INDUSTRIAL CUSTOMER NO.

1-5
INDOOR TYPE SUBSTATIONS
 DESIGN OF INDUSTRIAL CUSTOMER REQUIRING INDOOR TYPE SUBSTATION

PLANT NO. 1

Lighting Load- 50 KW, 3-Ø, 230 volts

Demand Factor- 70%

Motor Load- 209 KW, 3-Ø,230 volts

Demand Factor- 80%

Average Power Factor- 88%

Diversity Factor- 102%

I. DISTRIBUTION TRANSFORMER RATING

SINCE,

Maximum Demand
Demand Factor =
Connected Load

Diversity Factor=
∑ MD ' s
SIMD
Where:
∑ MD ' s= MD + MDML
LL

Thus,
MDLL= (Lighing Load)(Demand Factor) = 50KW(.7) = 35KW
MDML= (Motor Load)(Demand Factor) = 209KW(.8) = 167.2 KW

Therefore,

∑ MD ' s= 35KW + 167.2 KW= 202.2KW

Hence,
 ∑ MD ' s 202.2 KW
SIMD= = = 198. 235 KW
Diversity Factor 102 %

Thus,

SIMD 198.235 KW
KVAT= = = 225.267KVA
Ave . Power Factor .88
KVAREF= 1.25(KVAT)= 1.25(225.267KVA) = 281.584KVA

Using 3 1- Ø Units:

281.584 KVA
KVAREF= = 93.861 KVA
3

Therefore use 3 pcs. O 100 KVA 1- Ø D.T.

Using of a single 3- Ø Unit:

KVAREF= 281.584KVA

Therefore use 1 pc. Of a 300 KVA 3- Ø D.T.

II. Size of Secondary Feeder

21.4 I d '
Circular Mill=
Safe DCVD

Where: d’= 540 ft.

I= KVAT/ √3 Vs = 225.267*103/√3 (230) = 565.469 A

Since,

3% .03
Safe DCVD= (Vs) = (230V) = 4.6V
150 % 1.5

Thus,

21.4 I d ' 21.4(565.469)(540)

Circular Mill= = = 1,420,556.47 Cir-Mil
Safe DCVD 4.6
Therefore:

Minimum Recommended Rating:

Use 3 pcs of 1,500,000 Circular Mills Copper Conductor

Use 1 pc of 750,000 Circular Mills Copper Conductor for neutral wire.

21.4 I d ' 21.4(565.469)(540)

Actual ACVD= = = 4.356V
ACTUAL CIR−MIL 1500000

Actual ACVD= 150% of Actual ACVD

= 1.5(4.356)

=6.534V

Thus,

ACTUAL ACVD
%VD= x 100
Vs

6.534
%VD= x 100=2.84%
230

Since, 2.84%< 3%, THE WIRE CAN SAFELY CARRY THE REQUIRED LOAD.
 DESIGN OF INDUSTRIAL CUSTOMER REQUIRING INDOOR TYPE SUBSTATION

PLANT NO. 2

Lighting Load- 80 KW, 3-Ø, 230 volts

Demand Factor- 84%

Motor Load- 269 KW, 3-Ø,230 volts

Demand Factor- 84%

Average Power Factor- 83%

Diversity Factor- 110%

I. DISTRIBUTION TRANSFORMER RATING

SINCE,
Maximum Demand
Demand Factor =
Connected Load

Diversity Factor=
∑ MD ' s
SIMD
Where:
∑ MD ' s= MD + MDML
LL

Thus,
MDLL= (Lighting Load)(Demand Factor) =80 KW(.84) = 67.2KW
MDML= (Motor Load)(Demand Factor) = 268KW(.84) = 225.96 KW
 Therefore,

∑ MD ' s=67.2 KW +225.96 KW= 293.16 KW

Hence,

∑ MD ' s 293.16 KW
SIMD= = = 266.509 KW
Diversity Factor 110%

Thus,

SIMD 266.509 KW
KVAT= = = 321.095 KVA
Ave . Power Factor .83
KVAREF= 1.25(KVAT)= 1.25(321.095 KVA) = 401.368 KW

401.368 KVA
KVAREF= = 133.789 KVA
3
USE 3-PCS 167.5 KVA, 1-Ø, DISTRIBUTION TRANSFORMER.

Using of a single 3- Ø Unit:

KVAREF= 401.369 KVA

Therefore use 1 pc. Of a 500 KVA 3- Ø D.T.

II. Size of Secondary Feeder

21.4 I d '
Circular Mill=
Safe DCVD

Where: d’= 540 ft.

I= KVAT/ √3 Vs = 321.095*103/√3 (230) = 806.019 A

Since,

3% .03
Safe DCVD= (Vs) = (230V) = 4.6V
150 % 1.5

Thus,
 21.4 I d ' 21.4(806.019)(540)
Circular Mill= = = 2,024,859.905 Cir-Mil
Safe DCVD 4.6

Therefore:

Minimum Recommended Rating:

Use 3 pcs of 2,125,000 Circular Mills Copper Conductor

Use 1 pc of 1,125,000 Circular Mills Copper Conductor for neutral wire.

