vi vil Xl il, Ail b) d) e) hy hy i) a) b) 4) a) b) ) a) b) dy e) ) a) b) a) b) ¢ 4 Table of Contents Introduction Conversion Table Function Numbers and Symbols Used in Electrical Drawings Switengears and Controlyears Starters Whte up Selection Chart for DOL Starters Seiection Chart for 8/0 Starters Wicing Diagram for Direct On Line Starter Wiring Giagram for Star Delta Starter Wiring Diagram for Auto Transformer Starter Wiring Diagram for Rotor Resistance Starter Wiring Diagram for Soft Starter Witing Diagram for Variable Frequency Drive sign of OG Panels & AMF Panels Write up Selection Chart Wiring Diagram for Standard DG Panel Wiring Diagram for Standard AMF Panel Design of Main Panel Wirite up with Diagrams Selection Chart for Busbars Selection Table for Interconnecting Cable / Busbars Design of APFC Panel Write up Selection Table for Capacitors Multialying Factor for Power Factor Improvement Recommended Ratings of Switching Equipments and Cables GA Diagram for Capacitor Panel Wiring Diagram for Capacitor Panel Cable Selection, laying and Termination Write up Selaction Charts for Cables Relays and its Application Elecical safety & Earthing Write up Selection Tabe for Equipment Earthing — Size of Conductor Selection Table for Transformer Neutral Earthing — Size of Conductor Qutdoor Substation Layout Important iS SpecificationsUtilization Category In IS 13947 (Part 3) / 1EC 947-3 Utilization category is completed by a suffix A or B. Suffix A: Indicates suitability for applications requiring frequent operations. Minimum electrical and mechanical lfe expectations are higher. Suffix B: Indicates suitability for applications requiring infrequent operations. Minimum life expectations are lower (20 % of that for suffix A) Applications requiring operations per month are less than indicated below. Current Rating, A Operations per month Category A Category B le<=100 16 3 100 2500 1 Once in five months >89d1 | Lodi | 99at | soat “|: - ~ | o9at 9 3 -| ssai | sat * < - | osat s : ~ -| rrat | erat | that | tat | OFA r - - . - | reat] eeat | ceat | teat | osat € a1 2 : . : ~| scat | cat | zat | oan a - e . “ = -| Zldl |} [dl | Old! t = . + = = = * = | 00d! 8 L 9 s r ¢ z t 0 ( SIGOd NOUTYOS AO WONT UNV LOVINOD LSNIVOY | SYELLLTT (aind11 40 SSAYONI LSNIVOV NOM IALOWd WOE) TWIRTNVAN | OLSRAL NOLLIALOUd YOA) TWUSWAN OLLSIWALIVYVHD UNOOS: J IVUVED LSU WAV C961 ~LPIT ¢SI NOLLOALOUd JO SAdAL mo i)Length Area Volume Mass Discharge Rate Power Energy Fps unit Vineh 1 foot 1 yard ‘mile 1 59. inch 1 Sq. foot 1 Sq. yard 1 Sq. mile 1 ere 1 Hectare | Hectare 1 Cubic inch + Cubic foot 1 Cubic metre 1 Cubic foot | Pound 1 Tonne 1 Cubic metre/Hour LHP LHP (Metric) 1 KW { Unit Il - Conversion Table Wet Metric Unit 254mm 304.8 mm 0.9144 metre 1.6093 Km 6.4516 Sq, Cm 929.03 sq. Cm 0.8336 Sq, m 2.589 Sq. Km 4047 Sq. m 10000 Sq. mm 2471 Acres 16.387 Cubie Crm 28317 Cubic Cm 1000 fit 28.32 lt 0.454 Kg 1000 Kg 16.67 li/Min 0.746 KW 0.736 KW 1000 1000 WH (or) 1 KWHIl - Important Formulae 1. Single Phase vA = Voltage ¥ Current = Voltage X Current X Power factor = VICOSe vl Hye = 1000 (¥ 105 6) \ kw = - 1000 HP = 746 Watts (or) 735.5 Watts (VCO 0) 746 VK = L34HP vA Current (1) = (or) v VCOSe Power = VI=IKIR=FR 2. Single Phase Transformer = vA Primary Current = = p= — Vp Secondary Current = 3. Three Phase : va = V3. Wk (0) 3 Vphiph \ Wats = V3ULK Cos 3 Vph Ip Cos @ Current ( lt) = WAINS Wor) W/V 3 KLCOS8 “iit ®4, Three Phase Transformer : = WAITS Mi (or) W/V3WLCO50 Current (1) = Primary Current = = VAIN Vp Secondary Current = = VA/V3 Vs 5. Series and Parallel Circuits i 1 WN —— ANY =| yp stance inseriss : RS = RI+ R2 (RI XR) R= {RI + R2) Inductance (XL) = 2nil Capacitance (Xe) V(RFR) " Impedance (2) iil-2 ORan AD a 6. Star to Delta Transformation ; ReRy+RvRe+RaRy Rw = Re i RaRy+RyRo+AeRe Ra= = Re RaRv+RyRe+RoRe Rar = Rev Raw a — Rev Rye + Raa Ris Rav Rie . Rat Re + Ra Reka Res - Rie + Rg Res 8. Calculation for BHP for Pumps : Discharge in LPM X Total head in metres BHP = - 4560 X Efficiency of Pump Where 4560 is Constant and LPM = Litres Per Minute.48, Master element Time-delay starting or dosing relay Checking or interlocking relay Master contactor ‘Stopping device Starting circuit breaker Anode circuit breaker Control power disconnecting device Reversing device Unit sequence suitch Reserved for future application Over ~ speed device Synchronous ~ speed device Under speed device Speed or Frequency matching device Reserved for future application ‘Shunting or Discharge switch " Accelerating or Decelerating device Starting — to — running transition contactor . Valve Distance relay Equalizer circuit breaker Temperature control device . Reserved for future application 3. Synchronizing or Synchronismn ~ check device 3. Apparatus thermal device . Under voltage relay Flame detector Isolating contactor ‘Annunciator relay . Separate excitation device Directional power relay Position switch Master sequence device . Brush — operating or Slip —ring short reiting device Polarity or Polarizing voltage device . Under current or Under power relay earing protective device 1. Mechanical condition monitor Field relay - Field circuit breaker Running circuit breaker Manual transfer or Selector device Unit sequence starting relay >. Atmospheric condition monitor Reverse phase or phase - balance current relay Phase sequence voltage relay Incomplete sequence relay IV - Switchgear Device Function Numbers, 49. Machine or Transformer thermal relay 50. Instantaneous over current relay 51. AC Time over current relay 52. A-C Circuit breaker 53. Exciter or D-C Generator relay 54, Reserved for future application 55. Power factor relay 56. Field application relay 57. Short — circuiting or Grounding device 58. Rectification failure relay. 59. Over voltage relay 60. Voltage or Current balance relay 61. Reserved for future application 62. Time — Delay stopping or opening relay 663. Liquid or Gas pressure or Vacuum relay 64. Ground protective relay 65. Governor 66. Notching or jogging device 67. ALC Directional over current relay 68. Blocking retay 69, Permissive control device 70. Rheostat 71, Liquid or Gas —level relay 72, D4 Cirevit breaker 73, Load — Resistor contactor 74. Alarm relay 75, Position changing mechanism ‘76, D-C over current relay 77, Puise transmitter 78. Phase - Angle measuring or Out ~ of ~ step protective relay 79, AC Reclosing relay —, 80. Liquid or Gas flow relay } 81. Frequency relay 82. D-C Reclosing relay { 83, Automatic selective control or transfer relay 84, Operating mechanism 85. Carrier or pilot —wire receiver relay 86. Locking — out relay 87. Differential protective relay 88. Ausiliary motor or motor generator 89. Line switch £0, Regulating device 1. Voltage directional relay 92. Voitage and Power directional retay 93, Field — changing contactor 4, Tripping or Trip ~free relay 95 — 99, Used for only specific applicationsgree ffm @ RG the UNH SL Ro) Om ce SYMBOLS USED IN ELECTRICAL DRAWINGS TERWINAL AT MARSHALLING BOX: TERWINAL BLOCK AT DCs TERMINAL AT Me TERMINAL AT MOTOR TERMINAL AT LOCAL PUSH SUTTON STATION/PELD TERMINAL AT OCS PANEL REMOVABLE LINK KEY LOCKABLE STAY PUT TYPE 8 ruse un be siuNT ‘OVER LOAD. RELEY DIGHAL ENERGY METER INDICATING LED WITH CURRENT LIMITING RESISTOR R-RED, AMAMBCR, G~GREEN, 1B~ BLUE, we mote CASTELL Lock ws KEY TRMEETOR METER win RS 4a PORT uve ‘NO. NECESSARY SOFTWARE FOR OATA UNLOADING &PROCESSING MICRO PROCESSOR BASED RELEASE MIN 0/6, 5/6 & E/F STARTER NODULE DRAWOUT TYPE AR CIRCUIT BREAKER ‘wit MOTOR WOUND SPRING CHARGED OPERATING MECHANISM LOCAL PUSH BUTTON STATION woTOR SPACE HEATER SQUIRREL GAGE WOUCTION MOTOR MINIATURE CIROUIT BREAKER aca ou. sume Fuse UNGER GROUND CABLE MECHANICAL INTERLOCK. SWITCH BCASD DISTRIBUTION FUSE BOARD DISTRIBUTION FUSE WT MCBS. ON {UGG sh OY fm a w #2} TO@eooRA [AMETER SELECTION SWITCH i VOLTMETER SELECTION SWITCH AMMETER VOLIMETER DOUBLE VOLTMETER DOUBLE FREGENCY METER ‘SYNCHROSCORE FUSE SWITCH UNIT DISCONNEGNTOR SWITCH NORVALLY OPEN CONTACT NORUALLY CLOSE CONTACT “TRANSDUCER: KW-KILO WATT, _KVAR-REACTVE, PF-POWER FACTOR, “CURRENT, = V-VOLTAGE (OPERATING COIL FOR POWER CONTACTOR/ NUK. COKTACTOR (CURRENT TRANSFORMER TR {(ON)-ON DELAY TIMER. {{OFF)-OFF DELAY TIMER (ON LoAD ISoLATOR POTENTIAL TRANSFORUER/ (CONTROL, TRANSFORMER DRAWOUT TYPE ‘A CIRCUIT BREAKER LGHMING ARRESTOR 2.0/H.G FUSE/FUSE ( GIRCUMT BREAKER (NR CIRCUIT BREAKER OW swmeH FUSE SWITCH FUSE DOUBLE BREAK ISOLATOR ‘cONTACTOR [ALTERNATORV- Switchgears and Control Gears | Low voltage switch gears and control gears have wide range of application in Industry. The switchgear are selected based on the following, \ Operating Voltage Operating current System fault ievel and Utiization category Some ofthe switching devices and their applications are detailed here under. Air Gireuit Sreakers + ACB are used to make or break the circuits under normal operating conditions. Under fault conditions the «rcuit breaker trips and protects the equipments, | ACBs are available from 630 to 6200 amps and manufactured as per IS 13947-2 and IEC 947-2. The verious types of ACBs available are Fined type ACBs (manually operated) 3 poles & 4 poles Draw out type manually operated ACBs c Diaw out type electrically opevated ACB The ACBs are fitted with Over Load and short circuit release, | The Oi and SiC release senses the eurrent fling through the ACB and trips the breaker when the current ‘exceeds the set value Therinal over load relay setting: 75 to 100 % of the rated current Short circuit protection + 600 to 800% of the rated current in Microprocessor releases wider settings can be achieved and earth fault protection also can be incorporated. a) Under Voltage Release : Linder Voltage release permits closing of breaker when the supply voltage is above 80% of the normal voltage and trips the breaker during under voltage. The drop off voltage is 35 % of the nominal voltage, b) Shunt Release : Shunt release trips the breaker when itis energized. It fs normally used for tripping the breaker through external relays or remote Push Buttons. 6) Shutter assembly In dra out type breakers, automatic shutter assembly is used for shroutlng the live terminals when the breaker is drawn out. |) Auniiany switch Provides aurdiary contacts for interlocking with other equipment and also alarm / indication purpases.| Other accessories are trip indication, door interlocking, lockable trip PBs etc., Moulded Case Circuit Breakers CCB are also used for switching ON / OFF the circuit in normal condition. In MCCBs, fixed and moving contacts with operating and ripping mechanism are assembled in a moulded case of thermosetting plastic. The current carrying parts are made out of electrlytic copper or siver alloy depending on the rating of the breaker, Non ferrous, non rusting metal parts are used and the current carying parts are designed te have higher cross section to minimize the temperature rise even under high ambient temperature. Current rating 16 to 1600 Amps. Miniature Circuit Breakers : MCB are extensively used in low voltage and low current applications, They replace conventional fuses and combine the features of HRC fuses and switch. itis used as a switch during normal operation and during fault Condition it automatically trips. MCBs are available in Single, double, three and four poles. | Ratings are 0.5 to 63 Amps. Voltage rating is 240/4 15V AC SOV/1 10¥ OC Rupturing capacity is 10KA@ 415VAC Switch Fuse Units The combination of switch and fuse is very widely used in tedium voltage installations. They are available in DP, TP, TPN, or 4 pole versions. They can safely break three times rated current. Ranges are 60 to 800 Amps. Change Over Switch + In power eicuis change over switches are used to change over power from one source to other source. ( E-g: TNEB source to Generator source or vice versa ). On load Change Over switches are capable making or breaking the circuits with load. ‘Change Over Switches fitted with motor operation mechanism enable to transfer power from one source fo the ‘ther. Hence it is also called Auto Transfer Switch. Ranges are 125 to 630 Amps. Motor Protection Circuit Breakers MPCBs constructed with built in over load relays. They protect the motor from over load and short jrcuit conditions. Ratings 10.1 100.16 Amps to 55 to 63 Amps V-2 ®Contactors Contactor is an electromagnetic device, which makes or breaks the circuit. When the coil of the magnet gets ‘energized the contactor makes the circuit and when it de-energizes it breaks the circuit. It has power as well as avaliaty contacts. Power contacts will carry power as per the rating of the contactor. The auxiliary contacts are used for indication, interlocking and hold on surposes. Bimotal Over Load Relays: Deflection of a bimetallic strip due to the heat caused by the motor current, which may pass either directly tirough the bimetal or indirectly through a separate heater, provided below the bimetallic strip. This deflection releases the tp bar. The bimetalc strip is made up of two dissimilar metals with dliferent coefficients of ‘expansion. When such strip is heated, it bends due to the unequal expansion ofthe two metals and this bending action is used for actuating the trip element, Time Delay Relays TOR is an electrically operated device in which the actuation of the contacts is delayed when the relay is energized or de-energized. It can be further classified as ON delay relay and OFF delay relay. Time delay relays «an have contacts for normally open (NO) and normally closed (NC). Many timers are made with non-imed contacts as well as time delayed contacts. These non-timed contacts also referred as instantaneous contacts, change their positions immediately when the coll is energized and change back to their normal positions immediately when the coll is de-energized. Temperature Controllers Temperature conirollers can be used to switch ON or switch OFF the power circuit at pre-determined temperature level. The temperature indication and alarm are incorporated for better control of temperature. arth Leakage Circuit Breakers ELCBs co Rasidual Current Devices have a built in core balance current transformer, The CBCT senses any tunbalance in the circuit and trips the ELCBs if the unbalance current exceeds pre set value. All supply lines including neutral is taken through the CBCT. If the difference between line current and neutral current is not equal fo zero, the CBCT senses the difference. Range + 25, 40, 63 and 80 Amps. Fault current setting 130/ 100 / 300 mAmps. Push Buttons : Push Buttons are used for actuating a circuit (or) to start / stop a motor feeder. PBs are fitted with NO or NC elements depending upon the application, Indicating lamps : Indicating lamps are used for visual identification of the status ofa feeder (On, Of, or Trp). Selector Switches : Selector switches are miniature cam operated switches used in control circuits to select an equipment or operating mode. 