Demand Factor = Maximum Demand on system in a given time period / Total Connected Load.

1. It is always less than 1.

2. The demand factor measures how much of the system’s capacity is used. Therefore, it is
important to know the demand factor to determine whether or not the system is overloaded.
3. If the demand factor is close to 1, then it means that the system is being overloaded, and
additional capacity needs to be added.
4. If the demand factor is less than 1, there is spare capacity in the system, and it may be possible to
reduce the size of some components to save costs.

Load Factor = Average load / Maximum Demand on system in a given time period.

1. Its value is always less than 1 because maximum demand is never lower than average demand,
since facilities likely never operate at full capacity for the duration of an entire 24-hour day.
2. It is a measure of the utilization rate, or efficiency of electrical energy usage; a high load factor
indicates that load is using the electric system more efficiently, whereas consumers or generators
that underutilize the electric distribution will have a low load factor.
3. It provides an indication of how well any customer is utilising any utility asset. If one has a low
load factor it means that the customer has a very high peak load for a very short period. Thus the
utility would have to provide assets such as transformer which are way over sized and for which
there will be a long return of investment on any such asset. So it is like buying a taxi capable of
carrying 50 passengers at once for one day but only having 2 passengers per every other day of
the month. This is why the closer the load factor to 1 (unity) the better, as it shows the utility
asset is being properly and fully utilised.

Diversity Factor= Sum of Individual Maximum Demands / Maximum Demand of the Whole System

4. More than 1.
5. Diversity factor helps in sizing the equipment more accurately by accounting for the likelihood
that not all loads will be operating at their maximum simultaneously.
6. It provides an indication of how well the utility is managing their network and utility assets. So
the larger the diversity factor the better.
7. For example if one has a 1000 kVA transformer and a single client with a demand of 1000 kVA the
the DF is 1. If on the other hand one has ten customers each with a demand of 1000 kVA then the
DF is 10 and what this shows is that the system is being well managed as an asset of 1000 kVA is
being used to supply a load of 10000 kVA.

Types of loads:

1. Normal Load: No automatic restart after restoration of supply; No safety impact if loads are out of
service due to failure of power supply.
2. Essential Load: Automatic restart after restoration of gone power supply; No requirement of
emergency supply; No safety impact if loads are out of service due to failure of power supply.
3. Critical Load: Requires UPS
4. Emergency Load: Requires DG

Load duty: Continuous, Intermittent and Stand by: To be provided by process team

Total Plant Running Load (TPRL): 100% Continuous load + 40% Intermittent Load + 0% Standby load

Total Plant Peak Load (TPRL): 100% Continuous load + 40% Intermittent Load + 10% Standby load
Process team gives the rating of motor at maximum from which absorbed load is found out by multiplying the
given rating with load factor (for motors=0.9) and dividing by diversity factor (for motors=1).

Connected load (Input load) is higher than the absorbed load because absorbed load is divided by
efficiency to get the input load.

Absorbed load: At operating conditions

Shaft power: At rated output

IS 12615: IE1, IE2, IE3 motors classification

CABLES:

IS 1554 (Part 1)- PVC Insulated cables (LV cables)

IS 1554 (Part 2)- PVC Insulated cables (MV and HV cables)

PVC A General purpose (Max. conductor temp. 70 degree C)

PVC B General purpose for MV cables

PVC C Heat resisting (Max. conductor temp. 85 degree C)

IS 7098 (Part 1)- XLPE Insulated cables (LV)

IS 7098 (Part 2)- XLPE Insulated cables (MV and HV)

IS 694: Light duty PVC insulated cables upto 1.1 kV

IS 1255: Installation of cables upto 33kV

IS 8130: Conductor selection for cable

Material: Cu and Al

Class 1- Solid (generally upto 16 sq.mm),

Class 2-Stranded (Types- Non compacted, Compressed circular, Compact circular, Compact sector
shaped),

Class 5-Flexible (Household wire cables)

Class 6-Extra Flexible (In lift cables, crane cables, welding cables, Reeling and unreeling purpose, etc)

IS 3975: Armour

Al/Galvanized Steel; Types: Round wire (cable dia. upto 13mm), Flat strip (cable dia. greater than
13mm)

IS 5831: Sheath material- provides bedding under cable armouring to protect the laid up cores

Types: Extruded, Wrapped (PVC tape), ST1 (max rated conductor temp of 70degreeC), ST2(max rated
conductor temp of 90degreeC). ST1 is generally for PVC insulated and ST2 for XLPE insulated cable.

Outer sheathing process is done through extrusion only

IS 3961: Current rating of cable

IEC 60502: Extruded solid dielectric insulated power cables for rated voltage from 1kV to 30kV
IEC 60364-5-52: Selection and erection of electrical equipment

LSZH (Low smoke Zero halogen) cables: In areas like hospital

Conductor screen and Insulation screen are applicable for only MV and HT cables and not for LT cables.

Cable installation job for XLPE is easier than PVC insulated cables because of less weight, less diameter and
less bending radius.

W=Round steel wire armouring

WW= Double Round steel wire armouring

A Aluminum conductor
Y PVC insulation or PVC sheath
2X XLPE
W Round steel wire armouring
WW Double Round steel wire armouring
F Flat (strip) steel wire armouring
FF Double Flat (strip) steel wire armouring
C Metallic screening (Usually of Cu)
CE Metallic screening (usually of Cu) over each individual core
Wa Aluminum round wire
Fa Aluminum flat (Strip) steel wire armoring

Cable sizing and selection:

1. Connected load
2. System- Single phase/three phase
3. System fault level/SC requirement
4. Voltage grade-LV/MV
5. Rating factors to be considered for
a. Laying conditions
b. Environment conditions
c. Route length
d. Voltage drop

IEC 60364-5-54: S(in mm2)= (Isc*Square underoot(t))/k; k=0.094 for Al and k=0.143 for Cu

Derating factors: Ambient or soil temperature of site; Grouping factor, depth, Soil thermal resistivity

IEC 60502-2 defines calculation for cable correction/derating factor: Temperature rating factor, cable
grouping factor, cable depth of laying factor, Ground thermal resistivity factor, etc.

