
Walkways 2
Roadways 1

3.11.4.1 Fluorescent. Fluorescent luminaires used indoors shall be one


of four basic types:

x Recessed type with a lens;


x Surface type with a lens;
x Open-chassis type;
x Enclosed and gasketed.

All lenses shall be specified to be 100 percent clear acrylic.

Recessed fluorescent luminaires with a prismatic acrylic lens shall


normally be used in office areas, and lab areas. The luminaire specified
must be coordinated with the type of ceiling being installed, because the
luminaire to be recessed in a lay-in ceiling cannot be installed in a plaster
board ceiling and vice versa. Two-lamp luminaires are preferred but
three- and four-lamp luminaires shall be used where higher footcandle
levels are required and/or two-level switching is desired. Where three-
and four-lamp luminaires are installed in office areas, two-level switching
shall be provided.

Surface-mounted fluorescent luminaires with a lens may be substituted for


recessed luminaires in areas where plasterboard ceilings are being
installed.

In areas that contain equipment having video display terminal (VDT)

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screens, special care needs to be taken in selecting the lighting units to be
used. High-angle brightness, better known as glare, must be controlled to
avoid discomfort and fatigue. Proper selection of lighting units can
substantially reduce this brightness and thus improve the work
environment. Lighting control systems that utilize a parabolic louver
assembly of preanodized specular low-iridescent aluminum, Lithonia
OPTIMAX, or equal, shall be used in all areas where VDT screens will be
used.

Open-chassis fluorescent luminaires shall be specified for all industrial


type areas in the plant where moisture is not a problem if they can be
mounted at 15 feet or less. Higher mounting heights result in difficulties in
relamping and the need for higher wattage luminaires. Again, two-lamp
luminaires are the preferred type. Where more lamps are required to
provide the footcandle levels required, higher wattage lamps should be
considered. Open-chassis luminaires with reflectors shall normally be
used. Where the luminaires are to be suspended, a minimum of
10 percent uplight shall be provided. In situations where surface mounting
is necessary, no uplight is required and an open-chassis luminaire without
the reflector may be used. All open-chassis luminaires specified shall be
heavy duty type.

Enclosed and gasketed luminaires shall be specified for damp and wet
locations. They shall be UL-listed as suitable for the type of area that they
will be installed in. Luminaires shall be manufactured of molded, high-
impact resistant ABS plastic or reinforced fiberglass with a diffuser of high-
impact resistant acrylic.

3.11.4.2 High-Pressure Sodium. High-pressure sodium (HPS) lumi-


naires installed indoors shall be either open or enclosed and gasketed as
best suits the needs of the area where they are to be installed. Open
luminaires shall be installed in dry low and high bay areas where they will
be suspended and uplight is required. They shall be installed in areas
where the ceiling height exceeds 15 feet. Enclosed and gasketed HPS
luminaires shall be installed in all damp and wet areas where the mounting
height exceeds 12 feet. Luminaires shall be installed suspended and shall
be constructed using an acrylic or glass refractor that totally houses the
lamp.

High-pressure sodium lamps shall be used for all lighting applications


outdoors except where decorative lighting is to be provided at the
entrances of administration buildings.

Security lighting shall be provided on the outside of buildings and at


entrances by wall-mounted HPS luminaires that use a prismatic glass or
acrylic refractor to direct the light over a broad horizontal area. Each

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luminaire shall put a minimum of 2.25 footcandles of light on the ground
within a space of at least 10 feet in front of and at both sides of the
luminaire when it is mounted at 10 feet above final grade.

Illumination shall be provided at parking areas and on roadways by pole-


mounted luminaires. Mounting heights shall not exceed 25 feet, and lamp
size shall be 150 watt. In most situations, IES Type II luminaires will
provide the best illumination on roadways whereas IES Type IV or V
luminaires provide the best lighting for parking areas. Parking area and
roadway luminaires shall be wired for operation at 480 volts if the voltage
is available.

3.11.5 Emergency/Standby Lighting


For the purposes of this section, the term "emergency lighting" shall mean
those lighting systems that are required by NFPA 101 for the protection of
human life when the normal power supply fails. The term "standby
lighting" shall mean those auxiliary lighting systems that are not required
by code but are required for safety reasons should the normal power
supply fail. The same equipment shall be used for both lighting systems.

Emergency/standby lighting needs in office, lab, and control room areas


shall be provided by either recessed emergency lighting units or
emergency lighting units that are supplied integral to the fluorescent
luminaires. In either case, sufficient units shall be installed in all areas to
provide adequate egress lighting for all occupants in the building. Units
supplied shall provide a minimum of 90 minutes of light as required by
UL 924.

Emergency/standby lighting needs in enclosed process areas of the plant


shall be provided by 12-volt unitized lighting units. At least one unit shall
be installed in each area where motors or other process equipment exist
and one unit shall be installed in each electrical room that houses
switchboards, unit substation, or motor control centers. Lighting units may
also be installed in other areas where the exitway may be blocked by
equipment or materials and a hazard may exist. Each lighting unit shall be
located to provide maximum illumination on the normal exitway.

The NEC requires that all unit type emergency lighting systems be
supplied power from the circuit that normally supplies the lighting in the
area where the unit is to be located. Where more than one circuit supplies
the area, the one that supplies the largest part of the traveled area shall
be selected as the source of power.

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3.11.6 Exit Signs


The Life Safety Code, NFPA 101, that defines the need for exit signing
and lighting contains no requirement that would require exit signs in most
buildings of a water treatment plant. There are some locations, however,
where exit signs should be provided.

Exit signs and lighting shall be provided in the administration building


where the public and persons unfamiliar with the building may have
access. Exit signs shall provide adequate direction to the exits. Rooms
that have a single door that does exit to the outdoors need not be
equipped with an exit sign. In addition, process buildings that contain
multiple rooms so that the means of egress is not obvious shall be
equipped with exit signs to direct a person to the nearest exit. All exit
signs shall be electrically powered and shall contain an integral battery
and low-voltage lamps to provide uninterrupted illumination should the
normal power supply fail.

3.11.7 Controls
Controls for lighting systems shall be designed to meet the needs of the
space where the lighting system equipment is to be installed. Areas that
will require illumination 24 hours per day shall be provided with switching
duty circuit breakers and no local switches. In all office and process areas
where illumination is not required continuously, provide a separate switch
for each room. Where large rooms are encountered, at least one switch
shall be provided for each two 20-amp lighting circuits.

In office areas where lighting requirements will vary depending on the task
at hand, dimmers, two-level switching, or occupancy lighting control
sensors shall be provided to maximize energy savings.

All outdoor lighting circuits shall be routed through a photocell or photocell


controlled contactor to assure that they will be OFF when not required.
Where outdoor lights are controlled by photocell controlled contactor, a
three-position switch shall be provided so that they can be turned on for
testing. In some pole-mounted lighting applications, an individual ON/OFF
switch shall be installed on each pole of the lighting fixtures.

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3.12 LOW VOLTAGE POWER DISTRIBUTION

3.12.1 Voltage Selection


Low-voltage power for lighting, receptacles, and miscellaneous power
needs shall be distributed at 208Y/120 volts unless some other power
need dictates a different voltage. Low-voltage power shall be supplied by
installation of 480-208Y/120-volt, three-phase dry-type transformers
located at each load center. Instruments shall be powered from a
separate supply transformer and panelboard unless their number is very
limited and the low-voltage power panel is connected to no loads that can
be expected to generate harmonics back onto the bus. The instrument
power supply transformer may be a 480-120/240-volt, single-phase
transformer.

3.12.2 Panelboards
Panelboards shall be installed as necessary to provide power to the
120-volt, single- phase and 208-volt, single- and three-phase loads shown
on the drawing. Branch circuit breakers shall be thermal-magnetic type
and sized in accordance with applicable paragraphs of Articles 210, 220,
225, and 430 of the NEC. Where Article 220 allows the use of demand
factors, they shall be used with caution. Demand factors may be used for
feeder and transformer sizing calculations but not branch circuit
calculations.

Where more circuits are required than can be provided by a single


panelboard, provide a subfeed breaker in the panelboard supplied by the
transformer to supply a second panelboard. The second panelboard may
be located remote from the first panelboard. All panelboards supplied
from a transformer shall have a main circuit breaker (transformer
secondary breaker) that has been sized in accordance with the National
Electrical Code (see paragraph 2.3.7 in this manual for sample
calculations).

The load on 20-amp branch circuits that supply lighting and receptacles
must be limited to 80 percent of the rating of the branch circuit protective
device, a 20-amp molded case circuit breaker per Article 210 of the NEC,
because lighting and receptacle loads must be considered "continuous." It
is recommended that the load on these circuits be limited further to
1,800 VA to limit voltage drop on these circuits.

Branch circuit breakers for instruments, instrumentation panels, and so on


where the exact load is unknown but is small in magnitude shall be sized
at 15 amps to allow installation of multiple conductors in the same
conduit. (Number of conductors limited by derating required by Article
310.15(B)(2) of the NEC.) In addition, these circuits often pass through an

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instrument panel and become No. 14 AWG control conductors.

A separate branch circuit shall be provided for each instrument and


instrumentation panel unless several instruments are located at the same
location, are all associated with the same flow stream or process, and
monitor different parameters. In the above case, a toggle switch shall be
located adjacent to each instrument to disconnect it from the branch
circuit.

Branch circuits for heating, ventilating, and air conditioning equipment


rated 120 or 208 volts shall be supplied power from the lighting and power
panelboards. Branch circuit protective devices shall be rated 15 amps
unless a larger size is required to supply the load.

The Engineer shall make an effort to group circuits that perform a common
function together within a panelboard (e.g., all lighting together, all
receptacles together). In addition, three- and four-wire branch circuits
should be shown on the drawings wherever they are appropriate to
minimize the amount of conduit that is required. These circuits should be
connected to adjacent circuit breakers in the panelboard.

Each panelboard shall be provided with a minimum of 20 percent spare


breakers corresponding in size with the breakers being used.

3.12.3 Convenience Receptacles


Convenience receptacle outlets shall be located throughout each facility to
provide a ready power supply for portable tools. These receptacles shall
be located such that no item of process equipment is located more than
40 feet from a receptacle whether inside or outside of a building.
Additional receptacles shall be provided in areas where portable tools may
need to be used and where the above criteria does not require one in the
area. These receptacles shall all be in addition to receptacles that may
need to be provided for connection of portable process equipment.

Inside of the administration building, maintenance buildings, etc., which


are being designed primarily for the use of personnel, coordinate the
location of receptacles with the needs of the design architect. In office
areas, provide outlets on at least three walls. In laboratory areas multiple
outlets shall be located at work stations; coordinate these locations with
the laboratory designer.

Duplex receptacles shall be NEMA configuration 5-20R and shall be rated


20-amp, two-wire, three-pole grounding type unless requirements dictate
otherwise. All receptacles shall be installed in boxes as described in
paragraph 3.9. Receptacles located outdoors or in locations subject to
washdown where they cannot be protected by mounting height (4-foot

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minimum above finished floor) shall have a weatherproof cover.

Ground fault interrupter type outlets shall be installed in all outer locations
and locker rooms and bathrooms where personal hygiene items may be
used.

Receptacles to be installed in underground structures and in areas where


a corrosive atmosphere can be expected shall be manufactured of
corrosion-resistant materials.

3.12.4 Hazardous Area Receptacles


Receptacles to be installed in hazardous locations shall be of the type
suitable for use in classified areas in accordance with Article 500 of the
NEC and shall be UL approved.

3.12.5 Power Receptacles


Plugs and receptacles specified for use on Metropolitan projects shall
meet applicable NEMA and UL standards and shall be selected from
Figure 3-7.

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3.13 GROUNDING

3.13.1 General
Electrical circuits, equipment, and equipment enclosures shall be bonded
and grounded as required by Article 250 of the NEC. All process
equipment and structures subject to potential and current flow due to
lightning, static accumulation, or other abnormal conditions shall be
grounded by two ground connections.

References to be used in designing grounding systems shall include the


following:

x NFPA 70--The National Electrical Code;

x ANSI/IEEE Standard 80--IEEE Guide for Safety in AC


Substation Grounding;

x IEEE Standard 142--IEEE Recommended Practice for


Grounding of Industrial and Commercial Power Systems.

Three types of grounding are discussed in IEEE Standard 142: system


grounding, equipment grounding, and static and lightning protection
grounding. The following sections will cover grounding of both plant
electrical systems and substation grounding.

3.13.2 System Grounding


Electrical distribution systems can be either ungrounded (no intentional
ground) or grounded (intentionally grounded). For the purposes of this
manual, a grounded system shall be a system of conductors in which at
least one conductor or point is intentionally grounded, either solidly or
through an impedance. The basic reasons for system grounding are the
following.

x To limit the difference of electric potential between all


uninsulated conducting objects in a local area;

x To provide for isolation of faulted equipment and circuits


when a fault occurs;

x To limit overvoltages appearing on the system under various


conditions.

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3.13.2.1 Low-Voltage System Grounding. Low-voltage 480/277 and


208/120-volt, wye-connected three-phase and 120/240-volt, single-phase
transformers shall have their neutral solidly connected to ground. This
ground connection shall be of sufficient size and low enough impedance to
effectively ground the low-voltage distribution system.

3.13.2.2 Medium-Voltage Grounding. Systems 2.4 to 12 kV shall be


low-resistance grounded. Installation of the ground grid required shall be
calculated using measured soil resistivities. The system grounding
resistor shall be sized to allow sufficient ground current to flow to provide
immediate and selective clearing of the ground fault.

The zero sequence current transformer method shall be used to monitor


for ground currents because of their increased sensitivity over a residual
scheme using the high-ratio phase current transformers.

3.13.3 Grounding Electrode Systems and Grounding Grids


A grounding electrode system shall be provided for all premises' wiring
systems as required by the NEC. The grounding electrode system shall
be used for ground of the neutral of the low-voltage power supply and the
equipment ground conductors. A grounding grid shall be provided in
substations and at low- and medium-voltage transformers and switchgear
located outdoors to provide equipment grounding, system grounding, and
to minimize step and touch potentials.

The NEC permits the following to be used as grounding electrodes:

x Metal underground water pipes


x Metal frame of the building or structure
x Concrete-encased electrode
x Ground ring
x Rod and pipe electrodes
x Plate electrodes

However, because of galvanic action between buried steel pipes and other
nearby dissimilar metals, Metropolitan does not use buried large diameter
steel pipes in its distribution system as grounding electrodes.

3.13.3.1 Service Entrance Grounding. Each power supply system shall


be connected to a grounding electrode system meeting all requirements of
Article 250 of the NEC. Each item within the system shall be bonded
together by a bonding conductor sized in accordance with the
requirements of the NEC. Where made electrodes are included in the
grounding electrode system, they shall be 5/8-inch by 10-foot (minimum)
copper-plated steel rod (copperweld or equal).

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3.13.3.2 Transformer Grounding. A grounding grid shall be installed at


each transformer or switchgear assembly located outdoors. Where soil
resistivity is measured, a complete grounding system design can be
prepared. It is often sufficient to determine the approximate needs of the
grounding system, install a system based on tables that are available, and
then verify that the system is adequate.

Using the latter method of approximation, the following grounding system


should be adequate in areas where soils with reasonably low levels of soil
resistivity are present. Supply transformers (pad-mounted or unit
substation type) 1,000 kVA and smaller shall be provided with a minimum
of two No. 2 bare copper ground connections to a ground mat constructed
under and around the transformer. The ground mat shall be constructed
of No. 2/0 bare copper conductors and copper clad steel ground rods in
sufficient quantity to result in a measured resistance to ground of 1 ohm.
For larger transformers, the entire grounding system, including the
connections to the transformer, shall be No. 2/0. Where high resistivity
soils are encountered, a complete grounding system design shall be
performed using procedures contained in IEEE Standard 80.

3.13.3.3 Substation Grounding. A grounding grid system designed in


accordance with the requirements of IEEE Standard 80 shall be installed
in every substation. The soil resistivity shall be determined by field
measurement, and using that data, a grid system shall be designed to
keep step and touch potentials within safe limits.

The grounding grid shall be constructed of copper-plated steel rods


3/4-inch by 10-foot driven full length into the ground and bare stranded
copper or copper-coated steel conductors. The minimum conductor size
used shall be No. 2/0 AWG, but larger conductors shall be used where
high fault currents are expected. Smaller conductors may be used to
connect noncurrent carrying equipment to the grid; these must be sized
based on the fault current they could be expected to carry should a fault
occur. All underground connections shall be made with thermoweld
process. Bolted connections may be used abovegrade and shall be used
at equipment and structures to be grounded.

Because copper and copper-plated steel form galvanic cells with buried
steel pipes and conduits, the design of the substation grounding system
must be coordinated with other designs to minimize the effects of
corrosion.