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Direct on ine Starters : | A three phase Sq. Cage induction motor can be started direct on line by supplying rated three phase voltage to the motor winding. The starting current will be G times of full load current. A bimetallic thermal over load relay provides protection against overload. There is no reduction in starting torque, during starting. Star Delta Starters In order to limit the starting current of motors this methed is followed. Initially motor windings are conneciad in star configuration, The applied voltage across the winding is reduced 1/'3 times of the rated voltage The starting current also reduced ta 1/3 times of DOL Starting current. Once the motor reaches rated speed the windings are connected in delta. There is a 66% reduction in starting torque, ‘Auto Transicrmer Starters : In this method the windings of the motor fs permanently connected in delta. Reduced starting current is ach eved by applying reduced voltage by means of an Auto Transtormer while starting. The tapping of the auto transiormer will be 60, 70 & 80 % . Mier attaining full speed the auto transformer is bypass from the circuit and {ul system vollage is applied to the winding, There is @ proportional reduction in starting torque depending upon the tapping selected Rotor Resistance / Stator Rote Starters, ‘The slarter is used to start Slip Ring Induction Motors. Resistances are included in the rotor circuit while starting. The resistance are reduced gradually and finally resistance are bypassed by shorting the slip ring. In this method wie obtained full rated torque and also considerable reduction in starting current. In fully automatic Stator Rotor Starter the resistance are cutoff from the rotor winding in 3 (or) 4 steps and finally the rotor windings are peimavently shorted. Soft Starters Soft Starters are Thyristor drives, The rms value of the applied voltage is reduced by controling the fring angle i power Thyustor, After achieving the full speed Thyristor conducts in full. Here the starting voltage can be froin zero to maximum value and the motor starting is very smooth, Similarly soft ~ stop faci is also thereby the motor can be stopped by gradually reducing the speed. Variable Frequency Drive ln VEDs the 50 HZ AC is rectified into DC and again inverted as variable frequency supply. The variable frequency is achieved by thyristor coniroled inverir. The frequency can be varied from 0 — 200 %. This makes Speed control possible in squirrel cage induction moter. At maximum frequency the voltage will be equal to maximum supply vatage.Methods of Starting of Induction Motors Motors | ‘Squirrel Cage Induction Motors Siip Ring Induction Motors Direct | [Star Auto Soft | [Variable] [Manual] [Fully Automatic Online | | Delta | [Transformer] | Statt | |Frequency| |Stator Rotor] | Stator Rotor Starter | | Starter | |_ Starter orive | |_ Drive Starter Starter Comparison Table ] - — | | Direct | Star-Delta Starter | Auto Transformer | Soft Starter Variable — | onine | | Starter | Frequency Drive + —_____1 Applied 100% | 51% 60% (or) 70% | 0-100% 0-100% Voltage (or) 80% Variable Voltage / | Frequency | 100% | 33% 30% 0-100% 0-100% | 4 | ac Variable fae! Tequency Starting | Gtimes of | 3times of ful | 3to-4 times of ful | Smooth Smooth Current fullload | load current load current Variable Variable current | M-2Selection Chart for DOL Starters ~~ Motor Ratings Oil Relay _| Contactor [Fuse Rating] SDF KW A Range A A A ms | 009 | 04 0305 9 2 32 fr a2 045 03.05 9 2 32 0: 0.15 0.57 0.45075 9 2 32 5 0.19 075 06-1.0 9 4 32 0.33 025 | 09 9 4 32 8 0.37 12 9 6 32 O75 0.55 16 9 6 32 10 O75 21 g 8 32 15 WA a7 9 10 32 475 1.3 3 g 10 32 2 35 9 16 32 5 48 9 16 32 3 5 9 16 32 4 64 9 20 4 5 79 9 20 32 55 as 9 20 32 6 3 12 2 32, 75 We 12 32 32 0 148 16 32 32 19 25 50 63 22 25 63 63 | 2 32 83 3 20 2o 32 63 63 Pa 35, 45 80, 100 30 40 45, 80 100 35 aT 65 100 100 40 55 65 100 100 45 60 65 100, 100 30 66 80 125 125 60 80 95 160 200 7S ‘J 110 160 200 0 120 140 200 200 100 135 140 200 200 110 139 265 200 200 125 165 135-225 265 250 250 150 110 200 135-225 265 315 315 175 130, 230 180-300 265 315 315 197 147 260 180-300, 205 400 400 200 150 275 180-300, 325 400 400 215 160 280 180-300 325 400 400 225 168 300 270-450 325 400 400 285 180 320 270-450 325 400 400, 270 200 | 40 270-450 400 500. 630 W-3Selection Chart for Star Delta Starters Motor Ratings | Current at 415v | O/L relay Contacior (A) | Fuse | SOF TP | RW | tine | Phase | Range [Star ] line | Oeha A A 1 [ows [21 | 12 [oss] 9 g 4 32 is |i | 27 | we jisea] 9 | 9 6 32 2 | 15 | 35 | 202 J raza] 9 8 8 é 2 f | 3 | 225] 5 | 2ee | 233 9 % 9 8 32 a }oy | oa | at [300] 9 ' 4 wo | 2 =—5 |a75 | 79 |) 46 | 3050] 9 4 9 we | 32 6 | 45 | 9 | sz} 4575] 9 | 9 | 16 | 32 75 | 85 | m2 | 64 45-75 3 a [| 2 20 32 vo | 75 | 14a | 855 | 6010] 9 | 9 9 2 | 3 125) 93 iog7 | gon | 9 J 2 2 3 32 1 wl y 12.70-| 9015 | 12 16 4G 32 32 zo | 15 | 2 | wre] i423 | 2 | a5 | as | 4 | 83 | 185 | 35 | zo | 1423 | 16 | 2 25 50 63 30 | 225 | 40 | 2303 | 2033 | ih | 25 | 2 8B | 6 35 | 2 | ar | arsa | 2033 | 2s | a2 | 32%] 63 | 100 40 55 | 3176 | 3050 | 2 | 32 | 32 | 63 | 100 45 60 | 34.64 | 3050 a5 45 80 100 50 oe | 3811 | 3950 as. | 45 | 80 | 100 so | 45 | to ! 46.19 | 30-50 a | q5 | 100 | 100 65 | 8s | a7 | 5023 | 4575 | 4 | ob | gs | 100 | 100 wo | s2 | 98 | sa2r | 45.25 | as | ob Ss | 125 | 125 75 | 35 | 100 | sz7a} 4575 | 45 | d a 125 | 125 g | 675 | tao | 6928 | 4575 | eo | so | a0 | 160 | 200 roo | 75 | 135 | v794 | Gero |.'80 | e0 | 80. | 160 | 200 125. | 90 | tes | 9527 | ceria | ao | 95 | 95 | 200 | 200 150 | sto | 200 | tisaz] goaso] 95 | sao | tao | 250 | 250 75 | 130 } 230 | 13229 | 9oa50} vv | 140 | 140. | 250 | 250 200 | 150 | 275 | 158.73] 135-225] 140 | 265 | 265. ] 315 | 315 240 | 175 | ato | 17898 | 135-225 | 140 | 265 | 265 | 400 | 400 250 | 185 | 325 | 19764] 138-225]. 140 | 265 | 265 | 400 | 400 275 | 20a | 360 | 207.85 | 135-225] 265 | 265 | 265°]. 400 | 400 300 | 225 | 385 | 222.29 | 180-300] 265 | 265 | 265] 500 | 630 400 | 300 | 500 | 288.68 | 180-300; 265 | 325 | 325 |* soo | 630 alas adSoIA CONTACTOR 5 a s a g g ‘EMR 2 stop. PS “pret REMOTE stop #182 an — @) 8 : es) “Op, Op START START SIRES if + NOTE: 4, C1 = MAIN CONTACTOR 2, BMA — BI-METAL OVER LOAD RELAY A OR DIRECT ON LINE STARTER Boha " y y 8 No : uw D Ee . a cas) 423] | Lob of 72942 19) 3 tala Hl 5, es hk 2 z : a \ 5 Lj 3 l 4 - lf - | | | emeee g | ’ be ‘ aaun SxIRBSKTGa IddNS OV AOSTp3s(or—0) ~ wanlt oas(or-0) ~ SONVISIS3Y Guo GUS SSF BOLOYINOD HOLM - ness “+ wrt MOLOVINOD HOLOY - 49% NOLOVINOD HOWWIS - 19 “1 =a0N‘ONIOONI aa ¥ N SNOLING HSMd ~ Bd ‘S | HOLIMS 319901 ~ SL “6 SSfiy “IGHINGS — 30) "y oon (2-2 AVIBY ONISNIS “dNBL — HL “@ AVTBY GVOT UBAO WWIGN Id ~ BNE “e HOUMS 319901 — si °Z — HOMMS NOLOTTIS UALSNY — SSV ~Z UALMVIS LIOS — Sus “9 UaLaWAV ~ VF | | HON ws) L a OTT Hs | i Su SS: VI-9 eS VAOQL oa n0ze/Si¥ asng HOSry ae & To: CONTROL 8CUI 260yA conr. Pe marci 30_MOTOR POWER WIRING FOR VARIABLE FREQUENCY DRIVE STARTER NOI 1. K1&K2 — ISOLATING CONTACTOR 2. K3 — BY-PASS CONTACTOR 3. R10 ~ BIMETAL OVER LOAD RELAY 2. VED — VARIABLE FREQUENCY DRWEI UaINVIS SNS AONSNOSET J ISVIEVA UOT ONIN TOSINGO MI=11 (enVil — Design of DG Panel & AMF Panel DG Panel : Diesel genset is 2 standby power supply urit. Hence it fs important to keep the DG set always in working condition, DG set comprising of two major equiprnents, 1) Diesel Engine and 2), Alternator: Aerator isan elecvical equipment, hence itis to be protected against the following. {J 7 | sino Description Rating upto 100KVA | Above 100 KVAto | Above S00 KVA to | 500 KVA 1000 KVA __| | Over Load v v v & Short Circuit v v v 3 eat Fault - v v 4. | Restricted Barth Fault ~ — v 5. | Diferential Protection — se v 6 | Over/Under Voltage we = v Diesel engines are protected agains the following, a) Low Oil Pressure +b) High Water Temperature (or) High Cylinder Head Temperature <) Over Speed Normally for higher rating DGs the engine protection panel will be supplied by the engine manufacturer as.a part of the engine. The rating of MCCBs, CTs and metering equipments for various ratings of DG sets are detailed in the schedule, Vil-1 Gi)AMF Panel : Automatic Mains Fallure panels are used in hospitals, commercial complexes and software parks, where DG pbwer is required immediately when mains power fais. The sequential working principle of AMF panel s detailed bee v. a} Line Voltage Monitor (LVM) always senses the stability of mains supply. ») Engine start relay provides signal to the starting motor of the engine to start, when mains supply fails) and gets signal rom LM, ©) DG Contactor / ACB closes automatically as soon as DG voltage reaches stable value. i) When set is running LLOP, WT, Over speed relays monitors the value and gives alarm / trip signal ding abnormal conditions. } then supply is resumed LVM senses and trips the DG contactor / ACB and. closes the mains contactor / AB. f} LVMalso gives signal to the stop timer. 