Torque Voltage curve (both at 100% voltage and at 80% voltage as per IEEE 399) of motor to be asked to
ensure that during starting of motor the torque should not drop excessively and should be able to drive the
load torque because Torque is directly proportional to square of Votage.

Voltage drop (line to neutral) = IRcos$+IXsin$

For HT cable sizing: 1. Short circuit rating capacity, and 2. Full load current carrying capacity.

For LT cable sizing: Voltage drop becomes important criteria

For only motor, starting pf to be considered. For other feeders, no requirement of calculating starting pf.
IEC 60364 for cable installation underground

BUSBAR SIZING:

Applicable IS codes:

1. Busbar clearance as per IS4237

2. IS 8084: Specifications for interconnecting bus bar for AC voltage above 1KV till 36kV
3. CBIP manual

Sizing

1. Meet the continuous rating and short time current rating for 1 sec
2. Configuration of bus bar
3. Proximity effect

Continuous current carrying capacity:

1. This is the max. current that the busbar can carry before exceeding the max defined temp rise
(70degree Celsius)
2. Its defined by the max. required current capacity of all the sources connected to busbar including
transformers/overhead lines/cables.
3. 100A, 250A, 400A, 750A, 1000A, 1250A, 1600A, 2000A, 2500A, 3000A, 4000A
4. Calculate the full load current of transformer and then bus bar shall be equal or next available
rating of the full load current.
5. Breaker size to upstream of busbar will be equal to full load current.

Fault current rating:

1. This is the max. fault current that the busbar can carry for a defined period.
2. All fault current on the electrical system is created by the generators, but the transformers naturally
limit the fault current that passes through them.

Area of busbar = (Isc*sqrt(t))/[14*1000*sqrt(log(T2+258)/(T1/258))] sq. inch

Where A=cross sectional area of bus bar in sq inch

I= Short time rating in Amps

t=duration in sec.

T2=Final temperature of Al alloy=260degree Celsius

T1=Initial temperature of Al alloy=90degree Celsius

Thumb rule: for Al 0.8A/mm2 and for Cu 1.2A/mm2

Standard bus bar size: 20X6mm, 20X10mm, 30X10mm, 40X10mm, 63X10mm, 80X10mm, 100X10mm;
Former no. denotes width and latter no. denotes thickness. For earthing usually 6mm thickness and for
power 10mm thickness bus bar is used.

Density: Cu bus bar: 8940kg/m3; Al bus bar: 2700kg/m3

TRANSFORMER DESIGNING:

1. CBIP Manual on Transformers

2. IS 11171 Dry type transformers
 3. IS 1180 Energy efficient transformer upto 2.5 MVA
4. IS 2026 and IEC 60076 Power transformers
5. IS 335/IEC 600296 Transformer mineral insulating oil

Noise level limit: 75dB in day and 70dB at night

As per standard, noise is limited to 75dB in morning and 70dB in night.

NBC guidelines on selecting dry type and oil type transformer

Transformer sizing calculation:

1. To calculate the transformer capacity based on a) load requirements and also carry out b) voltage
regulation check on transformer secondary terminals within tolerable limits of 15%.
2. The recheck on the selected transformer rating as mentioned in point 1 with regards to the c) largest
motor starting when other base loads are in running condition.
3. DESIGN INPUTS:
a. Load list;
b. voltage regulation check while starting largest motor when base load in running condition;
c. X/R ratio (as per IEC 60076 or equivalent IS standard);
d. Impedance of transformer (as per IEC 60076 or equivalent IS standard)
4. Transformer should not be loaded beyond 80% and 90% of its rated kVA for oil type and dry type
respectively while max. consumed load is considered in the transformer sizing calculation.

Power triangle:
kVA
kVAR kVA2=sqrt(kVAR2+kW2)

kW

Impedance triangle:
Z
X Z2=sqrt(R2+X2)

R
5. Steps in calculation:
a. %Z and X/R ratio can be found from the standard
b. Calculate %R
c. Calculate %X
d. For largest motor, calculate starting kVA by formula= [(current ratio of motor)*( reduce
current ratio of motor starting current)*(running kVA of motor)]/(efficiency*running cos@)
e. Calculate starting cos@ and starting sin@ of motor. Also calculate @
f. Calculate cos@ and sin@ of base load from which @ to be calculated
g. Active power of combined load=Base load in kW + Starting kW of motor. Starting kW of
motor can be found out by Starting kVA*starting cos@
 h. Reactive power of combined load=Base load in kVAR+ Starting kVAR of motor. Starting kVAR
of motor can be found out by Starting kVAR*starting sin@
i. Combined load kVA=sqrt(g2+h2)
j. Calculate combined load cos@ and combined load sin@ from (g) and (h).
k. Voltage regulation in %= [(kVA from (i))/(selected transformer rating)]*[(%R*combine load
cos@)+(%X*combine load sin@)]. The value at transformer secondary terminal should be
less than 15%.