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3.13.4 Equipment Grounding


The NEC requirements for equipment grounding are covered in Arti-
cle 250. In Metropolitan-owned premises, all noncurrent carrying metal
parts of fixed equipment likely to become energized shall be grounded.
The equipment grounding connection shall be provided by an equipment
grounding conductor sized in accordance with Table 250-122 of the NEC
routed with the phase conductors. Use of the raceway system for
grounding is not acceptable, but all metallic segments of the raceway
system shall be bonded to the equipment grounding conductor installed in
it.

3.13.5 Instrumentation and Computer Grounding


Each piece of equipment shall be connected to the equipment ground
point at the electric service equipment by an equipment ground conductor
run with the branch circuit conductors to provide the equipment ground
required by the NEC. Where isolated grounding type receptacles are
used, the requirements of NEC Section 250.146(D) shall be applied. A
dedicated grounding conductor connected directly to the equipment
grounding conductor terminal of the applicable derived system or service
may be required in some instrumentation and computer grounding
applications.

3.13.6 Lightning Protection System Grounding


Even though southern California is in an area of relatively low thunder-
storm activity, grounding for lightning protection is still a subject that
should be dealt with. NFPA 78 The Lightning Protection Code and IEEE
Standard 142 both deal with the grounding requirements of a lightning
protection system. The need for a lightning protection system is a
separate subject and will not be addressed here.

Where a lightning protection system is installed on a building or structure,


its grounding system shall be installed separate from the electrical system
ground, but the two shall be interconnected to provide a common ground
potential.

3.14 EMERGENCY AND STANDBY POWER SYSTEMS

3.14.1 General
Because emergency and standby power systems both use the same
equipment and often serve the same purpose, they are both discussed in
this section. For the purposes of this manual, the following definitions of
emergency power and standby power systems will be used:

x Emergency power system. An independent reserve source


of electric energy that, upon failure or outage of the normal

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source, automatically provides reliable electric power within
a specified time to critical devices and equipment, of which
failure to operate satisfactorily would jeopardize the health
and safety of personnel or result in damage to property.

x Standby power system. An independent reserve source of


electric energy that, upon failure or outage of the normal
source, provides electric power of acceptable quality and
quantity so that the user's facilities may continue in
satisfactory operation.

To put it another way, emergency power systems are those required by


law or code that are intended to provide safety of human life. Standby
systems are those that are required for continuous operation of a plant or
a process should the normal source be interrupted; they are usually
installed by user choice. The NEC, however, defines two types of standby
systems: the legally required and the optional standby systems. The
legally required standby systems are those that are required by local,
state, federal, and other codes to supply power to facilities where
interruption of normal electrical supply could create a hazard or hamper
rescue or fire fighting operations.

ANSI/IEEE Standard 446--IEEE Recommended Practice for Emergency


and Standby Power Systems for Industrial and Commercial Applications,
is an excellent reference on the subject of emergency and standby power
systems.

3.14.2 Emergency Power Systems


Emergency power systems shall meet all applicable requirements of
Article 700 of the NEC. Where large amounts of emergency power are
required, the need shall be supplied by an onsite diesel engine driven
generator. Where emergency power is only required for emergency
lighting and egress illumination, unit equipment as defined in Article 700
shall be used.

3.14.3 Legally Required Standby Power System


Legally required standby systems shall meet all applicable requirements of
Article 701 of the NEC. Where large amounts of power are required,
diesel driven engine generators shall be installed onsite. Lighting
requirements shall be provided by unit type equipment as defined in
Article 700 of the NEC.

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3.14.4 Optional Standby Systems


Standby power supply equipment shall be installed to provide an alternate
source of power for critical control and monitoring functions, and
processes that, when stopped during any power outage, could cause
discomfort, serious interruption of the process, damage to the product or
process, or the like. Optional standby systems shall meet all applicable
requirements of Article 702 of the NEC.

Lighting requirements shall be provided by unit type equipment as defined


in Article 700 of the NEDC.

An interruptible power supply system shall be provided for all computer-


based control and monitoring equipment that may not have integral battery
backup capability.

3.14.5 Engine Generators


Engine generators are the most often used source of onsite emergency or
standby power. They can be diesel, natural gas, gasoline, or even
propane powered. To be used as an emergency or legally required
standby power supply, the NEC requires onsite storage of sufficient fuel
for 2 hours of full load operation; therefore, natural gas engines are not
often used. In addition, due to fuel volatility nature, gasoline engines are
seldom used except in very small sizes. Synchronous generators shall be
used for all applications.

3.14.5.1 Diesel Engine Driven Generator. The diesel engine driven


generator is the preferred source of emergency and legally required
standby power because of its low first cost. For optional standby power,
the natural gas engine driven generator should be given first consideration
due to its cleaner burning and longer run time between maintenance.
Gasoline engine driven and propane engine driven generators should not
be used unless other sources of fuel are not available.

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3.14.5.2 Generator Ratings. Engine generators are available in ratings


from less than 1 KW to several thousand KW, with both diesel and natural
gas being available in most ratings.

3.14.5.3 Generator Sizing. Sizing of the engine generator shall be


based on the needs of the anticipated connected system electrical load
and shall take into account the starting requirements of the larger motors
on the system. Generator sizing computer software available from most
manufacturers shall be used to make the initial selection and then the
generator manufacturer shall be consulted to verify that proper generator
selection has been made. Selection shall be made once a complete list of
loads and their sequence of application has been completed. It must be
remembered that either one large motor or a number of smaller motors
that are equal in total horsepower and are started simultaneously will have
the same impact on the sizing requirements of the generator. If there are
several motor loads that must be started immediately when the generator
is connected to the load bus, each motor starter should be equipped with
a time delay relay so that they can be automatically sequenced on, thus
limiting the initial inrush. This will allow the generators to be sized more
closely to the actual load requirements.

3.14.5.4 Considerations for Load Types. Special consideration must


be given when sizing a generator when the electrical system being
supplied includes loads such as adjustable frequency drive systems,
uninterruptible power supplies, and similar solid state power equipment.

3.14.6 Unit Equipment


Unit type emergency lighting units shall consist of a sealed lead acid or
lead calcium battery, two 6-watt (minimum) lamps, a battery charger, and
appropriate indicating lights and test switches all contained in a single,
compact case. The unit shall meet all applicable requirements of NEC
Article 700.12(F) and NFPA 101.

Unit equipment shall be installed as required to provide egress lighting.


Units shall be powered from the branch circuit that supplies normal lighting
in the area where it is to be installed as required by Article 700.12(F) of
the NEC. The connection to the branch circuit shall be made ahead of all
local switches.

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3.14.7 Computer Power Systems


Power shall be supplied through uninterruptible power supplies (UPS) to
computer systems and microprocessor-based equipment such as remote
terminal units (RTUs) and programmable logic controllers (PLCs) that
have volatile memories. The UPS provides conditioned power to the
equipment during normal operation and provides uninterrupted standby
power should the normal source fail. Where multiple units are located in
close proximity to each other, a single large UPS system shall be
specified. Where the equipment is dispersed, multiple smaller UPSs shall
be specified.

Batteries supplied with UPS systems shall be of the low-maintenance type


specifically designed for use with UPS modules.

3.15 SPECIAL SYSTEMS

3.15.1 Plant Communication System


A complete plant communication system consists of a telephone system
and a paging system. The objective of the plant communication system is
to locate people within the plant and to communicate with the world
outside the plant. The operation of the plant will be simpler and the design
easier if these systems work together. It is important to get the users'
early input to the communication system design.

The objective of this section is to point out the steps to be followed to


design a communication system for a medium to large water treatment
plant. For smaller plants, which may not require paging systems, it is
usually advisable to have the telephone system supplied by the local
telephone company.

3.15.1.1 Telephone System. The engineer/designer should give detailed


attention to how the telephone system should work; as noted below, this
does not mean that a detailed design is necessary.

The first option to consider in getting the users their preferred type of
telephone system is to exclude it from the design package or include it as
an allowance. The reasons for this are:

x Leaving the telephone system selection to installation time


will get a more up-to-date system. Telephone systems are
changing rapidly. The telephone systems available at design
time may have all been replaced with significantly changed
models by the time the contractor places an order.

x Putting the telephone system selection in the competitive

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bidding process will result in the users getting the system
they want at a reasonable price. The engineer/designer
should have enough knowledge to assist the users with the
selection.

x Telephone system suppliers are generally willing to work


closely with contractors so that coordination of an activity
that occurs outside the contract should be no problem. The
contractor shall be responsible for any claim that will occur
during such coordination activities with the telephone system
suppliers. Check on the cooperation offered by the suppliers
in the local area.

x Getting design information from a telephone system supplier


will be difficult. The telephone industry is presently order
driven; most suppliers will provide little information about
their system, beyond sales brochures, until they have a
purchase order.

If the telephone system is going to be included in the design package,


design around a specific system. The system supplier shall be respon-
sible for the complete installation. Since NEC requirements on telephone
installations are changing more rapidly than the code revision cycle, this
will allow the latest installation methods to be used. It will also avoid
having the engineer/designer act as merely a pass-through for vendor-
supplied information.

With the design included in the documents, it is important to get as much


input from the user as is available. Find out if the user currently has any
telephone systems installed that they especially like or dislike. How
heavily will the system be used? How many options do they want? How
much complication are they willing to put up with to use these options?

The engineer/designer will need to determine the following before


beginning the design:

x Local phone company contact, policies on interface with


private exchanges, and requirements for service (e.g., who
supplies raceway, where does it go, and what size?);

x Number of stations that are active (in place), equipped (can


be made active by adding a phone set), and wired future
(with addition of future switch modules);

x Number of and configuration of paging zones;

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x Features and options desired (see specification and
manufacturer's current literature);

x Location of telephone switch, attendant's console, and


telephone sets;

x Atmosphere (dry, wet, hazardous) at every point that a piece


of telephone equipment will be installed.

The engineer's/designer's tasks are then to:

x Select a system that will meet the users' requirements;

x Modify the specifications so that they reflect the users'


preferences, the equipment available from the selected
supplier, and result in a biddable document that several
reputable suppliers can meet;

x Locate the telephone switch and distribution frame (with


assistance from selected supplier) and provide more than
sufficient power to this area; provide about twice the number
of receptacles that the telephone system supplier requires;

x Provide a ground bus in the vicinity of the distribution frame


connected to a grounding electrode and the plant grounding
system; typically this bus would be 1/4-inch by 2-inch copper
(check with the system supplier);

x Locate a telephone terminal box in each building that will


have a phone set and connect these boxes back to the
building that contains the telephone switch by large empty
conduits;

x Locate a telephone outlet near each point where a phone set


is to be installed.

3.15.1.2 Paging System. Paging systems are of two types: public


address or hand-held units. The choice will depend on whether you need
to locate a few people or anyone that happens to be on site. Hand-held
units have the advantage of rarely being out of range while on the
plantsite; their disadvantage is that the pager has to be carried and it
cannot (or only with great difficulty) be tied into the telephone system.

The engineer/designer must locate an amplifier in each building where


paging will be required, provide an empty raceway from the amplifier to
the telephone terminal cabinet, provide a receptacle near each amplifier,

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and provide a conduit system between the paging system amplifier and
the paging speakers for installation of conductors by the communications
system supplier. Paging speakers shall be located on the drawings as
required to provide coverage of areas where process equipment are
located.

3.15.2 Fire Alarm System


Fire alarm systems at industrial facilities are provided in facilities where
several people are consolidated in one area and in facilities where there is
a high fire hazard. Since most industrial facilities are not open to the public
and are staffed by personnel knowledgeable of the process and of the
hazards associated with the process, extensive fire alarm systems are not
usually required.

3.15.2.1 Building Occupancy. The following buildings shall be provided


with fire alarm systems:

x All industrial occupancy buildings, unless the total capacity is


under 100 persons and fewer than 25 persons are above or
below the level of exit discharge (NFPA 101 28-3.4.1).

x All business occupancy buildings where (a) the building is


two or more stories in height above the level of exit
discharge, (b) the occupancy is subject to 100 or more
occupants above or below the level of exit discharge, or
(c) the occupancy is subject to 1,000 or more total occupants
(NFPA 101 26-3.4.1).

x Underground structures in which the story is below the level


of exit discharge, except where the story has at least two
sides with at least 20 square feet of opening above the
grade level (NFPA 101 30-1.3.4).

x Windowless structures without grade level doors, access


panels, or windows on two sides of the building (NFPA 101
30-1.3.5).

3.15.2.2 High Fire Hazard. Sources of fire hazard at water treatment


plants include gases, some chemicals, and combustible dusts. Gases
used for laboratory analysis (e.g., hydrogen, oxygen), unit processes (e.g.,
chlorine, ozone), and welding operations may provide flammable/explosive
conditions when acting alone or mixed with other substances. Chemicals
or combustible dusts (e.g., carbon, potassium permanganate) used in
various unit processes may be combustible or cause potential flammable
and explosive conditions.

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Mitigation of fire hazards or potential ignition sources is best achieved by
physical separation of reactive chemicals and ventilation. Fire alarm
systems are required in the following areas:

x Laboratory buildings if a fire may not, of itself, provide


adequate warning to building occupants (NFPA 45 4-5.1).

x High hazard occupancy, operation, or process areas with an


automatic extinguishing system. The system shall
automatically initiate an occupant evacuation alarm signal
(NFPA 101 28-3.2 and 28-3.4.3.2).

3.15.2.3 Design Criteria. Where fire alarm systems are required, alarm
and detection devices shall be provided as shown in Table 3-3.

For the basic functions of protective signaling and control systems


including fire detection, alarm, and communication, see NFPA 101
Section 7-6.

3.15.2.4 Code References. Other documents from NFPA, as well as


other sources, provide specific information on fire alarm system
requirements, installation, sources of hazards, and sources of ignition.
The following documents contain additional information:

x NFPA 45, Laboratories Using Chemicals;

x NFPA 49, Hazardous Chemicals Data;

x NFPA 70, National Electrical Code;

x NFPA 72A-E, Standards for Fire Alarm System Installation;

x NFPA 101, Life Safety Code;

x NFPA 491M, Chemical Reactions;

x NFPA 497A, Classification of Class 1 Hazardous (Classified)


Locations for Electrical Installations in Chemical Process
Areas;

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1
Table 3-3. Requirements for Fire Alarm and Detection Devices
Area Initiation Notification

Industrial occupancy Manual or automatic Audible alarm in continuously attended location for
initiating action

Business occupancy Manual or automatic detection General audible alarm or live public address from
or sprinkler alarm at continuously attended location

Underground structure Manual or automatic Audible alarm in continuously attended location for
initiating action

Windowless structure Manual or automatic Audible alarm in continuously attended location for
initiating action

Laboratory (not specified) All persons endangered and local fire department
to be alerted

High hazard area Automatic extinguishing system General audible alarm


1
In addition to an audible alarm, a visual alarm may be required by the governing authorities in some cities and
counties.

x NFPA 820, Fire Protection in Wastewater Treatment Plants;

x Chlorine Institute, Properties of Chlorine.

3.16 ELECTRICAL TESTING

3.16.1 General Requirements


The electrical testing and equipment checkout process cannot be
designed into a project. Thus, it is necessary that the required testing and
checkout procedures be established in the project specifications.

Electrical testing of the power system and its associated equipment is an


absolute requirement that will provide a safe and reliable electrical system,
as well as prevent damage to equipment and possible injury to operating
personnel. The testing and checkout process must be started during the
period the equipment is being manufactured, and should be continued by
the electrical contractor during, and upon completion of, the plant
construction. It is the designer's responsibility to be familiar with the
testing and checkout procedures in order to be able to specify what is
required of the contractor.

In general, the electrical testing and system checkout should include the
following:

x The power supply as furnished by the serving electric utility


company;

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x Manufactured electrical equipment;

x Electrical distribution and branch circuit wiring;

x Electrical connections and terminations;

x Grounding;

x Lighting levels and controls.

3.16.2 Plant Electrical System

3.16.2.1 Utility Service Tests. The utility company's incoming three-


phase service voltages should be continuously recorded for a period of
24 hours at the point of termination after the installation is essentially
complete and the plant is in operation. Voltage amplitude and balance
between phases for loaded and unloaded conditions should be recorded
and reviewed. If an unbalance, as defined by NEMA, exceeds 1 percent,
the cause of the unbalance should be located and corrections should be
made. Should the voltage vary by more than plus or minus 4 percent
throughout the day from loaded to unloaded conditions, a request should
be made to the utility company to have the condition corrected.

3.16.2.2 Equipment Line Current. The line current in each phase


conductor for all three-phase equipment and/or for each substation,
switchgear, switchboard, and panelboard should be measured and
recorded after the utility company has made final adjustments to the
incoming service voltage.

3.16.2.3 Equipment Operations. Require the contractors and/or


equipment suppliers to check out each item of equipment and demon-
strate that it operates in accordance with the requirements of the project
specifications. The contractor must demonstrate that protective functions
are operating properly and are properly incorporated into the electrical
system protection and control schemes and into the plant control system.