21.4 I d ' 21.4(806.019)(540)

Actual ACVD= = = 4.1397V
ACTUAL CIR−MIL 2250000

Actual ACVD= 150% of Actual ACVD

= 1.5(4.1397)

=6.2096V

Thus,

ACTUAL ACVD
%VD= x 100
Vs

6.2096
%VD= x 100=2.70%
230

Since, 2.70%< 3%, THE WIRE CAN SAFELY CARRY THE REQUIRED LOAD.
 DESIGN OF INDUSTRIAL CUSTOMER REQUIRING INDOOR TYPE SUBSTATION

PLANT NO. 3

Lighting Load- 90 KW, 3-Ø, 230 volts

Demand Factor- 82%

Motor Load- 169 KW, 3-Ø,230 volts

Demand Factor- 84%

Average Power Factor- 84%

Diversity Factor- 120%

I. DISTRIBUTION TRANSFORMER RATING

SINCE,
Maximum Demand
Demand Factor =
Connected Load

Diversity Factor=
∑ MD ' s
SIMD
Where:
∑ MD ' s= MD + MDML
LL

Thus,
 MDLL= (Lighing Load)(Demand Factor) = 90KW(.82) = 73.8KW
MDML= (Motor Load)(Demand Factor) = 169KW(.84) = 141.96 KW

Therefore,

∑ MD ' s= 73.8KW + 141.96 KW= 215.76 KW

Hence,

∑ MD ' s 215.76 KW
SIMD= = = 179.8 KW
Diversity Factor 120 %

Thus,

SIMD 179.8 KW
KVAT= = = 214.048 KVA
Ave . Power Factor .84

KVAREF= 1.25(KVAT)= 1.25(214.048 KVA) = 214.048 KW

Using 3 1- Ø Units:

214.048 KVA
KVAREF= = 267.56 KVA
3

Therefore use 3 pcs. O 100 KVA 1- Ø D.T.

Using of a single 3- Ø Unit:

KVAREF= 214.048 KW
Therefore use 1 pc. Of a 300 KVA 3- Ø D.T.

II. Size of Secondary Feeder

21.4 I d '
Circular Mill=
Safe DCVD

Where: d’= 540 ft.

I= KVAT/ √3 Vs = 214.048*103/√3 (230) = 537.037 A

Since,

3% .03
Safe DCVD= (Vs) = (230V) = 4.6V
150 % 1.5

Thus,

21.4 I d ' 21.4(537.037)(540)

Circular Mill= = = 1,349,808.629 Cir-Mil
Safe DCVD 4.6

Therefore:

Minimum Recommended Rating:

Use 3 pcs of 1,500,000 Circular Mills Copper Conductor

Use 1 pc of 750,000 Circular Mills Copper Conductor for neutral wire.

21.4 I d ' 21.4(537.307)(540)

Actual ACVD= = = 4.139V
ACTUAL CIR−MIL 1500000

Actual ACVD= 150% of Actual ACVD

= 1.5(4.139)

=6.209V

Thus,

ACTUAL ACVD
%VD= x 100
Vs

6.209
%VD= x 100=2.70%
230

Since, 2.70%< 3%, THE WIRE CAN SAFELY CARRY THE REQUIRED LOAD.
 DESIGN OF INDUSTRIAL CUSTOMER REQUIRING INDOOR TYPE SUBSTATION

PLANT NO. 4

Lighting Load- 59 KW, 3-Ø, 230 volts

Demand Factor- 82%

Motor Load-159 KW, 3-Ø,230 volts

Demand Factor- 83%

Average Power Factor- 28%

Diversity Factor- 101%

I. DISTRIBUTION TRANSFORMER RATING

SINCE,
Maximum Demand
Demand Factor =
Connected Load
 Diversity Factor=
∑ MD ' s
SIMD
Where:
∑ MD ' s= MD + MDML
LL

Thus,
MDLL= (Lighing Load)(Demand Factor) = 90KW(.82) = 73.8KW
MDML= (Motor Load)(Demand Factor) = 159KW(.83) = 131.97 KW

Therefore,

∑ MD ' s= 73.8KW + 131.97 KW= 205.77 KW

Hence,

∑ MD ' s 205.77 KW
SIMD= = = 203.733 KW
Diversity Factor 101 %

Thus,

SIMD 203.733 KW
KVAT= = = 248.455 KVA
Ave . Power Factor .82
KVAREF= 1.25(KVAT)= 1.25(248.455 KVA) = 310.569 KVA
Using 3 1- Ø Units:

310.569 KVA
KVAREF= = 103.522 KVA
3

USE 3-PCS 125 KVA, 1-Ø, DISTRIBUTION TRANSFORMER..

Using of a single 3- Ø Unit:

KVAREF= 310.569 KVA

 II. USE 1-PC OF 500 KVA, 3-Ø, DISTRIBUTION TRANSFORMER
III. Size of Secondary Feeder
21.4 I d '
Circular Mill=
Safe DCVD

Where: d’= 540 ft.

I= KVAT/ √3 Vs = 248.455*103/√3 (230) = 623.676 A

Since,

3% .03
Safe DCVD= (Vs) = (230V) = 4.6V
150 % 1.5

Thus,

21.4 I d ' 21.4(623.676)(540)

Circular Mill= = = 1,566,782.577 Cir-Mil
Safe DCVD 4.6

Therefore:

Minimum Recommended Rating:

Use 3 pcs of 1,750,000 Circular Mills Copper Conductor

Use 1 pc of 875,000 Circular Mills Copper Conductor for neutral wire.

