E402 Electrical System Design and

Estimation

Module-4
 Industrial Installations

1. More sophisticated installation

2. Take care of diverse load requirement in economic manner

3.Preserving safety and reliability with electrical installations

4.Easiness of maintenance and fault location features

5.Energy conservation
 Classification of Industrial Buildings

(A) Fire hazard

(B) Power Consumption

(C) Pollution hazard

 (A) Classification based on fire hazard
(i) Group G1- Building used for low fire hazard
industries

Operation/process conducted in those

buildings, there are no possibilities of self
propagation of fire to occur. Only effect of fire
from external sources.

E:g; Cement factories, Glass factory, Rice mill,

Soap and detergent factory etc.
(ii) Group G2- Building of moderate fire hazard
In this type, operation/process are liable
to give rise to fire that will burn with
moderate rapidity, produce considerable
volume of smoke or non-toxic fumes and will
not result in an explosion

E:g; Ship repairing docks, coir industry,

chemical manufacturing, flour mill etc
(iii) Group G3- Buildings with high fire hazard
In this type, operations/ process are
liable to give rise to a fire which will burn
with extreme rapidity, generate poisonous
fumes, lead to explosions.

E:g; Alcohol distilleries, explosive

manufacturing, fire work industries, oil
mill, petrochemical
 (B) Classification based on power consumption

(i) Light industries(Small)

(ii) Average industries (medium)

(iii) Heavy industries

Description Average power requirement Examples

Light industry Up to 50 kVA Hosiery, garment making,

ornament making etc

Average Industry above 50 up to 2000kVA Furniture pottery, glass,

tobaco, electrical gadgets,
textiles, engine fitting, light processing etc.

Heavy industry above 2000kVA Heavy electrical quipment,

steel mills, foundaries, ship building,
chemical plants, fertilizer plants, metal
extraction, petrochemicals, paper
mills etc.
 (C ) Classification based on pollution level
(i) Pollution degree 1
No pollution or only dry, non conductive
pollution occurs. The pollution has no
influence

(ii) Pollution degree 2

Only non-conductive pollution occurs
except that occasionally a tempory
conductivity caused by condensation is to be
expected.
(iii) Pollution degree 3
Conductive pollution occurs or dry non-
conductive pollution occurs which becomes
conductive due to condensation

(iv) Pollution degree 4

Continuous conductivity occurs due to
conductive dust, rain or other wet conditions.
 Power distribution architecture of Industrial
Installation-Factors considering
1. Activity
2. Site topology
3. Layout latitude
4. Service reliability
5. Maintainability
6. Installation flexibility
7. Power interruption sensitivity
8. Disturbance sensitivity
1.Activity- The type of activity carried out in
the building. i.e; whether manufacturing,
food processing, logistics etc.
2. Site topology- Here consider the number
of buildings, number of floors in each
building, floor area. E.g; single storey or
multistorey or highrise buildings
3. Layout Latitude-Consider constraints in
terms of the layout of electrical equipment
in the buildings
Some parameters
 Aesthetics
 Presence of dedicated location
 Use of technical corridor(horizontal service
duct) per floor
 Use of technical service duct(vertical)

Three layout categories

Low- The layout latitude is low when the positions

of the electrical equipments are virtually imposed
on the building and cannot be changed to achieve
above said parameters
Medium- There is some flexibility in positioning the
electrical equipments.

High- Layout latitude is high if there is no constraints

in positioning the electrical equipment in the building
to satisfy the parameter mentioned above.

(4) Service reliability-

It is defined as the ability of the power supply
system to meet the supply function under
stated conditions for a specified period of time.
There are 3 categories of service reliability
(a) Minimum service reliability
(b) standard
(c) Enhanced service reliability

Service reliability will be minimum if the

installation is subjected to interruption related to
geographical(positioning of buildings with reference
to power production centre), technical(Power supply
through OH or UG or Ring system),
economic(Maintenance aspects)
Service reliability can be enhanced by taking
measures to reduce the power consumption
(5) Maintainability-During design stages
to limit the impact of maintenance on
the operation of the whole or part of the
installation.
Maintenance activity can be carried out
without disturbing the operation of the
production
(6) Installation flexibility
This is the possibility of easily moving of
power delivery points within the installation or
the facility to increase the power availability at
certain points.
• Non-flexible
• Design flexibility
• Implementation flexibility
• Operation flexibility
(7) Power interruption sensitivity
This is the capability of the process or system to
accept interruptions.
Sheddable loads-Possible to shut down a portion
of the load at any time
Long interruption acceptable loads-Accepting
interruption for more than 3 minutes
Short interruption acceptable-Accepting
interruption less than 3 minutes
No interruption acceptable- Power interruption
cannot be accepted
(8) Disturbance sensitivity- It is the ability of an
industry to work properly in the presence of
disturbance(over voltage, voltage distortion due
to harmonics, voltage fluctuations, voltage
unbalance).
It is classified as
Low sensitivity-very little effect on the
operation(e;g; heating devices
Medium sensitivity- a notable deterioration in the
operation (e;g; induction motors, lighting loads)
High sensitivity- stoppage of operation(e;g; IT
equipment, sensitive instrument)
 Selection of Transformer Substation
 Consider economy of operation
 Technical suitability
 Cost
 Long term gains
 Transportation constraints
 Handling facilities
 Availability of supporting switchgear
Factors deciding selection of transformers
• Maximum demand