3.16.2.4 Plant Illumination. The plant illumination system should be


visually checked after the fixture installation has been completed. The
initial lighting levels should be checked against the design criteria and for
compliance with Title 24 of the State Administrative Code requirements.
Exterior lighting should also be checked for proper fixture aiming.

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3.16.3 Medium and Low Voltage Equipment

3.16.3.1 Transformers. Liquid-filled and dry-type transformers should


receive all standard commercial tests in accordance with ANSI C57.12.90
at the factory. These standard transformer tests include the following:

x Applied potential;
x Induced potential;
x No load losses;
x Voltage ratio;
x Polarity;
x Continuity.

The manufacturer will also perform the following additional tests on units
identical to the design type being supplied:

x Sound level;
x Temperature rise;
x Full-load losses;
x Regulation;
x Impedance.

Prior to energizing a transformer, the contractor should perform the


following checks:

x Perform phase-to-phase and phase-to-ground megohmeter


test to verify winding integrity and dryness.

x Check for proper installation of vibration dampeners.

x Check the adequacy of wall or floor mounting/anchor bolts.

x Check and exercise all auxiliary devices such as fans,


alarms, and gauges.

x Obtain liquid sample from liquid-filled transformers and have


analyzed for moisture content, voltage breakdown limits, and
amount of contamination.

x Visually check liquid-filled transformers for proper oil level


and oil leaks at the bushings, valves, gauges, covers,
handholes, and radiators.

x Insulation power factor test on transformers with windings


rated 2.4 kV and above.

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After a transformer has been energized, the contractor should make the
following checks and/or tests:

x Proper voltage level;


x Load balance between phases;
x Correct polarity;
x Phase rotation;
x Ambient temperature.

3.16.3.2 Switchgear/Switchboards. Switchgear should be conformance


tested at the factory in accordance with ANSI C37.51 standards.
Switchboards are designed, built, and tested under the requirements of
NEMA PB-2 and Underwriters' Laboratories UL-891 standards.

Field tests performed by the contractor consist of operational tests of all


instrumentation and protective devices and ground fault protection
devices. All protective device and instrument circuits should be tested
using primary injection.

3.16.3.3 Motor Control Centers. Motor control centers are designed,


built, and tested under the requirements of NEMA ICS-2-322 and
Underwriters' Laboratories UL-845 standards.

Field tests should be performed by the contractor to demonstrate


operation of all protective devices and correct operation of all control logic.

3.16.3.4 Automatic Transfer Switches. Automatic transfer switches are


designed, built, and tested in accordance with Underwriters' Laboratories
1008 standards. Field inspections and tests should be performed to verify
that the phase rotation of the two sources are the same and that all time
delays are set in accordance with the requirements of the specifications.

3.16.3.5 Medium and Low Voltage Motors. Motor insulation is


generally field and/or shop tested by utilizing a megger-type insulation
tester, which is essentially a high-range resistance meter (ohmmeter) with
a built-in dc generator. Motor insulation is also tested using a power factor
test set. This test measures the ratio of the insulation loss and volt-
amperes at a specified test voltage. Alternating current is sometimes used
for high potential testing; voltage is increased to some specified point to
determine whether or not the insulation will fail at that particular voltage.
This ac test procedure is a "go, no go" type of test and can cause
insulation damage, in contrast to the dc test, which is basically nonde-
structive. Ac tests are used for proof testing of equipment (that is, to verify
that a motor meets prescribed standards), while dc tests provide more
qualitative results.

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3.16.4 Conductors

3.16.4.1 Medium Voltage Conductors. The method of testing medium


voltage conductors in the field involves the application of a high potential
direct-current (DC) source to a series-connected cable assembly. This
field test should only be utilized to assure freedom from electrical
weakness in the circuit caused by such things as mechanical damage,
poor workmanship when making splices and/or terminators, unexpected
environmental factors, etc. This field test should not be used to create a
complete failure in the dielectric or shielding systems, nor should the dc
potential be excessive such that it would initiate punctures in otherwise
good insulation.

3.16.4.2 Low Voltage Conductors. Low voltage conductors are tested


by the use of a megger insulation tester, which is essentially a high-range
resistance meter (ohmmeter) with a built-in dc generator. This test
method is nondestructive; that is, it does not cause deterioration of the
insulation. This field test can be performed with the conductors either
connected to or disconnected from the equipment being served by the
circuit.

3.16.5 Emergency/Standby Generators

3.16.5.1 Engine Generators. Engine generators are generally packaged


as a single unit. Thus, it is common practice to have a manufacturer
performance test the engine generator set in accordance with
MIL-STD-705 and IEEE Standard 115. In addition to these standard test
requirements, the manufacturer should factory test the engine generator
unit a minimum of 3 hours with 2-hour continuous operation at 100 percent
rated load having a 0.8 power factor, and 1-hour continuous operation at
110 percent rated load.

After the engine generator has been installed, the contractor should
perform an onsite test at full load using resistive load banks for a minimum
of 4 hours. Results of this test should be compared with the test
performed by the manufacturer and the requirements of the specifications.

3.16.5.2 Switchgear/Transfer Switches. Switchgear and transfer


switches, having been factory tested, should then be tested after the
engine generator has been installed, tested, and connected to the plant
distribution system. Power failure should be simulated to verify that the
emergency power system will function as intended. The various alarms
and shutdown devices should also be checked during this operational test.

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3.16.6 Grounding

3.16.6.1 Ground Rods/Grid. The ohmic value of a single ground rod is


usually obtained by the use of a direct-reading earth tester. The testing of
a grounding grid system is accomplished by using a null-balance earth
tester. Each of these testers has a voltage source, an ohmmeter to
measure resistance directly, and switches to change the instrument's
resistance range.

The basic test method used to determine earth resistance is the direct
method (known as the Two-Terminal Test) and the fall-of-potential method
(known as the Three-Terminal Test). The direct method is the simplest
way to make an earth-resistance test because only two electrodes in
series are measured; however, this method is not as accurate at the fall-
of-potential method, which requires three electrodes.

3.16.6.2 Equipment Ground Busses. Equipment ground busses and


the ground wire connection to the equipment bus is generally tested by the
direct method of testing.

3.16.6.3 Ground Fault Devices. Ground fault devices such as ground


fault interrupter receptacles should be tested for operation with methods
and instruments prescribed by the manufacturer. Generally, all that is
required to test these devices is a push of a button. Circuit breakers that
include ground fault protection devices should be tested by the current
injection method.

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Chapter 4

CONTROL SYSTEM
DESIGN PROCEDURES MWD Electrical Design Manual

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4.1 CONTROL PANELS


Control panels shall concentrate local process control and monitoring
functions from within a given area. Control panels shall provide manual
control of process equipment. Control panels shall be designed to permit
interfacing with the field equipment and the remote terminal units.

Control panels shall provide the means for the operator to take over
control from remote terminal units (RTU). The panels shall only be used
in case of RTU unavailability. The panel design shall consolidate
functions wherever possible.

This section contains design standards for panel layouts, construction,


and some representative control and monitoring devices mounted on or in
the panels.

4.1.1 NEMA Standards


Panel types shall be compatible with and suitable for the environment of
their installed location, and shall protect instruments and equipment
enclosed. The choice of location for panels shall minimize exposure to
ambient temperature extremes, moisture, dirt, and gaseous contami-
nants. Panels shall be designed, manufactured, and tested in accordance
with the latest applicable standards of NEMA, IEEE, and ANSI. See
Appendix D for the complete list of NEMA enclosure types that shall be
used to select an enclosure.

4.1.2 Panel Design


Panels and cabinets shall be designed to accommodate all necessary
accessories such as instrument air, power supplies, mounting hardware,
terminal blocks, and signal conditioning or conversion equipment
required. Panel layout and equipment spacing shall allow for device
removal, calibration, and maintenance without disassembly or adjacent
devices.

Removable eye bolts shall be provided for sling handling of enclosures.


Eye bolt mounting shall be a part of the structural support bracing to
distribute stresses and enclosure weight.

Sufficient structural reinforcements shall be provided to ensure a plane


surface, to limit vibration, and to provide rigidity during shipment,

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CONTROL SYSTEM DESIGN PROCEDURES MWD Electrical Design Manual

installation, and operation without distortion or damage to the panel or


injury to any mounted instruments. Enclosure seams shall be continu-
ously welded and ground smooth to be undetectable after painting.

Enclosures shall be designed for wall-mounting or be free-standing, as


appropriate. For enclosure installation seismic requirements, refer to
ESD-103, Structural Design Manual.

Free-standing enclosures for areas accessible through manholes shall


have maximum dimensions of 72 inches high by 24 inches wide by
24 inches deep to allow passage through 36-inch round manholes.

4.1.3 Indicating Devices


Indicators include rectangular panel meters, edgewise panel indicators,
digital readouts, and graphic displays. Instruments or devices shall be
suitable for panel mounting.

4.1.4 Switches, Pushbuttons, and Lights


Refer to Metropolitan's Standard Specifications for detailed specifications
of switches, pushbuttons, and lights.

Selector switches, pushbuttons, and indicating lights shall be supplied by


one manufacturer to assure similar appearance.

Selector switches and pushbuttons shall be supplied with operator


mechanisms, appropriate number of contact blocks, legend plate, and
necessary inserts. Contact block terminals shall be labeled for identifi-
cation and contain not less than one single pole, double throw contact.

Indicating lights shall be LED type. Indicating lights shall have bulb
removal and bulb replacement possible from the front of the panel. A
push-to-test feature shall be provided for lamp testing.

Panel indication lamps--the color of indicator lights shall denote the lamp
functions as follows:

x Status and alarm lights:

Color Function

AmberOverload
Red Equipment running, valve fully open, circuit
breaker closed, or high speed
Green Equipment stopped (safe), valve closed, circuit
breaker open, or low speed
White Valve intermediate position or alarm and

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automatic or manual

4.1.5 Annunciators
Indication of alarms shall be displayed on a panel-mounted, internally
illuminated, solid-state annunciator.

Annunciator power rating shall be 120 volts ac, 60 Hz.

Lamps shall have a nominal 20,000 hours minimum life at rated voltage.

All positions in the annunciator cabinet shall contain one solid state alarm
plug-in module. Each annunciator alarm point shall have one alarm
module. The alarm module shall be capable of accepting a normally open
field contacts that close on alarm or normally closed contacts that open on
alarm, selectable by a slide switch.

The annunciator sequence shown in Table 4-1 is an example of the many


sequences available. For other annunciator sequences refer to
ANSI/ISA-518.1.

The annunciator cabinet shall be suitable for front-panel mounting.


Terminals for field connections shall be accessible from the rear. The
design of the unit shall permit front-of-panel relamping.

Annunciators shall provide auxiliary signals for remote annunciation of


each and every point.

The annunciator shall be provided with horn and pushbuttons for reset,
silence (acknowledge), and lamp test functions.

Annunciator pushbutton colors shall be:

Color Function

Green Reset
Blue Test
Yellow Acknowledge

Specific alarm functions shall be described in English block-type letters


and front engraved on a white, translucent material, 3-inch-by-7/8-inch
display window with characters 5/32-inch high. Engraved characters shall
be filled with black heat-resistant epoxy resin.

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Table 4-1. Annunciator Sequences


Condition Visual Audible
Annunciator Annunciator
Normal Off Off
Off Normal
1st alarm Intermittent On
Fast flash
2nd alarm steady Fast flash On
Operator Acknowledgement
1st alarm Slow flash Off
2nd alarm Steady on Off
Operator Reset
1st alarm Steady on Off
2nd alarm Steady on Off
Return to Normal Off Off

4.1.6 Relays and Timers


Control logic relays shall be heavy-duty, machine tool industrial-type with
contacts rated not less than 10 amperes at 600 volts ac. Relay coils shall
be molded construction and operate on 120 volts ac 60 Hz, ±10 percent.

Auxiliary interposing relays shall be supplied by the same manufacturer to


assure similar appearance and uniform operating characteristics. Relays
shall have a clear polycarbonate dust cover. Relays shall be UL
recognized.

Operating temperature range shall be compatible with the environment in


which the relay will be installed. Contact material shall be gold or gold
flashing over silver and rated 0.5 amperes at 125 volts ac in instances
where low-level signal currents are being switched.

Relay shall be an octal or 11-pin base plug-in type furnished with


appropriate sockets.

Electrical timing relays shall be supplied by the same manufacturer to


assure similar appearance and time setting procedures.

Operating voltage shall be 120 volts ac 60 Hz ±1 percent. Contact rating


shall be 10 amperes at 120 volts ac and have a minimum mechanical life
of 1 million operations. Operating temperature range shall be compatible
with the environment in which the timer will be installed.

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CONTROL SYSTEM DESIGN PROCEDURES MWD Electrical Design Manual

On-delay and/or off-delay shall be supplied as required. Repeat accuracy


shall be ±5 percent or better. Reset and recycle time shall be
200 milliseconds maximum. Time delays shall be adjustable with a
graduated knob on the timer body.

4.1.7 Control Panel Layout


The primary function of a panel and the I&C items on it is to provide the
best possible communication between the operator and the process. To
establish this communication, the operator has to (1) be able to clearly see
the information the instrumentation is providing, and (2) be able to react
quickly and accurately to that information. For the operator to see the
information clearly on the instruments, lighting is important. Also, the
information has to be within the range of vision; therefore, the position of
the instrumentation is also important. Thirdly, for the operator to react
quickly and accurately, the controls have to be within easy reach.
Therefore, the position of the controls is important. Not only must the
operator be able to reach the controls, they must also be placed in a
logical manner so that the hands will tend to reach for the correct control
automatically with the least chance of error.

All panels for a given facility shall be designed with the same format so
that the operator need not relearn panel configuration concepts while
moving around the plant.

The following guidelines shall be followed in designing front panel layouts


for consistent and efficient operator interface.

x Front panel components shall be grouped functionally. The


grouping of components shall be clearly distinguished by
extra spacing between groups and by the use of group
nameplates. The group nameplates shall be larger or longer
than individual component nameplates.

x Functional groupings shall be arranged from left to right


corresponding to process flow or equipment number. For
example, controls for Pump No. 1 would be on the left and
controls for Pump No. 2 would be on the right.

x Panel components shall be located in the following general


areas of the panel:

Annunciators and alarms, uppermost panel area

Graphic panels, uppermost panel area

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CONTROL SYSTEM DESIGN PROCEDURES MWD Electrical Design Manual

Indicators, 36 to 60 inches from the floor

Recorders, 36 to 60 inches from the floor

Hand switches and lights, lowest panel area but no lower


than 30 inches from the floor

x Status indicating lights shall be located directly above their


corresponding control switches.

4.1.8 Wiring and Terminations


Refer to Metropolitan's Standard Specifications for detailed specifications
on wiring and terminations within a control panel.

Internal panel wiring and terminations shall be in accordance with the


National Electrical Code.

Low-level signal wiring shall be segregated from control power wiring,


grouped functionally, and arranged neatly to facilitate circuit tracing. No
combination of analog, digital input, or control output wiring shall be within
the same bundle or duct or panduit within a panel. Signal wiring shall be
uniformly twisted.

Plastic wiring wraps shall be used to bundle wires, except within wiring
ducts. The bundles shall be securely fastened to the steel structure at
intervals not exceeding 12 inches.

Solderless ring lug connectors with insulating sleeves shall be used for
connecting wires to terminal blocks.

Flexible stranded wiring shall be used throughout.

Where shielding is required, shields shall be continuous foil or metalized


plastic providing 100 percent coverage. A drain wire in continuous contact
with the shield shall be included.

The dc signal wiring shall be segregated from wire conducting ac signals.

Power wiring insulation shall be rated to 600 volts and be type MTW.
Conductors shall be stranded copper. No wire smaller than 12 AWG
90o C shall be used for power wiring.

Wiring must not be spliced. Wire must be run in continuous lengths from
screw terminal to screw terminal. Wire service loops shall be provided to
permit device removal and to permit front door of control cabinet, if
equipped and wired with door-mounted devices, to open 90 degrees.

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CONTROL SYSTEM DESIGN PROCEDURES MWD Electrical Design Manual

Terminal blocks shall be provided for interconnections with field


instruments and termination cabinet wiring. Design of the terminal layout
shall include a grounded barrier to segregate those terminals devoted to
current type signals. The terminal blocks shall be factory assembled on a
mounting channel and the channel bolted to the inside of the panel.
Terminals shall accept wire size 12 AWG and smaller.

Terminal blocks shall be rated 300 volts for NEMA general industrial
control devices and 600 volts NEMA for power circuits. No miniature
terminal blocks shall be permitted. The terminals shall have a continuous
marking strip. Separate terminals shall be provided for terminating the
shield wire for each signal.