21.4 I d ' 21.4(623.676)(540)

Actual ACVD= = = 4.118 V
ACTUAL CIR−MIL 1750000

Actual ACVD= 150% of Actual ACVD

= 1.5(4.118)

=6.177 V

Thus,
 ACTUAL ACVD
%VD= x 100
Vs

6.177
%VD= x 100=2.69%
230

Since, 2.69%< 3%, THE WIRE CAN SAFELY CARRY THE REQUIRED LOAD.

DESIGN OF INDUSTRIAL CUSTOMER REQUIRING INDOOR TYPE SUBSTATION

PLANT NO. 5

Lighting Load- 90 KW, 3-Ø, 230 volts

Demand Factor- 82%

Motor Load- 149 KW, 3-Ø,230 volts

Demand Factor- 83%

Average Power Factor- 86%

Diversity Factor- 109%

I. DISTRIBUTION TRANSFORMER RATING

 SINCE,
Maximum Demand
Demand Factor =
Connected Load

Diversity Factor=
∑ MD ' s
SIMD
Where:
∑ MD ' s= MD + MDML
LL

Thus,
MDLL= (Lighing Load)(Demand Factor) = 90KW(.82) = 73.8KW
MDML= (Motor Load)(Demand Factor) = 149KW(.83) = 123.67 KW

Therefore,

∑ MD ' s= 73.8 KW + 123.67 KW= 197.47 KW

Hence,

∑ MD ' s 197.47 KW
SIMD= = = 181.165 KW
Diversity Factor 109 %

Thus,

SIMD 181.165 KW
KVAT= = = 210.657 KVA
Ave . Power Factor .86
KVAREF= 1.25(KVAT)= 1.25(210.657 KVA) = 263.321 KVA

Using 3 1- Ø Units:

263.321 KVA
KVAREF= = 87.774 KVA
3

Therefore use 3 pcs. O 100 KVA 1- Ø D.T.

Using of a single 3- Ø Unit:

 KVAREF= 263.321 KVA

Therefore use 1 pc. Of a 300 KVA 3- Ø D.T.

II. Size of Secondary Feeder

21.4 I d '
Circular Mill=
Safe DCVD

Where: d’= 540 ft.

I= KVAT/ √3 Vs = 210.657*103/√3 (230) = 528.795 A

Since,

3% .03
Safe DCVD= (Vs) = (230V) = 4.6V
150 % 1.5

Thus,

21.4 I d ' 21.4(528.795)(540)

Circular Mill= = = 1,328,425.004 Cir-Mil
Safe DCVD 4.6

Therefore:

Minimum Recommended Rating:

Use 3 pcs of 1,500,000 Circular Mills Copper Conductor

Use 1 pc of 750,000 Circular Mills Copper Conductor for neutral wire.

21.4 I d ' 21.4(528.795)(540)

Actual ACVD= = = 4.074V
ACTUAL CIR−MIL 1500000

Actual ACVD= 150% of Actual ACVD

= 1.5(4.074)

=6.111V
Thus,

ACTUAL ACVD
%VD= x 100
Vs

6.111
%VD= x 100= 2.66%
230

Since, 2.66%< 3%, THE WIRE CAN SAFELY CARRY THE REQUIRED LOAD.

SIZE OF PRIMARY FEEDER FOR PLANT 1 TO 5

ANGLE OF PLANT 1= cos-1 0.88 = 28.358o
ANGLE OF PLANT 2= cos-1 0.83 = 33.901o
ANGLE OF PLANT 3= cos-1 0.84 = 32.860o
ANGLE OF PLANT 4= cos-1 0.82 = 34.915o
ANGLE OF PLANT 5= cos-1 0.86 = 30.683o
Thus,
KVAT= KVA1+ KVA2 +KVA3+ KVA4+ KVA5
=3(100)<28.358o+3(167.5)<33.901o+3(75)<32.860o
+3(125)<34.915o+3(100)<30.683o
KVAT= 1701.079<32.443 KVA
Since,
21.4 I d '
Circular Mill=
Safe DCVD

Where,

d’= 5(140)= 700 ft

I= KVAT/ √3 Vp = 1701.079*103/√3 (7620)= 128.887 A

Also,

5% .05
Safe DCVD= (VP) = (7620V) = 254 V
150 % 1.5

Thus,

21.4(128.887)(700)
Circular Mill= =7,601.288 cir-mil
254

Therefore,

Use 3 pcs of 16,510 CM(AWG NO.8) of copper conductor

Using Method 2:

Actual ACVD=
√3 I d ' [Ra cos θ +Xt sin θ]
5280
Where,

cos θ = cos(32.346)=0.844
 sin θ = sin (32.346)=0.536
From wire table
Ra= 3.79 Ω/mi
Xa=.665 Ω/mi

GMD = √3 (44)(44 )(88) = 55.437

55 .185
55.437 xd
56 .187

Xd= 0.187-((0.187-0.185)*(56-55.437)/(56-55))
Xd = 0.186Ω/mi
XT= Xa+Xd= 0.665+0.186 = 0.851 Ω/mi

Thus,

Actual ACVD=
√ 3 (128.887)( 700) [(3.79) (0.844) + (0.851)(0.536)]
5280
ACTUAL ACVD= 108.171 V
Therefore,
%VD = (108.171 Volts / 7620 Volts)*100 = 1.42%
1.42 % is less than the Allowable Voltage Drop of 5.00%. Therefore,
load is SAFE!