• Future expansion

• Spare capacity

• Statutory requirements

• Site condition
Standard rating of Distribution Transformers (11/0.433kV)-
50,63,80,100,160,200,250,315,400,500,630,800,1000,1250,
1600 and 2000kVA
Cooling- Oil Natural Air Natural(ONAN), Oil Natural Air
Forced(ONAF),
Parallel operation of transformers- A pair of transformer is
said to be parallel if they are connected in parallel on at
least two sides for meeting higher loads
Condition for parallel operation
• Same vector group
• Turns ratios should be similar
• Same % impedance voltage
• Ratio of the rated capacities of the transformers shall not
be more than 3:1
Typical single line layout of Transformer Substation and Main Switch
Board(MSB)
Types of 11kV Substations

Consider distribution

1.Outdoor Substation
(i) Pole mounted outdoor substation
(ii) Floor mounted outdoor substation

2.Indoor type-Floor mounted

(i) With Oil filled transformer
(ii) With dry type transformer
Outdoor Substation
2 Pole Substation with Transformer
• H-pole structure, base channel of
100mmx50mm size
• Erected at a height of 2.44m from ground level
• 11kV Lightning arrestors(3 numbers) are
erected at the top
• Earth terminals of all 3 LAs are joined together
and connected to earth
• The 11kV gang operated switch( Air Break
switch) installed below the 11kV conductor
taps the 11kV supply to the transformer
• Operating handle located on one pole of the
structure 1.25m from ground
• 11kV horn gap(HG) fuses, installed below the
gang operating switch
• On LT side 3.5 core LT cables are used, LT
cables are selected according to capacity of
transformer
• Connecting jumpers from the 11kV line to the
G O switch, from the G O to HG fuse , and
from the fuse unit to transformer bushing,
covered with empire tape or polythene pipe
for safety
 11 kV LA
• Lightning
protection
• One side of three of
the LAs earthed for
surge bypassing
11kV Air Break Switch
AB Switch
HORN GAP FUSE is a protective device used to protect the
equipment from higher voltage, horn gap fuse is a thin wire
element compared to load line when a high current is drawn
from the line, fuse wire melts and protects the equipment
 11kV Drop Out (DO) Fuse
• Protection fuse
• Fuse breakage easily
detected
• Easy refusing from
ground
Indoor Substation
 11 kV/415V are frequently used
 HT and LT switchgear and cable trench for
incoming and outgoing cables
 Adequate clearance between walls and
equipment to ensure safety
 Adequate ventilation
 The supply from the OH line is brought inside
the substation through UG cable using an
outdoor cable box
 The secondary terminal is to be connected to
an LT CB or switch fuse unit using 3.5 core LT
cable
 For current upto 300A switch fuse unit are
used
 For metering PTs & CTs are installed at HT side
and measure Maximum demand, PF etc
 Two separate distinct earth electrode shall be
provided for neutral earthing, body earthing
and lightning arrester earthing.
 Tutorial
• Design a Pole Mounted 11kV/415V substation
with a 100KVA Transformer used for Consumer
Power Distribution
– No need of Energy Meter
– TRF will be mounted on the 2 Pole Structure
– No need of Power Cables, as bare conductors are
used for interconnections
– Currents: 5.25A(11KV), 133.3A (415V)
100KVA Distribution Transformer on a Two
Pole Structure
 Selection of Cables
• Copper conductor cable only will be used for submain/ circuit/ point
wiring.
• Minimum
• Lightsize of wiring:
Wiring (Lamp, Fan, 6A Socket) : 1.5 sq. mm.
• Power Wiring(16A or 20A Socket) : 2.5 or 4.0 sq. mm.
• Power circuit rated more than 1 KW : Size as per calculation based on Voltage drop
* (Refer Tutorial for more details)

• Insulation : Copper conductor cable shall be PVC insulated conforming to BIS

Specification.