The terminal blocks shall have point identification strips. Terminal strips
shall be labeled horizontally from left to right (facing enclosure front) 1F,
2F, 3F, 4F, etc., and facing rear of enclosure 1R, 2R, 3R, 4R, etc.
Vertically the terminations shall be marked with a permanent, continuous
marking strip from top to bottom. One side of each terminal strip shall be
reserved for field incoming conductors. Common connections and
jumpers required for internal wiring shall not be made on the field side of
the terminal. No more than two wires shall be terminated at any one
terminal.

A minimum of 25 percent spare terminals shall be provided.

Two 1/4-by-1-inch copper ground buses with M5 and M6 tapped holes and
insulated mounting brackets shall be provided in each cabinet or panel,
one for shield and cabinet grounding and one for signal grounding.

Wiring shall be identified at each termination by marking with a number to


correspond with the wiring diagram and shall be color coded as follows:

x Line and load circuits, ac or dc power: black;

x ac control circuits: red;

x dc control circuits: blue;

x Interlock control circuits on the panel energized from


external source: yellow;

x Equipment grounding conductors: green;

x Current carrying grounded conductor (neutral): white.

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External wiring shall be color coded as shown in paragraph 4.2, Field


Wiring.

Wires and cable terminated within control panels, instrumentation panels,


and termination cabinets shall be provided with identification tags as
shown in paragraph 4.2, Field Wiring.

4.1.9 Nameplates
Nameplates shall be installed on the doors or covers of panels, panel-
boards, starters, contactors relays, and other electrical equipment.
Equipment within panels shall be identified.

Front panel nameplates for devices shall be black laminated plastic with
white letters, attached with No. 2-56 stainless steel machine screws,
Phillips type, counter sunk head.

4.1.10 Installation
Before any circuits are energized, internal and external electrical and
mechanical clearances must be checked to assure that installed
equipment will function safely and properly.

Free standing panels shall be shimmed level and grouted. Panels shall
bear evenly over the full length and be installed plumb. Panel structures
must be accurately leveled such that panel structures will not be distorted
and all doors must operate without binding.

4.1.11 Seismic Design Requirements


Equipment base and anchorage shall be designed and installed to
withstand stresses caused by seismic forces. Refer to Metropolitan's
Structural Design Manual.

Panels, consoles, and cabinets mounted on concrete floor shall be bolted


through a structural member to the floor at four corners.

Equipment located on a raised floor in the control and computer rooms


shall be secured to the concrete floor with tie-down cables at four corners.
The cables shall be angled to prevent tipping.

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4.2 FIELD WIRING

4.2.1 Field Signal Wiring

4.2.1.1 General. Field signal wiring includes monitoring and control


signal wiring between field equipment (sensors, valves, and motor control
centers), control panels and remote terminal units (RTU).

4.2.1.2 Sizing. Single pair wires shall be 18 AWG or larger. Multipair


conductors shall be 22 AWG or larger. Thermocouple extension wires
shall be solid conductors of the same material as the associated
thermocouple.

4.2.1.3 Insulation. Signal wiring insulation shall have a minimum


dielectric strength of 600 volts. Insulation temperature range shall extend
to at least 75o C in dry locations and 90o C in wet locations. Multipair
cable overall jacket material shall be moisture-resistant, abrasion-
resistant, flame-retardant, and compatible with the environment in which it
is installed and shall be type TC tray cable.

4.2.1.4 Color Code Identification. Each wire shall have a color code
identification to facilitate wiring and troubleshooting.

The colors of individual conductors shall be in accordance with NEMA


WC-70 as follows:

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CONTROL SYSTEM DESIGN PROCEDURES MWD Electrical Design Manual

1-Black 7-Red/Black 13-Blue/Red


2-Red 8-Blue/Black 14-Orange/Red
3-Blue 9-Orange/Black 15-Yellow/Red
4-Orange 10-Yellow/Black 16-Brown/Red
5-Yellow 11-Brown/Black 17-Black/Blue
6-Brown 12-Black/Red 18-Red/Blue
19-Orange/Blue

The following abbreviations shall be used for identification of multi-


conductor cables and colored wires when developing wire lists or
documentation:

Color Abbreviation Color Abbreviation


Black B Brown BR
White W
Red R
Green G
Orange O Gray GY
Blue BL
Yellow Y

4.2.1.5 Twisting. Signal wires shall be uniformly twisted with a


minimum of six twists per foot (2-inch lay). Cable lays and pairs shall be
twisted in the same direction.

4.2.1.6 Shielding. Where shielding is required, shields shall be


continuous foil or conductive metalized plastic providing 100 percent
coverage. A drain wire in continuous contact with the shield shall be
included.

4.2.1.7 Signal Wire and Cable Selection.

Type Description

I Single, unshielded, twisted pair


II Single, shielded, twisted pair

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CONTROL SYSTEM DESIGN PROCEDURES MWD Electrical Design Manual

III Multipair, overall shielded cable of Type I wire


IV Multipair, overall shielded cable of Type II wire

x Analog Signals

Analog signals are isolated 4-20 mA inputs received from


remote instruments and isolated 4-20 mA outputs trans-
mitted to remote control elements.

Type II and IV wiring shall be used for individual and


multipair runs, respectively.

x Contact Inputs

Contact inputs originating from isolated contact closures


and conducting less than 10 mA at 48 volts dc.

Type I and III wiring shall be used for individual and multi-
pair runs, respectively.

4.2.1.8 Instrument Power and Control Wiring. Wire and cable


insulation shall be 600-volt type THHN or THWN. Conductors shall be
stranded copper.

As a general rule, no wire smaller than No. 12 AWG shall be used for
power wiring.

Contact outputs are isolated contacts from interposing relays actuated by


the RTU for controlling 120-volt devices.

No wire smaller than No. 14 AWG shall be used for control wiring.

4.2.1.9 Shield Grounding. Signal shields shall have one ground point
located at the source of the signal (e.g., analog transmitter or contact
closure) unless otherwise recommended by the instrument or equipment
manufacturer. Shields shall be continuous through cabinets, panels, and
junction boxes.

4.2.1.10 Splicing. A minimum distance of 1,000 feet between splices


shall be maintained. Splicing shall only occur at a junction or pull box.
Continuity of conductors and shields shall be maintained at each splice.
Connections shall be made gas tight by compressing the two wires to be
joined with an isolated compression device or bolted connection.

Thermocouple, RTDs, and other low-level signal lines shall be continuous

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CONTROL SYSTEM DESIGN PROCEDURES MWD Electrical Design Manual

from the thermocouple connection head to the final termination point.

4.2.1.11 Terminations. Wire at both ends of the cable shall be


terminated with preinsulated solderless or compression type spade or ring
lugs for maximum physical strength and electrical conduction. Use ring
lugs for terminations subject to vibration and for all current transformer
secondary circuits. Wires shall not be terminated on adjacent terminal
points if accidental short circuiting could cause tripping or closing of a
breaker.

4.2.1.12 Separation of Signal Wiring.

x Analog Signals

Signals in one cable or conduit shall be of the same mag-


nitude. The following peak voltage levels define the
different signal magnitude:

- 0 to 100 mV;
- 100 mV to 5 V;
- 5 V to 75 V.

Analog signals shall be physically separated from contact


output and power wiring using separate conduit for each.

Low-level analog and control or power wiring shall cross


at right angles. Parallel runs of analog and control or
power wiring shall be avoided, but, where required, shall
be separated by at least 3 feet.

x Digital Signals

Digital input and control wiring, using unshielded pairs,


shall be run in separate conduits. If they are run in the
same conduit, the pairs must be twisted and shielded.

4.2.1.13 Installation. Wiring inside enclosures shall be supported at


least every 24 inches unless longer unsupported runs are required for
access or maintenance. Wiring to doors shall be installed such that
bending is axial, with no tension exerted on wiring with doors in any
position.

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CONTROL SYSTEM DESIGN PROCEDURES MWD Electrical Design Manual

4.2.2 Conduit

4.2.2.1 Construction. Conduit construction must be in accordance


with the latest revision of the National Electrical Code. The conduit shall
be of galvanized rigid steel with a flexible section for connection to
devices. Conduit that has been crushed or deformed in any way shall not
be used.

4.2.2.2 Number of Bends. Bends of rigid conduit shall be made such


that the conduit will not be injured and that the internal diameter of the
conduit will not be effectively reduced. The radius of the curve shall not
be less than that recommended by either the National Electrical Code or
manufacturer of the wires or cables to be contained within the conduit.
The maximum angle of bends between pulls shall not total more than
180 degrees including entrance and exit to pull boxes or access fittings.

4.2.2.3 Distance Between Pull Points. The maximum allowable


distance between pull points shall be 300 feet or the distance based on
allowable maximum cable pulling tension, whichever is less. When the
distance between the two pull points contains the maximum angle of
bends, as stated above, the maximum allowable distance shall be 75 feet.
A lubricating agent compatible with the wire insulation shall be used. The
pull boxes shall be sized to allow adequate bending radius for the wire or
cable being pulled.

4.2.2.4 Conduit Fill. The combined cross-sectional area of conductors


and cables in a conduit shall not exceed the fill percentages specified by
the National Electrical Code.

4.2.2.5 Conduit Support. Conduit shall be firmly supported within


3 feet of each pull box, junction box, or termination point. The conduit
shall be sufficiently supported elsewhere in accordance with the National
Electrical Code requirements.

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CONTROL SYSTEM DESIGN PROCEDURES MWD Electrical Design Manual

4.2.2.6 Continuity. Conduit runs shall be solidly connected to assure


the ground continuity of the entire run. Ground jumpers shall be installed
where the possibility of losing continuity exists.

4.2.2.7 Condensation Drains. Conduit runs shall be provided with


condensation drains at low points.

4.2.2.8 Installation. Exposed conduit runs shall be parallel or


perpendicular to building walls.

4.2.3 Spare Conductors


Spare conductors in each conduit equal to 25 percent of the number
required for both present and (defined) future conditions, but in no case
less than two spare wires, shall be installed. Each cable shall have
10 percent spare conductors but not less than two conductors.

4.3 CONTROL DEVICE INTERFACING


This section covers the design requirements for the interface between
remote terminal units and field control devices. Included are the types of
input and output hardware at the RTU, interlocks and manual control
equipment at field control panels, stations and alarm monitoring at the field
control devices, and control hardware at the field devices.

Control circuit diagrams for various types of field devices are shown on
Figures 4-1 through 4-10 (located at the back of this chapter).

The following are the types of field devices specifically covered in this
section. Design requirements for other field devices shall follow the
general requirements established in this section.

x Modulating control valves:

Electric motor operator;


Hydraulic actuator.

x Open/close control valves:

Electric motor operator;


Hydraulic actuator.

x Electric motors:

Constant speed;
Multiple speed;
Variable speed.

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CONTROL SYSTEM DESIGN PROCEDURES MWD Electrical Design Manual

4.3.1 Remote Terminal Unit Outputs

4.3.1.1 RTU Termination Cabinet


Remote terminal units (RTU) shall have a termination cabinet. The size of
the termination cabinet is slelected based on the number of I/O
terminations in the RTU. Termination cabinets shall be 36” or 48” or 60”
wide, 24” deep and 72” or 76” high for Metropolitan’s small or standard
RTU, and 20” wide x 20” high x 8” deep for wall-mounted RTU.

Separate terminal blocks shall be provided for analog discrete signals.


Analog signals shall have three terminal blocks, one each for signal (+),
signal(-) and shield. Each discrete input and output shall have two terminal
blocks. The terminal blocks for analog and discrete signals shall be switch
type terminal block to permit isolating and testing of the signal loop.

Termination cabinets shall be supplied with non-UPS 120V AC power for


enclosure lights and outlets, and a copper grounding bar with M5 and M6
tapped holes and insulating mounting brackets.

It is Metropolitan’s practice to terminate all conductors between TRU and


the corresponding termination cabinet for the construction contractor to
terminate field wiring between termination cabinet and field mounted
devices.

4.3.1.2 Contact Outputs. Contact outputs to field control devices


shall be momentary contact closures using interposing relays, with the
duration of the closure controlled by RTU hardware. Two contacts shall
be provided for each control device; one to initiate control action, the other
to stop or reverse control action. The time between initiating and stopping
or reversing control action shall be controlled by RTU software. Seal-in
circuits shall be provided in either the field control panel or the motor
starter.

4.3.1.3 Modulating Outputs. Modulating devices such as variable-


speed pumps and automatic control valves shall be controlled by isolated
4-20 mA outputs. Contact closure-type outputs shall be used for constant
speed motor-operated valves and gates. For contact closure-type
outputs, two separate contacts are required for each device. Closing one
of the contacts shall cause the motor to operate, the other shall cause the
motor to reverse.

When neither contact is closed, the motor is stopped. The position of the
device shall not change during loss of remote control. In addition,
transfers between remote and local control are made without changing
position.

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CONTROL SYSTEM DESIGN PROCEDURES MWD Electrical Design Manual

4.3.2 Control Panels

4.3.2.1 Control Transfer Switch. Control transfer switches shall be


provided at control panels to select either remote (from RTU) or local (at
the control panel) control. Auxiliary contacts shall be available for
reporting to the RTU. Field devices may be grouped or be individually
controlled by one control transfer switch. The control transfer switch shall
be maintained in each position.

4.3.2.2 Panel Controls. Pushbutton controls on the control panels


shall be momentary to match the RTU outputs. Pushbuttons shall not
operate unless the control transfer switch is in the local position. (See
Figure 4-1.)

Indicating lights, of the colors shown on the figures, shall be provided on


the control panel adjacent to pushbuttons to show control device status.
Indicating lights may be incorporated into the pushbuttons if desired.

4.3.3 Status Monitoring

4.3.3.1 Valve Monitoring. Limit switches shall be furnished to monitor


the fully closed and open position of flow routing valves and gates. Full
open-close type valves that are remotely controlled shall have limit
switches for both the open and closed positions. Manual valves and gates
used solely for maintenance (e.g., pump suction and discharge isolation
valves) shall have limit switches as required.

Throttling valves shall have limit switches for fully opened and closed
position monitoring and a 4-20 mA output signal for monitoring valve
position.

Limit switches and the position signal shall be furnished by the valve
manufacturer as an integral part of the valve assembly. Whenever
possible, a 4-20 mA position signal is preferred instead of a potentiometer.

4.3.3.2 Motor Monitoring. Motor starter auxiliary contacts shall be


provided for remote monitoring of the running status of motors that are
controlled by the RTU.

Large motors, generally over 100 horsepower, that are critical to the
process, plant, or system shall be monitored for alarm conditions such as
high bearing temperature, high motor winding temperature, and motor
vibration.

Equipment and personnel safety interlocks shall be locally hardwired to

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CONTROL SYSTEM DESIGN PROCEDURES MWD Electrical Design Manual

the control panels to function independently of the RTU. Examples of


interlocks are a low-level switch contact used to prevent pumps from
running dry and a valve limit switch used to prevent a pump from being
started against a closed valve.

Motors controlled by the RTU shall be equipped with a pushbutton switch


control or other type of disconnect in accordance with the National
Electrical Code, which is capable of interrupting power to the motor starter
pilot circuit.

4.3.4 Signal Convertors


Signal converters shall be provided as needed to condition analog signals
for input to the computer system RTUs and control panel devices.

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ESD-106 4-25 01/06


Appendix A

REFERENCES MWD Electrical Design Manual

Note: The most current edition of referenced publications applies, unless otherwise
specified.

