The Electrical Systems Design & Specification Handbook for Industrial Facilities

449 Pages·1998·19.899 MB·English

by  Steven J. Marrano, Craig Dilouie

Electrical System
Design & Specification
Handbook for
Industrial Facilities
Steven J. Marrano, D.E., C.E.M
Craig Dilouie
Published by
THE FAIRMONT PRESS, II
700 Indian Trail
Lilburn, GA 30047
Library of Congress Cataloging-in-Publication Data
Marrano, Steven J., 1966-
The electrical systems design & specification handbook for
industrial facilities/ by Steven J. Marrano, Craig DiLouie.
>. cm.
Ξ
ncludes bibliographical references and index.
ISBN 0-88173-194-3
I. Factories—Electric equipment. 2. Buildings—Electric
equipment. 3. Electric engineering. I. DiLouie, Craig, 1967-
II. Title.
TK4035.F3M34 1998 621.3-dc21 98-3948
CEP
The electrical systems design & specification handbook for industrial facilities
by Steven J. Marrano, Craig DiLouie.
©1998 by The Fairmont Press, Inc. All rights reserved. No part of
this publication may be reproduced or transmitted in any form or by
any means, electronic or mechanical, including photocopy, recording,
or any information storage and retrieval system, without permission in
writing from the publisher.
Published by The Fairmont Press, Inc.
700 Indian Trail
Lilbum, GA 30247
Printed in the United States of America
10 9 8 7 6 5 4 3 21
ISBN 0-00173-1^-3 FP
ISBN 0-13-3075^-0 PH
While every effort is made to provide dependable information, the publisher, authors, and
editors cannot be held responsible for any error sor omissions.
Distributed by Prentice Hall PTR
Prentice-Hall, Inc.
A Simon & Schuster Company
Upper Saddle River, NJ 07458
Prentice-Hall International (UK) Limited, London
Prentice-Hall of Australia Pty. Limited, Sydney
Prentice-Hall Canada Inc., Toronto
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Prentice-Hall of India Private Limited, New Delhi
Prentice-Hall of Japan, Inc., Tokyo
Simon & Schuster Asia Pte. Ltd., Singapore
Editora Prentice-Hall do Brasil, Ltda., Rio de Janeiro
Table of Contents
Preface ix
Acknowledgments xi
Introduction xv
Part I: MANAGEMENT ASPECTS
Chapter 1: The Role of the Electrical
Design Team in an Engineering and
Construction Project 3
Chapter 2: Managing an Electrical Design Project 19
Chapter 3: Considerations for Effective Electrical Design 63
Chapter 4: Professional Development 75
Part II: TECHNICAL ASPECTS
Chapter 5: Conductors 89
Chapter 6: Switchboards and Panels Ill
Chapter 7: Electric Motors 123
Chapter 8: Transformers 137
Chapter 9: Motor Control Centers 159
Chapter 10: Power Factor and Capacitors 182
Chapter 11: Transfer Switches 187
vii
Chapter 12: Grounding 199
Chapter 13: Switchgear 215
Chapter 14: Common Power System Calculations 229
Chapter 15: Power System Studies 255
Chapter 16: Short Circuits and Overcurrent Protection 265
Chapter 17: Industrial Lighting Design 313
Appendices 393
Index 433
vni
Preface
This book is written for electrical engineers and designers who de­
velop electrical systems for industrial facilities. This discipline, or inte­
grated area of specialization, incorporates both system design and speci­
fication of electrical equipment for new construction, renovation or ret­
rofit.
Greater quality and scheduling demands made by corporate facil­
ity owners, in addition to the trend within the engineering and construc­
tion industry toward streamlining, requires that electrical design engi­
neers be more versatile and more effective managers of time, people and
resources.
The Electrical Design & Specification Handbook supplies a comprehen­
sive discussion of design and specification implementation including
project coordination, power delivery and utilization, lighting and
grounding. Note, however, that this book does not intend in whole or in
part to replace the standards now used by the reader's company; it is
designed purely to supplement the reader's knowledge and assist in his
(we are using the generic "he" for brevity throughout the text) profes­
sional development.
The Handbook covers each topic comprehensively within a modular
format, from theoretical fundamentals to a practical discussion. As such,
its content and structure are relevant to electrical engineers and design­
ers concerned with electrical power systems design, in addition to pro­
viding value to the veteran and novice professional, the engineering stu­
dent, and future design engineers at the professional's company.
IX
PART I:
Management Aspects
Chapter 1
The Role of The Electrical
Design Team In an Engineering
And Construction project
An electrical design team is a group of engineers and designers
within an engineering and construction firm or an in-house design en­
gineering department. Effective execution of this team's role in the
construction of an industrial facility requires proper understanding
and coordination with other disciplines and the non-technical profes­
sionals involved.
ENGINEERING AND CONSTRUCTION FIRMS
A project is defined as all activities that result in the installation,
start-up and commissioning of a piece of equipment, several pieces of
equipment, a complete process or an entire facility. All projects start with
justification, or a need by the owning corporation, then project cost and
scope are assessed. Once the design phase is complete, equipment will
be purchased, installed and commissioned. Projects of more than
$500,000 may be performed by an in-house team but often involve a con­
tracted engineering and construction firm.
Engineering and construction firms supply corporations within the
manufacturing and process industries (called the "owner" in a contract
relationship) with a range of services that, if within the firm's scope of
work, can culminate in the complete construction and start-up of an in­
dustrial facility. These services can include a combination of design engi­
neering, construction, contract maintenance and various environmental
services. In this book, we will concentrate on complete facility design as
a typical project to provide the reader with a broad view.
3
4 The Electrical Systems Design & Specification Handbook for Industrial Facilities
Working on such a large project at any given time at the engineer­
ing and construction firm will be a collection of teams under an overall
coordinator called the Project Manager. Each team represents a separate
discipline such as electrical engineering.
PROJECT MANAGEMENT PROFILE