The permitted voltage drop for any given equipment from the control switch is 3%
for LT-AC system. The conductor size need to be increased if the voltage drop
exceeds this value. Voltage drop along a conductor mainly depends on current
flowing through it and the length and cross sectional area of the conductor
 High Current Cables used for LT System

• Used to transfer power between

– KSEB supply (11kV) to step-down Transformer
– Transformer to Main Switch Board (MSB)
• Usually aluminium (Al) conductor used
– lower cost, here conductor area is much higher due to high current flow
• Insulation materials
– Conductor insulation - PVC or XLPE (Cross Linked Poly Ethylene) - Seen in Red, Yellow or Blue Color
– Outer Insulation – PVC for water proofing
• Size selection based on current flowing and manufacturer derating charts
Cable Coding System (IS 7098)

• Components listed from inner core

to outer sheath

• AYFY – Al cable, PVC insulated, Steel

strip armour, PVC outer sheath

• A2XFY - Aluminum cable, XLPE

insulated, , Steel strip armour and
having PVC outer Sheath

• YWY - Copper cable, PVC insulated,

Steel round wire armour, PVC outer
Sheath
Cable Coding System
• Calculation of
– Ampacity: Current rating and deration based from cable data sheet
– Voltage drop: Based on cable impedance/km and load current
based – from cable data sheet
– SC rating: From fault current calculation and cable data sheet
Material Load Current Fault Current
Density Permitted Density
(A) Permitted (A)

Copper 1.2 A/mm2 120

Aluminium 0.8 A/mm2 80
GI 0.48 A/mm2 48
 Armoured Power Cable - Parts
• Conductor material – Copper or Aluminum
– Cu cable is smaller in thickness
– Al cable is cheaper

• Inner insulation material – Paper, PVC or XLPE

• XLPE is a better insulator than PVC and Paper
– Higher current rating
– Higher SC rating
– Higher operating temp
– Higher insulation rating and life

• Mechanical Protection Sheath – GI strip

– always grounded

• PVC is water and chemical resistant, hence used for outer

protection
– Black color used
 Earth wire sizes - Standard Wire Gauge (SWG)
• Uninsulated Copper conductor is
used as the earth wire Each number
• Higher current will heat the represents a size of
cable and damage the insulation wire
and may result in short circuit
• Design 500KVA, 11kV/415V transformer substation
used for power supply to a medium industry
– Assume the Transformer as Indoor Oil Filled Type
1. TRF Current Ratings: 26.2A/666.5A (Ref. Table 31 of DB)
2. DO Fuse: 50A (Refer Table-34 of DB)
3. HT Cable: 3 Core, 150mm3, XLPE (From NEC)
4. HT CB: Load Break Switch (LBS) with Trip at 26A
5. LT Cable: 3 Runs of 3.5Core 400mm2 AYFY Cable(Refer
Table-34, 54 of DB)
6. LT ACB: 800A with Over Current Trip set at 666A (Refer
Table-108 or 109 for MCB or 110 for ACB)
7. Busbar Sizing
• Permitted Current Density of Aluminium = 0.8A/mm2
• Busbar Area = 666A/(0.8A/mm2) = 833mm2
• Busbar Size: Single Bar of 76mm X 6mm Aluminium (Refer Table 38A
of DB)
• Design 100KVA to 630KVA , 11kV/415V transformer
substation used for power supply to a medium industry
– Assume the Transformer as Indoor Oil Filled Type
1. TRF Current Ratings: (Ref. Table 31 of DB)
2. DO FuseRating: (Refer Table-34 of DB)
3. HT Cable: 3 Core, 150mm3, XLPE (From NEC)
4. HT CB: Load Break Switch (LBS) with Trip at ---A
5. LT Cable: 3 Runs of 3.5Core ----mm2 AYFY Cable(Refer Table-
34, 54 of DB)
6. LT MCCB or ACB: ----A with Over Current Trip set at ---A
(Refer Table-108 or 109 for MCB or 110 for ACB)
7. Busbar Sizing
• Permitted Current Density of Aluminium = 0.8A/mm2
• Busbar Area = ---A/(0.8A/mm2) = ---mm2
• Busbar Size: Single Bar of --mm X --mm Aluminium (Refer Table 38A
of DB)
 Installation of transformer substation
Outdoor type
 Minimum clearance between suppliers and
consumers 11kV structure shall be 3m
 Phase to phase clearance 915mm and phase to
earth 610mm
 Minimum safety clearance of 2.6m between bare
conductor and live parts
 Lightning arrestors –between AB(Air Break)
Switch and D.O(drop out) Fuse
 AB switch operating handle- 1m to 1.25m from
ground level
 11kV AB switches shall be three insulators types
Indoor Type
Recommended for rating above 630kVA
 Only dry type
 In case of oil indoor type
 free access for fire engines to the transformer
stations
 Minimum clearance of 1.5m from building
 substation building shall be weatherproof and
fireproof, walls of 355mm thick brick or
230mm thick RCC
 AB switch fuse unit/ VCB shall be provided on
the primary side
 Minimum size of cable on 11kV side -150 sq.mm
XLPE
 Fire separation walls shall be provided in
between oil filled transformers
 Oil drainage facility/soak pits shall be insisted for
oil type
 All round clearance shall be provided- minimum
1.25m if wall are provided at four sides
 Adequate ventilation easy access
 Doors and windows of transformer room –non
flammable material
 Minimum 50cm headroom clearance
 Minimum phase to phase 130mm and phase to
ground 80mm clearance of busbars in 11kV
panel
 Selection of Switchgears
Basic Functions
• Electrical protection( Overload, short circuits,
insulation failure)
• Electrical isolation of a section of the
installation( a gap interposed insulating
barrier between the open contacts)
• Local or remote switching( functional,
emergency switching, emergency stopping,
switching off for maintenance)
Electrical Protection
Protection of circuit elements( against overloading,
provided by fuse or CB)
Protection of persons and livestock( due to insulation
failure, protection through fuses, CBs, ELCB or RCCB)
Protection of equipment (against overheating , single
phasing, protection through thermal relay)
Electrical isolation- Separate a circuit or equipment
from other installation to carry out work. In the
isolation neutral pole must be opened, provided with
mechanical locking, comply with national standards,
visual indication complete opening of contacts
Switching control
Functional control-Includes all switching operations
during normal conditions for energizing and de-
energizing of a part of a system or installation or
equipment
Emergency control- It is a built in facility to de-energise a
live circuit which could be dangerous to person and
property. Provide large red mushroom headed
emergency stop button, single action guarantee complete
switching off.
Maintenance operation-To enable maintenance work,
stopping or disconnect a piece of equipment or circuit
 Switching Devices
1.Isolators-Manually operated ON/OFF switch with
provision for locking and provides safe operation.
Cannot operated under loaded condition
2.Load break switch-Design for operation on
loaded circuit, under normal operating condition.
Non-automatic ON/OFF switching device
3.Contactors-It is a solenoid operated switch which
is held closed by a current through a solenoid
coil.
4.Discontactors-A contactor equipped with a
thermal relay for protection against over current
is defined as a discontactors. It is not a CB
5.Changeover switches-Wide application in
situations when the reliability of electrical supply
from utility is low and are used in
lighting/industrial applications wherever continuity
of supply is necessary. ON load as well as OFF load
available
6.Automatic transfer switch (ATS)-Automatic
transfer of power. By using Automatic Main
Failure(AMF) system. It is self acting equipment
containing the transfer switching devices and other
accessories for monitoring the supply sources and
for transferring load circuit from one supply to
another.
Material Load Current Fault Current
Density Permitted Density
(A) Permitted (A)