American National Standards Institute


ANSI C2, National Electrical Safety Code

California Code of Regulations


CCR Title 8, Division 1, Chapter 4, Subchapter 5, Electrical Safety Orders
CCR Title 24. California Building Standards Code

Institute of Electrical and Electronics Engineers


Note: Many IEEE documents are adopted by ANSI and have an ANSI/IEEE document
number similar to the IEEE document number.
IEEE Std 80, IEEE Guide for Safety in AC Substation Grounding
IEEE Std 141, IEEE Recommended Practice for Electric Power Distribution for Industrial
Plants
IEEE Std 142, IEEE Recommended Practice for Grounding of Industrial and
Commercial Power Systems
IEEE Std. 242, IEEE Recommended Practice for Protection and Coordination of
Industrial and commercial power systems
IEEE Std 399, IEEE Recommended Practice for Industrial and Commercial Power
Systems Analysis
IEEE Std 422, IEEE Guide for the Design and Installation of Cable Systems in Power
Generating Stations
IEEE Std 433, IEEE Recommended Practice for the Design of Reliable Industrial and
Commercial Power Systems
IEEE Std 446, IEEE Recommended Practice for Emergency and Standby Power
Systems for Industrial and Commercial Applications
IEEE Std 484, IEEE Recommended Practice for Installation Design and Installation of
Large Lead Storage Batteries for Generating Stations and Substations
IEEE Std 493, IEEE Recommended Practice for the Design of Reliable Industrial and
Commercial Power Systems
IEEE Std 519, Recommended Practice and Requirements for Harmonic Control in
Electrical Power Systems

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Appendix A

REFERENCES MWD Electrical Design Manual

IEEE Std 525, IEEE Guide for the Design and Installation of Cable Systetms in
Substations
IEEE Std 605, IEEE Guide for Design of Substation Rigid-Bus Structures
IEEE Std 739, IEEE Recommended Practice for Energy Management in Industrial and
Commercial Facilities
IEEE Std 979, IEEE Guide for Substation Fire Protection
IEEE Std 980, IEEE Guide for Containment and Control of Oil Spills in Substations
IEEE Std 1050, IEEE Guide for Instrumentation and Control Equipment Grounding in
Generating Stations
IEEE Std 1100, IEEE Recommended Practice for Powering and Grounding Electronic
Equipment
IEEE Std 1187, IEEE Recommended Practice for Installation Design and Installation of
Valve Regulated Lead-Acid Storage Batteries for Stationary Applications
IEEE Std C37.2, IEEE Standard Electrical Power System Device Function Numbers
IEEE Std C37.20-1, IEEE Standard for Metal-Enclosed Low-Voltage Power Circuit-
Breaker Switchgear
IEEE Std C37.20-2, IEEE Standard for Metal-Clad and Station-Type Cubicle Switchgear
IEEE Std C37.20-3, IEEE Standard for Metal-Enclosed Interrupter Switchgear
IEEE Std C37.96, IEEE Guide for AC Motor Protection
IEEE Std C37.100, IEEE Standard Definitions for Power Switchgear
IEEE Std C37.101, IEEE Guide for Generator Ground Protection
IEEE Std C37.102, IEEE Guide for AC Generator Protection

Illuminating Engineering Society


IES Lighting Handbook

National Electrical Manufacturers Association


NEMA MG 1, Motors and Generators
NEMA 250, Enclosures for Electrical Equipment (1000 Volts Maximum)
NEMA WC 70/ICEA S-95-658, Nonshielded Power Cables Rated 2000 Volts or less for
the Distribution of Electrical Energy
NEMA WC 71/ICEA S-96-659, Standard for Nonshielded Cables Rated 2001-5000
Volts for Use in the Distribution of Electric Energy

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Appendix A

REFERENCES MWD Electrical Design Manual

NEMA WC 74/ICEA S-93-639, 5-46 kV Shielded Power Cable for Use in the
Transmission and Distribution of Electric Energy.

National Fire Protection Association


NFPA 45, Fire Protection for Laboratories Using Chemicals
NFPA 70, National Electrical Code (2005 Edition)
NFPA 70E, Standard for Electrical Safety in the Workplace
NFPA 72, National Fire Alarm Code
NFPA 75, Protection of Information Technology Equipment
NFPA 76, Fire Protection of Telecommunications Facilities
NFPA 79, Electrical Standard for Industrial Machinery
NFPA 101, Life Safety Code
NFPA 110, Emergency and Standby Power Systems
NFPA 780, Installation of Lightning Protection Systems
NFPA 820, Protection in Wastewater Treatment and Collection Facilities
NFPA 851, Fire Protection for Hydroelectric Generating Plants

Underwriters’ Laboratory
UL 845, Motor Control Centers
UL 891, Switchboards
UL 1008, Transfer Switch Equipment

Miscellaneous Documents
Electrical Installations in Hazardous Locations, Peter J. Schram and Mark W. Earley,
editors, National Fire Protection Association
Electric Service Requirements, City of Los Angeles Department of Water and Power
Electrical Service Requirements Manual, Southern California Edison
Electrical Engineer’s Portable Handbook, Bob Hickey, editor, McGraw-Hill
Electrical Systems Analysis and Design for Industrial Plants, Irwin Lazar, editor,
McGraw Hill
Handbook of Electric Power Calculations, H. Wayne Beaty, editor, McGraw-Hill
Industrial Power Systems Handbook, Donald Beeman, editor, McGraw-Hill

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Appendix A

REFERENCES MWD Electrical Design Manual

Motor Application & Maintenance Handbook, Robert W. Smeaton, editor, McGraw-Hill


Standard Handbook for Electrical Engineers, Donald G. Fink and H. Wayne Beaty,
editors, McGraw-Hill
Switchgear and Control Handbook, Robert W. Smeaton and William H. Ubert, editors,
McGraw-Hill

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Appendix B

ABBREVIATIONS MWD Electrical Design Manual

A or AMP Ampere
A/C Air Conditioner (Conditioning)
AC Alternating Current
AF Ampere Frame
AFF Above Finished Floor
AFG Above Finished Grave
AG Above Ground
ASD Adjustable Speed Drive
AT Ampere Trip
ATS Automatic Transfer Switch
AUX Auxiliary
AWG American Wire Gauge

BAT Battery
BC Bare Copper
BET Between
BOT Bottom
BLDG Building
BKR Breaker
BTU British Thermal Unit
BTU/H British Thermal Unit Per Hour

C Conduit
CAB Cabinet
CAT Catalog
CB Circuit Breaker
CHLOR Chlorine
CONC Concrete
CKT Circuit
CMIL Circular Mil
CNTL or CONT Control
CONT’D Continued

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Appendix B

ABBREVIATIONS MWD Electrical Design Manual

D Depth
DC Direct Current
DIA or ‡ Diameter
DN Down
DISC Disconnect
DIST Distribution
DPDT Double Pole Double Throw

EL or ELEV Elevation
EXIST Existing
EM Emergency
EPR Ethylene Propylene Rubber

F Frequency
FDR Feeder
FL Floor
FLEX Flexible
FS Flow Switch
FVR Full Voltage Reversing
FVNR Full Voltage Non-Reversing

G Ground
GFI Ground Fault Interrupter
GFCI Ground Fault Circuit Interrupter
GND or GRD Ground

H or HGT Height
HDAF Hot Dipped After Fabrication
HH Handhole
HOA Hand-Off-Automatic
HP Horsepower

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Appendix B

ABBREVIATIONS MWD Electrical Design Manual

HPF High Power Factor


HPU Hydraulic Power Unit
HTR Heater
HV High Voltage
HZ Hertz

IEEE Institute of Electrical and Electronics Engineers


INST Instantaneous
INSTR Instrument
I/O Input/Output
ITC Instrument Terminal Cabinet

J Junction
JB Junction Box

K Kilo (1000 times)


KAIC Kiloamp Interrupting Current
KCMIL Thousand Circular Mils
KW Kilowatt
KV Kilovolt
KVA Kilovolt Ampere
KVAR Kilovolt Ampere Reactive

LP Lighting Panel
LS Level or Limit Switch
LT Liquidtight
LTG Lighting
LV Low Voltage

M Motor

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Appendix B

ABBREVIATIONS MWD Electrical Design Manual

mA Milliamp
MAX Maximum
MCC Motor Control Center
MCP Motor Circuit Protector
MFE Metropolitan Furnished Equipment
MFR Manufacturer
MIN Minimum
MH Manhole
MOD Module
MV Medium Voltage
MVA Megavoltampere
MWD Metropolitan Water District

NC Normally Closed
NEC National Electric Code
NEMA National Electrical Manufacturers Association
NFPA National Fire Protection Association
NIC Not In Contract
NO Normally Open
NO. or # Number
NTS Not To Scale

P Pole
PB Pullbox or Pushbutton
PDR Preliminary Design Report
PF Power Factor
PH or ‡ Phase
PLC Programmable Logic Controller
PNL Panel
PS Pressure Switch
PVC Polyvinyl Chloride
PWR Power

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Appendix B

ABBREVIATIONS MWD Electrical Design Manual

R Resistor
RECPT or RCPT Receptacle
RGS Rigid Galvanized Steel
RTU Remote Terminal Unit

SCE Southern California Edison


SHLD Shield
SHT or SH Sheet
SN Solid Neutral
SP Spare
SPDT Single Pole Double Throw
STD Standard
STR Starter
SV Solenoid Valve
SW Switch
SWGR Switchgear

TB Terminal Box
TC Terminal Cabinet
TD Timer Delay
TEL Telephone
TERM Terminal
THRU Through
TM Thermal Magnetic
TS Temperature or Time Switch
TSP Twisted Shield Pair
TST Twisted Shield Triad
TYP Typical

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Appendix B

ABBREVIATIONS MWD Electrical Design Manual

UG or U/G Underground
UPS Uninterruptible Power System
UL Underwriters Laboratories
USA Underground Service Alert

V Volt
VA Voltampere
VFD Variable Frequency Drive

W Watt
W/ With
WP Weatherproof

XDCR Transducer
XFMR Transformer

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Appendix C

SAMPLE ELECTRICAL DESIGN


CRITERIA MEMO MWD Electrical Design Manual

The (title of facility) is a new facility. This document is intended to provide guidance
for the electrical system design. If there is a better way to meet the design
objectives, submit a recommendation to the project lead electrical engineer for
processing.

See the preliminary design report (PDR) for a description of the electrical system to
be provided for this project.

OBJECTIVES
The design objectives on this particular project are clarity, simplicity, and
standardization. In addition, the usual standards of the profession will apply such as
constructibility, completeness, and reasonable accuracy.

Clarity
The design and presentation must be clear. Show how you arrived at significant
decisions. If you want a specific result, show the contractor what shall be done for
the particular situation.

Simplicity
The design itself, of course, shall not be more complex than necessary to produce a
good electrical system. In addition, the presentation shall be as simple as clarity
permits. Simplicity shall not go so far as to shift tasks normally accomplished during
design into the construction phase.

Standardization
The design must show uniformity throughout so that similar problems are solved in
similar ways. If several people work on areas that can share solutions, they shall
only produce one solution and reference it elsewhere. Where possible,
manufacturers' standard assemblies shall be used.

SCHEDULING
An electrical work plan will be provided separately. This section tells what
information must be available before beginning the design for each part. The object
of having this information available before the design begins is to minimize changes
in the electrical design. If the information listed below is not available at the time the
design for a particular portion is scheduled to begin, do not begin that portion of the
design. Problems that you encounter in obtaining the necessary information will
either be immediately resolved or referred to the Design Manager and/or Project
Manager.

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Appendix C

SAMPLE ELECTRICAL DESIGN


CRITERIA MEMO MWD Electrical Design Manual

Single-Line Diagram
A single-line diagram for the plant electrical distribution system is included in the
PDR. I will modify this single line as necessary to accommodate changes that have
been made since the PDR was completed. Single-line diagrams for motor control
centers (MCC) will not be started until a reasonably complete motor list has been
developed for the area where the MCC is to be located. The P&IDs shall be used to
check the equipment lists given to us by the process leads. Each motor and
equipment number shall be checked against the current P&ID set before the
equipment list is considered complete.

Facility and Process Plans


The process electrical design for any area will be started only after the following
things have been accomplished for that area:

x Equipment data sheets are complete and reviewed by the lead


engineer in charge of the process;

x Equipment selection calculations have been reviewed;

x P&IDs completed.

Facility electrical design, lights, and outlets, for any area will be started only after the
process design is completed and building plans and sections are prepared and
drafted by the architects (changes in process design may still take place).

REFERENCE MATERIALS
Besides the usual codes and standards, the following documents are available as
information.

x The PDR and single-line diagrams

STANDARDS AND CODES


Electrical design shall conform to the latest editions of the following applicable
standards and codes:

x National Electrical Code (NEC);

x National Electrical Safety Code (NESC);

x California State Electrical Code;

x State of California Code, Title 8, CAL/OSHA Standards Board,

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SAMPLE ELECTRICAL DESIGN


CRITERIA MEMO MWD Electrical Design Manual

Subchapter 5, Electrical Safety Orders.

Standards and codes of the following organizations shall also govern where
applicable:

x American National Standards Institute (ANSI);


x National Electrical Manufacturers Association (NEMA);
x Institute of Electrical and Electronic Engineers (IEEE);
x Insulated Cable Engineers Association (ICEA);
x Occupational Safety and Health Act (OSHA);
x American Society for Testing and Materials (ASTM).

Local codes and standards shall be applied as appropriate. Where the requirements
of more than one code or standard are applicable, the more restrictive shall govern.
Requirements of applicable codes and standards are not repeated in this section.

Applicable state and local codes and UL listing requirements shall be followed for
electrical inspection. Exit signs, emergency egress lighting, and emergency lighting
power supply shall conform to requirements of the building inspector.

VOLTAGES
The primary distribution voltage within the plant shall be 4,160-volt, three-phase.
The secondary distribution voltage shall be 480-volt, three-phase, wye, high-
resistance grounded.

Under normal circumstances, the voltage for fluorescent, high pressure sodium, and
incandescent lighting shall be 120-volt, single-phase. This voltage also shall be
supplied to heaters up to 1,500 watts, convenience outlets, motor controls, and
motors of less than 1/2 horsepower (hp). Heaters above 1,500 watts and motors
from 1/2 to 200 hp shall be 480 volts, three-phase. Motors above 200 hp shall be
4,160 volts, three-phase.

The code allowable total voltage drop from the 480-volt source bus (excluding site
distribution) to the point of use (including feeder, branch circuit, and transformation)
shall not be exceeded.

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CRITERIA MEMO MWD Electrical Design Manual

In addition, due to the complexity and expense of providing ground fault protection
for three-phase 4-wire double ended substations with multiple grounds, no phase to
neutral loads shall be supplied directly from the 480-volt transformer secondaries.

DRAWINGS

Legend Sheet
In general, the standard Metropolitan symbols shall be used. The legend sheet shall
contain only the symbols and final abbreviations actually used in the drawing set.
The development of this sheet is my responsibility, with input from the project team.
A preliminary legend sheet is included in the PDR.

Site And Area Plans


The site plan shall show the location of all facilities and major equipment, duct bank
routes, handholes, and manholes. Area plans shall show all of the above items and
facility designs where the facility does not require a separate drawing such as
clarifiers, thickeners, etc. Site and area plans shall be overlayed on civil
backgrounds (base sheets).

Single-Line Diagram
The single-line diagram shall show the entire electrical distribution system from the
elec trical service down to 460-volt utilization devices and 208Y/120-volt
panelboards. Circuiting of 208Y/120-volt panelboards shall be shown on the panel
schedules. Circuiting of 480Y/277-volt panelboards shall be shown on the panel
schedules where possible, but where motors are powered from panelboards, the
branch circuit, including all combination motor starters and disconnect switches,
shall be shown on the single-line diagram.

Information on single-line diagrams shall include bus capacity, short circuit ratings,
overcurrent device types and ratings, C.T. and P.T. ratios, protective relay types and
ratings, metering and load ratings (horsepower or kilowatt), and circuit breaker and
switch ratings.

Conduit and conductor sizes shall be indicated on the single-line as well.

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Appendix C

SAMPLE ELECTRICAL DESIGN


CRITERIA MEMO MWD Electrical Design Manual

Elevations
Front elevations shall be shown for all medium-voltage switchgear, low-voltage
switchboards, unit substations, and motor control centers. Elevations shall be drawn
to scale and shall show the locations of MCC units, overcurrent devices, metering,
and conductor entrances. MCC units with extra height shall be shown where
required for relays. Switchboard and switchgear elevations shall be informally
reviewed by the first-named manufacturer for placement of units and overall
dimensional accuracy. Where important, note depths of assemblies on elevations.
Elevations of the equipment shall be developed by the designer of the facility that
the equipment is located in and reviewed by me.

Remember that even one control relay in a motor starter will usually require an
additional 3 inches of compartment height. Assume that this will be the case when
you need to have relays. Two will fit in the added 3 inches; if you need 3, add
another 3 inches, etc.

Motor Elementary Control Diagrams


Motor elementary control diagrams (ECDs) shall be done in the style shown on the
attached example. The ECDs shall show control circuit devices, which are not
mounted in I&C panels. Single controls in an I&C panel (on/off selector switch,
start/stop pushbuttons) may be shown. More complex control in an I&C panel shall
be shown as two terminals in a dashed rectangle with a reference to the signals as
they are labeled at the I&C panel, such as "RUN M-1-1 @ FP-2." Except as noted
below, all control devices shall be shown on the P&IDs. Talk to the I&C engineer
before adding control devices. The following control devices, not shown on the
P&IDs, shall be shown on the ECDs where we feel that they are necessary:

x ON/OFF/REMOTE switch (where required and not shown)

x Elapsed time meters (will be provided if the motor falls into the criteria
described hereinafter)

x Ground fault relays

x Metering

x Motor heaters

x Motor thermal devices

x ON/OFF status lights

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Appendix C

SAMPLE ELECTRICAL DESIGN


CRITERIA MEMO MWD Electrical Design Manual

ECDs shalll be developed by each facility designer for the equipment located in that
facility.

Schedules
Luminaire and panel schedules shall be put on the drawings. The luminaire
schedule shall be prepared in a format similar to the lighting fixture schedule shown
on attached example. A preliminary list of luminaires shall be developed before
design is started and the same luminaire shall be used for all similar applications
throughout the plant. Addition of a new luminaire to the schedule shall require
review with the project lead electrical engineer. A preliminary list of luminaires
shown in the format to be used is enclosed hereinafter.