48). Stop timer gives signal to stop solenoid to stop the set after idle. run time. Hence paver supply is ensured tor all criical loads immediately. The panel also has inbuilt battery charger to keep the Lalteries alvays n charged condition, ‘Note 1) DG set ratings upto 250 KVA can be provided with 2 Nos.4 pole contactors of suitable ratings along with other accessories for auto change over. 2), DIG sets higher than 250 KVA can be provided with 2 Nos. 4 pole motor operated MCCB (or) Electrically opcvated ACBs along with olher accessories for auto change over. Incase the location of DS and Main panel where mains supply is present is far away than DG panel with Auto sat / slop can be provided near OG set and the auto power transfer arrangement can be provided at Uifferent convenient location. 4) In-an installation where one common 6 set feeding to two or more diferent EB supply, a common auto start stop pariel with auto transfer of poner can be provided. 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Eh - ETZTH (o3sor-o) wm AMSG _NO ~ 1 OW "AWE SST dol INNS — HS Houiws wouomas HOUMS BOLOSDS & BVESNE NVA =e VIB 4Vill — MAIN PANEL Main Panel / Main Switch Board is an Electrical equipment which receives power from ene er more sources and distributes to various sub panels or loads as per IE and CEIG regulation. Switchgears like ACBs, MCCBs, SFUs, Isolators are used in the panels for controlling the power depending upon the current ratings required for various loads. |. Various Types of Panels : | le Bus Panel:—Two Source Single Bus Panel with Auto Change Over:— | INCOMER=2 ) TPN TPN TPN wen > ¥ wicca j cc weca 7 cca cca weesd) Iwo Source Single Bus with Buscoupler:— INCOMER=1. INCOMER=2 MECHANICALLY MoO 1 | | }------— wee ________8 | NER OGRED os nea 0% 2, | A 1 AA | ! oe 1 415V SOHZ SP |4W AL, BUSBAR my | 7 z s oa + 5 6 I woo ee rx 8) yO) TH guste ven rex 9) tN) ro | gues o)uecs 6 were wees oJuccs oAucce | ' | 1 1 1 1 thf —- {dd 1 ' 1 1 ' I 1 } oo i woo PDD ico i woo) ne oD” a! i Op Om Sam I i ' 1 x i | _#19v_s0H2_ se] aw AL_susieaR O { I T > ‘0 oO» z = 5 I | Do | 1 A) a ACE i | i TPN BUSCOUPLER ary EH Ten! ; veca 9? wee cca o/ucca cea | { i \ 1 a a---4f-- 2 aaedL aes! ad| f) Three Source Single Bus with Two Buscoupler: INCOMER—1 INCOMER~2 a) 7 Oo O—>» = l “E DO i MDO | ©) Ten ©) Ten ACB TPN TPN Meee TEN TPN | g/mcca o/mccs B/C-1 Mecca ‘MCCB ccs o/Mcca, \ | lwo Source Double Bus Panel:— EB INCOMER i \ : | : 1 | _£B sussar i 97 [ E oi 0) ap ») 4° °. 4p oy ap i cea Mocs yea duces wece MCCB | | I f ey roe I I 9, ea? 6, i | t [3 4p 4p Sire "ap |! ' pure o/weca wece ? WoC ? CCB weca | 1 |} arma } 4 1 | ' Moo 1 i i i | DG_INCOMER | | vil 4 (3?uvesne [oo aa NOG T=SSNOONT 9d f e000, I “8h | ¢ ‘ ef 8990 [ = Z=WaNOONT GF sigs 9 — ABML + HOOT - © Sias Z — Agvz + yOOTE - G TSTEarIODENg OM YYIM ST VII-5| ev BOv ov ¢ ro/a ¢ z-o/a ¢ ba SP oc Se axe OOK oy me? oan oan OW A-8 -*8 3 O-> oO uvesna [90 I Lend TY cand J BOON soon 00/0, BOOK 00K oon \ do a a ob eo es { i met Set tet tee wl wl oF, a, 2 4a a Me each coat oot ook ooo soo? ? a i a q er i a ‘i oo i a i = ' 7 . a - - 2? — a3 . ' a ma | oe oye aa gov ey, Sov w } ¢ oy oan e ev oan ¢ eov | 1 { oan q oat oon | 1 L-------4 + ee { Leer tee psa j S=NSWOONT EF Z-8SROONT ES T=NSNOONT 83 SI9S 9 - AaML + HOOT - @ SSS Z — ANE + OTS - @ ( SIajgnOsENg INO] GWM Sng ejqnog SoINGS xisSize of Interconnecting Cable / Flat busbars Rating of Copper Copper ‘Numinium feeders Cable Size Fat Flat eA 4sqmin - - | 32k 10 sq.mm_ = aA 16sqmm - = 100A 35sqmm 25X3 25X6 1254 50 sq.m 25K4 25X6 1604, 50 sq.m 25X5 30X6 2004 70 sqm 256 25X10 2508 2X 50sqimm 25X8 40X6 (or) 30% 6.25 3158 2X 70sqinm 40 6.25 50K6 (or) 25% 10 4008 50X6.25 50X10 6008 50K 10 50K 12.5 800A 60x10 100 10 (on) 50K 125 (or) 75 12.5 | 10008 = 75K 125 100K 12.5 (or) | | (or) 1008 2X100X 6.25 Vill -7) GS)Aluminium Busbar Ratings Sze | Svein | 1 BarAluminium 2 Bar Aluminium | 3 Bar Aluminium 4 Bar Aluminium Inches mn DC ac [OC aC oc] Ac [ oc | AC xa] sxe] 355 | 355 | 710 | 705 | 980 | 970 | 1120} 1100 1172x114] 375x6| 520 | 520 | 1030 | 1020 | 1380 | 1350 ] 1585} 1535 2x14 | sox6| 670 | 670 | 1315 | 1290 | 1765 | 1705 | 2050) 1940 3x14] 75x6| 970 | 960 | 1805 | 1740 | 2440 | 2310 | 2860 2620 4x14 | to0x6 | 1260 | 1235 | 2260 | 2140 | 3060 | 2800 | 3640 | 2300 xis | 125x6| 1545 | 1505 | 2700 | 2510 | 3060 | 3240 | 4410) 2700 6x14} 150x6| 1840 | 1780 | 3130 | 2860 | 4290 | 3680 | 5250) «240 2x38} soxio| 840 | 830 | 1560 | 1500 | 2090 | 1970 | 2460 3x38] 75x10] 1210 | 1180 | 2180 | 2050 | 2940 | 2660 | 3510 4x38] ioox10| 1550 | 1495 | 2710 | 2480 | 3660 | 3150 | 4400 | 2560 5x38 | 125x10| 1940 | 1860 | 3290 | 2930 | 4450 | 3660 | 5400 | «200 6x38 | 150x10| 2260 | 2120 | 3770 | 3340 | 5140 | 4080 | 6320 | «280 8x38 | 20010) 2940 | 2750 | 4800 | 4150 | 6500 | 4900 | 8060) £740 axve| 75x12) 1405 | 1355 | 2450 | 2240 | 3290 | 2830 | 4000 | 3240 4x12 | 100%12| 1830 | 1740 | 3100 | 2720 | 4170 | 3360 | 5100 | 3900 5x12 | 12x12] 2230 | 2080 | 3720 | 3120 | S040 | 3900 | 6170 | 4550 x12 | 150X12] 2620 | 2420 | 4300 | 3500 | 5850 | 4400 | 7200 | 5100 x12 | 200x12) 3380 | 3060 | S450 | 4450 | 7420 | 5300 | 9110 | 6150 x12 | 225x12] 4080 | 3640 | 6500 | 5000 | 8860 | 6000 | 10900] 6850 - - i 7 Note_: Exact Calculation : Copper Bus = 1.3A per squm. Aumninium Bus: 0.8A per sq.m Vill- 8 eq SbIX- Power Factor Correction AVact majority of Electrical ioadsinfow voltage industrial instalation are inductive in nature. Typical examples are Motors, Transformers, Drives, Fluorescent lamps. Such loads consume both Active ‘and Reactive Power. The active power is used by the load to meet its real output requirements snhere as Reactive Power is used by the load to meet its magnetic field requirements. The Reactive Power (inhctive) is abways 90" lagging with respect to Active Power as shown in fig COS @ = Power factor KW = Active Power KUAR = Reactive Power (Inductive) Ku = Apparent Power Resistance load Th aati Power BY Vist Inductance Capacitance VIsing Resale ae EVAR Apparent Power BA ‘Tie supply system should be capable of supplying both Active and Reactive Power. The supply of Reaetive Power from the system results in reduced installation efficiency due to: © Increased current flow fora given load. # Higher voltage drop in the system. ‘© Increase in losses of Transformers, Switchgear and cables. ‘+ Higher KVA demand from the supply system, «Levy of penalties by the Electricity authorities. It is therefore necessary to reduce and manage the flow of Reactive Power to achieve higher, efficiency of the Electrical system and reduction in cost of Electricity consumed. | ‘The most cost effective method of reducing and managing Reactive power is by Power Factor Improvement through Power capacitors. The concept of power factor improvement is shown above. K-41 = = S$? |fs power factor tends to unity the electrical system efficiency will improve. Due to the changing nature of modern electrical installations it has now become necessary to use various types of fixed and variable power capacitors to achieve desired power factor improvement, The niethodology followed to achieve a consistently high power factor under modem application conditions is referred to as “Reactive Power Management” and involves proper selection and use ‘the following products. = Power capacitors © Automatic Power Factor Correction systems Benefits of Power Factor Correction = ‘© Saving in KVA (DEMAND) charges ‘© Elimination of Power Factor penalties, Release of system capacity by which addtional loads can be easily added. ‘© Reduction in current drawn, © Reduced transformer/switchgear! cable losses. ‘© improved Voltage Regulation. ‘© Increased ile of Switchgear / Cables due to reduced operating temperatures. Comparison Table for the Connected load of S0OKW [Installation | Power Factor KVA Current drawn Savingsin | | status Demand (np VA Charges | Without 0.75 | 1067 1484 wit | | capacitors | fo I j | | wth 095 | 842 17 225KVA [patos | _ Caleuation of KVAr requirement The folleving table gives the recommended ratings of poner capacitors, which are to be used cinvcty sith 3 phase AC induction motors. 