Design Basis Report-R0

PROJECT: Hindustan Coco Cola Beverage, Bangaluru
DESIGN BASIS REPORT-R0
Sheet 1 of 14
Hindustan Coco Cola Beverages
ELECTRICALS
CONTENTS
Section 1: Scope of Work
Section 2: Site Conditions
Section 3: Electrical Supply Specifications
Section 4: Standards
Section 5: Calculation of distributed loads
Section 6: System Detail
HT Distribution
Transformer
LT Distribution
Metering
Reactive Power Compensation
Power Cable
Cable Routing & Cable Tray
Lighting
Point/Circuit Wiring
UPS
DG Backup
Earthing & lightening Arrestor
Section 7: Energy Conservation and Environmental Measures Undertaken
Section 8: List of make
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1.
Sheet 2 of 14
SCOPE
This specification covers the requirements of supply, installation & commissioning of
miscellaneous equipment, installation materials, wiring materials, safety accessories etc.
The installation shall be carried out in accordance with Indian Electricity Rules, relevant
statutory requirements, specification, design drawings and applicable Engineering Standards.
Any variations or changes to be carried out at site shall be done with the prior approval of the
Consultant / Client/ PMC representative.
2.
SITE CONDITIONS
Temperature
3.
4.
Average of Maximum 33 OC (System will be designed at 50 OC

ambient
condition)
Humidity
Not more than 82 % at maximum temperature.
Altitude
900 meters above MSL
ELECTRICAL SUPPLY SPECIFICATIONS

Distribution Voltage
433 V
Voltage variation limits
-15% to +5% on LT Side
No. of phases
Frequency
50 c/s
Frequency variation limits
+5%
Fault level
65 KA
Neutral earthing on LV side
Solidly earthed
STANDARDS
All equipment and installation shall generally conform to the requirements of relevant Indian
Standards and Codes of Practice.
All the materials shall carry ISI mark unless otherwise agreed.
The installation shall conform to the requirements of latest editions of Indian Electricity
Rules, supplementary regulations of local Authorities and the Utility Company.
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Sheet 3 of 14
The installation shall further conform to the requirements of Fire Insurance Regulations &
FM Global Standards.
The standards shall include but not be limited to the following.
Indian Electricity Rules (1956) amended up to date.
National Electrical Code 1985.
IS: 732 / 1989 - Code of practice for Electrical Wiring Installation (System Voltages
below 650V)
IS: 3043 / 1987- Code of Practice for Earthing.
IS: 5216 / 1982 - Guide for safety procedure in Electrical work.
IS: 3646 / 1992 - Code of Practice for Interior illumination: Part 2 to 3
IS: 10118 / 1982 - Code of Practice for selection, Installation & Maintenance of
Switchgear &Control gear: Part 2.
IS: 10008 / 1981 - Code of Practice for selection, Installation & Maintenance of
transformers: Part 3.
IS: 14927 / 2001 Cable trunking& Ducting systems for electrical installation: Part
2.
IS: 14930 / 2001 Conduit systems for electrical installation: Part 2.
National Building Code 2005
Applicable BIS, IEEE & FM Global standards for various equipment and installation
work covered in the specification.
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Sheet 4 of 14
5. CALCULATION OF DISTRIBUTED LOAD