Copper 1.2 A/mm2 120

Aluminium 0.8 A/mm2 80
GI 0.48 A/mm2 48
INDUCTION MOTOR FEEDER DESIGN
IM Feeder Components
1. MCCB in MSB or PDB (Power Distribution
Board)
2. 3.5 Core Cable form MSB to Motor Location
3. Starter near the IM (DOL, SD, VFD Drive)
1. Up to 1HP: DOL Starting
2. 1HP to 10HP: Star Delta Starting
3. Above 10HP: Soft Starting using Power Electronic
drive
4. Induction Motor
5. Body Earthing of IM at 2 points
Q. Design a feeder for installing
a 40HP induction motor in an
industry
From the data book (Refer Table 28 on Page 21)

• Full load current of 40HP motor = 55A

• Cable size = 35mm2
• CB rating = 100A approx.
• Earthing conductor = 6SWG Copper
 
SOLUTION
• MCB or MCCB
• Use 100A MCCB with 100A setting
• Cable: 3.5 Core 35mm2 AYFY Cable
• Starter: Soft Starter with VFD operation type
as the motor is 40HP
• Safety earthing from two points on motor
body using 6 SWG Copper strip.
Selective Coordination: Page 194 – 195

MSB: 100A, 63A, 40A, 26A, 16A

SSB: 63A, 40A, 26A, 16A

DB: 26A, Lowest Tripping Time

(Fault)
• MV Switch Boards Page: 214
• Diesel Generator Set, Change over Switch:
Page 185-186
• Automatic Transfer Switch
(ATS)
 Cable Voltage Drop Calculation
• Single Phase Loads
• Max V Drop: 3% from DB to Load
• PF=0.8 assumed

• VD = 2(i*R*l) Volts R- resistane/m of Cable

• % VD = V*100/VD %
 Cable Voltage Drop Calculation
• 3 Phase System
• Assume Balanced, PF = 0.8, Calculate I, r

• VD = (i*r*l) Volts
• % VD = (V*100)/ VD %

• ‘r’ Values?? (DBook, AYFY Al: Page- 49, 50)

Thank You