1) Ihs considered uneconomical in industrial applications to improve power factor by individual omperisation for ruotor ratings below 15 hp. 2) For motor ratings above 250 hp the capacitor KVAr rating would be about 25% of the motor tating in bp, 4) all cases it should be ensured that the capacitor current at rated voltage is always less then 90% of the no load current of the motor. This is to the fact that when capacitor current exceeds the no load magnetizing current of the motor excessive voltage surges can occur due to self excitation in the event of an interruption in power supply, which will prove harmful to tolh the inojor as well as capacitorSelection Table for Capacitors Motor | Rating Capacitor ratings in KVAR when motor speed (1pm) is inp [3000 1500 1000 750 500 25 1 15 2 25 5 2 2 25 35 4 78 25 3 35 45 55 10 3 4 45 5S 65 15 4 5 6 7s 3 20 5 6 ? 9 2 25 6 7 9 10.5 14.5 cit 7 8 10 12 7 40 9 10 13 15 ai 50 uw 125 16 18 2 co) 13 145 18 20 28 70 15 16.5 20 22 31 80 7 19 2 24 34 90 9 a 24 26 37 100 21 2B 26 28 40 110 2B 25 28 30 a 120 25 a7 30 32 46 130 a 23 32 34 49 140 29 3 34 36 52 145 30 32 38 7 34 150 34 3 36 38 55 155 32 4 67 39 56 160 33 35 38 40 7 165 4 36 39 At 59 170 35 7 40 42 60 175 36 38 41 43 or 180 a7 39 42 44 62 185 38 40 43 45 68 190 38 40, 43 4S 65 200 40 42 45 47 67 250 45 50 55. 60 70 K-3Multiplying Factor for Power Factor Improvement litiat PF Final PF 09 Tost | 092 | 093 | 094 | 095 | 096 | 097 | 098 | 099 ‘a4 | 1.907] 1.836 | 1.865| 1.896} 1.928 | 1.963] 2 | 2.041 | 2.088 } 2.149 oz | 1.676| 1.705 | 1.735] 1.766 | 1.798 | 1.832 | 1.87 | 1.91 | 1.958) 2.018 ‘aaa | 1.557) 1.585 | 1.615] 1.646 | 1.678 | 1.712 | 1.75 | 1.79 | 1.838 | 1.898 4s | 15 | 1529] 1859] 1.589 | 1.622 | 1.656 | 1.69 | 1.734 | 1.781 | 1.842 ‘ote | 1.446) 1.475] 1.804] 1.535 | 1.567 | 1.602 | 1.64 | 1.68 | 1.727 | 1.788 oa | 1.343) 1.372 | 1402] 1.432 | 1.465 | 1.499 | 1.54 | 1.577 | 1.625] 1.685 cas | ir4s| 1.276 | 1.306] 1.337 | 1.369 | 1.403 | 1.44 | 1.481 | 1.529) 1.59 os2 | iiss] 1187} 1217] 1.247 | 128 | 1.314 | 135 | 1392 | 144 | 15 cosa | 1074) 1.103 | 1.133] 1.163 | 1.196 | 1.23 | 1.27 | 1.308 | 1.356 | 1.416 } oss | 1.034) 1.063 | 1.092] 1.123 | 1.156 | 1.19 | 1.23 | 1.268 | 1.315] 1.376 0s |0.995| 1.024 | 1053] 1.084 | 1.116 | 1.151 | 1.19 | 1.229 | 1.276) 1.337 a2 | 0949 0979) 1.c09} 1.042 | 1.076 | 1.11 | 1.154 | 1.201 | 1.262 0.849 | 0.878 |0.907 | 0.938 | 0.97 | 1.005 | 1.04 | 1.083 | 1.13 | 1.191 o.7a1| 08) [0.839] 087 | 0.903 | 0.937 | 0.97 | 1.015 | 1.062 | 1.123 0.716 | 0.745 |0.775 | 0.805 | 0.838 | 0.872 | 0.91 | 0.95 | 0.998} 1,058 ses | 0.714 [0.743 | 0.774 | 0.806 | 0.84 | 0.88 | 0.919 | 0.956 | 1.027 o.664 | 0.683 [0.712 | 0.743 | 0.75 | 0.81 | 0.85 |, 0.888 | 0.935) 0.996 0,504 | 0.623 ]0.652 | 0.683 | 0.715 | 0.75 | 0.79 | 0.828 | 0.875 | 0.936 0.565 [0.594 | 0.625 | 0.657 | 0.692 | 0.73 | 0.77 | 0.817 | 0.878 o.48 | 0.508 |0.538| 0.569 | 0.601 | 0.635 | 067 | 0.713 | 0.761 | 0.821 0.425| 0.453 |0.483| 0.514 | 0.546 | 0.58 | 0.62 | 0.658 | 0.706 | 0.766 04 | 0.43 | 0.46 | a49 | 0,519 | 0.553 | 0.59 | 0.631 | 0.679 | 0.739 asi] 04 [0429] 0.46 | 0.492 | 0.526 | 0.563 | 0.605 | 0.652 | 0.713 at 0.347 | 0.376 | 0.407 | 0.439 | 0.474 | 0.511 | 0.552 } 0.599] 0.66 0.266 | 0.294 | 0.324 | 0.355 | 0.387 | 0.421 | 0.548 | 0.499 | 0.547 | 0.608 0.214 | 0.242 [0.272 | 0.303 | 0.335 | 0.369 | 0.406 | 0.447 | 0.495 | 0.556 0.162| 0.19 | 0.22 | 0.251 | 0.283 | 0.317 | 0,354 | 0.395 | 0.443 | 0.503 0.135| 0,164 | 0.194 | 0.225 | 0.257 | 0.291 | 0.328 | 0.369 | 0.417 | 0.477 Example Calculation: The requiced K\iAr compensation far a 500 KW installation to improve the PF from 0,75 to 0:96. KvAr = KW X multiplying factor from above table: = 500K 0,59 = 295 KVAr, Average Fi hy KVAR Operating load KW = KVA demand X Average PFRecommended Ratings of Switching Equipments and Cable For 3 Phase 415/440 Volts 50 HZ Capacitors Capacitor | A Conductor] WACKise | Switchiuse Ratings of output PVC insulated ratings ratings Contactors in armoured cable in in ACB. KAR size in sqm. Arnps. Amps. Amps. 1 25 5 16 16 2 25 5 16 16 3 6 10 16 16 4 6 1S 32. 16 5 10 15 32 16 10 10 30 63 25 125 10 55 63 25 5 16 50 8 32 75 16 50, 63 45 20 16 50 63 45 25 25 80. 100 63 30 35 80 100 63 40 50 100 125 95 50 70 125 200 cy 60 95 150 200 110 Ey 120 200 400 140, io | 185, 250 400 200 150 2X 120 (or) 315 630 300 1x 240 200 2X 186 (or) 400 630 — 1490 250 2x 240 400 630 —< 300 2% 300 500 800 aes: 400 3X 300 - 1000 _ K-5TANYd YOUOvEYD 18 aes je fe lisAWISONAGHL = HI YOLOVINOD ABYTIIKNY ~ XV AVIEH NOULOSERICD NOLIN HSNd GELYNINNTH — 9) HOLMS WOLOITES “WRNVA OLNY ~ W/¥ MOLOVS H3MOd SUVADINY JovIS 9 — BOLeY = ¢ ess ob ay i. ae or (owe ros) = ns aT ann OC oa Soo i ef era 3 =X - Cables | Cable is raade of Copper or Aluminium conductor surrounded by insulation and sheath. The cross sectional area of the conductor depends on current carrying capacity of material used. The conductors of the cables are usvally of electroiytic copper or Aluminium. The larger conductors are of stranded type to faciitate the cable to tre more current and to have flexibility, | ‘The cable should be selected such that it carries specitied load without over heating and without voltage dep. Construction Conductor : ‘The construction of the conductors shall be as follows. The conductors are covered with PVC insulation. Size of Size of Copper ‘Nuniniuen Type of Conductor Flexibility Class min? mam? 15 15 Solid {ass | (Table-1) ofS :8130 25106 25to 10 Solid / Stranded -do- 10/and above 16 ond above Stranded Class 2 (Table-2) of IS: 8130 i Inner Sheath | | The Cores of multicore cables are lad up and the surrounded by PVC covering either by PVC extrusion|or by a | Armouring ‘Arowurmy shall be applied ever the insulation in case of single core cables and over the inner sheath in case of twin, three and multi core cables. I the calculated diameter below the armouring does not exceed 13 mm the armicur shall consist of galvanized round steel wires. For diameters above 13 mm the armour shall consist of galvanized round steel wires or galvanized steel strips. Outer Sheath This is provided by means of an extruded PVC over the armour for armoured cables over inner sheath for unarmaured Cables and over the insulation for single core unarmoured cable, Unarmoured multicore cables shall have mono sheath ( single extrusion covering inner & outer sheath ). The outer sheath is made up of PVC suitable to operate maximum conductor temperature of 70°C. The folowing are other types of cables are widely used in control and power applications, Mel &Heat Resisting PVC Cables = HR PVC Cables can be operated at a maximum conductor temperature of 85°C and are also suitable for intermittent use at temperature upto 105°C. Flame Retardant Low Smoke Cables | ‘These cables with special PUC formulation for sheathing material, prevents the propagation cf flame along the length ofthe cable when exposed to fire In ation these cables emit very law smoke and halogen emission ‘ibe reduced under fice conditions. These properties help immensely in fie fighting operation and prevention of further loss to costly equipment to which the cables are connected. Gross Linked Poly Ethylene cables: XLPE cables have excellent Mechanical, Electrical & Thermal characteristics when compared with PVC cables. Their advantages are listed below. High current rating High short circuit rating High lnsulation resistance | High resistance to moisture, chemicals and corrosion Better resistance to surge current High operating temperature ~ 90°C High short ciruit temperature - 250°C Cable Selection: The following points are to be considered while selecting the cables, Maximurn operating voltage Maximum operating current Possible overloading duration & magnitude Route length Voltage drop Mode of instalation considering ambient temperature & chemical properties of soll Requirement of fame retardant properties Glanding : Single compression or double compression glands depending