Using Method 3:

Using IEEE Exact Voltage Drop Formula

VD= V + I R cos θ + I X sin θ - √(V2 -(I X cos θ - I R sin θ)2))

Since, Rt=3.79(700)/5280= 0.502 Ω
 Xt= 0.851(700)/5280= .113 Ω
Thus,
VD= 7.62*10^3+(128.887*0.502*0.844)+(128.887*0.113*0.536)-
√7.62*10^3-(128.887*0.113*0.844)-(128.887 *0.502*0.536) 2
VD= 62.472 Volts
Actual ACVD = 62.472 * √3 = 108.205 Volts
%VD = 108.205 / 7.62*10^3 = 1.42 %
1.42 % < 5.00%. Therefore, THE WIRE CAN SAFELY CARRY THE
REQUIRED LOAD.

Sizes and Ratings of Different Equipment For Plant 1,2,3,4 and 5.

I. BUSBAR RATINGS
The busbar rating is a copper alloy UNSC1100 using the electrical busbar
ampacity of 100-149A at 30 o C rise 60 Hz. The dimension of the busbar is

1 3
x inches.
16 4
 II. OPEN FUSED CUT-OUT RATINGS
For plant 1,3 and 5
KVA 300 x 103
I= = = 22.730 A
√ 3 Vp √ 3 (7620)
Therefore,
Use 3 pcs of 100-200 A, A type R and type T fuse link.
For plant 2 and 4
KVA 500 x 10 3
I= = = 37.884 A
√ 3 Vp √ 3 (7620)
Therefore,
Use 3 pcs of 100A, Standard Fuse Link(k Type) and Polymer
concrete Cut-outs.
III. INSTRUMENT TRANSFORMER AND ACCESSORIES
A. Current Transformer Ratings
For Plant 1,3 and 5
KVA 300 x 103
I= = = 22.730 A
√ 3 Vp √ 3 (7620)
For plant 2 and 4
KVA 500 x 10 3
I= = = 37.884 A
√ 3 Vp √ 3 (7620)

Therefore, Use an indoor type current transformer bushing with primary voltage of 7.72
KV to 40.5 KV, primary current of 500 A to 5000 A, A secondary current of 1A to 5A,
frequency of 50Hz-60Hz.

B. Potential Transformer Rating

 Use an indoor type of potential transformer with primary voltage of
1KV to 35 KV, secondary voltage of 0.1 to 0.12 KV and frequency of
50-60Hz.
C. Accessories
 Maximum Demand Meter
Bi-Metallic maximum demand meter
 Power factor meter
A digital PQQWE factor meter input voltage, 3- Ø wire system
110+10% or 45+ 10%, 3- Ø 50 Hz.
 AC Kilowatt-Hour meter
220 “H”-series DIN panel nominal voltages 63.5
V,110V,120V,220V,240V,400V,415V,440V, and 480 V AC.
 AC Voltmeter
VMD 1-2 Voltmeter for AC and DC from 0-600 V.
 AC Ammeter
AMT- 01-AC, Amperes with scales from 15A-999A.
 Frequency Meter
FRZ-DIG Frequency meter from 40-80 Hz.
 Switchboard Style

LV Switchboard(Modular Steel Sheet Construction).

IV. LIGHTNING ARRESTER

7620
KVref= = 4.399 KV
√3

Therefore,
 Use 3 pcs of Series 1 Polymer Housed, Zinc-Oxide Lightning Arrester
without cap, 6.3 KV to 36 KV, All ratings are available from 5to 10 MVA.

V. TRANSFORMER RATINGS
For Plant 1,3 and 5, use 1 unit of 300 KVA, 3-Ø Distribution Transformer.
VI. SHUNT CAPACITOR RATINGS
Capacitor bank 3-35 KV high voltage passive collective compensation
used in the system up to 35 KV to enhance power factor.
VII. TRANSDUCER RATINGS
Use 5-010 A current transducer, VT-120 A voltage
transducer and PC-010 A power transducer.
VIII. RECLOSER RATING
Use type 6H, 3- Ø, 100 A recloser
IX. CIRCUIT BREAKER RATINGS
7620
KVAref= = 4.399KV
√3

For Plant 1,3,and 5

Iref= 250%(22.730)=56.825 A

For plant 2 and 4

Iref= 250%()=56.825 A

Therefore,

Use 4.76 KV, 1200A continuous current rating circuit breaker.