Please find enclosed herewith load summary.
Detail load attached
HV Distribution
As per your communication on mail 11 KV line is available at the proposed location of the
facility.
HT meter room with Trivector Meter along with Vaccum Circuit Breaker for
isolation is provided near the entry gate where state electricity board would terminate power
through a GO/DO switch mounted on a two pole structure along with lightening arrestor.
Vaccum circuit Breakers are provided with necessary protection relays.
We are carrying underground HT Cable in hume pipes up to Utility block. Here it is
terminated into an incomer of the ring main unit. Provision is given in this unit for future
feeders along with a spare.
Transformers
The anticipated maximum demand for the entire project is 2437 KVA. Based on the
calculation in the attached sheet 3150 KVA Oil Cooled Distribution Transformer is selected.
The transformer would be backed up by one numbers of 11 KV, rated current 800 amps, VCB
circuit breakers with necessary protection relays along with CTs and PTs
The transformer, vector group DYN 11 is proposed with OLTC with range of +5 to 15%
with
regulation in steps @ 1.5%. The transformer shall be copper wound with ONAN
cooling. The transformer
shall be fitted with cable box on primary side and bus duct flange
on secondary side.
The following accessories / protections are proposed for the above rated transformer.
a) Buchloz relay
b) Minimum oil level guage
c) Winding temperature indicator
d) Oil temperature indicator
e) Magnetic oil gauge
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Sheet 5 of 14
Fault level at the secondary of the transformer is calculated as 64.62 KA in the enclosed
sheet.
This transformer would be connected to the PCC through an IP 65 Aluminium Bus duct. Fault
level at PCC is calculated as 63.35 KA at the PCC level. All switchgear like ACB and MCCB
are selected for 65 KA fault levels.
LT Distribution
Main PCC shall have two bus bar system. The bus duct from the Transformer would be
terminated into an electrically operated microprocessor based Air circuit breakers with under
voltage, over voltage releases along with various other protections like earth fault and over
current.
The PCC will also have feeder coming in from back up Diesel Generating Sets. These DG
sets would feed power to a synchronizing Panel capable of auto load management along with
synchronizing facility.
The power would be fed to the bottom bus bar from the DG and Power from SEB would be
fed to the Top of the bus bar of the PCC. Feeders would be provided as shown in the block
diagram in such a way that any of the feeder could be getting power from either the DG or the
SEB power,
Each of the outgoing Circuit breaker has been sleceted on the basis of the following
philosophy.
Maximum expected connected Load + 25% spare x 1.25 to nearest standard breaker frame
size
Each of the out-going feeders would be fitted with metering units capable of communication
over networks using Ethernet, modem, RS-232/485.
All ACB/MCCB will be TPN/4P with 65 KA breaking capacity in the Main PCC with
necessary BMS interfacing as per the specified requirements under BMS guidelines.
1. ON, OFF, TRIP indications of all switchgear in Main PCC panel
2. Metering status for all incoming and out-going switchgear.
MCCBs selected for downstream power distribution would have diminishing fault levels as
per the
requirement. A calculation for the same would be forwarded.

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Sheet 6 of 14
Metering
HT metering is considered since we will be using bulk power.
All Main LT panels, sub main LT panels will be with digital metering.
Reactive power compensation

Keeping in view switching of heavy loads at frequent intervals Detuned filters with
capacitors are proposed to suppress the harmonics. This would have a power factor
compensation relay along with contactors to automatically correct the power factor
It is proposed to have the common capacitor bank for the entire cluster at the PCC level,
besides a compensating capacitor backed by an MCC near the Transformer. With this the load
power factor is proposed to be maintained at 0.99.
The preliminary capacitor capacity is estimated as -1332 KVAR (Please refer to enclosed
calculation). We propose to use 2x700 KVAR capacitor banks. These banks will be kept in
PCC Room located in the Utility Block. We have taken care that there is smooth correction
and, therefore, lower size capacitor banks have been considered, which also avoid leading P.F.
Power Cables and Bus Ducts
HT cables shall be 11 KV XLPE armoured FRLS with AL conductor.
LT cables shall be XLPE insulated armoured FRLS Aluminium/Copper.
We are proposing to use PVC insulated braided copper cables for indoor installation of LAPP
make. The samples for the same are being submitted to your approval.
It is proposed that IP 65 Bus duct be run from Transformer secondary to the Main PCC and
similarly Bus Duct would be run from DG set to the PCC.
XLPE cables will be following IS: 7098
PVC cables will be following IS: 5831
Cables routing & cable trays
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Sheet 7 of 14
All HT cables 11KV to transformer will be directly buried underground with tiles for
mechanical protection or taken in Hume pipes or underground trenches.
We understand that HCCB have the following area use and classification.
\
a) Basis/Generic Areas with office type environment