The various design teams at a typical engineering and construction
firm are coordinated and supported by an infrastructure of non-techni­
cal professionals, including a Project Manager, Scheduler, Document
Controller, Estimator and Expediter. These professionals perform man­
agement, trafficking and administrative support duties. These functions,
although not technically related, are invaluable in ensuring that the
project is completed to owner satisfaction on time. In the future, Project
Managers and Project Engineers may be able to perform some of the
administrative duties themselves time-effectively as personal computers
become more powerful, versatile and economical.
Project Management
The Project Manager is the chief representative for the engineering
and construction firm and as such, reports project progress to the owner
regularly. He ensures that the design teams' comments and questions
reach the right people at the owner's organization and that these teams
coordinate their efforts to avoid waste. Most documents and communi­
cation from each design team is channeled through the Project Manager.
Additionally, the Project Manager oversees scheduling, procedures, fi­
nancial aspects such as cost control, and general staffing requirements
for the project.
Project Engineering
A project engineer may be involved on larger projects. On such
projects, the Project Manager handles liaison with the owner and all
other project aspects as usual with the exception of coordination of the
design teams, which is handled by the Project Engineer. A Project Engi­
neer reports to the Project Manager in the project chain of command and
handles technical issues.
Scheduling
A Scheduler ensures that each design team's work is completed in
a timely fashion. He develops a list of activities, determines the time
The Role of the Electrical Design Team in an Engineering and Construction Project5
budget for each activity, and then develops schedules based on direction
from the Project Manager. The final schedule may be presented to the
Project Manager in one of a variety of formats depending on the consult­
ing design firm; the most common is the "Critical Path Method."
Document Controlling
A Document Controller ensures that shop drawings, specifications
and plans from each design team and vendor are distributed to the
right people who need this information for their design activities. Typi­
cally, Document Controllers place a distinctive stamp on each draw­
ing prior to distribution and then check the corresponding design team
that needs to review or make comments or corrections. He also places
this stamp on all vendor shop drawings and specifications, records
when these documents were received, and ensures their timely internal
distribution.
Estimating
An Estimator is responsible for producing cost data. In general, an
estimator will maintain records of costs of various equipment and labor
(man-hours) associated with a given structure or project. Some engineer­
ing and construction firms supply their estimators with RS-Means Esti­
mating® Handbooks which contain published construction data and are
updated annually. Some design firms continuously develop their own
cost and labor (man-hour) data using unit price files. The data for each is
updated as directed by the discipline Lead Design Engineers or depart­
ment heads.
Estimators also develop, maintain find update information regard­
ing contract labor rates and labor productivity multipliers for each trade.
(See Ascertaining Labor Requirements Information, Chapter 2.)
Expediting
An Expediter is responsible for equipment procurement. He en­
sures that the specified equipment and its shipment are properly coordi­
nated in a cost-effective, timely manner. Since the various design teams
will review and consider up to hundreds of items of equipment as re­
quired by the nature of their work, the expediter's role is extremely im­
portant. As stated, he also coordinates shipment of equipment to a job
site and ensures that the total cost of taxes, freight and insurance for the
item shipped are acceptable to the owner.
6 The Electrical Systems Design & Specification Handbook for Industrial Facilities
Computer-Aided Design and Drafting (CADD)
As nearly every design drawing is prepared on a computer, many
engineering and construction firms have organized a computer-aided
design and drafting (CADD) group to perform the sizable task of
archiving, networking and standardizing CADD drawings. This group's
functions specifically include contact with the owner to determine
owner requirements and preferences; maintenance of symbol libraries
for each design discipline; archiving project CADD drawings; establish­
ing and maintaining drawing numbering systems (when applicable);
and, should the engineering and construction firm use AutoCAD® or
Intergraph®, coordination of the project's layering systems. (See Coordi­
nation with Computer-related Professionals, Chapter 2.)
Management Information Systems (MIS) Group
As noted above, engineering and construction firms rely heavily
on computer systems to expedite a project quickly and with minimal er­
ror. In larger engineering and construction firms, a management infor­
mation systems (MIS) group may be formed that configures and main­
tains computer networks (smaller firms may employ an outside consult­
ant). Additionally, the MIS group coordinates individual computers,
specifies software, loads software onto computers, and conducts mainte­
nance and troubleshooting. (See Coordination with Computer-related
Professionals, Chapter 2.)
THE ELECTRICAL DESIGN TEAM
The electrical design team represents a group of professionals who
collectively produce the drawings and specifications that will result in
installation of a complete electrical system.
At most engineering and construction firms, such a team is typi­
cally structured under a Lead Electrical Design Engineer, who is chosen
by the department head to manage a particular project based on his
knowledge, experience and aptitude. He oversees a group of Engineer­
ing Specialists or Project Engineers who each specialize in or are as­
signed responsibility on the project for a particular subdiscipline of elec­
trical design. These in turn oversee Designers and Drafters, whose pri­
mary function is drafting and equipment sizing.
Depending on the size of the engineering and construction firm,