upon the requirement, ae provided at both ends of the cables. The armouring is secured in the gland and the gland is secured to the body of the equipinent. Through out the length of the cable the armour is at earth potential. i Termination Masirnuin care ig to be taken while terminations are made because terminations are vulnerable in a power or control cicut, Suifable lugs are to be selected depending upon the cable sq mm. Crimping or Soldering to be done cavefuly without any ait gap so that no heat is developed. Application of inhibiting compound before crimping prevents oxidation. Every terminatic is to be checked thoroughly for any loose connection. @Specification The following are the abbreviations used in cable specification A ‘Numinium conductor x SUPE ound steel wire Flat steel strip Double armour Non magnetic FC sheath Y Aluminium Conductor PVC insulation round steel armour and PVC outer sheath cable. ‘The baneling radius shall be minimum of 12 times of the diameter of the cable. Model calculations : - Example 1: Calculate cable size for a 3 phase 10 HP motor located at a distance of 500 metre from power supply. Full load current 2148 Applied voltage 415V Let us consider a 3 core 16sq. mm cable. Current rating a8 per manufacturer's recommendation when laid in ground = 60A Resistance of cable = 23 ohms per Kn Voltage drop in 3 phase circuit = N3XIKR = V3 X14X23K05 = 27.9Vots, Percentage Voltage drop 279 =X 100 = 67% 415 Considering alternative, 25 sq, mm cable Resistance of cable per Km = 1.44 Ohms. the voltage drop wil be = 17.5 Volts Percentage drop in Voltage 42% Its advisable to select 25 sq mm cable in this case. Note: For Single phase circuits the drop willbe = 2K1KR X-3 =~ (a)Example 2 : Calculate cable size for 2 500 KYA 3 phase 11 KV/ 41S V transformer when a) laid in the ground at a depth of 75 amb) lad in cable tray with clearance c} laid in cable tray touching each other. (Ambient temperature 40°C and Ground temperature 30° C} | Letus consider 3 runs of 3 ¥ecore 400 sq. mm PYC Aluminium cable. | | Current ratings as per marvifacture’s specification when laid in ground is 335 Amps. and when laid in air a75Anps i | Full load current of 500 KVA Transformer = 695 Amps. a) When lid in ground, Rating factor for ground temperature 30° = 1 Rating factor for 3 cables lad in ground Touching each other 0.69 Current carrying capacity of 3 runs =3X335X0.69 693.45 Amps. | 'b) When laid in cable tray with clearance. Clearance between cables = Diameter of cable. | Rating factor for ambient temperature 40° Rating factor for 3 cables laid in cable tray with clearance = 0.96 \ Current carrying capacity of 3 rans = 3X375X0.96 = 1080 Amps. ‘¢) When laid in cable tray with cables touching each other. | Rating factor for ambient temperature 40° = Rating factor for 3 cables laid in cable tray touching each other =08 Current carrying capacity of 3 runs = 3X 335X08 i = 804 Amps. | | X-4 (G? |ARMOURED MULIICORE POWER CABLES 650/110 iu [il saaeagaens seeea 2 ug || eases ByeaS eguaa ag afafre (f] 29988 09208 BSREE 28 ke i a TS f] 11182888 daseg a2 amane oooda qeten oe §| Anca Sida dedisia OO arina GAM Meine SS9S9 NVGSS SS 11111 BRIT BASSE ree é “ayqe> Jo aoueysysas_->°p pasmbas ja 0} paurequye aes sod oan enpetpu ose 4 z aR Dip) Seeos nese RR irl eeees BeaRR HEL | | BT aig PE HE |ifss i | |es een | aH fa] can8k ARE Le | - ] Egee Be EEEES SE: GeaSt [9500 ]ceo0 acco] oss | troz | st | see] ve | ve sre |soxr un wu [siaurxae] wr |9s00| zv0 | coro | zeaz | evss | 49 | szo| we | ze [sre |sox| ocest zez19 jostomexye | «7 vet | ae00 Jost | sero | 9609 | 999 | S09 | sos | ze | of | sz sox seusl Sezze locUaRexte |” ter | zs00 | zero | ovo | veor | zaze | o¥s | sos | ez | gz | sz |eoxr g| USL ULE | serseixcne| let | za00 | zbz'0 | gozo | ecse | ca0e | Say | Ssh] 9% | 9% | OF |s'OxF] 5 PLU6L OCG | OdSTx*NE |“ wet | Ze0°0 |F0E0 | eseo | esce | 950 | ove | ote] oz | ¥z | oz [goxr| a BUTT SB'UEE | OLIOZLX%E] * oz't | o6o'0 | veo | oreo | cose | sez | sor | ose | vz | zz | oz |soxs 2 rare zswer| ogsexene ari | coo} zeso | erro | sez | acct | 9e | Ove | Te | Tz | o7 |sOxP g zs'te PI'S) SEOLXINE zor |ser0| acco | w90| ect | ort | oe | oe | zz | zz | 91 |soxr fag sree wee | semsmee 260 | ceo'o | evor | evo | exit | v6 | oez | oz | oz | oz | 91 [0x5 Bl zeus | Susexene ero | ceva) art | oct | ese | ese | e9z | ost | oz | oz | 91 jsoxr 7 stu | ousexme| sv1 | 9e0'0 | e600 | azcora | secur} ove | oe | oes | ve | we |sre|eoxy HE sezi9 cory | tt | 9900 zo | core | coe | s1z9 | o12 | 59 | ve | ve |sre|eoxr re [eS wes ooexe |” vet | zao0 | ocro | sevo | ees | sais | or | oop | ve | ve | szjsoxt| go | zz seus ower | tet | zso0| cera | sovo| ciss | cere | ous | oes | of | wz | szfsoxr| 90 | oz [Pe wu BDF . wre | sts | oa | az | oz |ezieox| co | at [28 weer | osixy ass | oe | sty | oz | oz jozleoxr) so | ot [Zc se u6t Ozixy core | ey | oor | re | oe |ox|eox| vo | ot leg feet | “exe | eset | ose | soe | zz | zz | ozleoxs] ro | rr [2 o ower zest | sve | oze | zz | zz | oz}eoxe] ro | 1 [oe wren sat | ove | saz | zz | ot j atleoxs| co | zr 12zi wud we |ow|os| oz | oz | otieoxr| co | zi [Bo bree tec | ose | oe | oz | oz | 91]goxs) co | ot |Fz| acu xe | ow | voz] oz | oz | ot|soxr] co | ot | Bl asen = [oo | - 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C. Systems. These factors are valid bient termperature is not perceptibly increased by the heat generated by rele Distance from the wall >2cm Number ofCables Clearance between Cables « diameter d ‘ % 3 6 ° Rating Facer Gainnonndaintatormaton enn poo sumer £ racks | é s bi 7 fF es & | rot 2 100 055 0930.90 (0.89 3 100 (OM) =—092 0890.88 3 6 1 (0.93 (0.90 0.87 0.86 225 min | Saosin omatan GNC) | 7. eae Nunberot racks: : iT a a #1 th th te on te 3 100 0.78 «(074 (070 0.68 3 im Gas tom bat oe ie xX-8Protective Covers Cables Laid in Sand and Covered with Bricks or Hoods or in Covered Troughs TypealCover Punned down sandand cover of bricks hollow filled hollow withsand Conversion factor 1 0.4 0.82 Grouping in Ground Rating factors for grouping of Single-Core Cables laid direct in ground in horizontal formation (3 Cables in Trefoil Touching) Number of SPAENG Circuits 7 ingroup Touching | 15cms 30ems 45ems coems 2 0.76 0.81 0.86 0.88 0.89 3 0.66 O71 o7 0.81 0.83 4 0.61 0.64 0.72 07 0.80 5 | 0.56 0.60 0.68 0.73 0.76 6 | 0.83 0.56 0.66 0.72 0.76 7 0.51 0.55 0.66 0.69 0.7% 8 0.88 0.53 0.63 0.68 0.74 8 0.46 052 0.62 0.67 0.73 10 045 0.51 0.60 0.66 0.73 i 0.48 0.50 059 0.66 072 2 0.43 0.89 059 0.65 072«for Grouping of twin and Multicore Cables Laid Direct in keting t [Member spacing when Ind in horizont formation ‘Spacing when laid in tier formation cables 7 prpsfiouching) Sem | 30cm [45cm | 600m [Touching] 18cm | 30em | 48em | Em 2 os | os7 | og | om | om |oge | 088 } 0.90 | 092 3 835 | ob | 083 | 086 | 06 | 073 | 079 | 062 | oss 4 oe | or | 07 | asa | os | om7 | 073 | 076 | 078 5 oe | oz | ove | ogo | 055 [oer | 067 | o7 | a7 6 8a | oa | 075 | 078 | om | os7 | 069 | 067 | 069 7 | Qs | oe | 07 | 077 | cas | oss | 059 | 069 | 0.66 | 8 SS | ove | o72 | 075 | o45 | 051 | 057 | 059 | 0.61 | 9 oss | os | om | 07 | oas | oas | 054 | 056 | 058 0 Sar | oes | 070 | 074 | 042 | 04s | 051 | 05s | 56 u $35 | 8S | oes | ozs | om | o4s | 050 | oss | 05s [2 oar | oe2 | 068 | 0.73 | 040 | 04s | 049 | O52 | O54 Rating factors for the Ground Temperature (lor cables laid direct in ground) [Ground Temperature in °C Dp sos wo 8 © 4 50 For normal PVC T2106 100 0% 087 0.79 O71 [For Feat Resisting PVC To 10; 100 095 0.90 0.85 0.80} Rating factor for Depth of Laying RATING FACFORS-FOR DEPTH OF LAYING FOR 650/1100 VOLTS ‘CABLES LAID DIRECT IN THE GROUND [pamotme [Sd Upto ‘Above25 min? ‘Above, 25mm? Upto300 mm? ri] 1.00 1.00 #0 0.98 105 - 097 120 . . . i 150 180 or more Multz-core Cables in Steel or Earthenware Pipes and Single or Multiway Ducts; 1 Power Cable per Pipe " | Number of Pipes mEeypapepepey7 | bey” | Conversion Factor “pat 074 | 0.70 | 0.67 | 0.65) 0.63 | 0.62 | 0.60] 059] 058 X-10 3Recommended