CESEEPS RE-ENGINEERING PROGRAM

THE CESEEPS RE-ENGINEERING PROGRAM

Thirty five years ago, there was a dream...

Electrical Engineering as a college course wasn’t enough and the realities in the electrical world were too overwhelming to the guts of an engineer fresh from school. Caught amidst this limbo, a young electrical engineer dreamt of a book that would someday guide and mentor him in the various facets of designing electrical systems of industrial plants.

That dream book proved elusive until recently when the serial entitled, “DESIGN PRACTICES IN INDUSTRIAL ELECTRICAL SYSTEMS” becomes available.

Interestingly, that ‘young engineer’ (who is now 56 years old) wrote it – not for himself but for others who may find these books valuable.

In a series of five ‘power’ books, “DESIGN PRACTICES IN INDUSTRIAL ELECTRICAL SYSTEMS” is written as materials for a re-engineering and/or competency program intended for electrical practitioners, plant engineers, maintenance engineers, electrical designers, construction engineers & project managers.


To the young engineers, these materials open up real-life applications on the theories learned from college that would make them conversant on actual systems found in industrial plant environments.

To the practicing electrical engineers, these books provide quick design practices that translates into shorter technical planning, prompt equipment procurement and short execution time; the results of which, are cost effective, safe and reliable power systems.

The concepts, procedures and pronouncements written in these books are based on the established engineering practices and publications in reference to the PEC of the Philippines; NEC, IEEE & ANSI of the USA; CENELEC of Europe; and IEC of the World.

Experiences in best designing practices by others as well as the benchmarks gathered from several technical audits are interpreted herein, viz-a-viz the behavior of industrial plant electrical systems. Attempts to simplify and focus on specific applicable areas in the Philippine scenario but cognizant to international standards are typical in these books.


“DESIGN PRACTICES IN INDUSTRIAL ELECTRICAL SYSTEMS” is composed of five (5) component books, as follows:

1) LOW VOLTAGE SYSTEMS & APPLICATIONS IN INDUSTRIES (The Red Book)

2) MEDIUM VOLTAGE SYSTEMS & APPLICATIONS IN INDUSTRIES (The Blue Book)

3) FAULT CALCULATIONS & APPLICATIONS IN INDUSTRIES (The Gray Book)

4) INDUSTRIAL SUBSTATION DESIGN & SYSTEM PROTECTION (The Gold Book)

5) SUBSTATION & PLANT MAINTENANCE SYSTEMS (The Green Book)



THE RED BOOK (Module 1.0):

The “Red Book” deals with the basic circuits up to the largest low voltage components in an industrial plant or commercial complex.


Written simplistically understandable to the engineer reader, this book attempts to achieve a design of a model medium size-industrial plant or commercial complex in the Philippine setting. It discusses in some satisfactory details how low voltage electrical systems are designed from scratch i.e., from the remotest branch circuits, feeders & sub-feeders, motor & group motor circuits, to transformer circuits, distribution systems and integration into the power centers.


Eye opener treatments on Single Line Diagrams, Load Densities & Load Metrics, System Dimensioning, Introduction to Fault Calculations, System & Equipment Grounding and Sizing Neutral Conductors are included in this book in an effort to make the engineer grow in these particular fields. It also includes a special chapter on Powering Internet Hotels & I. T. Environments where practices in advanced countries are given emphasis.

This book likewise discusses traditional myths and folklores in system component designing where provisions of the IEEE/ANSI, IEC and other International Standards are cited as reference.




THE BLUE BOOK (Module 2.0):

The “BLUE BOOK” as it is known, is the second of a series of five books written as reference material for electrical design engineers.


As a sequel to Book 1, The Blue Book provides demonstrations for the next phase in the design process for the industrial power system in concept. It covers the development of single line diagrams, system dimensioning, application of upstream load metrics, applications of medium voltage fuses & power circuit breakers, overview of system fault duties, power distribution systems and a glimpse of an entire system configuration of the industrial plant or commercial complex. It also covers power transformers, medium voltage cables, cable terminations and power centers - all from the viewpoint of the medium voltage side.


Envisioned as a design guide, The Blue Book contains in detail how electrical systems are dimensioned from the Power Centers, to the Primary Unit Substations, Medium Voltage Distribution System Configurations and the Power Generating Plants. Written simplistically understandable to any engineer reader, this book attempts to achieve the design of a model medium sized-industrial plant in the Philippine setting.



THE GRAY BOOK (Module 3.0):

Module 3.0 is the third phase in the design of the industrial power system on the drawing board. Without Fault Calculations, the design can never be considered complete. Usually not fully understood, applications of fault calculations in industrial plants or large commercial complexes are however frequently taken-for-granted.


As a sequel, Book 3 follows the first two CESEEPS Power Books. Book 3 (otherwise called as the Gray Book), discusses the design considerations for system abnormal conditions such as faults. Book 3 covers the establishment of Three-Phase Short Circuit Fault Duties as basis for circuit breaker interrupting ratings, switchgear withstand ratings and fuses as circuit protection, among others. It also covers Single-Line-to-Ground Fault Calculations by Symmetrical Components necessary in establishing the behavior of the system in events of these faults. Sizing NGR’s for applications in the industry the output of which also carry the fundamental reference in arming up protective relays or other protective devices wherever they are placed in the system are also treated in this Module.


Envisioned as a design guide, the Gray Book therefore deals in some satisfactory details how electrical systems are designed from the points of view of abnormal conditions. It is then assured that practice designing with this book as guide provides the necessary understanding on the above subjects. Written simplistically understandable to any engineer reader, this book attempts to achieve a design of a model medium sized-industrial plant in the Philippine setting.