CURRENT TRANSFORMERS and POTENTIAL TRANSFORMER

1. ALF is for Protection class CT and ISF is for metering class CT.
2. ALF and ISF is the ratio of Primary current to the rated primary current.
3. IEEE C57.3: Have standard burden, terminal connection, ratings for CT with one or two ratios,
standard accuracy class for CT and PT
4. Standard Accuracy class for CTs as per IEC 61869-2 & Standard Accuracy class for PTs as per IEC
61869-3
5. In PT, voltage factor is to be considered. Not solidly earthed system:1.9 and Solidly earthed
system:1.5
6. In primary and secondary of PT, fuses to be provided to prevent damage of PT from short circuit. But
in secondary of CT only shorting terminals to the secondary of CT should be provided to short the CT
secondary.
7. The first value of insulation level voltage is called power frequency voltage and is measured in V(RMS)
8. The second value of insulation level voltage is called lightning impulse voltage and is measured in
kV(peak)

EARTHING SYSTEM:

Codes and standards:

1. IS 3043 2018
2. IEEE 80: Guide for safety in AC substation grounding. Mostly used for HV substations and switchyards
where there is chance of high ground potential rise.
3. NFPA 70
4. ANSI C2
5. IEEE 142: Recommended practice for grounding of industrial and commercial power systems. Green
Book
a. System grounding
b. Equipment grounding
c. Static and Lightning protection grounding
d. Connection to earth
e. Electronic equipment grounding: To divert stray RF energy from sensitive audio, video,
control, and computer equipment.

Step potential: The step potential is the voltage across the two points on the floor level in an electrical
system during an earth fault. The two points being at a distance of one human step i.e. 1 meter.

Touch potential: The touch potential is the potential between finger of raised hand touching the metallic part
and the feet. This voltage gets distributed along the current path between the fault point and earth mat.

Equipotential bonding
Ground potential rise: It is the maximum electrical potential that a substation grounding grid may attain
relative to a distant grounding point assumed to be at the potential of the remote earth. GPR should be less
than tolerable touch potential, earthing is safe.

Types of grounding:

1. System Grounding (NEUTRAL)

a. Ungrounded system: In ungrounded system if ground fault is intermittent or allowed to
continue, the system could be subjected to possible severe over-voltages to ground which
can be as high as 6 to 8 times the phase voltage.
b. Effectively grounded or solidly grounded: One disadvantage of the solidly grounded system
involves the high magnitude of destructive, arching ground fault current that can occur.
c. Resistance grounding
i. High resistance grounding
ii. Low resistance grounding
d. Reactance grounding
e. Transformer grounding: Star delta and Zig Zag grounding
2. Equipment Grounding (SAFETY)
3. Lightning Protection grounding

Earth fault occurs when any of the phase touches earth. Detected by CTs. Three connection: 1. Residual
connection 2. CBCT connection and 3. Neutral CT connection. In case of 1. CT polarity should be checked and
should be in same direction otherwise EF relay will inadvertently operate.

The fault current in bolted ground fault is much more than arching ground fault resulting in pick up of the
earth fault relay in bolted ground fault. In arcing ground fault since air is medium, the fault current is less
resulting in not pick up of the earth fault relay which could cause huge arcing which is dangerous to operating
personnel.

HT Power Factor Controller

Applicable IS codes:

1. IS 13925/IEC 60871-1: SHUNT POWER CAPACITORS FOR ac SYSTEMS HAVING A RATED VOLTAGE
ABOVE 1000 V
a. The capacitor banks shall be suitable for continuous operation at 110% of rated rms voltage
& 150% of rated rms current.
b. The switching and protection devices and the connections shall have a capacity
corresponding to 1.5 times the rated current of the capacitor bank.

HT APFC panel shall consists of:

1. 6.6kV capacitor banks

2. Isolating switch (Load Break Switch) with HRC fuse
3. Push button with indicating lamps for the opening of the Load Break Switch. Push buttons shall be
provided with inscription plates engraved with their functions.
4. Series Reactors: Air core air cooled ; Designed to have a linear V-I characteristics up to 150% of rated
capacitor current.
5. Core balance current transformers: 51N tripping on Inverse time earth fault relay
6. Copper Busbars
7. Red and green lamps for capacitors ON/OFF indication, etc

LT APFC:

Applicable IS codes:

2. IEC 61921: Power Capacitors- LV power factor correction banks

3. IEC 60664-1 / IEC 61326: Power Factor Controller
4. IS 13585/IEC 60931-1: SHUNT POWER CAPACITORS OF THE NON-SELF-HEALING TYPE FOR ac
SYSTEMS HAVING A RATED VOLTAGE UP TO AND INCLUDING 1000 V
a. Permissible overvoltage: 1.1 times of rated voltage 8h per 24h
b. Permissible overcurrent: 1.5 times of FLC; Min. current rating under site conditions of circuit
breakers, contactors and cables shall be at least 150% of rated capacitor current to take
care of harmonics.

Each capacitor bank should withstand short circuit rating of 50 kA for 1sec.

Each capacitor bank shall be provided with 7% of capacitor reactance (Xc) detuned filter

Operation of Capacitor banks:

Steps and Sizes of APFC

At capacitor switching while one or more capacitors are connected to the system, the switching
capacitor will see a high inrush current. This is due to the current flow from the already connected
capacitor(s) (which will act as a source) through the least impedance path set by the switched capacitor along
with the current from the main source. This means that when the number of capacitors in parallel increases,
the amount of inrush current also increases. Inrush current will damage the capacitor as well as the switching
device. In order to prevent inrush current, it is required to use current limiting devices such as capacitor duty
contactors or inductor coil.

After switching off a capacitor, a delay of at least 1 minute must be allowed before switching on again
to ensure the discharge of individual capacitor step/unit before reconnection. Solid State switching (Thyristor
Switches) can be used when fast switching in APFC Panels is needed.