b) Standard Care Areas with industrial type environment
c) Medium Care Areas (GMP) where production operation is carried out. These
may be further sub-divided into ATEX classified zones or non-classified ATEX
zones as set out in USA National Code or IEC.
.
The above areas have specific requirements of equipment to be used. This is noted and would
be suitably incorporated in the design.
Main LT cables from substation PCC to each Power Distribution boards, AC Panels and
others would be routed internally on Galvanized steel cable trays and in medium care areas
steel cable trays and receptacles would be used.
Lighting
Lighting design will be as per standard lux level.
Internal lightingUniformity factor > 0.6
Maintenance Factor = 0.8
Reflection factor (70% ceiling, 50% wall, 30% floor)
Lighting Lux levelsProduction Area 300 Lux
Corridors -100 Lux
Office 400 Lux
Rest room - 100-150 Lux
Utilities 180 lux
Staircases 100 Lux
Kitchens 300 Lux
Common Areas 300-400 Lux
External Street Lighting 50 lux
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Sheet 8 of 14
The normal lighting is proposed with occupancy sensors for public spaces with movement
sensors for Toilets, utility areas like AHU room, cabins etc.
We would be using high efficiency electronic chokes with T-5 fluorescent fittings besides
LED and solar lights for conserving energy.
Emergency & Exit lightingEmergency and Exit lights would be used in line with Fire Safety Hardware
recommendation which is enclosed herewith.
25 % of the lighting would be on emergency supply backed up by a central inverter in order
to provide minimum 5 Lux during power breakdown.
All lights would, however, be backed up by DG sets that would come up on failure of Main
power and located near the PCC.
Type of light fixtures will be in-line with guideline by HCCB for various areas.
Point/Circuit Wiring
The system of wiring shall consist of PVC insulated Copper Conductor wires in GI conduits.
Minimum size of copper conductor shall be 2.5 sq. mm. for Lighting, 2.5 sq. mm and 4 sq.
mm. for Power.
Light circuit with 6 amps sockets : 2x2.5 sq mm + 2.5 sq mm PVC insulated copper wire
Power circuit with 16 amps sockets : 2x4sq mm + 1x2.5 sq mm PVC insulated copper wire
The above is a conventional and accepted norm. However we propose to use LAPP wire
which has higher current carrying capacity and efficiency. The configuration that we propose
is as follows.
Light circuit with 6 amps sockets : 2x1.5 sq mm + 1.5 sq mm PVC insulated copper wire
Power circuit with 16 amps sockets : 2x2.5sq mm + 1x1.5 sq mm PVC insulated copper
wire
Please refer to enclosed sheet Price comparison and Technical comparison of LAPP with
others
In case this is accepted then we shall forward to you entire details of 4x2.5 sq mm copper
braided cable and other sizes to show the economy, better technical parameters and energy
saving.
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Sheet 9 of 14
Universal Colour code shall be maintained for the entire wiring installation, i.e., Red, Yellow
and Blue for the three phases, Black for Neutral& Green for Earth.
UPS
Dedicated 2x100% redundant, totally separate 24X7 UPS backup will be provided to the
BMS, security & IT systems at the LT Panel room. This UPS will be back up by DG set.
Sealed maintenance free lead acid batteries will be provided for 30 minutes backup. The UPS
will be IGBT/12 pulse rectifier.
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Sheet 10 of 14
DG Backup
Two DG sets of 1250 KVA & one of 750 KVA are selected. These DG sets are connected to
the Main PCC through Microprocessor based ACB to a dedicated bus bar. Operation of DG
sets would be with
auto mains failure Panel which would be capable of auto load management and
synchronizing.
The total load requiring DG back up is presently estimated as3046 KVA based on the Load
Summary.
These DG sets would be located in the Utility Block and would be complaint with CPCB
norms. The
DG sets would be housed in acoustically treated, weather proof enclosures to
give at least 82 DB at one meter.

In order to get better efficiency water cooled DG sets are selected. Cooling towers would be
located on the roof top, while the pumps for water circulation in the Utility block itself.
The Exhaust stack is taken up to a height of 30 Meters as per the pollution control norms. The
exhaust stack is insulated with mineral wool of 100 mm thickness and then covered with
Aluminium sheet.
Earthing& Lightning arrester

We are working out on Earthing and bonding design for the building and the equipment. It
would be made available for review by the end of next week.
Clean earth system established for earthing of electronic equipment such as UPS, Server, and
racks router, PA, Telephone, ACS, BMS and FAS etc. The clean earth will be totally insulated
from the electrical; earthing system inside the building.
All earth electrodes will be interconnected for equi-potential bonding.
Preliminary Earth pit requirement are envisaged as follows;
Transformers - 4nos.(For Neutral Earthing-Cu Earth Pit and For Body Earthing-GI
Earth Pit)
HT Panel& Meter Panel 4 nos.