Panel schedules shall be prepared similar to the panel schedule shown on attached
example. The lead design engineer for each facility shall be responsible for the
preparation (and review) of all panel schedules related to that facility. A separate
panel shall be provided within each facility for the power supply to process related
instruments and equipment. In smaller facilities, this panel may be subfed from the
lighting panel, but in larger facilities it shall be fed from a transformer and transfer
switch that is separated from the building facilities power supply.

The panel schedules shall be included on the drawings with the buildings or facilities
where they are located or with the single-line diagrams or equipment elevation of the
related equipment. The panel schedule format is available upon request.

Details
Details shall be numbered as noted in the project instructions. The project lead
electrical engineer will act as, or appoint a detail coordinator. A preliminary set of
design details will be selected and a copy of each will be provided to each design
team member. Details will generally be Metropolitan standard details. When you
need to use a detail that has already been used, find out the number from the detail
coordinator. If it has not been used, obtain a new number from the detail coordinator
and tell the coordinator the standard detail number, whether you are modifying the
detail or whether you are creating a detail from scratch. Every 1 to 2 weeks, the
detail coordinator shall send a copy of details being added to the project to each
electrical designer on the project.

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Process And Facility Plans


Process and facility plans shall show the location of and connection to all equipment
that requires raceway or conductors. A separate connection point shall be shown for
each device located within an area, even if they are all supplied as part of the same
package, unless the specifications clearly require that all of the devices are to be
wired to a single panel or TJB by the supplier of the equipment. Spare raceway for
future equipment shall also be shown, where appropriate. If the plans become
crowded, the process plans shall be separated from the facility plans. Receptacles,
lights, water heaters, HVAC equipment, and other non-process loads shall be shown
on the facility plan. See the preliminary drawing list for the buildings and facilities
where separate plans are expected.

At each connection, show the connected load in kW (where it is 0.5 kW or greater),


raceway size, fill, and routing, unless the raceway has an assigned number, in which
case just show the raceway and circuit number. Fill shall be called out by number
and size of conductors or by circuit name where the circuit appears on the circuit
schedule. A list of circuit types with single letter designators shall be prepared for
circuit types that will be used repeatedly.They shall be used on all plan sheets where
such information will not cause confusion. Routing shall consist of showing the
actual routing in cases where this is important or, more usually, showing a homerun
and destination. If everything in the conduit is going to the same final destination
with no intermediate junctions, just give the destination; e.g., "MCC5A." If,
everything in the conduit is going to the same final destination, but has intermediate
junctions, give the final destination and the next junction; e.g., "MCC5A via JB-3." If
there are several final destinations for the circuits in a conduit, make the destination
the next junction point and give the final destinations in the size and fill callout; e.g.,
"3/4" C, 3#12 to MCC5A, 6#14 to FP-3, 3#4 to MCC5A, 1#12G." Process and
facility plans shall be developed by the designer responsible for that facility.

DIVISION 11 SPECIFICATIONS
Division 11 specifications for equipment that requires electrical connections shall be
reviewed for electrical requirements by the electrical design engineer responsible for
the area where the equipment will be installed. In addition, the project lead electrical
engineer shall review each equipment specification before it is returned to the
Design Manager for processing. A list of Division 11 specifications will be prepared
that identifies which electrical design engineer is to review which sections.

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DIVISION 16 SPECIFICATIONS
Refer to Metropolitan's ESD-135, Standard Specifications Sections Catalog for a list
of specifications necessary for this job. These specifications shall be developed by
the project lead electrical engineer with input from each electrical design engineer
where a specification affects an area they are designing. When developed, these
specifications shall be compatible in requirements to Metropolitan Standard
Specifications Sections Catalog.

CIRCUIT AND RACEWAY SCHEDULES


A computer-developed circuit and raceway schedule shall be used for all circuits that
are routed through the duct bank system, with the exception of those shown on the
area plans (1"=20' scale site plans) where the ultimate destination of the circuit is
also shown on the same plan. To coordinate the efforts of all staff having input to
the schedules, each electrical designengineer shall be responsible for all circuits that
leave their facility and enter the duct bank system. They shall verify that each of their
circuits is completely routed through the duct system to its final destination.

For cable and circuit identification, refer to AppendixG.

Information to be presented in circuit and raceway schedules shall show the


following information:

x Circuit number;

x Circuit end points;

x Circuit type (power, control, instrumentation, etc.);

x Conductor size, count and type - identify neutral and grounds;

x Routing—list raceways in the order that the circuit passes through


them.

The raceway schedule shall show the following information:

x Raceway number;
x Raceway end points;
x Number, size, and type of conduits, e.g., 2-4 inch PVC;
x Circuits carried in the raceway.

The multiconductor cable schedule shall show the following:

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x Cable number;
x Circuits carried in the cable.

Each multiconductor cable shall also appear in the circuit schedule.

What to include in circuit and raceway schedules. The following circuits and the
raceways containing them shall be identified and entered into the circuit and
raceway schedule:

x Circuits which leave a sheet (exception: circuits which leave one floor
plan to a second floor of the same building but do not leave the
building).

x Circuits which leave a facility, unless they do not leave the sheet, and
the routing between facilities is clear.

x Circuits which are part of a control cable. An interconnection diagram


similar to that shown in Figure 5 shall be prepared for all terminal
junction boxes (TJBs) from which a control cable originates. These
diagrams may or may not be on the drawings depending on the
complexity of the diagram.

If a circuit is identified anywhere on its route, it shall be identified for its entire route.
All raceways containing that circuit shall also be identified unless the raceway
remains entirely within one facility. In such a case, that portion of the circuit may be
identified in the circuit schedule and the circuit will be identified as part of the
raceway fill on the drawings.

Information shall not be duplicated on the drawings and circuit and raceway
schedules. For anything appearing in the schedules, just give enough information
on the drawings to locate it in the schedules. This means that once the need to
identify a circuit has been established, the only information that needs to be put on
the drawings about that circuit is the circuit number and the raceways that contain it.

FAULT STUDIES
A preliminary fault study shall be completed for the entire plant as part of the PDR
but no later than the start of final design. The following assumptions shall be made:

x An infinite source is available on the high side of each utility service


transformer.

x The utility service transformers shall not be operated in parallel.

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x The standby engine generators shall not operate in parallel with the
utility source but the gas utilization generator shall.

x The maximum load operating on each 480-volt bus at each load center
shall be equal to 100 percent of the installed transformer capacity at
that load center.

The study shall show the load and fault duty on each bus and feeder overcurrent
device rated 460 volts or higher.

The final fault study shall be an update of the preliminary fault study.

The final load study shall show the load at each distribution assembly in the following
categories:

x HVAC;
x Process;
x Lighting;
x Other facility loads;
x Total.

Other categories may be added to the above, if required by the electric utility.

PROCESS CONSIDERATIONS

Hazardous Areas
The project lead electrical engineer shall review the various areas of the plant that
may contain hazardous concentrations of hazardous gases. Based on the
requirements of NFPA 820, a drawing shall be developed to deal with each area.
The areas that will be affected include enclosed areas, scum pits, and similar areas.
These are areas open to raw sewage or secondary influent (i.e., up to the aeration
basin), which shall be considered Hazardous Class I, Division I due to the presence
of methane and gasoline unless adequate ventilation is provided. In addition, the
digester gas compressor rooms shall also be classified as Class I, Division I areas.
Other areas may be classified hazardous as required by NFPA 820. Devices that
contain contacts located in hazardous areas shall generally be wired intrinsically
safe, except in Class I, Division II areas where hermetically sealed contacts may be
installed.

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Reliability
This plant requires EPA Class I reliability. One utility source is available at the plant
and a standby generator shall also be provided. The plant shall be designed with
double-ended unit substations and MCCs in all facilities. Power for duplicate
equipment shall be put into different conduits so as to maintain the Class I reliability.
Redundancy of supply criteria shall comply with EPA Bulletin EPA 430-99-74-001
definitions for a Class I plant.

UTILIZATION EQUIPMENT CONSIDERATIONS

Utilization Equipment Identification

Permanent. Utilization equipment shall be identified by I&C tag numbers as those


numbers become available. Utilization equipment that does not appear on the
P&IDs will be identified in the same manner as electrical distribution equipment (see
below) using an appropriate equipment type; for example, UH for unit heater.

Interim. Until I&C tag numbers become available, utilization equipment will be
identified by the following format:

x FF-SS

x Where FF is the facility number in or near which the equip ment is


located and SS is a sequence number. Sequence numbers shall be
assigned in order by the facility designer. Sequence numbers for
deleted equipment shall not be reused.

Miscellaneous
Provide disconnects where required at process equipment, especially at
motor-operated valves. Work with the equipment specified to see if integral
disconnects are a standard option. Do not ask that they be specified unless they are
a standard option. Provide disconnect switches for all HVAC equipment that has
any integral controls (i.e., unit heaters, compressors, duct heaters, air handlers,
etc.).

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ELECTRICAL EQUIPMENT CONSIDERATIONS

Electrical Distribution Equipment Identification


A logical and consistent naming and numbering system shall be developed to
designate equipment associated with electrical systems. Distribution equipment
numbers shall reference the building or facility in which the equipment is located.
Several examples of equipment designations based on function and voltage are
given below; note that the numeral 5 indicates the equipment is located in Building
No. 5.

480 Volts

Distribution Panel 5DP1, 5DP2, 5DP3, etc.


Switchboard 5SB1, 5SB2, 5SB3, etc.
Motor Control Center 5MCC1, 5MCC2, 5MCC3, etc.
Emergency Panel 5EP1, 5EP2, 5EP3, etc.

208Y/120 Volts

Lighting, Receptacles,
and Miscellaneous Power 5LP1, 5LP2, 5LP3, etc.

Emergency Lighting Panel 5EL1, 5EL2, 5EL3, etc.

Equipment-type designations shall be as follows:

x CMS = Combination motor starter;


x JB = Junction box;
x MCC = Motor control center, medium, or low voltage;
x MSR = Grouped motor control, not part of a manufactured
assembly;
x PNL = Panelboard;
x DPNL = Distribution panelboards;
x SB = Switchboard, low voltage;
x SWG = Switchgear, medium voltage;
x TJB = Terminal junction box;
x TX = Transformer;
x USB = Unit substation.

Other equipment-type designations may be used.

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Sequence numbers are required even if only one of a particular type of equipment is
in a particular facility. For TJBs only, the sequence number will be followed by "A"
for analog, "D" for discrete, or "P" for power.

The following equipment will be identified:

x Motor control centers;


x Panelboards;
x Distribution panelboards;
x Switchboards;
x Switchgear;
x Terminal junction boxes;
x Transformers;
x Unit substations;

Other equipment may be identified if identification is required for other purposes; for
example, junction boxes may need to be identified in order to homerun to them.

Major electrical equipment, i.e., MCCs, SWBDs, etc., shall be located on the site
plan and the 1"=20' scale area plans in addition to the facility and process electrical
plans.

Distribution System Protection


The following types of protective devices shall be used for the medium- and
low-voltage distribution systems:

x 4.16-kV main switchgear assembly: Draw-out vacuum type power


circuit breakers in NEMA Type 1 enclosure for indoor or NEMA Type
3R enclosure for outdoor.

x 4,160-volt motor control—: Draw-out type vacuum contactors with


current limiting fuses in NEMA Type 1 gasketed enclosure.

x 480-volt switchboard: 100 percent rated insulated case circuit breaker


with solid-state trip for mains and feeders 600 amperes and larger.
Smaller feeder breakers shall be molded case with solid state trips.

x 480-volt motor control center main circuit breaker: 100 percent rated
molded case with solid state trips.

x 480-volt motor control center branch circuit breaker (other than com-
bination motor starters): molded case thermal magnetic.

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x 480-volt feeder circuit breaker in motor control centers and power


distribution panelboards, 400-ampere and larger: molded case
solid-state trip, 100 percent rated. Smaller circuit breakers shall be
molded case thermal magnetic.

Equipment shall have adequate momentary and interrupting capacity to withstand


fault currents that may occur at the point in the system where the equipment shall be
applied.

Each circuit breaker that is located immediately downstream from the secondary
main on a 480Y/277-volt secondary transformer shall be equipped with ground fault
protection unless that circuit breaker is rated 200 amps or less. Each circuit breaker
protecting a motor of 100 horsepower or more shall be equipped with ground fault
protection. Ground fault protection on motors shall be instantaneous type and
ground fault protection on main breakers and feeder breakers shall be equipped with
time delay setting and restraint systems.

Motor Protection and Control


Magnetic-only circuit breakers shall be provided as a branch circuit protection in
motor starters for all motors 50 hp and smaller. Branch circuit protection for larger
motors shall be provided by thermal magnetic breakers with adjustable magnetic
trips.

Motor control center type construction shall be used where multiple three-phase
motors are located in the same general area.

Each motor shall be provided with thermal overload protection in all ungrounded
phases. Controller-mounted thermal overload relays shall have external manual
reset.

Internal temperature detectors embedded in motor windings shall be specified for


motors of 100 hp and larger and all motors 10 hp and larger that are powered by an
adjustable frequency drive. Multi-function protective relays for overload, phase
protection, and ground fault protection shall also be provided on large motors.

All motor control circuits shall operate at 120 volts and shall be supplied by individual
control power transformers fused both in the primary and secondary sides.

Electrical motor starter control shall normally consist of indicating lights,


pushbuttons, or switches. Devices connected with process controls, such as timers
and auxiliary relays, shall be provided in instrumentation and control panels or
operated by a programmable logic controller as part of its internal control logic.

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Panelboards
A separate circuit breaker shall be provided for instruments that perform the same
function on parallel flow streams, such as DO meters, flow meters, etc. Instruments
of different types that are all associated with the same flow stream may be
connected to the same branch circuit to simplify the design. Where multiple
instruments are connected to a single-branch circuit, a toggle switch shall be
provided at each tap to allow each individual instrument to be disconnected from the
branch circuit.

A common branch circuit shall be provided for all valve and gate operators that are
associated with a single-flow stream.

Examples:

x One circuit per bar screen channel

Branch circuits or feeders shall be identified on the drawings with the panelboard
and device protecting the individual circuit or feeder.

Lighting panelboards shall be surface-mounted, 208Y/120-volt, three-phase,


four-wire type with the main circuit breaker sized to match the lighting transformer
capacity. Separate panelboards shall be provided to supply power to instruments
and control panels where the equipment to be supplied requires a conditioned power
supply. Where two 480-volt power supplies are available, an automatic transfer
switch shall be provided to supply power to the lighting panelboard transformers
from either 480-volt source.

Each panelboard shall be equipped with a minimum of 20 percent spare breakers


with spaces, bus work, and terminations to complete the standard size panelboard.

Panelboard schedules shall show the circuit description, protective device trip rating,
number of poles, rating of main lugs or main circuit breaker, neutral bus size, ground
bus size, and interrupting rating of breakers. Computer-generated panelboard
schedules shall be included in the drawings.

Panelboard schedules shall be prepared indicating circuit description, protective


device trip rating, number of poles, load in volt-amps by phase, rating of main lugs or
main circuit breaker, neutral bus size, ground bus size, and interrupting rating of
breakers.

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Convenience Receptacles
Duplex receptacles for general service shall be spaced not more than 40 feet apart
inside all process buildings and 75 feet apart in outside process areas and shall be
located on the surface of walls or columns. Receptacles in outdoor locations and
areas subject to washdown shall be weatherproof. Receptacles shall be located as
needed in commercial areas.

Ground Fault
Ground fault systems shall be zero sequence type. Coordination shall be obtained
by hard-wired trip restraints (about 2ms restraint). Facilities shall be provided for
testing the ground fault circuit by secondary current injection, with or without tripping
and for indicating the occurrence of a ground fault. Current and time trip levels shall
be adjustable. Ground fault shall be supplied external to the circuit breaker. Motor
ground fault shall be an instantaneous trip.

Power Factor
Power factor correction capacitors shall be applied to all motor starters for motors of
40 hp and larger. Capacitor banks shall generally be located on top of motor control
centers.

Raceways
Specific types of raceway shall be chosen for use in various locations in the facility
based on moisture, temperature, exposure to damage, corrosion, voltage, and cost.
Separate, concrete-encased, polyvinyl chloride (PVC) conduit, underground duct
bank shall be provided for the following systems:

x Power wiring above 600 volts;


x Power and discrete control wiring below 600 volts;
x Process instrumentation analog and communication wiring.

Underground raceways that are not installed in a duct bank shall be direct-buried,
schedule 40 PVC conduit.