Contactors shall be used to switch capacitors in or out of service of each individual step. The
contactors shall prevent inrush current to a safe level when the capacitor steps are switched on. Contactor for
switching of capacitor banks shall have AC-6b utilization category according to IEC 60947-4-4: Capacitor duty
contactors are recommended in APFC equipment to minimize inrush currents experienced during the
switching of capacitors. These contactors have special early make contacts with series resistances which
dampens the inrush currents. However, when normal Power contactors are used, and when there are no
reactors in series, a suitable inductor coil has to be connected in series with the contactor for limiting the
inrush currents.

Capacitor duty contactors are normally rated up to 60kvar. While using detuned reactors which acts
as a inrush current limiter user can use normal power contactor (AC3 Duty) for capacitor switching.

IP 42 enclosure

Min. 8 steps and max. 16 steps in APFC of 5kVAR, 10kVAR, 15kVAR, 25kVAR, 50kVAR and 100kVAR. Rating of
APFC panel shall be based on 50% of running load on each bus section and not on connected load basis.
kVAR is required for magnetizing current to energize the magnetic field

No load current= 25% to 30% of full load current

Power factor is a measurement that how effectively the power is utilized in a power system. The higher the
value of pf, the more effectively power is utilized in the system. Low pf in a distribution system indicates very
poor utilization efficiency.

Pf is the sum of displacement pf and distortion pf. Distortion pf is disturbed by the harmonics present in the
system.

Capacitor bank design aspects:

1. Compensation required at nominal system voltage

2. Overvoltage in system and duration
3. Voltage rise at the point of connection of capacitor bank
4. Harmonics due to presence of non linear load

Types of capacitors:

1. APP (All Polypropylene Capacitors): Usually used at HT side

2. MD (Mixed Dielectric)
3. MPP (Metalized Polypropylene Capacitors): Also called self-healing capacitors.

Thumb rule for capacitor sizing:

1. 90% of no load motor current gives approximately kVAR value.

2. If only full load Amps is known, then no load current as a thumb rule is 30% of full load current.

Capacitor sizing in kVAR= P*(tan @1-tan @2) where cos@1 is existing pf and cos@2 is targeted pf and P is
load in kW. 20% of margin to final kVAR value is taken to take care of future load.

Detuned Reactor:

1. Capacitors and reactors are configured in a series resonant circuit, tuned so that the series resonant
frequency is below the lowest harmonic frequency present in the system.
2. The use of detuned reactors thus prevents harmonic resonance problems, avoids the risk of
overloading the capacitors and contributes to reducing voltage harmonic distortion in the network.
3. In a detuned filter application, the voltage across the capacitors is higher than the nominal system
voltage. Then, capacitors must be designed to withstand higher voltages.
4. Depending on the selected tuning frequency, part of the harmonic currents is absorbed by the
detuned capacitor bank. Then, capacitors must be designed to withstand higher currents, combining
fundamental and harmonic currents.
5. The detuned reactors (DR) are designed to protect the capacitors by preventing amplification of the
harmonics present on the network. They must be connected in series with the capacitors. The
detuned reactors generate an overvoltage at the capacitor terminals. The rated voltage of capacitors
has to be increased accordingly.

Why Capacitor banks are connected in Delta? When the capacitor generates kVAR then that is proportional
to the square of the voltage applied. So, if the voltage is higher, the KVAR is also more. So the capacitor in this
connection will provide high KVAR compared to the bank connected in star connection because, in star type
connection, the applied voltage is low compared to delta connection.

DIESEL GENERATOR
Applicable standards and codes:

1. IEC 60034: Rotating machines

2. IEEE 387
3. ISO 5828: Generator ratings
a. Performance class:
i. Class G1: This applies to generating set applications where the connected loads are
such that only basic parameters of voltage and frequency need to be specified. Eg:
General-purpose applications (lighting and other simple electrical loads)
ii. Class G2: This applies to generating set applications where its voltage characteristics
are very similar to those for the commercial public utility electrical power system
with which it operates. When load changes occur, there may be temporary but
acceptable deviations of voltage and frequency. Eg Lighting systems, pumps, fans and
hoists.
iii. Class G3: This applies to applications where the connected equipment makes severe
demands on the stability and level of the frequency, voltage and waveform
characteristics of the electrical power supplied by the generating set. Eg
Telecommunications and thyristor-controlled loads.
iv. Class G4: This applies to applications where the demands made on the stability and
level of the frequency, voltage and waveform characteristics of the electrical power
supplied by the generating set are exceptionally severe. Eg Data-processing
equipment or computer systems.
b. Generating sets meeting the requirements of this International Standard are used to
generate electrical power for continuous, peak-load and standby applications.
c. Power rating categories:
i. Continuous power: Continuous power is defined as being the maximum power
which the generating set is capable of delivering continuously whilst supplying a
constant electrical load (Only base load and no variable load) when operated for an
unlimited number of hours per year under the agreed operating conditions with the
maintenance intervals and procedures being carried out as prescribed by the
manufacturer.
ii. Prime Power: Prime power is defined as being the maximum power which a
generating set is capable of delivering continuously whilst supplying a variable
electrical load when operated for an unlimited number of hours per year under the
agreed operating conditions with the maintenance intervals and procedures being
carried out as prescribed by the manufacturer. The permissible average power
output over 24 h of operation shall not exceed 70 % of the Prime power. For
applications requiring a permissible average power output higher than stated, a
continuous power rating should be used.
iii. Limited time running power: Limited-time running power is defined as the maximum
power available, under the agreed operating conditions, in non-variable load
condition, for which the generating set is capable of delivering for up to 500 h of
operation per year with the maintenance intervals and procedures being carried out
as prescribed by the manufacturers. Limited time running power at 100 % is limited
to a maximum of 500 h per year. No overload is permitted.
iv. Emergency Standby Power (ESP): Emergency standby power is defined as the
maximum power available during a variable electrical power sequence, under the
stated operating conditions, for which a generating set is capable of delivering in the
event of a utility power outage or under test conditions for up to 200 h of operation
 per year with the maintenance intervals and procedures being carried out as
prescribed by the manufacturers. The permissible average power output (Ppp) over
24 h of operation shall not exceed 70 % of the ESP. The actual average power output
(Ppa) shall be below or equal to the permissible average power output (Ppp) defined
for ESP.
4. ISO 3046: Reciprocating IC Engine