INDUSTRIAL CUSTOMER NO. 6 AND 7

OUTDOOR TYPE SUBSTATIONS
 1260 FT

1120 FT

INDUSTRIAL CUSTOMER NO. 8 AND 9

OUTDOOR TYPE SUBSTATIONS
1680 FT

500 FT

DESIGN OF INDUSTRIAL CUSTOMER REQUIRING OUTDOOR TYPE SUBSTATION

PLANT NO. 6

Lighting Load- 305 KW, 3-Ø, 220 volts

Demand Factor- 86%

 Motor Load- 302 KW, 3-Ø,220 volts

Demand Factor- 84%

Average Power Factor- 86%

Diversity Factor- 110%

I. DISTRIBUTION TRANSFORMER RATING

SINCE,
Maximum Demand
Demand Factor =
Connected Load

Diversity Factor=
∑ MD ' s
SIMD
Where:
∑ MD ' s= MD + MDML
LL

Thus,
MDLL= (Lighing Load)(Demand Factor) = 305 KW(.86) = 262.3 KW
MDML= (Motor Load)(Demand Factor) = 302 KW(.84) = 253.6 KW

Therefore,

∑ MD ' s= 262.3 KW + 253.6 KW= 515.98 KW

Hence,

∑ MD ' s 515.98 KW
SIMD= = = 469.73 KW
Diversity Factor 110 %

Thus,

SIMD 469.73 KW
KVAT= = = 545.434 KVA
Ave . Power Factor .86
KVAREF= 1.25(KVAT)= 1.25(545.434 KVA) = 681.793 KVA
 Using 3 1- Ø Units:

681.793 KVA
KVAREF= = 227.264 KVA
3

Therefore use 3 pcs. of 250 KVA 1- Ø D.T.

Using of a single 3- Ø Unit:

KVAREF= 681.793 KVA

Therefore use 1 pc. Of a 750 KVA 3- Ø D.T.

II. Size of Secondary Feeder

21.4 I d '
Circular Mill=
Safe DCVD

Where: d’= 500 ft.

I= KVAT/ √3 Vs = 545.434*103/√3 (220) = 1431.393 A

Since,

3% .03
Safe DCVD= (Vs) = (220V) = 4.4V
150 % 1.5

Thus,

21.4 I d ' 21.4(1431.393)(500)

Circular Mill= = = 3,262,023.886 Cir-Mil
Safe DCVD 4.4

Therefore:

Minimum Recommended Rating:

Use 3 pcs of 3,500,000 Circular Mills Copper Conductor

Use 1 pc of 1,750,000 Circular Mills Copper Conductor for neutral wire.

 21.4 I d ' 21.4(1431.393)(500)
Actual ACVD= = =4.376V
ACTUAL CIR−MIL 3500000

Actual ACVD= 150% of Actual ACVD

= 1.5(4.376)

=6.564 V

Thus,

ACTUAL ACVD
%VD= x 100
Vs

6.564
%VD= x 100=2.98%
220

Since, 2.98%< 3%, THE WIRE CAN SAFELY CARRY THE REQUIRED LOAD.

Size of Primary Feeder

Angle of Plant no. 6 = cos-1(.86)= 30.863o

Thus,

KVAT= 750<(30.863)= 750< 30.863o KVA

Since,

21.4 Id '
Cir-Mil=
SAFE DCVD

Where, d’= 9(140)= 1260 ft

KVAt
I=
√ 3 Vp
 750 X 10 3
I= = 56.826A
√3 (7620)
Also,

5%
Safe DCVD= (7620)
150 %

= 254V

Thus,

21.4(58.826)(1260)
Cir-Mil= = 6244.820 Cir-Mil
254 V

THEREFORE,

USE 3 pcs OF 16,510 CM (AWG NO. 8) OF COPPER CONDUCTOR USING

METHOD 2:
ACTUAL ACVD = ( Id’√3/5280)* [Ra cos θ +Xt sin θ]

Where, cos θ= .86o

sin θ= .51o
From wire table
Ra=3.79 Ω
Xa= 0.665 Ω
GMD= √3 (44)(44 )(88)= 55.437
55 .185
55.437 xd
56 .187

Xd= 0.187-((0.187-0.185)*(56-55.437)/(56-55))
Xd = 0.186Ω/mi
Therefore,
 XT= 0.665+0.186=0.851 Ω/mi
Thus,
Actual ACVD= ( (58.826)(1260)√3/5280)* [(3.79)(0.86) +(0.851)(0.51)])
Actual ACVD= 89.804 V

Therefore,
ACTUAL ACVD
%VD= x 100%
Vp

89.804
%VD= x 100% = 1.17 %
7620

Since,

1.17%< 5%, THE WIRE CAN SAFELY CARRY THE REQUIRED LOAD.
 DESIGN OF INDUSTRIAL CUSTOMER REQUIRING OUTDOOR TYPE SUBSTATION

PLANT NO. 7

Lighting Load- 305 KW, 3-Ø, 220 volts

Demand Factor- 84%

Motor Load- 325 KW, 3-Ø,220 volts

Demand Factor- 86%

Average Power Factor- 85%

Diversity Factor- 105%

I. DISTRIBUTION TRANSFORMER RATING

SINCE,
Maximum Demand
Demand Factor =
Connected Load

Diversity Factor=
∑ MD ' s
SIMD
Where:
∑ MD ' s= MD + MDML
LL

Thus,
MDLL= (Lighing Load)(Demand Factor) = 305 KW(.84) = 256.2 KW
MDML= (Motor Load)(Demand Factor) = 325 KW(.86) = 279.5 KW

Therefore,

∑ MD ' s= 262.3 KW + 253.68 KW= 535.7 KW

 Hence,

∑ MD ' s 535.7 KW
SIMD= = =510.190 KW
Diversity Factor 105 %

Thus,

SIMD 510.190 KW
KVAT= = = 600.224 KVA
Ave . Power Factor .85
KVAREF= 1.25(KVAT)= 1.25(600.224KVA) = 750.28 KVA

Using 3 1- Ø Units:

750.28 KVA
KVAREF= = 250.093 KVA
3

Therefore use 3 pcs. O 333 KVA 1- Ø D.T.