size of cables on secondary of Transformers and for M.V. Alternators Transformers Capacity in KVA 3 phase at 433 volts PVC Aluminium cable size (Armoured) 100 ‘One Run of 3 % core 95sq.mm 150 ‘One Run of 3 ¥2 core 185squnm 160 ‘One Run of 3 ¥2 core 240sq.mm 200 ‘One Run of 3 Ye core 300sq.mm 250 One Run of 3 Ye core 400sq.mm (or) Two Runs of 3 Ye core 185sqmm 315 Tuo Runs of 3 Ye core 240sqanm 400 Three Runs of 3 ¥ core 300sq.mm 500 Three Runs of 3 Ye core 400sq.mum (or) Four Runs of 3 % core 300sq.nm 630 Four Runs of 3 Ye core 400sqinm 750 & above Busbar trunking i H.W Alternators PVC Aluminium cable size KVA, 3 phase (Armoured) No One Run of 3 % core 95sq.mm 160. One Run of 3 Y2 core 240sq.mm 200 One Run of 3 Ye core 300sq.0m 250 ‘One Run of 3 Ye core 400sq.mmn (or) Two Runs of 3 % core 185sq.mm 310 Two Runs of 3% core 240sq.mm 550 Four Puns of 3 Ye core 400sqsnm 860 Busbar trunking X-1h OPSelection Chart for Cables Motor Ratings | Current at 415) DOL 5/0 Supply 5/0 motor TP] RW Line | Phase [Al Samm] Cu. Samm [AL Sqanm]Cu-Sqanm AL Samm Cu, Sqm 05 | 037 1 06 25 25 ve om: 075) oss | 13} a7 | 25 | 25 - - - 1 075 | 2.1 1.21 25 25 = - we - 15 a 27 1.6 28 25 _ > = 2 aA) 35 | 202 25 25 - Ea - - 3 | 225) 5 | 288} 25 | 25 - = = - 375 | 79] 46 | 25 | 25 a = - - 75 55 | 112) 647 4 25 4 25 25 25 10 75 | 148| 855 4 25 4 25 25 25 125] 93 19 | 10.97 6 4 6 4 25 25 15 W 22 | 12.70 10. 6 } 10 6 25 25 2 15 29 | 16.74 16 10 16 10 6 4 25 | 185 | 35 | 2021 16 10 16 10 10 6 30 | 225 | 40 | 2309 2 16 2 16 10, 6 35 26 47 | 27.14 2a 16 25 16 16 10 40 30 55 | 31.76 35 25 35 25 16 10 50 | 37.5 | 66 | 3811 35 % 35 2 25 16 60 45 80 | 46.19 50. 35 50 35 35 25 re 55 100 | 57.74 70 50 70 50 50 35 joo | 75 | 135 | 794] 95 70 5 70 70 50 125 | 9 165 | 95.27 150 5 150 95 95 50 150 | 110 | 200 | 115.47 185 120 185 120 120 70 40 | 132 | 230 | 132.79} 240 150 240 150 120 5 200 | 150 | 275 | 158.78 300 185 300 185 150 120 L L | Note The above sizes of cables are recommended for a cable length of ‘approximate 15 meters. Ifthe actual length of 2, then select the cable based on voltage drop and other rating factors. Current Ratings of Copper Cables | - - | | tf | | |szeinmm® | 1 |15 |25 to |te [25 |35 [50 [70 | 95) __ | | | Current in’ «=| 14 | 18 | 24 55 | 75 | 100 [ss 165 | 240 | 300 | |_| | | | \ X-12XI- Relays and its Applications | ete, Relays are used in lectical circuits to protect the equipments tke transformer, ARernator, Motors, UPS, These relays are classified based on the application. | | Instantaneous Over Current Relay \vhon the current inthe circuit exceeds the set value the relay operates and trips the circuit breaker instantly. TSecondayy SAor 1A Definite Tine Over Current Relay : ‘ADetrte tine over current relay operates after a predetermined time when the current exceeds its pickup value. The operating time is constant irespective ofthe magnitude of current above the pickup value. (nverse Definite Minimum Time Over current Relay: This relay gives an inverse time current characteristics at lower values of the fault current and definite’ time characteristics at higher values of faut current, IDMT relays are widely used for protection of distribution lines. ,Inverse-tima Charactenstic \\ LAOS 7 dotnitetime Characteristic YS LZ i L i Operating Time | 1 Pup vate ¥ - - Actuating Quantity ‘Single pole over current relays are used for selective phase over current or earth fault protection of asystern. “he set values for tripping will be in percentage of CT secondary current. CT Secondary Shor 1A Settings Over current 50 to 200 % Earth faut 10-40 % or 20 to 80 % Time setting 1.3 secs or 3 secs. Thice pole over current relay is three pole version of a single pole unit. This can be used as three phase over Canicnt ct combination af tao ever current and one earth fault relay. | | The current and tine setting wil be same as single pole relay.IOMT relay with built in instantaneous high set unit: Tis ely has a bul in instantaneous over current relay rit to ensure selective and rapid clearance of igher fault curents, in addition to IDMT features. CTSecondary SAF 1A | Instantaneous Setting | Over Current 250 to 2000 % \ Earth fait 100 to 800 % | The three pole version can be used as three phase over current unit or two phase over current and one earth Faull nit Reverse Power Rely: | The reverse power relay is used to protect'DG sets operating in parallel When one ofthe prime movers fall then the respective alternator wil take power from other sets and run as a motor. The relay monitors the reverse power and isolates the defective set Under Voltage / Over Voltage Relay : ‘These relay are used to protect the equipment against over voltage or under voltage conditions. Motor Prot: vation Relay : | Mini motor protection relay is @ numeric relay gives protection to motors against over load, earth faut, single phasing, under current and lacked reter. Normally motors upto 7SHP can be fitted with this type of relays. For imotors above 75HP the felowing additional protections are to be provided. | Current Untalance Phase Reversal Repeated and Prolonged Starts Under Frequency | Over Frequency Under Voltage / Over Voltage Synchronising Relay = Synchronising relays is used for paralleling of two DGS during Auto / Manual Synchronising. It compares supply of incoming DG with respect to bus supply and permits the breaker to close when the following conditions are salsfied Both supply phase sequence are same. Phase angle diference to be zero (or) maximum difference of 7°. Frequency ofthe two sources to be equal (or wihin tolerance of 0.15 Hz. Voltage of the two sources to be equal (or) within the tolerance of 196.Current Vs Time Characteristics of Inverse Definite Minimum Time Relay z 8 2 6 3 B Zz 2 = o z E.Xl - Electrical safety & Earthing Sub Station = 1. Mil cables on secondary side of transformer shall be designed to take care of full load current of transformer, Refer to recommended cable size, 2. Greil breakers provided on the secondary side ofthe transformer should be of correct rating and draw out type. If higher ratings circuit breakers are used, relays J Cis / releases are to be set taking in to consideration of fll load current of transformer. 3. Earth leckoge protection should be provided on the secondary side of the transformer. 4, When two or more transformers operated in parallel the following points are to be taken care. Voltage ratio Phase sequence Vector group Percentage impedance | 5, In case of transtormer or DG set for capacity 750 KVA or more busduct is preferred on the: secondary side. 6. Fleible expansion joints are to be provided it the length of bust is more than 4.5m long. 7. Transformer room should be fitted with ventilators at roof level. Grill doors or grifled rolling shunted to be provided at the entrance. 1 8, Control gears for primary and secondary of transformers should be within 50 feet from the transfor ner. If ‘exceeds 50 feet the isolating device has to be provided near the transformer. 9, Transiormer rated 1MVA and above to be fitted with Buchholz’s relay, Circuit breaker also to be prov ded in the primary side. 10. Two separaic earth pits should be provided for connecting the secondary neutral of transformer. 11. 0.75Metre clearance should be available around the transformer. 12, The earthing conductors should be selected to withstand the fault current for maximum duration.Switchgear Room 1 Metre + Front side clearance. 0.75 Metre + Rear side clearance if rear access is required. The following clearances are recommended while erecting HV or MV switch boards or Generator contro! panel For double front both sides. (on) Clearance should be less than 200mm if doors are not provided and no work to be carried out on the rear side i O75 Metre Side clearance to be provided if rear clearance is 0.75m. 2 Metre For suitch boards erected opposite to each other. 