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DG sets
Sheet 11 of 14
- 12 nos. (For Neutral Earthing -Cu Earth Pit and For Body Earthing-GI
Earth Pit)
LT switchgear section - 2 nos.
UPS- dedicated - 1 no for UPS unit
Lightning arrester- 2 nos
Lifts- 1 dedicated / elevator
Earthing will be as per I.S: 3043.

a. Two advanced early emission lightening arresters would be provided. These arresters provide
an umbrella protection to the building in early stages for timely protection against lightning.
Instead of providing a mesh of earth strips across the length and breadth of roof we shall
provide only two electrodes and two earthing pits connected through a special cable capable
of carrying high currents for short duration.
Lightning Protection system shall be as per BS EN62305.
ENERRGY CONSERVATION AND ENVIRONMENTAL MEASURES
UNDERTAKEN
The basis of green movement is conservation and reduction of energy consumption along
with use of natural power resources like water, sun or the wind. We are achieving this by
using products that save on material and are recyclable. The highlights are as follows.
a
b
We propose to use LED Lights along with energy efficient T 4 lamps.

Frequent switching of machines and UPS generate harmonics that are responsible for
higher energy consumption. In order to avoid the harmonics we are using Detuned filters
c
d
e
along with capacitor banks.

Building automation system controls optimize energy consumption. All Distribution
Boards are provided with meters with RS485 ports to achieve this.
Use of solar geysers for heating water supplied to Canteen and any other area
Lighting Control Methodology
Intelligent lighting system Use of occupancy sensors for all closed cabins.
Electronic ballast < 10% THD APFC type / Energy efficient lamps
ANA DESIGN TEAM

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Sheet 12 of 14
LIST OF APPROVED MAKES

1. HT switchgear
Siemens
ABB
Schneider Electric
Areva
2. Transformer
Raychem
Kirlosker
Crompton greaves
GE
3. Power Distribution Panel

a). P.C.C., LT Panel and others
Siemens/Jakson/Adelec
b) Wing/Block Floor Panel
L&T, MK Engineers, Popular
4. Sub Distribution Board
Legrand, Siemens, Schneider
(LDB / PDB)
5. Air Circuit Breaker
Schneider Electric
(Masterpact)
Larsen & Toubro (U-Power)
Siemens (3 WL)
ABB (E max)
6. Moulded Case Circuit Breaker(MCCB)
MDS Legrand
Schneider Electric (MG)
Larsen & Toubro (D sine- Series)
Siemens (3 VL)
ABB (T max)
7. Miniature Circuit Breakers (MCB)
MDS Legrand
Hager (L & T)
Siemens
ABB
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Sheet 13 of 14
8. Residual Current Circuit Breaker (RCCB)
MDS Legrand
Hager (L & T)
Siemens
ABB
9. Power / Aux. Contractor
Larsen & Toubro

Schneider Electric
Siemens
10. Change Over Switch
H HElcon
Larsen & Toubro
11. Switch & Socket
Clipsal
Anchor (Woods)
MDS Legrand
M K India
12. Industrial Metal Clad Socket
MDS
Schneider
13. Exhaust Fan
Crompton Greaves
14. Indoor Lighting Fixture
Philips
Wipro
Bajaj Electricals Ltd
Asian
15. Selector Switch, Toggle switch
Kaycee
Salzer (Larsen & Toubro)
16. Timer
Larsen & Toubro

Schneider Electric (Telemechanique)
MDS Legrand
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Sheet 14 of 14
Siemens
17. Sealed Maintenance Free Batteries
Amraja
HBL NIFE
Exide
Hitachi
18. Battery Charger
Masstech
19. Cable Trays (Factory Fabricated
Profab
/Raceways
Globe
20. UPS / Inverter
Emerson
APC
MG
Numeric
ANA DESIGN TEAM

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PROJECT: Hindustan Coco Cola Beverage, Bangaluru