Inputs required:

1. Load list
2. System parameters viz voltage, frequency, allowable voltage dip
3. Datasheet of largest starting motor

Vendor recommended factors for DG sizing:

1. Annual Generator set running time

2. Applied load: Variable or constant
3. Minimum load: Generator should not be run below 30% of the rated load.
4. Overload capability: Minimum 10% overload capacity
5. Check capacity of non-linear load: Non linear loads on a generator must be less than approx. 50% of
generator capacity to limit harmonic distortion to less than 15%.

Design criteria:

1. Continuous operating load

2. Capacity while considering momentary voltage drop limitation due to inrush kVA of largest rating
motor but without base load (10% Voltage drop)

PG2 = PM x ( Xd` + Xd`` ) ( 1- V )

2 V
WHERE
PM = INRUSH KVA OF LARGEST MOTOR
Xd` = TRANSIENT REACTANCE OF GENERATOR
Xd`` = SUB TRANSIENT REACTANCE OF GENERATOR
V = PERMISSIBLE VOLTAGE DROP ( 15% MAX.)

Xd` = TRANSIENT REACTANCE OF THE GENERATOR

SUB TRANSIENT REACTANCE OF THE
Xd`` = GENERATOR
V = PERMISSIBLE VOLTAGE DROP ( 10% MAX.)

3. Capacity while considering overload capacity (50% overload for 15 sec.) of generator

PG3 = Po + PM
GW
WHERE
BASE WORKING LOAD ( EXCLUDING KVA OF LARGEST RATING MOTOR
Po = )

OVERCURRENT CAPACITY OF GENERATOR (1.5

GW = i.e. 15% for 10 sec.)

PM = STARTING KVA OF LARGEST RATING MOTOR

Crux of CPWD DG specifications:

DG will be tested on load of unity power factor for the rated kW rating. During testing, each of the DG sets
shall be operated for a period of 12 hours on the rated kW at DG set’s kW rating including one hour on 10%
overload after continuous run of 12 hours. Current, Voltage ,kW, kVAR and Hz reading should be within 2.5%
of declared value.

POL i.e. HSD oil and lub. oil for diesel engine for testing & commissioning for 12 hours including 1hr of 10%
overloading at OEA/ OEM works shall be arranged by the contractor. POL i.e. HSD oil and lub. oil for trial run
of 4 Hrs. at site at available load shall be arranged by the department. After successful testing of the DG Set, a
trial run at available load will be carried out for 120 Hours or 15 Days whichever is earlier. The DG Set will be
operated and a log of all relevant parameters will be maintained during this period.

DG sets upto 1000kVA are required to be supplied with acoustic enclosure and should be tested for Noise and
emission norms as per CPCB. Should be less than 75dB.

The engine shall be capable for delivering specified prime power rating at variable loads for pf 0.8 lag with
10% overload capacity in excess of specified output for one hour in every 12 hours. The average load factor
for engine over period of 20 hours shall be 0.85 (85%) for prime power output.

Alternators above 500 kVA should be fitted with RTD and BTD and space heaters.

Performance:

Voltage dip shall not exceed 20% of the rated voltage for any step lot for transient load as per ISO 8528 part
1. The windings shall not develop hotspot exceeding safe limits due to imbalance of 20% between any two
phases from no load to full load.

The generator cell preferably be capable of withstanding a current equal to 1.5 times the rated current for a
period of not more than 15 seconds as required by clause 14.1.1 of is 4722:1992.

The performance characteristic of the alternative shall be as below:

efficiency at full load 0.8 pf 1. up to 25 KVA- not less than 82% 2. above 25 KVA and up to 62.5 KVA- not less
than 86% 3. above 62.5 kVA and up to 250 KVA- not less than 90% 4. Above 250kVA- not less than 93.5%

total distortion factor- less than 3%

1. 10% overload one hour in every 12 hours of continuous use

2. 50% overload- 15 sec.

SEE CHAPTER 3 SYNCHRONIZATION

UPS & BATTERY SIZING:

AC UPS for Emergency Lighting, AC UPS for control system and AC UPS for motor loads.

Applicable Standards:

1. IEC 60623: Vented Ni-Cadmium single cells

2. IEEE Std 1106: Recommended practice for installation, maintenance, testing and replacement of Ni-
Cd batteries for stationary applications
3. IEEE Std 1115: Recommended practice for sizing Ni Cd batteries
4. IEC 60896 Part 1: Lead acid battery (Vented type)
5. IEC 60896 Part 2: Lead acid battery (Valve regulated type)
6. IEEE Std 450: Recommended practice for maintenance, testing and replacement of Lead acid
batteries for stationary applications
 7. IEEE Std 484: Recommended practice for installation design and installation of Lead acid batteries for
stationary applications
8. IEEE Std 485: Recommended practice for sizing lead acid batteries for stationary applications
9. IEEE Std 1184: IEEE guide for selection and sizing of batteries for UPS

MOTOR:

Important standards:

1. IS 15999: Rotating electrical machine, rating and performance

2. IS 12615: Energy efficient motors from IE1 to IE4
3. IEC 60034: Rotating electrical machinery
4. IS 13555: Guide for selection and application of three phase induction motors for different types of
driven equipment.
5. IS 1231: Dimensions and output series for foot mounted induction motors Frame no. 56 to 315: FOR
LT MOTORS
6. IS 14568: Dimensions and output series for rotating electrical machines Part 2 Frame no. 355 to 1000
and flange nos. 1180 to 2360
7. IEC 60079: Electrical equipment for Explosive atmospheres
8. IEC 60529: Enclosure protection
9. Mounting type shall be as per IEC60034-7
10. IS 12075: Vibration limits of motor
11. Noise limit of motor shall be as per IS 12065 or IEC 60034.
12. Space heater, WTD, BTD, vibration monitor

Motor operating through VFD shall be suitable for inverter duty with VPI insulation

The preferable paint shade shall be as per grades of IS 631. Usually the paint shade for non-flameproof
(Weatherproof) is blue and flameproof motors are grey shade.

Requirements:

1. Thermal limit characteristics graph: Overload requirement to be set from here. Hot start and cold
start decide from here.
2. Motor speed torque and load speed torque curve superimposed.
3. Starting current vs time graph
4. Efficiency and pf graph
5. Test reports
6. Negative sequence curves

P(power)=(2*pi*T*N)/60

Where T=torque, N=speed

P(in kW)=((rho)*g*Q*H)/(1000*eff.)

Where rho=density in kg/m3; Q=flow rate in m3/sec; g=gravitational constant (9.81 m/sec2); H=Total
developed head in meter; eff.=efficiency between 0 and 1

If the load is constant then sizing the motor consists of choosing a motor whose rated torque is slightly above
the torque required by the load. The load torque should be between 75%-100% of the rated motor torque
with 95% being an ideal choice.
For constant speed applications where the motor will run continuously at rated speed you do not need to
work out torque. You can simply look at rated power and motor power and use the same 75%-100% rule. This
is the case for standard induction motor without a VFD.

In order to get the load up to speed, the motor must start off from zero speed and accelerate the load up to
speed. Torque is what causes acceleration. The motor torque will cause the load to accelerate but the load
produces its own torque which resists acceleration.

The torque produce by motor varies with speed and the torque produced by a load also varies with the
speed. If the motor torque is greater than the load torque then the load will accelerate. If the load torque is
greater than motor torque then load will decelerate.

Accelerating torque=T(motor)-T(load)

In order for the motor to start the load and get it upto correct speed then the motor torque must be higher
than the load torque at zero speed (starting torque) and at every speed up to the desired operating speed. If
the load torque ever exceeds the motor torque at any intermediate speed the motor will stall at that speed
and the system will not start up correctly.

Some loads do not represent a constant torque even after they have got up to full speed. This represents a
variable power to the motor and complicates the sizing problem.

In general we should ensure that

1. Peak load torque (or power)< Rated motor torque (or power) * (1+service factor/100%)
 2. The RMS load torque(power) requirement must be less than 100% of the rated motor torque (power)
and ideally greater than 75% of rated motor torque(power).
3. Check that the motor can start the load and get it upto its operating speed.

Types of Enclosure of motor:

1. Totally Enclosed Fan Cooled (TEFC): Fan at non driving end.

2. Screen Protected Drip Proof enclosure: IP 21/22/23 protection; used for high quality motors; External
air is sucked inside through a wire mesh screen by means of shaft mounted fan.
3. Totally Enclosed Non Ventillation: Cooling though natural convention of air.
4. Totally Enclosed Air Over/Airtight (TEAO): dust tight frame or enclosure;
5. Totally enclosed Air-to-Air Cooled: Also known as CACA coolers (Closed Air Circuit Air-cooled) are a
form of air-to-air heat exchanger effective in cooling a HT motor.
6. Totally Enclosed Water-to-Air Cooled
7. Explosion proof motor

IEC 60034-1 Duty cycles of electrical motors:

MOTOR STARTERS:

1. IS/IEC 60947-4-1 contains motor starters.

2. Direct-on-line starters shall be suitable for Class AC 3 utilization category as per IS: 13947 (Part 4).
3. Star Delta starters shall be suitable for Class AC 3 utilization category as per IS: 13947 (Part 4).
4. Reversing starters shall be suitable for Class AC-4 duty.
5. Auto transformer shall be air cooled type having 3 tappings of 50%, 65% and 80%.
6. Soft Starters:
a.
7. FCMA Starters:
a.
HV SWITCHGEAR AND CONTROL GEAR:

IEC 62271: High voltage switchgear and control gear

IEC 60282-1: HV fuses Part 1 Current limiting fuses

IEC 60470: HV AC contactors

IEC 60529: Degree of protection provided by enclosures (IP code)

IEC 60282: HV fuses

IEC 60265: HV switches

IEC offers wide range of selections of parameters than IEEE

Metal clad (Draw out circuit breakers) vs Metal Enclosed (Fixed type circuit breakers): Metal clad is metal
enclosed but metal enclosed is not metal clad.