Using of a single 3- Ø Unit:

KVAREF= 750.28 KVA

Therefore use 1 pc. Of a 1000 KVA 3- Ø D.T.

II. Size of Secondary Feeder

21.4 I d '
Circular Mill=
Safe DCVD

Where: d’= 500 ft.

I= KVAT/ √3 Vs = 600.224*103/√3 (220) = 1575.180 A

Since,

3% .03
Safe DCVD= (Vs) = (220V) = 4.4V
150 % 1.5
Thus,

21.4 I d ' 21.4(1575.180)(500)

Circular Mill= = = 3,830,551.364 Cir-Mil
Safe DCVD 4.4

Therefore:

Minimum Recommended Rating:

Use 3 pcs of 4,000,000 Circular Mills Copper Conductor

Use 1 pc of 2,000,000 Circular Mills Copper Conductor for neutral wire.

21.4 I d ' 21.4(1575.180)(500)

Actual ACVD= = = 4.214 V
ACTUAL CIR−MIL 4000000

Actual ACVD= 150% of Actual ACVD

= 1.5(4.214)

=6.321 V

Thus,

ACTUAL ACVD
%VD= x 100
Vs

6.321
%VD= x 100= 2.87%
220

Since, 2.87%< 3%, THE WIRE CAN SAFELY CARRY THE REQUIRED LOAD.

Size of Primary Feeder

Angle of Plant no. 6 = cos-1(.85)= 31.788o

Thus,
 KVAT= 1000< 31.788o KVA

Since,

21.4 Id '
Cir-Mil=
SAFE DCVD

Where, d’= 8(140)= 1120 ft

KVAt
I=
√ 3 Vp
1000 X 103
I= = 75.768 A
√3 (7620)
Also,

5%
Safe DCVD= (7620)
150 %

= 254V

Thus,

21.4(75.768)(1120)
Cir-Mil= = 7,149.636 Cir-Mil
254 V

THEREFORE,

USE 3 pcs OF 16,510 CM (AWG NO. 8) OF COPPER CONDUCTOR USING

METHOD 2:
ACTUAL ACVD = ( Id’√3/5280)* [Ra cos θ +Xt sin θ]
Where, cos θ= .85
sin θ= .53

From wire table

 Ra=3.79 Ω
Xa= 0.665 Ω
GMD= √3 (44)(44 )(88)=55.437
55 .185
55.437 xd
56 .187

Xd= 0.187-((0.187-0.185)*(56-55.437)/(56-55))
Xd = 0.186Ω/mi
Therefore,
XT= 0.665+0.186= 0.851 Ω/mi

Thus,
Actual ACVD= ((75.768)(1120)√3/5280)* [(3.79)(0.85) +(0.851)(0.53)])
Actual ACVD=102.234 V
Therefore,
ACTUAL ACVD
%VD= x 100%
Vp

102.234
%VD= x 100% = 1.34%
7620

Since,
1.34%<5%,THE WIRE CAN SAFELY CARRY THE REQUIRED LOAD.
 DESIGN OF INDUSTRIAL CUSTOMER REQUIRING OUTDOOR TYPE SUBSTATION

PLANT NO. 8

Lighting Load- 98 KW, 3-Ø, 220 volts

Demand Factor- 85%

Motor Load- 159 KW, 3-Ø,220 volts

Demand Factor- 85%

Average Power Factor- 86%

Diversity Factor- 109%

I. DISTRIBUTION TRANSFORMER RATING

SINCE,
Maximum Demand
Demand Factor =
Con nected Load

Diversity Factor=
∑ MD ' s
SIMD
Where:
∑ MD ' s= MD + MDML
LL

Thus,
MDLL= (Lighing Load)(Demand Factor) = 98KW(.85) = 83.3 KW
 MDML= (Motor Load)(Demand Factor) = 159KW(.85) = 135.15 KW

Therefore,

∑ MD ' s= 83.3 KW + 135.15KW= 218.45 KW

Hence,

∑ MD ' s 218.45 KW
SIMD= = = 200.413 KW
Diversity Factor 109 %

Thus,

SIMD 200.413 KW
KVAT= = = 233.038 KVA
Ave . Power Factor .85
KVAREF= 1.25(KVAT)= 1.25(233.038 KVA) = 291.298 KVA

Using 3 1- Ø Units:

291.298 KVA
KVAREF= = 97.079 KVA
3

Therefore use 3 pcs. O 100 KVA 1- Ø D.T.

Using of a single 3- Ø Unit:

KVAREF= 291.298 KVA

Therefore use 1 pc. Of a 300 KVA 3- Ø D.T.

II. Size of Secondary Feeder

21.4 I d '
Circular Mill=
Safe DCVD

Where: d’= 500 ft.