THE GOLD BOOK (Module 4.0):

At this point, let us step backwards and look at the forest.


CESEEPS Books 1, 2 & 3 are to guide the design engineer on the nitty-gritty of the internal viscerals of the industrial plant. But then the design of the industrial complex in concept shall not only focus on the trees in the forest but more importantly needs to consider & integrate system voltages, system loads, load behavior & future growths, transformer MVA sizes, system configuration, transformer connections, system grounding, distribution systems, system components and the protection system that the substations so deserve. This is what is known in the industry as “System Integration”.


System Integration requires the competency & working knowledge in Local as well as International Standards. The electrical components, devices, apparatuses & equipment involved in this task are manufactured abroad and these equipments are designed & meant to operate under the bounds of international standards. An engineer could not just specify equipment ratings because that’s what he wanted to. The engineer has to fit his design outputs to the standards. Remember that the people who made the standards are experts in the field to include the manufacturability aspect of the equipment.


Envisioned as a design guide, Book 4 (also known as The GOLD BOOK) covers in some satisfactory details how electrical systems are designed from the point of view of substations & power centers in industrial applications.

Among the subjects covered in Book 4 are the following: a) Power System Dimensioning, b) Distribution System Design, c) The Primary Unit Power Substation, d) Small Substations & Power Center Dimensioning, e) Substation Protective Devices, f) Auxiliary Systems in Substations, g) Substation Grounding, h) Grid Substations, i) Substation System Protection, and, j) Arming-Up Protective Relays.



THE GREEN BOOK (Module 5.0):

Contrary to the beliefs of many, MAINTENANCE ENGINEERING starts from the drawing boards and therefore must be seen as part of the design process of a commercial complex or industrial plant.


The design of the industrial complex in concept not only needs to consider & integrate engineering systems but also needs the concepts that the plant must be maintenance - friendly environments. This is what is known in the industry as “Over-All Design Concept”. The engineer must not design the plant just a he wished; it has to have a “design concept” from the very beginning.

At this point, let us imagine operating the plant we have designed. For instance, the engineer will soon find out that the plant he has built is “not maintainable” or later he finds out that corrections must be made in the distribution system because he cannot track down the power consumption of a certain process. Even if the engineer had the heart in maintenance management, who can recognize his efforts when there are no historical & recent records to be based upon?


Book 5 gives emphasis on measurement systems as management tools. Remember, you can’t control if you don’t measure. Written as a ready reference for maintenance practitioners, the paper is a product of years of experience, research and studies on how maintenance management of an industrial plant should be operated effectively. Starting from scratch in the 70’s, the mode of maintenance management underwent a series of evolution process in search for the strategies that would tailor-fit the prevailing conditions of plants in the Philippine scenario as models.



THE VALUE OF CESEEPS POWER BOOKS


“DESIGN PRACTICES IN INDUSTRIAL ELECTRICAL SYSTEMS” will form part, in fact the first set of a much bigger project envisioned by the CENTRE FOR STUDIES IN ELECTRICAL ENGINEERING PRACTICES & STANDARDS (CESEEPS INTL ASSN, INC). The output of this ambitious project will compile the wide aspects of electrical engineering practices not only in the industrial setting but also the subjects on Overhead Transmission & Distribution Systems, Energy Tariffs & Metering and Large Utility Systems - in other words, the “must know” competencies imperative to Filipino engineers.

Note that the series of books written by CESEEPS are focused on industrial plant applications only. Outside the industry will therefore be written by others who wish to join us in this crusade.

It is then assured that practice designing with CESEEPS POWER BOOKS SERIES as guide provides the necessary understanding on the real-life electrical engineering in industrial plants. It is therefore envisioned that the electrical engineer following through the entire CESEEPS series will be equipped with the necessary expertise & competencies in the scenario of industrial power systems. This will help catapult the Filipino electrical engineer into the level of a truly world-class technocrat. Hundreds of CESEEPS trainees had already found their places in various countries in the world.

Truly addressing the gap between the academe and the industry, that’s the greatest legacy that CESEEPS can offer.



DISCLAIMER

It would be neither practical nor economical to build a fault-proof power system. Thus, Electrical System Designing is often said to be an art rather than a science. It is an art because there is subjectivity in the judgments involved in making decisions. The sizing and selection of system components for instance oftentimes require compromises between conflicting objectives and anticipation to future events, whilst even with the best design possible and best materials available, systems tend to deteriorate as the likelihood of faults increases with age.


It is then expected that Design Practices as a form of art may vary in ways or techniques employed by one designer to that of another, but in the end what is imperative is that the design must make sense and the system created is determined to endure its entire lifetime.

Technologies in electrical engineering evolve everyday just as every Electrical Code or any Local and International Standards keep changing over a frequency of time. In fact, what may be true today may no longer be accurate in the immediate future.

Information contained in this work has been obtained from sources believed to be reliable, i.e., on top of personal experiences of the author and the benchmarked ‘best practices’ so far available at hand. However, neither CESEEPS nor its authors & lecturers guarantee the perfection, accuracy or completeness of any information written herein. Neither CESEEPS nor its authors & lecturers shall be responsible for any errors, omissions, misapplications arising out of the use of this information.


CESEEPS however will not stop in ever improving the contents and value of this work until perfection or at least, near perfection is achieved. Just as learning itself is a never – ending process.

Should there be perceived incompleteness or gray areas in the presentation of information in this work, it is advised that the reader will seek for other reference books or materials to reinforce the vague portions of this work; or the assistance of an appropriate professional should be sought.


CESEEPS INTERNATIONAL ASSOCIATION, INC.