Accessibility of compartment as per IEC 62271-200 clause 8.2.2

Interlock controlled accessible compartment: Mechanical and electrical interlock

Procedure based accessible compartment

Tool based accessible compartment

Non accessible compartment

According to IEC 62271-200 clause 4.6: peak value of short time withstand current (making current) is 2.5
times of breaking current i.e. short ckt current.
Partition class as per IEC 62271

Form of separation IEC 61439-2: Form 1, Form 2a and 2b, Form 3a and 3b, Form 4a (Type 1,2,3) and 4b (Type
5,6,7)

11kV two pole/four pole structure component:

1. GOD with earth switch (Gang Operated Disconnector): The purpose of this switch is to disconnect
the substation from the incoming line, not to disconnect the transformer from the load. It is like a
large safety switch with no load breaking capability. It can only break, or "interrupt" the relatively
small "magnetizing current" of the substation transformer. Voltage class: 11kV to 33kV; Current rating
(A): 200, 400 (for 33kV), 630, 800, 1250 A. Tender should include electrical and mechanical
endurance i.e. no. of operations for which GOD can withstand. IS Applicable: IS 9920 (Part 1 to 4): HV
Switches
a. Types: Centre-break, Double-break, Pantograph, Horizontal break knee, Vertical break,
Coaxial
b. Why mechanical interlock is required in isolator with earth switch?
i. The primary purpose of a mechanical interlock is to enhance safety. By enforcing the
correct sequence of operations, it prevents accidental closure of the earth switch
while the isolator is still closed. This eliminates the risk of electrical shock or damage
to equipment.
ii. Electrical equipment gets protected from potential damage by the mechanical
interlock against improper switching operations. In order to give fault currents a safe
discharge path, it makes sure that the isolator is opened first, separating the
equipment from the power source, and then the earth switch is closed.
c. Electrical interlock arrangement shall be provided between double break isolator (GOD) and
11kV circuit breakers: In case of deenergization first, CB to open then isolator open and last
earth switch close. If earth switch is closed while isolator is in circuit, phase to earth fault will
occur. In case of energization, first earth switch is opened, then isolator closed and last CB
closed.
2. HV DO fuses (Drop Out): These fuses stop the flow of current in the event of an internal fault or
short-circuit in the transformer. Overloads due to faults or short circuits on the distribution side of
the substation are prevented by low voltage protective equipment. IS Applicable: IS 9385 (Part 1 to
4): HV fuses. Voltage class: 11kV to 33kV; Current rating (A): 100A, 200A, 400A.
3. Station class LA:
a. IS Applicable
i. IS 3070 (Part 3): LA for AC system Specifications (Metal Oxide LA without gaps);
ii. IEC 60099-4: Metal oxide surge arrestors without gaps for AC system
iii. IS 2071: Methods of HV testing
b. CALCULATION OF VOLTAGE RATING OF LA
Voltage rating = ((Line Voltage / √3) x √2) x 1.1
Phase voltage (r.m.s. value) = Line Voltage/ 3
Peak value of voltage = Phase voltage (r.m.s. value) x 2
Additional factor = 10% of Peak value of voltage
c. B
d.

4. Difference between Isolator and Disconnector:

 a. All isolators are basically to be operated when no current is flowing through it. Whenever any
switch is closed or opened, there will be arcing. The arcing will be more when the switch is
opened. This is because during opening operation, the stored energy in the inductance of the
system gets dissipated. Since the isolators are not provided with arcing contacts, they cannot
be opened under load. Isolators are provided on either side of the circuit breaker and are
inter locked such that they cannot be opened unless the circuit breaker is in open All isolators
should be able to carry the full load current ,continuously and also should be able carry the
short circuit current for the duration of time the concerned protective device operates. The
specification of the isolator include the rated current and voltage and how much short circuit
current in KA, it can carry for 1 second.
b. Disconnector is similar to isolator bur can break small currents like no load current of
transformers and charging current of transmission lines. The most common application is on
the HT side of distribution transformers i.e.11KV/415V transformers. Specially in the case of
transformers less than 1000KVA, no circuit breaker is used on the 11KV side and a
disconnector is provided which is more economical. In this case to isolate the transformer
from 11 KV side first the load on the transformer is disconnected by the circuit breaker
provided on the L T side and then the disconnector on the 11 K V side is opened. Thus the
disconnector only breaks the no load current of transformer which is very small.
c. Switch can be operated on load and can switch off current up to its rated current. It is
designed to take care of arcing up to its rated current.