I= KVAT/ √3 Vs = 233.038*103/√3 (220) = 611.566 A

Since,
 3% .03
Safe DCVD= (Vs) = (220V) = 4.4V
150 % 1.5

Thus,

21.4 I d ' 21.4(611.566 )(500)

Circular Mill= = = 1,487,217.318 Cir-Mil
Safe DCVD 4.4

Therefore:

Minimum Recommended Rating:

Use 3 pcs of 1,500,000 Circular Mills Copper Conductor

Use 1 pc of 750,000 Circular Mills Copper Conductor for neutral wire.

21.4 I d ' 21.4(611.566 )(500)

Actual ACVD= = = 4.363 V
ACTUAL CIR−MIL 1500000

Actual ACVD= 150% of Actual ACVD

= 1.5(4.363)

=6.545 V

Thus,

ACTUAL ACVD
%VD= x 100
Vs

6.545
%VD= x 100=2.98 %
220

Since, 2.98%< 3%, THE WIRE CAN SAFELY CARRY THE REQUIRED LOAD.

Size of Primary Feeder

 Angle of Plant no. 8 = cos-1(.86)= 30.863o

Thus,

KVAT= 300<(30.863)= 750< 30.863o KVA

Since,

21.4 Id '
Cir-Mil=
SAFE DCVD

Where, d’= 12(140)= 1680 ft

KVAt
I=
√ 3 Vp
300 X 10 3
I= = 22.730 A
√3 (7620)
Also,

5%
Safe DCVD= (7620)
150 %

= 254 V

Thus,

21.4(22.73)(1680)
Cir-Mil= = 3217.279 Cir- Mil
254 V

Therefore,

Use 3 pcs. of 16,510 (AWG NO.8) of Copper Conductor

METHOD 2:
ACTUAL ACVD = ( Id’√3/5280)* [Ra cos θ +Xt sin θ]
Where, cos θ= .86
 sin θ= .51

From wire table

Ra= 3.79 Ω
Xa= 0.665 Ω
GMD= √3 (44)(44 )(88)=55.437
55 .185
55.437 xd
56 .187

Xd= 0.187-((0.187-0.185)*(56-55.437)/(56-55))
Xd = 0.186Ω/mi
Therefore,
XT= 0.665+0.186=0.851 Ω/mi

Thus,
Actual ACVD= ((22.73)(1680)√3/5280)* [(3.79)(0.86)+(0.851)(0.51)])
Actual ACVD= 46.266 V

Therefore,
ACTUAL ACVD
%VD= x 100%
Vp

46.266
%VD= x 100%=0.607%
7620

Since,
0.607%<5%, THE WIRE CAN SAFELY CARRY THE REQUIRED LOAD.
 DESIGN OF INDUSTRIAL CUSTOMER REQUIRING OUTDOOR TYPE SUBSTATION

PLANT NO. 9

Lighting Load- 93 KW, 3-Ø, 220 volts

Demand Factor- 83%

Motor Load- 149 KW, 3-Ø,220 volts

Demand Factor- 82%

Average Power Factor- 83%

Diversity Factor- 109%

I. DISTRIBUTION TRANSFORMER RATING

SINCE,
Maximum Demand
Demand Factor =
Connected Load

Diversity Factor=
∑ MD ' s
SIMD
 Where:
∑ MD ' s= MD + MDML
LL

Thus,
MDLL= (Lighting Load)(Demand Factor) = 93 KW(.83) =77.19 KW
MDML= (Motor Load)(Demand Factor) = 149KW(.82) = 122.18 KW

Therefore,

∑ MD ' s= 77.19 KW + 122.18 KW= 199.37 KW

Hence,

∑ MD ' s 199.37 KW
SIMD= = = 182.908 KW
Diversity Factor 109 %

Thus,

SIMD 182.908 KW
KVAT= = = 220.371 KVA
Ave . Power Factor .83
KVAREF= 1.25(KVAT)= 1.25(220.371 KVA) = 275.464 KVA

Using 3 1- Ø Units:

275.464 KVA
KVAREF= = 91.821 KVA
3

Therefore use 3 pcs. O 100 KVA 1- Ø D.T.

Using of a single 3- Ø Unit:

KVAREF= 275.464 KVA

Therefore use 1 pc. Of a 300 KVA 3- Ø D.T.

II. Size of Secondary Feeder

21.4 I d '
Circular Mill=
Safe DCVD
Where: d’= 500 ft.

I= KVAT/ √3 Vs = 275.464 *103/√3 (220) = 722.906 A

Since,

3% .03
Safe DCVD= (Vs) = (220V) = 4.4 V
150 % 1.5

Thus,

21.4 I d ' 21.4(722.906)(500)

Circular Mill= = = 1,757,975.955 Cir-Mil
Safe DCVD 4.4

Therefore:

Minimum Recommended Rating:

Use 3 pcs of 2,000,000 Circular Mills Copper Conductor

Use 1 pc of 1,000,000 Circular Mills Copper Conductor for neutral wire.

21.4 I d ' 21.4(722.906)(500)

Actual ACVD= = = 3.868 V
ACTUAL CIR−MIL 2000000

Actual ACVD= 150% of Actual ACVD

= 1.5(3.868)

=5.802 V

Thus,

ACTUAL ACVD
%VD= x 100
Vs

5.802
%VD= x 100=2.64%
220

Since,
 2.64%< 3%, THE WIRE CAN SAFELY CARRY THE REQUIRED LOAD.

