The electrical design and detail engineering process begins with the calculation of the total electrical load for all equipment and auxiliaries in the production plant, utility plant, boiler house, effluent treatment plant (ETP), raw material warehouse, fire hydrant system, solvent recovery plant, hydrogenator, quality control labs, admin building, and all other plant buildings. This also includes the lighting load for each building. Based on these calculations, the total electrical load of the plant is derived, and the capacity and technical specifications of the transformer and HT panel are determined.

The MCC panel for each individual plant is then designed, including technical specifications, bill of materials (BOM), and single-line electrical diagrams. Additionally, the PCC panel is designed for centralized power distribution, complete with BOM, technical specifications, and single-line diagrams. Technical offers from electrical panel vendors are reviewed and compared, followed by technical evaluation and vendor recommendations based on technical competency.

Panel designs submitted by vendors are thoroughly reviewed, discussed, and corrected to ensure compliance with specifications before approval for fabrication. Load tests are conducted at the vendor’s workshop for all panels to ensure performance standards. Cable sizes and lengths are calculated according to the electrical load of each piece of equipment, and a cable BOQ with all required fittings for HT and LT connections is prepared. The cable tray sizes are calculated, and routing is planned for the shortest possible length through the plant. Specifications, size, type, MOC, and BOQ for cable trays are provided.

A detailed earthing system design for the entire plant is prepared, including diagrams showing earthing chamber details, locations, and corresponding BOQ. Lighting layouts for the API pharma plant, pharma processing areas, utility buildings, raw material warehouses, boiler house, ETP, and other facilities are prepared based on the lux level requirements of each area. The BOQ for both flameproof and non flameproof light fixtures is compiled, considering capacity, size, and type of fixture installation. Stage-wise site inspections are carried out throughout the installation process to ensure the quality of electrical work is as per the design specifications.