The following general guidelines shall be used for raceway sizing, selection, and
installation:

x Conduit size shall be based on THWN insulation for sizes below No. 6
AWG, and THW insulation for all other wiring 600 volts and below.
x The minimum diameter of conduit in all areas shall be 3/4 inch.
x Exposed raceways shall be installed in process areas.
x Raceways in walls and ceilings in control rooms, offices, and all areas

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with finished interiors shall be concealed.


x Embedded and buried nonmetallic conduits shall be converted to
metallic conduit before exiting from masonry or earth.
x The number of conduit bends shall be limited to an equivalent of 270
degrees on long runs.
x Exterior, exposed conduit shall be aluminum and/or PVC-coated rigid
steel.
x Exterior, underground, direct-buried conduit shall be schedule 40 PVC.
x Exterior, underground, concrete-encased conduit shall be schedule 40
PVC.
x Interior, concealed conduit shall be electrical metallic tubing (EMT) in
frame construction and finished ceiling spaces, schedule 40 PVC when
embedded in concrete or direct-buried in earth.
x Interior conduit exposed in dry areas shall be steel, except that EMT
shall be allowed for lighting circuits more than 4 feet above finished
floor.
x Interior conduit exposed to damp or wet areas shall be aluminum
and/or PVC coated rigid steel.
x Interior conduit exposed to corrosive areas shall be schedule 80 PVC.

Wire And Cable


Copper conductors shall be used for all lighting and power wiring of 600 volts and
below. Solid conductors shall be used for No.10 AWG and smaller where required
by wiring devices. Stranded conductors shall be used for other applications.
o
The current carrying capacity of conductors shall be based on 75 C insulation
ratings. Conductors No. 6 AWG and smaller shall have THHN/THWN insulation;
larger conductors shall have XHHW insulation.

Individual No. 14 AWG conductors shall be used for discrete control circuits, unless
it is practical to use multi-conductor cables to group control circuits.

Twisted-shielded pair control cable No. 16 AWG with an aluminum mylar tape shield
shall be used for analog signals. Multi-pair cables shall be used where grouping of
circuits is practical. Conductors above 600 volts shall be 19-strand copper with
ethylene-propylene polymer (EPR) insulation, copper tape shield and PVC outer
jacket.

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Motor Control Centers


MCCs shall use NEMA 1B wiring. Limiters shall be shown where necessary.
Overloads will be non-ambient-compensated unless such compensation is needed,
for instance, at submerged pumps. MCCs shall be 20 inches deep. All solenoid
valves, thermal devices, etc., that need to be operated when the motor is on shall be
powered from the motor starter CPT. Where this is done, the need for additional
CPT capacity shall be called out.

A minimum of 5 percent spares and 10 percent spaces shall be provided. Allow


space for at least one future section at each MCC.

Switchboards
Switchboards shall be similar to Square D Power Style with individually mounted,
molded case circuit breakers that have solid state trip elements. See the
manufacturers data contained hereinafter for additional information.

Grounding
Load centers shall be bonded to a grounding electrode, which may consist of a
building steel column that is bonded to the underground rebar or the nearest
available effectively grounded metal water pipe. In addition, ground rods shall be
driven outside the building to supplement the ground electrode.

Grounding electrodes of ground mats or embedded rods and cables shall have a
maximum resistance to ground of 1 ohm. A minimum of No. 2/0 insulated copper
cable shall be used for interconnecting ground rods and connection to equipment.

The parts of all electrical equipment, devices, panelboards, and metallic raceways
that do not carry current shall be connected to the ground conductors. The
transformer neutrals of wye-connected transformers shall be solidly grounded
through a grounding conductor connected to the grounding system.

A ground wire shall be installed in all raceways that contain power conductors at any
voltage.

Lighting
Lighting levels in all areas of the plant shall be calculated following the procedures
recommended in the Illumination Engineering Society (IES) handbook. In general,
the following minimum foot-candle level shall be provided:

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Area Foot-Candle
Office 70
Process, inside 50
Process, outside 5
Storage, inside 10
Walkway 5
General site 1

The following general types of light service shall be used to provide the proposed
foot-candle levels:

AreaLight Service
Office Fluorescent
Process, inside to
12 feet mounting
height Fluorescent
Process, above
12 feet mounting High pressure sodium
height or metal halide
Storage, inside Fluorescent
Walkway, inside Fluorescent
Walkway, outside High pressure sodium
General site High pressure sodium

Transformers
Transformers to supply 208Y/120 volt requirements shall be dry type and suitable for
the area in which they are to be located. Transformers that include a small
panelboard in the same enclosure shall not be used, A small transformer with a
separate panelboard shall be used in every case.

Transformers to supply 480 volt 3-phase and 4160 volt 3-phase shall be of the pad
mount type where located outdoors and of the dry type where located indoors.

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Miscellaneous Systems
Fire alarm systems shall be included in buildings as required by applicable codes.

INTERFACES

Facility
Each facility shall have designated interface points for connection with conductors
that leave the facility. For each facility, make a list showing where the interfaces are.

x Power Interfaces. Power interfaces shall be done at an assembly or


device and shall not require a junction box.

x Discrete Instrument and Control Interfaces. Where all discrete I&C


circuits that leave a facility are in a single assembly, that assembly
shall be used as the interface. Where discrete I&C circuits that leave a
facility come from several assemblies, a TJB shall be installed for the
interface (see Figure ___).

x Analog Instrument and Control Interfaces. Where all analog I&C


circuits that leave a facility are in a single assembly, that assembly
shall be used as the interface. Where analog I&C circuits that leave a
facility come from several assemblies, a JB or TJB (if conversion to a
multiconductor cable is required) shall be installed for the interface.

CALCULATIONS REQUIRED
Calculations shall be done in an orderly manner either on a desktop PC computer or
on computation paper. Each sheet shall have the date on which the computations
were made, the project number, and the designers name. All information used in the
preparation of the design shall be kept in a notebook with tabs to properly divide the
different items such as telco memos, comps, letters, equipment data sheets, etc.
Each computation shall clearly identify the facility for which the calculations are
being made and the type of computation that is being performed. Copies of all
calculations shall be sent to project lead electrical engineer as they are completed
for his review and filing. At the completion of the project, all pertinent information
shall be assembled in a single set of notebooks for inclusion in the project files.

The computations listed below are the minimum that need to be documented. All
calculations shall be reviewed before the related drawings are drafted.

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Wire Sizing
Take into account wet/dry areas and ambient temperatures—see attached form for a
guide. Show wiring sizing for all services, feeders, and large branch circuits.

Calculations shall include a summary of all loads to be served where there is more
than one load. Calculations for feeders to panelboards shall reference the specific
panelboard being supplied and a copy of the panel schedule with all loads indicated
shall be included with the calculations.

Primary and secondary feeders to/from dry type transformers shall be sized in
accordance with the attached transformer table and the proper sized main breaker
shall be shown in the panelboard that is served from the transformer.

Dry Type Transformers


Include a list of all branch circuit panelboards to be supplied and the connected load
on each panel. Demand and diversity factors that are allowed by the NEC may be
used for sizing transformers that supply loads in areas that are not process related,
but transformers in other areas shall be adequately sized to supply the total
connected load connected to the process.

Pad Mounted and Unit Substation Transformers


All power supply transformers shall be sized to supply the total load that is normally
connected to the transformer's secondary bus without exceeding the air-cooled
rating of the transformer. Where there are three MCC buses, it shall be assumed
that the third MCC bus can be "normally connected" to either transformer. Each
transformer shall also be able to carry the total load of the load center that would be
expected to be operating during peak flow conditions without exceeding the
transformer's overload rating, assuming that one transformer has failed.

Voltage Drop
Prepare steady-state voltage drop calculations for all heavily loaded and/or long
branch circuits and feeders using the attached "Voltage Drop Calculation Data."
Base calculations for motor circuits on an 80 percent power factor. Motor starting
voltage drop calculations shall be shown for all motors that exceed 20 percent of the
rating of the serving transformer.

Steady state voltage drop shall be limited to the values listed in the Design Criteria
with not more than 2 percent drop on feeder. Motor starting voltage drop shall be
limited to 20 percent.

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Branch Circuits
Connected load and NEC requirements shall be used for sizing branch circuit
breakers and conductors.

A minimum wire size of No. 12 AWG copper shall be used for lighting and receptacle
branch circuits. No. 10 AWG shall be used where the first convenience receptacle is
more than 75 feet from the panelboard.

In general, 120 volt lighting branch circuit load shall be used for up to 1800
voltamps.

120 volt lighting loads shall be connected to circuits separate from receptacles
except in storage rooms where the lights may be connected to receptacle circuits or
vice versa.

Branch circuit shall be limited to five duplex receptacles in process areas and six
duplex receptacles in office areas. Special areas may require further reduction in
number of receptacles per circuit.

Conduit Size
Calculations shall be included for sizing of all conduits that are not covered by the
table of conduit sizes included hereinafter. Conduit fill shall not exceed that allowed
by the NEC when all conductors, including the ground conductor, are included in the
calculation assuming that ground conductors have TW insulation and phase
conductors have THW insulation.

Power Factor Correction


Calculations shall be made for the sizing of all power correction capacitors. The
calculations shall include a statement showing all assumptions that are made to
make the calculation. If tables are used, a copy of the table used with appropriate
values marked, shall be included in the calculation section of the notebook.

Lighting
Calculations may be in any form. For small areas, a statement that "so many" lights
of "such" a size will do the job, and is all that is required. For larger areas, use the
"Zonal Cavity Calculations" form attached. The foot-candle level resulting from the
actual fixtures to be installed shall be documented.

Fault Study and Coordination


This should take into account future loads and changed conditions. Presume the
utility is an infinite bus unless better information can be obtained.

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Appendix D

ENCLOSURE TYPES MWD Electrical Design Manual

NEMA Type 1, General Purpose. Enclosures intended for indoor use primarily to
provide a degree of protection against limited amounts of falling dirt.

NEMA Type 2, Dripproof. Enclosures intended for indoor use primarily to provide a
degree of protection against limited amounts of failing water and dirt. Enclosures have
provisions for drainage. If provision is made for the entrance of conduit at the top, it
consists of a conduit hub or equivalent.

NEMA Type 3, Dusttight, Raintight, and Sleet- (Ice-) Resistant. Enclosures intended for
outdoor use primarily to provide a degree of protection against rain, sleet, windblown
dust and damage from external ice formation. Enclosures have conduit hubs or
equivalent provision for watertight connection at the conduit entrance.

NEMA Type 3R, Rainproof and Sleet- (Ice-) Resistant. Enclosures intended for outdoor
use primarily to provide a degree of protection against rain, sleet, and damage from
external ice formation.

NEMA Type 3S, Dusttight, Raintight, and Sleetproof (Iceproof) Enclosures intended for
outdoor use primarily to provide a degree of protection against rain, sleet, windblown
dust and to provide for operation of external mechanisms when ice laden. Enclosures
have conduit hubs or equivalent provision for watertight connection at the conduit
entrance, mounting means external to the equipment cavity, and provision for locking.

NEMA Type 4, Watertight, Dusttight, and Sleet-Resistant. Enclosures intended for


indoor or outdoor use primarily to provide a degree of protection against windblown dust
and rain, splashing water, hose-directed water and damage from external ice formation.
Enclosures have conduit hubs or equivalent provision for watertight connection at the
conduit entrance and mounting means external to the equipment cavity.

NEMA Type 4X, Watertight, Dusttight, Sleet- and Corrosion Resistant: Same provisions
as Type 4 enclosure, and in addition, are corrosion-resistant.

NEMA Type 6, Submersible, Watertight, Dusttight, and Sleet- (Ice-) Resistant.


Enclosures intended for indoor or outdoor use primarily to provide a degree of
protection against hose-directed water, and the entry of water during occasional
temporary submersion at a limited depth and damage from external ice formation.
Enclosures have conduit hubs or equivalent provision for watertight connection at the
conduit entrance and mounting means external to the equipment cavity.

NEMA Type 6P, Submersible, Watertight, Dusttight, and Sleet- (Ice-) Resistant. Same
provisions as Type 6 enclosure except for protection against entry of water during
prolonged submersion at a limited depth.

ESD-106 D-1 01/06


Appendix D

ENCLOSURE TYPES MWD Electrical Design Manual

NEMA Type 7, Class I, Group A, B, C, or D Hazardous Locations, Air-Break.


Enclosures intended for indoor use in locations classified as Class I, Division 1, Groups
A, B, C or D hazardous locations as defined in the National Electric Code (NFPA 70).
Enclosures are designed to withstand the pressures of an internal explosion and not
ignite an explosive mixture outside the enclosure. Equipment within the enclosure shall
be able to interrupt in a flammable atmosphere. Enclosures are commonly referred to
as explosion-proof.

NEMA Type 8, Class I, Group A, B, C, or D Hazardous Locations, Oil-Immersed.


Enclosures intended for indoor or outdoor use in locations classified as Class I, Division
2, Groups A, B, C or D hazardous locations as defined in the National Electric Code
(NFPA 70). Enclosures are designed such that the enclosed equipment is oil-immersed
and can operate at rated voltage and most severe current conditions in the presence of
flammable gas-air mixtures without igniting these mixtures. Enclosures are commonly
referred to as oil immersed.

NEMA Type 9, Class II, Group E, F, or G Hazardous Locations, Air-Break. Enclosures


intended for indoor use in locations classified as Class II, Division I, Groups E, F and G
hazardous locations as defined in the National Electric Code (NFPA 70). Enclosures
prevent the ingress of hazardous dust and are commonly referred to as dust-ignition
proof.

NEMA Type 10. Nonventilated enclosures constructed for mine use and designed to
meet the requirements of the Mine Safety and Health Administration.

NEMA Type 11, Corrosion-Resistant and Dripproof, Oil-Immersed. Enclosures intended


for indoor use to protect the enclosed equipment against dripping, seepage, and
external condensation of corrosive liquids by providing for immersion of equipment in
oil.

NEMA Type 12, Industrial Use, Dusttight, and Driptight. Enclosures intended for indoor
use to protect the enclosed equipment against fibers, flyings, lint, dust, and external
condensation of noncorrosive liquids. Enclosures have no holes, conduit knockouts or
conduits openings, except that oiltight or dusttight mechanisms may be mounted
through holes in the enclosure when provided with oil-resistant gaskets.

NEMA Type 13, Oiltight and Dusttight. Nonventilated enclosures intended for indoor
use primarily to house control-circuit devices such as limit switches, foot switches,
pushbutton, selector switches, and pilot lights and to protect these devices against lint
and dust, seepage, external condensation, and spraying of water, oil, or coolant. All
conduit openings have provisions for oiltight conduit entry.

ESD-106 D-2 01/06


Appendix E

MOTOR ENCLOSURE TYPES MWD Electrical Design Manual

OPEN MACHINE: ventilation openings permit passage of external cooling air over and
around the winding of the machine

DRIP-PROOF MACHINE: ventilation openings are so constructed that successful


operation is not interfered with when drops of liquid or solid particles strike or
enter the enclosure at any angle from 0 to 15 degrees downward from the
vertical.

SPLASH-PROOF MACHINE: ventilation openings are constructed so that successful


operation is not interfered with when drops of liquid or solid particles strike or
enter the enclosure at any angle not greater than 100 degrees downward from
the vertical.

SEMIGUARDED MACHINE: ventilation openings in the machine, usually in the top


half, are guarded as in the case of a "guarded machine," but the others are left
open.

GUARDED MACHINE: all openings giving direct access to live metal or rotating parts
are limited in size by structural parts or by screens, baffles, grilles, expanded
metal, or other means to prevent accidental contact with hazardous parts.

DRIP-PROOF GUARDED MACHINES: a drip-proof machine with guarded ventilation


openings.

OPEN EXTERNALLY VENTILATED MACHINE: ventilated by means of a separate


motor-driven blower mounted on the machine enclosure.

OPEN PIPE VENTILATED MACHINE: openings for the admission of the ventilation are
so arranged that inlet ducts or pipes can be connected to them. Machine shall
be self-ventilated or force-ventilated, external from and not a part of the
machine.

WEATHER PROTECTED MACHINE TYPE I: ventilation passages constructed so as to


minimize the entrance of rain, snow, and airborne particles.

WEATHER PROTECTED MACHINE TYPE II: ventilation passages at both intake and
discharge are arranged so that high velocity air and airborne particles blown
into the machine by storms or high winds can be discharged without entering
the internal ventilating passages.

TOTALLY ENCLOSED MACHINE: enclosed to prevent the free exchange of air


between the inside and outside of the enclosure but not sufficiently enclosed
to be termed airtight.

ESD-106 E-1 01/06


Appendix E

MOTOR ENCLOSURE TYPES MWD Electrical Design Manual

TOTALLY ENCLOSED NONVENTILATED MACHINE: totally enclosed machine that is


not equipped for cooling by means external to the enclosed parts.

TOTALLY ENCLOSED FAN-COOLED MACHINE: equipped for exterior cooling by


means of a fan or fans integral with the machines but external to the enclosed
parts.