15 Metre + Rear side clearance between switch boards erected back to back. O75 Metre + Between adjacent switch boards. (or) 0. MH. Glearance should be less than 0.2m. Automatic Shutters to be provided to cover the lve terminals where the breaker is of drawout type. Cross section of Aluminium ar Copper busbars should be selected based on full load current as well as fault current. Door interlocking for Switch Fuse Unit and Breakers to be provided to ensure that the doors can be opened nly when suiciis in OFF condition | Alllive terminals are to be shrouded to avoid accidental contact. | AIISFUs //ACBs should be mounted such that all operations are possible from the front and within the reach of person with normat height. Suitable insulating barriers are to be provided between busbars, SFUs / ACBs to prevent fall of tools, bolts and muts ete, No direct tapping rom the busbars should be made without control gear. ‘0 be properly segregated and supported to withstand specified fault rent i Pope identification with arrow marks to be provided incoming and outgoing cables and also for individual outlets. Interconnections for switches more than 634 should be made with busbars. Mil-2 @ |12, Busbar clearances inside switchboard as per I5:4237 ~ 1967. i _ | Voltage | Phase to Phase Phase to earthed metal Gearance Clearance in mn in'mm 415 19 16 600 25 19 3300 51 35 6600 7 60 11000. 127 7 22000 242 140 33000 356 223 Current Values Affecting Human Body Effects Less than 1 mA | Could not be felt 110 8 mA Shock ean be sensed but not Painful Sale Values Unsafe Values 81015 mA al Current through Body | 30 to 50 mA 50 to 100 mA 10010 200 mA ‘Above 200 mA Muscular control is net lost, Individual can let go at wil Paintl shock, Muscular control is not lot, Individual can let go at wil Painful shock, Muscular control of adjacent ‘musdes last, Cannot lt go. Painful, Muscular contraction, breathing difficulty. \Venticular Fibrilation, Possible death. Instant death due to heart stoppage. Severe burns, Severe muscular contraction, Stoppage of heart. xl 1-3 @®Earthing : Earthing system and conductor size etc in accordance to 1S-3043/97. An earth bus of the sie 25mm X ihm copper or Gi of size 50 X'6 mm should run through out the instalation. ‘at earth wies of minimum size of 10 SWNG shall be connected to the above bus. Care should be taken thatthe snain earth, neutral earth and lightning arrester earth are always separated from each other. ‘he eanting electrodes shall be made of Gl o Cast Iron. Pate electrodes may also be used. |.SMletre stance should be maintained between two earth electrodes and between electrode and building, ‘The earthing system for computer should be separated from normal earth Earth Electrode Specification Type Materials Size Rod Hard drawn copper 125mm dia x 2.5m long Galvanized Iron 16 mm dia x 2.5m long Plate Bare copper {600mnx600mim 2.1mm thick Pipe Galvanized Iron 38 mm dia x 2.5 mm long Cast Iron 100 mm dia x 2.5 m long The resistance of earth system should be checked and recorded every year. ‘The combined over afl resistance of the earth system is recommended as follows : Major Power Station 0.5 ohms: Major Sub Station 4,0 ohms ‘Smal! Sub Station 2.0 ohms Distribution Transtormers 5.0 ohms (Other cases 8.0ohms Earth continuity between two peints in a system should not exceed one ohms. ‘As per UE Rule 61 the following are the check points for earthing arrangement. 1. Eaithing resistance should be within the permissible limit. Earth conductors should be as heavy a section as possible brazed or soldered together soliy after bonding and belted. Power equipments should have two separate and distinct earth connection. 4, Earth connection should be parallel. | Earthing lead should be effectively protected against damage, corrosion and plferage. | Earth leakage protect.on be provided. | euEquipment Earthing ~ Size of Erthing Lead (Transtormers, Motors, Generators, Switchgears etc) | | | | | Rating of 400V , Size of Earthing Conductor 3e , SOHZ Equipt in KYA oe - Bare Copper AL PVC. Galvanized Iron Insulated Conductor [ Upto 5 10 506 10sq..mm 7122 | Sto t8 10 SIG 16 5q. mm eSNG 151050 8SWG 16sq.mm } 1X 1/16" (25X 1.5 mm) 51 to 75 6 SWG 25sq.mm | IX 1/16" (25X 1.5 mm) 7510 100 6SNG 35.sq.inm | 1°X 1/8" (25X 3mm) | 101 0 125 4 SNG 50sq.mm } 1"X 1/4" (25X 6 mm) | 126 to 150 IX 116"(25X 1.5mm) | 70sq.mm 1" K 1/4" (25 X 6 mm) 151 to 200 1" 1/16"(25XK 1.5mm) } 70sq.mm 1 1/2" X 1/4" (40 X Smm) [ 201 and above | 1"X1/8"(25X 3mm) | 185sq.mm | 2"X 1/4" (50X 6 mm) 4 Transformer Neutral Point Earthing - Size of Earth Lead Transformer | Electrolytic Bare Copper | Insulated (PVC) | Galvanized Iron Conductor Rating Conductor or Strip Single Core OrStip - Standard AL. 50 KVA and below BSG 16 sq. mm 1" 1/8" (25X 3 mm) 7S KVA 6 SWG 25 sq. mm 1%" X 1/4" (40X 6 mm) 100 KVA 4 SUG 35sq.mm | 1 %"X 1/4" (40X 6 mm) 150 KVA 2SWGor 1" 1/16" 7Osq.mm | 1 %"X 1/4" (40X 6 mm) (25X 1.5mm) 200 KVA. 1"X 1/8" (25 X 3 mm) 95 sq. mm 1%" 1/4" (40 X 6 mm) 250 KVA, 1" K 1/8" (25 X 3 mm) 150 sq. mm 1%" 1/4" (40 X 6 mm) 300 KVA 1X 1/8" (25X 3mm) | 225sq.mm | 1 %"X 1/4" (40X 6 mm) 500 KVA 1X 1/4" (25X 6mm) | 300sq.mm | 2°X 1/4" (40X 6 mm) TSOKVA | 1X 1/4"(40X6 mm) | 2X 225sq. mm | Above 500 KVA only or copper or AL. Strip to be 1X 500 sqimm used | 800 KVA 40X6mm 1000 KVA 50X 6mm 1250 KVA 0X6 mm _ _ 1600 KVA 80X6mm | (or 50 X 10 mm) 2000 KVA 60% 10 ren 2500KVA | 75% 10mmAgs — AB SWITCH oT — pRPoUT FUSE LA ~ LIGHTNING ARRESTER u u T AcR — LT ARR CIRCUIT BREAKER IR — TRANSFORMER 8 sine CONSUMER'S SIOE INSTALL AT PONT OF SUPPLY 'SUB-STATION AWAY FROM POINT OF SUPPL’ — eee Ob eee jg FP wan av. ss poo joel | | | | ra | ~ pep a a JP oo QD pees (KV SYSTEM) LATIONS WITH INSTALLED TRANSFORMER CAPACITY UPTO AND INCLUSIVE OF 1090KVA x6 iSSNo. 10, Ret. Code No. 1: 3043 IS: 1886 Is:2274 18: 732 (Part | tol} 1s: 900 Is:5124 15: 3072 (Part-I) 1S: 4648 19: 722 (Part |) IS: 1248 (Part It) 521554 (Part) (5: 1897 152026 (Par |) 182551 XIll — Important IS Specifications Year of Publication 1987 1967 1963 1965 1965 1969 1965 1968 1986 2003 1988 1983 1977 1982 Description Code of practice for earthing. Code of practice for installation and maintenance of transformers. Code of practice for electrical wiring installations (System voltage 650 Volts). Code of practice for electrical wiring installation, Code of practice for instalation and maintenance of induction motors. Cade of practice for installation and maintenanc= of AC Induction motors starters(Vltage not excee dng 1000¥). Code of practice for installation and maintenarice of switchgear. Cede of practice for electrical layout in resicentil buildings. Code of practice for AC electricity meters. | Code of practice for direct acting indicating {analog clectical measuring instruments and their accessories — Ammeter and Volimeter. Code of practice for PVC insulated (Heavy duty) electric cables for working voltage up to and including 1100¥. Code of practice for Copper strip for electrical ‘purposes. | Code of practice for power transformers. Code of practice for danger notice plates.20, 24, 2. Rel. Code No. 15: 2705 (Part to 1) 15: 3156 (Part |&ll) 1524794 {Part i) 1s 15082 18: 5578 Is : 8623 (Part to tt) is:tni71 iS: 11353 IS: 12063 IS: 13703 (Part) 1S: 13947 (Part |to V) Year of Publication 1992 i992 1968 1998 1984 1993 1985 1985 1987 1993 1993 Description Code of practice for current transforiners Code of practice for voltage transformers. Code of practice for pushbutton switches. Code of practice for wrought aluminium and aluminium alloy busbars, rods, tubes and sections for electrical purposes. Code of practice for Guide for making of insulated conductors. Code of practice for low voltage switchgear and Controlgear and assemblies. Code of practice for dry type power transformer. Code of practice for quid for uniform system of ‘making and identification of apparatus terminals, Code of practice for degree of protection provided by ‘enclosures of electrical equipment. Code of practice for specification for low voltage fuses for voltages not exceeding 1000V AC or 1500V DC Code of practice for low voltage switchgear and controlgear. Xl - 2. ©