11kV HT SWITCHGEAR

1. Vacuum Circuit Breakers

a. Should be fully draw out type with test, service and isolated position.
b. Min. 6NO+6NC contacts per pole to be provided.
c. Closing coil, tripping coil, UV coil, shunt coil
d. Fully inserted and fully drawn out position of circuit breaker
e. All the HV compartments i.e. CBs, Bus bar and cable compartments shall be separated from
each other by metallic partitions in line with IEC 62271-100/200. These compartments must
have pressure relief flaps for exit of gas due to internal arc to ensure operators safety. All the
HV design must ensure conformity to IEC 62271-100/200 and must be type tested for
Internal Arc tests.
f. TNC switch, L/R selector switch, Anti pumping relay, Emergency trip push button, Test
Terminal block
g. Transformer outgoing feeders CBs shall be electrically interlocked with downstream LV
breaker such that if HV breaker trips, LV breaker shall also trip, and LV breaker cannot be
closed until HV breaker is closed.
h. Withdrawal or engagement of CBs or disconnecting switch shall not be possible unless it is
fully in service position, or in test position or in fully drawn-out.
i. Operation of CB or disconnecting switch shall not be possible unless it is fully in service
position, or in test position or in fully drawn out.
j. Rated operating duty: O-0.3s -CO- 3MIN- CO :
i. It shows the operating duty of the circuit breaker. If the breaker is closed, it can be
opened immediately. There should be a pause of 0.3 seconds for closing the breaker.
After that one opening sequence can be performed without time pause. After
opening the breaker there should be time gap of 3 min for closing the breaker. After
closing, the breaker can be switched off immediately
 ii. If we see the operating cycle the breaker must be closed after 0.3 sec first time and
after performing this the second closing is done after 3 minutes. The time gap is
made to rebuild the insulation level after arc quenching during circuit interruption.
k. https://www.electricalclassroom.com/circuit-breaker-positions-indications/
l.
2. Bus bars:
a. Applicable IS Code: IS 8084,
b. Bus bar material for switchgear panel shall be electrolytic copper.
c. Maximum temperature of the main bus bars and bus bar connections, under operating
conditions, when carrying rated normal current at rated frequency shall not exceed 90/105
degree Celsius for non-silver plated joints as per IEC 60694.
3. Loss of service continuity LSC 2B.
4. Relays
a. In case of primary protection relays do not have adequate no. of contacts for
protection/interlock schemes, suitable contact multiplying auxiliary relays shall be supplies.
b. Test terminal block for testing shall be provided.
c. Relays shall be suitable for SCADA with IEC 61850 protocol and Modbus RS 485.
d. Lockout/Master trip relay 86 shall be having 6 NO + 6 NC contacts.
e. All relay/auxiliary relay coils shall operate satisfactorily between 85% to 115% of rated control
voltage.
5. CTs
a. Applicable IS Code: IS 2705
b. Cast resin type (Class of insulation B)
c. Rated VA burden for metering/protection CTs shall not be less than 15VA or 120% of total VA
burden whichever is higher.
d. Accuracy class for metering CT shall be 1.0 or better.
e. Short time current rating and momentary withstand rating of CTs shall be as per breaker
short time current withstand capacity.
f. For CTs installed outside in switchyard, output shall be 1A. For CTs installed inside panel,
output shall be 5A.
6. PTs
a. Applicable IS Code: IS 3156
b. Rated VA burden for metering/protection PTs shall not be less than 100VA or 120% of total
VA burden whichever is higher.
c. Accuracy class for metering VT shall be Class 1.0/3P as required.
d. Fuses on primary side to be provided and shall have rupturing capacity equal to switchgear
rating.
e. For VTs, MCB shall be provided on secondary.
7. Annunciators:
a. 8 alarm input display for incomer and 16 alarm input display for transformer feeder
b. All alarm input contact to be NO. Only if fault, NC occurs.
c. Annunciators shall be suitable for accepting fleeting faults of duration as less as 15
milliseconds annunciating subsequent faults with the specified sequence immediately after
acknowledging the previous fault.
d. Time of auto acknowledge function can be set from 1-240 seconds.
e. “Mute”, “Acknowledge”, “Reset”, “Lamp Test/Function Test” push buttons on annunciators
i. “Lamp TEST” if push and hold this push button less than 3 seconds, it will light up all
LED lamps at the front panel only.
 1. During lamp test, if a fault occurs, the corresponding lamp circuit shall be
automatically disconnected from the “lamp test” and shall start flashing.
ii. “Function Test” if push and hold this push button more than 3 seconds, the LED lamp
will start flicking and Bell/Buzzer alarms.
f. Alarm sequences (Auto/Manual Reset /Indicator) of each input can be selected by software.
g. Alarm sound type (Bell/Buzzer) of each input can be selected by software.
h. Communication port : USB for configuration, RS485 – Modbus RTU for serial interface.
i. Alarm monitor software for remote monitoring and control ( Ack / Reset / Test )
j. Operating sequence:

Alarm condition Fault contact Audible Alarm Visual Alarm

Normal Open Off Off
Abnormal Close ON Flashing
Acknowledge Open Off Steady ON
Reset Open Off Off
Lamp Test Open Off Steady ON
Function Test Open ON Flashing

HAZARDOUS AREA

1. Applicable IS codes:
a. IS 5571: Guide for selection and installation of electrical equipment in hazardous areas (other
than mines)
b. IS 5572: Classification of hazardous areas (other than mines) having flammable gases and
vapours for electrical installation
2. V
3. D
4. A
5. W
6. R
7.

415V LT SWITCHGEAR

1. Separation of bus bars, functional units, and terminals from one another to varying degrees.
2. Form of separation as per IEC 61439-2/IS 8623-1:
a. Form 1
b. Form 2a and 2b
c. Form 3a and 3b
d. Form 4a (Type 1,2,3) and 4b (Type 5,6,7)
3. Panels should be complying to Form 4.
4. All the indoor switchgear panels shall be suitable for IP-54 degree of ingress protection for the
enclosure. Outdoor panels shall be with minimum IP-55, degree of protection.
5. Differences between Metal-Clad and Metal-Enclosed Switchgear
a. The main differences between metal-clad switchgear and metal-enclosed switchgear are as
follows:
 i. Enclosure Configuration: Metal-clad switchgear has separate enclosures for each
component, while metal-enclosed switchgear has a single enclosure for all
components.
ii. Voltage Rating: Metal-clad switchgear is typically used in medium-voltage
applications (2.4kV to 38kV), while metal-enclosed switchgear is typically used in low-
voltage applications (upto 1kV).
iii. Compartmentalization: Metal-clad switchgear is compartmentalized to separate the
circuit breaker from the busbars and other components, while metal-enclosed
switchgear has all components in the same compartment.
iv. Accessibility: Metal-enclosed switchgear provides easy access to all components,
while metal-clad switchgear may require more effort to access each component.
v. Space Requirements: Metal-clad switchgear requires more space due to the separate
compartments, while metal-enclosed switchgear requires less space.
6.

SWITCHYARD AND SUBSTATION DESIGNING:

1. Applicable IS/IEC/IEEE codes:

a. IS 10118: Selection, Installation and Maintenance of Switchgear and control gear
i. Consists of 4 parts out of which part 3: Installation is important
ii. IE acts and rules are important and are applicable with this standard
b. CBIP manual on substation layout Publication no. 299
c.