Size of Primary Feeder

Angle of Plant no. 9 = cos-1(.83)= 33.901o

Thus,

KVAT= 300<(33.901)= 300< 33.901o KVA

Since,

21.4 Id '
Cir-Mil=
SAFE DCVD

Where, d’= 5(140)= 700 ft

KVAt
I=
√ 3 Vp
300 X 10 3
I= = 22.730 A
√3 (7620)
Also,

5%
Safe DCVD= (7620)
150 %

= 254V

Thus,

21.4(22.730)(700)
Cir-Mil= = 1,340.533 Cir-Mil
254 V

Therefore,
 Use 3 pcs. of 16,510 (AWG NO.8) of Copper Conductor

METHOD 2:
ACTUAL ACVD = ( Id’√3/5280)* [Ra cos θ +Xt sin θ]
Where, cos θ= .83
sin θ= .56
From wire table
Ra= 3.79 Ω
Xa= 0.665 Ω
GMD= √3 (44)(44 )(88)=55.437
55 .185
55.437 xd
56 .187

Xd= 0.187-((0.187-0.185)*(56-55.437)/(56-55))
Xd = 0.186Ω/mi
Therefore,
XT= 0.665+.186=0.851 Ω/mi

Thus,
Actual ACVD= ((22.730)(700)√3/5280)* [(3.79)(0.83)+(0.851(0.56)]
Actual ACVD= 18.906 V

Therefore,
ACTUAL ACVD
%VD= x 100%
Vp

18.906
%VD= x 100%=0.248%
7620

Since,

0.248%<5%, THE WIRE CAN SAFELY CARRY THE REQUIERED LOAD.

SIZES AND RATINGS OF DIFFERENT EQUIPMENT FOR PLANT 6,7,8, AND 9.

X. BUSBAR RATINGS
The busbar rating is a copper alloy UNSC1100 using the electrical busbar
ampacity of 100-149A at 30 o C rise 60 Hz. The dimension of the busbar is

1 3
x inches.
16 4
XI. OPEN FUSED CUT-OUT RATINGS
For plant 6
KVA 750 x 10 3
I= = = 56.826 A
√ 3 Vp √ 3 (7620)
Therefore,
Use 3 pcs of type R and type T fuse link.
For plant 7
KVA 1000 x 103
I= = = 75.768 A
√ 3 Vp √ 3(7620)
 Therefore,
Use 3 pcs of type R and type T fuse link.
For plant 8 & 9
KVA 300 x 103
I= = = 22.730 A
√ 3 Vp √ 3 (7620)
Therefore,
Use 3 pcs of type R and type T fuse link
XII. INSTRUMENT TRANSFORMER AND ACCESSORIES
D. Current Transformer Ratings
For Plant 6
I= 56.826 A
For plant 7
I=75.768 A
For plant 8 & 9
I= 22.730 A

Therefore, Use an indoor type current transformer bushing with primary voltage
of 7.72 KV to 40.5 KV, primary current of 500 A to 5000 A, A secondary current of
1A to 5A, frequency of 50Hz-60Hz.

E. Potential Transformer Rating

Use an indoor type of potential transformer with primary voltage of
1KV to 35 KV, secondary voltage of 0.1 to 0.12 KV and frequency of
50-60Hz.
F. Accessories
 Maximum Demand Meter
Bi-Metallic maximum demand meter
 Power factor meter
 A digital PQQWE factor meter input voltage, 3- Ø wire system
110+10% or 45+ 10%, 3- Ø 50 Hz.
 AC Kilowatt-Hour meter
220 “H”-series DIN panel nominal voltages 63.5
V,110V,120V,220V,240V,400V,415V,440V, and 480 V AC.
 AC Voltmeter
VMD 1-2 Voltmeter for AC and DC from 0-600 V.
 AC Ammeter
AMT- 01-AC, Amperes with scales from 15A-999A.

 Frequency Meter
FRZ-DIG Frequency meter from 40-80 Hz.
 Switchboard Style

LV Switchboard(Modular Steel Sheet Construction).

XIII. LIGHTNING ARRESTER

7620
KVAref= = 4.399 KV
√3

Therefore,

Use 3 pcs of Series 1 Polymer Housed, Zinc-Oxide Lightning Arrester

without cap, 6.3 KV to 36 KV, All ratings are available from 5to 10 MVA.

XIV. TRANSFORMER RATINGS

For Plant 6 use 1 unit of 750 KVA, 3-Ø Distribution Transformer.
For Plant 7 use 1 unit of 1000 KVA, 3-Ø Distribution Transformer.
For Plant 8&9 use 1 unit of 300 KVA, 3-Ø Distribution Transformer.
XV. SHUNT CAPACITOR RATINGS
Capacitor bank 3-35 KV high voltage passive collective compensation
used in the system up to 35 KV to enhance power factor.
XVI. TRANSDUCER RATINGS
Use 5-010 A current transducer, VT-120 A voltage transducer and PC-010
A power transducer.
XVII. RECLOSER RATING
Use type 6H, 3- Ø, 100 A recloser