EXPLOSION-PROOF MACHINE: enclosure designed and constructed to withstand an


explosion of a specified gas or vapor that may occur within the enclosure and
to prevent ignition of the specified gas or vapor surrounding the machine by
sparks, flashes, or explosions of the specified gas or vapor.

DUST IGNITION-PROOF MACHINE: enclosure designed and constructed in a manner


that will exclude ignitable amount of dust or amounts that might affect
performance or rating, and which will not permit arcs, sparks, or heat to cause
ignition of exterior accumulations or atmospheric suspensions of a specific
dust.

WATERPROOF MACHINE: constructed so that it will exclude water in the form of a


stream from a hose, except that leakage may occur around the shaft that
provides for automatic drainage.

TOTALLY ENCLOSED PIPE VENTILATED: constructed with openings so arranged


that when inlet and outlet ducts or pipes are connected to them there is no free
exchange of the internal air and the air outside the enclosure may be
self-ventilated or force-ventilated.

TOTALLY ENCLOSED WATER COOLED MACHINE: cooled by circulating water, with


the water or water conductors coming in direct contact with machine parts.

TOTALLY ENCLOSED WATER-AIR-COOLED MACHINE: cooled by circulating air


which, in turn, is cooled by circulating water. Machine is provided with a
water-cooled heat exchanger for cooling the internal air and a fan or fans,
either integral with the rotor shaft or separate, for circulating the internal air.

TOTALLY ENCLOSED AIR-TO-AIR COOLED MACHINE: cooled by circulating the


internal air through a heat exchanger which, in turn, is cooled by circulating
external air. Machine is provided with an air-to-air heat exchanger for cooling
the internal air and a fan or fans, either integral with the rotor shaft or
separate, for circulating the internal air and a fan or fans, either integral with
the rotor shaft or separate but external to the enclosing part or parts, for
circulating the external air.

ESD-106 E-2 01/06


Appendix E

MOTOR ENCLOSURE TYPES MWD Electrical Design Manual

TOTALLY ENCLOSED FAN-COOLED GUARDED MACHINE: all openings giving


direct access to the fan are limited by size or design of the structural parts,
and have screens, grilles, expanded metal, etc. to prevent accidental contact
with the fan.

TOTALLY ENCLOSED AIR-OVER MACHINE: intended for exterior cooling by


ventilation external to the machine.

ESD-106 E-3 01/06


Appendix F

MOTOR DESIGN TYPES MWD Electrical Design Manual

The polyphase induction motor shall be of either the squirrel-cage or the wound-rotor
type. The squirrel-cage induction motor has been classified by National Electrical
Manufacturers Association (NEMA) Tests and Performance-AC (MG1-1987) according
to the following designs.

Design A. A Design A motor is a squirrel-cage motor designed to withstand full-voltage


starting and to develop locked-rotor torque. It has a breakdown torque as shown in
Table MG1-12-39. It has a locked-rotor current higher than the value shown in Table
MG1-12-35 and a slip at rated load of less than 5 percent.

Design A motors are usually used for applications where extremely high efficiency and
extremely high full-load speed are required. Therefore, Design A motors tend to be
special motors.

Design B. A Design B motor is a squirrel-cage induction motor designed to withstand


full-voltage starting, developing locked-rotor and breakdown torques adequate for
general application as specified in Tables MG1-12-38.1 and MG1-12-39, drawing
locked-rotor current not to exceed the values shown in Table MG1-12-35, and having a
slip at rated load of less than 5 percent. Motors with 10 and more poles may have a slip
slightly greater than 5 percent.

Design B motors are the standard general-purpose motors used where low locked-rotor
current and moderate locked-rotor torque are required along with high full-load speed
and efficiency.

Design C. A Design C motor is a squirrel-cage motor designed to withstand full-voltage


starting, developing locked-rotor torque for special high-torque applications up to the
values shown in Table MG1-12-38.2, breakdown torque up to the values shown in Table
MG1-12-39.2, with locked-rotor current not to exceed the values shown in Table
MG1-12-35, and having a slip at rated load of less than 5 percent.

Design D. A Design D motor is a squirrel-cage motor designed to withstand full-voltage


starting, developing high locked-rotor torque as shown in Table MG1-12-38.2, with
locked-rotor current not greater than that shown in Table MG1-12-35, and having a slip
at rated load of 5 percent or more.

Design F. A Design F motor is a squirrel-cage motor designed to withstand full-voltage


starting, developing low locked-rotor torque as shown in Table MG1-12-38.1 with
breakdown torque as shown in Table MG1-12-38.2, with locked-rotor current not to
exceed the values shown in Table MG1-12-35, and having a slip at rated load of less
than 5 percent.

ESD-106 F-1 01/06


Appendix F

MOTOR DESIGN TYPES MWD Electrical Design Manual

The following figure shows typical speed-torque curves of NEMA design-class squirrel
cage motors.

ESD-106 F-2 01/06


Appendix G

MOTOR TORQUE DEFINITIONS MWD Electrical Design Manual

The following terms are commonly used to describe motor torque.

Full load torque – Torque necessary to produce rated horsepower at full-load speed.
Locked-rotor (starting) torque – Minimum torque which the motor will develop at rest
for all angular positions of the rotor, with rated voltage applied at rated frequency.
Pull-up torque – Minimum torque developed by the motor during the period of
acceleration from rest to the speed at which breakdown torque occurs. For motors
which do not have a definite breakdown torque, the pull-up torque is the minimum
torque developed up to rated speed.
Breakdown torque – Maximum torque which the motor will develop with rated voltage
applied at rated frequency, without an abrupt drop in speed.
Pull-out torque (synchronous motor) – Maximum sustained torque which the motor
will develop at synchronous speed with rated voltage applied at rated frequency and
with normal excitation.
Pull-in torque (synchronous motor) – Maximum constant torque under which the
motor will pull its connected inertia load into synchronism, at rated voltage and
frequency, when its field excitation is applied.

ESD-106 G-1 01/06


Appendix H

STANDARD SPECIFICATIONS FOR THE


IDENTIFICATION OF ELECTRICAL
CURRENT CARRYING CONDUCTORS MWD Electrical Design Manual
The specification is provided by the Treatment Plant Design Team.

CABLE IDENTIFICATION
Conductor and multiconductor cables should be identified at each end of the installed
cable. Cable tags and fastening devices shall be made of nonconductive materials.
Cable tab marking should be permanent type and waterproof. The cable number should
be show on single-line diagrams, wiring diagrams, wire list, instrument-loop diagrams,
and panel-wiring diagrams. The cable number should be constructed as follows:

1. Feeder Cable From Unit Substation or Distribution Load-Center.


a. IP-1 (without suffix letter)
b. IP-1 A (with suffix letter)

Suffix letter as required (A,B,C,…etc.)


Feeder number from unit substation or distribution
loadcenter (1,2,3…etc.)
MSDS transformer’s secondary cable designation.

2. Feeder Cable from Motor Control Center or Power Distribution Panel.


a. 1P1-1 (without suffix letter)
b. 1P1-1 A (with suffix letter)

Suffix letter as required (A,B,C,…etc.)


Feeder number from motor control center or power
distribution panel (1,2,3…etc.)
Motor control center or power distribution panel
designation.

3. Branch Circuit Cable From Lighting and Receptacle Panel.


a. 2L-1 (without suffix letter)

ESD-106 H-1 01/06


Appendix H

STANDARD SPECIFICATIONS FOR THE


IDENTIFICATION OF ELECTRICAL
CURRENT CARRYING CONDUCTORS MWD Electrical Design Manual
b. 2L-1 A (with suffix letter)

Suffix letter as required (A,B,C,…,etc.)


Lighting or receptacle circuit number (1,2,3…etc.)
Lighting and receptacle panel designation (“L”
denotes lighting and receptacle cable or conductor)

4. Control Cable of Motor Starter or Controller.


a. 1C1-1 (without suffix letter)
b. 1C1-1 A (with suffix letter)

Suffix letter as required (A,B,C,…,etc.)


Feeder number from power source panel.
Motor control center or power distribution panel
designation, except “C,” which denotes “Control” is
substituted for power “P” or to any power designated
letters. Typical for all feeder-source-panel with control
cable or conductor.)

5. Control Cable of Instrumentation Equipment with Contract Closure


a. PS500C (without suffix letter)
b. PS500 C A (with suffix letter)

Suffix letter as required (A,B,C,…,etc.)


Denote “Control” cable.
Instrument tag number as show on the P&ID’s
without suffix number.

c. LI302C-1 (without suffix letter)


d. LI302C-1 A (with suffix letter)

ESD-106 H-2 01/06


Appendix H

STANDARD SPECIFICATIONS FOR THE


IDENTIFICATION OF ELECTRICAL
CURRENT CARRYING CONDUCTORS MWD Electrical Design Manual

Suffix letter as required (A,B,C,…,etc.)


Instrument tag number’s suffix number as
required (1,2,3…etc)
Control cable designation without suffix
number.

6. Instrumentation Cable of Instrumentation Equipment with Analog Signal


a. I-PS500 (without suffix letter)
b. I-PS500 A (with suffix letter)

Suffix letter as required (A,B,C,…etc.)


Instrument tab number as shown on the P&ID’s
without suffix number.
Denotes “Instrumentation” cable.

c. I-LI302-1 (without suffix letter)


d. I-LI302-1 A (with suffix letter)

Suffix letter as required (A,B,C,…etc.)


Instrument tag number’s suffix number as
required (1,2,3,..etc.)
Instrumentation cable designation without
suffix number.
Denotes “Instrumentation” cable.

Note: See Figure H-1 and Figure H-2 for samples.

ESD-106 H-3 01/06


Appendix H

STANDARD SPECIFICATIONS FOR THE


IDENTIFICATION OF ELECTRICAL
CURRENT CARRYING CONDUCTORS MWD Electrical Design Manual

Figure H-1. Examples of Power Feeder Cable Identifications for Water


Treatment Plant Section

ESD-106 H-4 01/06


Appendix H

STANDARD SPECIFICATIONS FOR THE


IDENTIFICATION OF ELECTRICAL
CURRENT CARRYING CONDUCTORS MWD Electrical Design Manual

Figure H-2. Examples of Control and Instrumentation Cable


Identifications for Water Treatment Plant Section

ESD-106 H-5 01/06


Appendix H

STANDARD SPECIFICATIONS FOR THE


IDENTIFICATION OF ELECTRICAL
CURRENT CARRYING CONDUCTORS MWD Electrical Design Manual

ELECTRICAL BRANCH
HYDRO PLANT DESIGN SECTION

STANDARD SPECIFICATION
FOR THE IDENTIFICATION OF
ELECTRICAL CURRENT

1.0 SCOPE:
This standard provides the means of identifying electrical current
Carrying conductors on single line diagrams, wiring diagrams, wire lists.
Instrument loop diagrams, and internal/external panel diagrams. Also
provided is the installation requirements for cable identification tags.

2.00 DEFINITIONS:
Cable: A current carrying conductor/ conductors enclosed in an insulating
sheath and bound by an outer jacket of insulating material.
Conductor: A single current carrying material enclosed by an insulating jacket.

3.0. INSTALLATION REQUIREMENTS:

3.10 Cable identification tags shall be non-metallic material and permanently


affixed to outer cable jacket.
3.20 Identification tags should be affixed within 6” of conductor separation from
outer jacket except as noted.

3.21 EXCEPTIONS:
I. where taping or shielding is required the tag shall be placed as close
to the termination point as physically possible.

3.30 All conductors and multi-conductor cables identified on design documents


as requiring identification tags should have a Thomas & Betts WSL self-
laminating vinyl marker, or equal attached or shrink wrapped to the cable.

3.31 single conductors and individual conductors of multi-conductor


cables should be identified with a Thomas & Betts type WWSL self-
laminating vinyl marker, or equal attached or shrink wrapped to the
conductor indicating the point of termination.

3.32 All conductor voltage levels shall be identified by the following color
code in Table-A.

TABLE - A
BACKGROUND CHARACTER
VOLTAGE LEVEL
COLOR COLOR

RED WHITE 12KV AND UP


ORANGE BLACK 4.16KV
BLUE WHITE 480V
BLACK WHITE 240V
BROWN WHITE 120V
GREEN WHITE SIGNAL

ESD-106 H-6 01/06


Appendix H

STANDARD SPECIFICATIONS FOR THE


IDENTIFICATION OF ELECTRICAL
CURRENT CARRYING CONDUCTORS MWD Electrical Design Manual

4.0.0 IDENTIFICATION REQUIREMENTS:

4.1.0 All cables that require identification should be identified by the


following alpha-numeric code as shown in Figure H-3

4.1.1 The alpha-numeric code shall be used on all design documents


where cable identification is required

4.2.0 UNIT OR EXPANSION NUMBER

The unit or expansion number indicates the phases of the project.


This number or letter will increase as subsequent phases of the
project are started.

4.2.1 ASSOCIATED PLANT SYSTEM


The associated plant system indicates the system that the cable is
related to. See page H-10 for a sample listing of plant system.

4.2.2 EQUIPMENT NUMBER


The equipment number or letter identifies a particular piece of
equipment that is related to the associated plant system.

4.2.3 CABLE TAG NUMBER 00 THROUGH 99


The cable tag number identifies a particular cable that is related to a
specific piece of equipment located within a particular plant system.

X XX X X X

CABLE TAG NUMBER 00 THROUGH 99


EQUIPMENT NUMBER
ASSOCIATED PLANT SYSTEM
UNIT OR EXPANSION NUMBER

Figure H-2. Cable Identification

ESD-106 H-7 01/06


Appendix H

STANDARD SPECIFICATIONS FOR THE


IDENTIFICATION OF ELECTRICAL
CURRENT CARRYING CONDUCTORS MWD Electrical Design Manual

Figure H-3. Identification of A Multi-Conductor Cable

Figure H-4. Identification of A Single-Conductor Cable

ESD-106 H-8 01/06


Appendix H

STANDARD SPECIFICATIONS FOR THE


IDENTIFICATION OF ELECTRICAL
CURRENT CARRYING CONDUCTORS MWD Electrical Design Manual
ASSOCIATED PLANT SYSTEMS CABLE CODES

MECHANICAL SYSTEMS ELECTRICAL SYSTEMS

AD ALUM DISTRIBUTION SS STATION SERVICE


BD BASIN DEWATERING US UNIT SUBSTATION
BP BACKWASH POLYMER MC MOTOR CONTROL CENTER
CI CHEMICAL INJECTION ST STATION TRANSFER
CD CHLORINE DISTRIBUTION UT UNIT SUB-STATION
DP DRY POLYMER MT MCC TRANSFORMER
EQ EFFLUENT WATER QUALITY L1 LIGHTING PANEL 1
FA FILTER AID DISTRIBUTION D1 DISTRIBUTION PANEL 1
FB FLOCCULATION BASINS
FD FLOOR DRAINS
FI FILTER OPERATION
FO FOAM ABATEMENT
FL FLOCCULENT AID
DISTRIBUTION
FW FIRE WATER DISTRIBUTION
GW GRAY WATER
IW INDUSTRIAL WATER
IQ INFLUENT WATER QUALITY
PA PLANT AIR
PI PLANT INFLUENT
SD SUBDRAINS
SP SPARGER PUMPS
SW SURFACE WASHWATER
TB TRAVELING BRIDGE
WP PORTABLE WATER PUMPS
WS WATER SAMPLING
WW WASHWATER

ESD-106 H-9 01/06


Appendix H

STANDARD SPECIFICATIONS FOR THE


IDENTIFICATION OF ELECTRICAL
CURRENT CARRYING CONDUCTORS MWD Electrical Design Manual

XXXXXX

BOX TAG NUMBER


BOX IDENTIFICATION
UNIT OR EXPANSION NUMBER

TYPICAL MANHOLE IDENTIFICATION

1MH123
TYPICAL MANHOLE IDENTIFICATION

1MHH123

TYPICAL PULLBOX IDENTIFICATION


1PB123

TYPICAL JUNCTION BOX IDENTIFICATION


1JB123

TYPICAL TERMINATION BOX IDENTIFICATION

1TB123

Figure H-5. Typical Box Identification

ESD-106 H-10 01/06


Appendix H

STANDARD SPECIFICATIONS FOR THE


IDENTIFICATION OF ELECTRICAL
CURRENT CARRYING CONDUCTORS MWD Electrical Design Manual

X X X X X X

COLUMNS 01 TO 99

01 02 03 04 05

1A1101 1A1102 1A1103 1A1104 1A1107

1A1201 1A1202 1A1203 1A1204 1A1205


ROWS
1 TO 9 3

1A1301 1A1302 1A1303 1A1304 1A1305

1A1401 1A1402 1A1403 1A1404 1A1405

1A1501 1A1502 1A1503 1A1504 1A1505

TYPICAL DUCT ALPHA-NUMERIC CODE

Figure H-6. Typical Duct Bank Identification

ESD-106 H-11 01/06

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