MODULE 3

INDUSTRIAL INSTALLATIONS
CLASSIFICATION
Based on the following criteria.
1. Fire Hazards.
2. Power consumption.
3. Pollution Hazards.
CLASSIFICATION BASED ON FIRE HAZARD
National Building Code (NBC-2005) classifies industrial buildings in
group G.
Group G1 – Buildings used for low fire hazard industries.
Low combustibility contents.
Low combustibility process/operations.
No possibility of propagation of fire.
Possibility of fire only due to panic, fumes or smoke or fire from
external source.
Example – Cement factories, Glass factory, Rice mills, soap &
detergent factory, sugar industry etc.
CLASSIFICATION BASED ON FIRE
HAZARD (Contd)
• Group G2 – Buildings of moderate fire hazard.
• Process/operations with possibility of fire with moderate rapidity.
• Will give considerable volume of smoke.
• Generate Non – toxic fumes with no possibility of an explosion.
• Example – Ship repairing docks, Coir Industry,Chemical
manufacturing, Flour mills, fertiliser plants etc.
CLASSIFICATION BASED ON FIRE
HAZARD (Contd)
• Group G3 – Buildings with high fire hazard.
• Process/operations with possibility of fire which will burn with
extreme rapidity
• Or generate poisonous fumes.
• Or may lead to explosions.
• Example – Alcohol distillery, Explosive manufacturing, Fire work
industry, oil mills, Petrochemicals, paint factory etc.
CLASSIFICATION BASED ON POWER
CONSUMPTION
Based on NEC 2011.
Description Average power Examples
requirement
Light Industry Upto 50 kVA Hosiery, Garment making, Ornament
making etc

Average Industry Above 50 upto Furniture, Pottery, Glass, Tobacco,

2000kVA Electrical gadgets, Textiles, Engine fittings
etc.

Heavy Industry Above 2000kVA Heavy electrical equipment, steel mills,

foundries, Ship building, chemical plants,
fertilizer plants, metal extraction,
petrochemicals, paper mills etc.
 CLASSIFICATION BASED ON
POLLUTION
Based on NEC 2011. LEVEL
Pollution degree 1
No Pollution or only dry , non conductive pollution occurs. The pollution has no
influence.
Pollution degree 2
Only non conductive pollution occurs except that occasionally a temporary
conductivity caused by condensation is to be expected.
Pollution degree 3
Conductive pollution occurs or dry , non conductive pollution occurs which
becomes conductive due to condensation – Which is to be expected.
Pollution degree 4
Continuous conductivity occurs due to conductive dust ,rain or other wet
conditions.
 General characteristics which define the power distribution
architecture of industrial buildings.
Activity carried out in the building.
Manufacturing buildings
Food & Beverage processing
Logistics etc.
Site Topology (No. of buildings, number of floors, floor area etc.).
Single storey buildings
Multi storey buildings
High rise buildings.
Layout latitude (Equipment/systems layout).
Aesthetics
Presence of dedicated location
Use of technical corridor (horizontal service ducts) per floor.
Use of technical service ducts(vertical).
 Lay out categories – Low, Medium & high (Based on positioning of electrical equipment on the floor)
SERVICE RELIABILITY
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.
1. Minimum service reliability.
Installations subject to power supply interruptions related to geographical, technical
or economic factors. Example – remotely located industries from power production
centres or industries powered by isolated power systems.
2. Standard Service reliability.
Whether supply is from OH line or from a purely radial network. The system is
subjected to all sorts of natural fury.
3. Enhanced service reliability.
Using of UG cables & Ring main supply system & timely maintenance.
Providing overloading capability at the time of design itself.
Maintainability
• Refers the design considerations taken during
design to limit maintenance.
• Maintainability will be minimum if the installation must be stopped to
carry out maintenance operations.

• Maintainability will be standard if the maintenance can be carried out

during the operations but with reduced performance levels.
• Enhanced maintainability - Maintenance can be carried out without
disturbing the operations of production. Normally achieved by double
ended supply configuration.
Installation flexibility
Possibility of easily moving the power delivery points within the
installation or the facility to increase the power availability at certain
points. Different categories of installation flexibility are
1. Non Flexible – If equipment position is rigidly fixed due to weight
or constraints related to building.
2. Design flexibility – Capability of providing satisfactory performance
even when the number of power delivery points , their power rating
and locations are not known.
3. Implementation flexibility – Power delivery installation is
completed before the installation of loads and a satisfactory
performance is guaranteed.
4. Operational Flexibility – Position of loads can be changed according
to the process reorganization or extension of the existing facility.
POWER INTERRUPTION SENSITIVITY
Capability of the system to accept power interruptions.
1. Sheddable loads – Capability to partially shut down a portion of the
load at any time.
2. Long interruption acceptable loads – Interruption accepting
capability for more than 3 minutes.
3. Short interruption acceptable – Interruption acceptable time is less
than 3 minutes.
4. No interruption acceptable – Power interruption cannot be accepted
 POWER INTERRUPTION SENSITIVITY (Contd)
The importance of power interruption on the operation of industry
and severity in this context are categorised as-
No notable consequences.
Loss of production.
Deterioration of production facility.
Mortal Danger.
All these consequences can be expressed in terms of criticality of
the supplying loads.
 Non Critical loads – Can be shed at any time(Ex- Domestic water
heating).
 Low criticality loads –Creates discomfort without financial
implications.(Ex - HVAC).
 High criticality loads – Mortal & Huge financial loss(Ex –
Underground mining operations)
DISTURBANCE SENSITIVITY

Ability of the industry to work properly in the presence of power

disturbances. Various power disturbances are –
• Brown outs
• Over voltages
• Voltage distortion due to harmonics.
• Voltage fluctuations
• Voltage unbalance.
Disturbance sensitivity is classified as
• Low Sensitivity – Little effect
• Medium sensitivity – Notable effects – (Ex – Induction motors)
• High sensitivity – Serious effects and damage – (Ex- IT equipments)
Selection of distribution architecture

• Involves spatial configuration, the choice of power sources,

different distribution levels, SLD & choice of equipment.
• Best architecture – A compromise between various
performance criteria, Financial situations and Technical
matters.
• Committed interaction with various players associated in the
establishment of industry is very important.
• With Civil Engineering architects
• Lighting , HVAC designers etc
• Design Professionals.
Stage 1. Choice of power distribution architecture
• General feature of electrical installation is defined.
• Macroscopic characteristic of the industry is taken into
account.
• Schematic diagrams are used as a starting point for finalising
the SLD.
• SLD can be broken down into several key parts; such as
• Connection to the power utility
• Configuration of the HV circuits.
• Number of distribution transformers and sub stations.
Choice of power distribution architecture (Contd)

Flow
Chart of
Design
process
Connection to the power utility network
Different Types of service connections.
1. Medium Voltage Service connection.
2. High voltage single line service
connection.
3. High Voltage ring main service connection.
4. High voltage duplicate supply connection.
5. High voltage duplicate supply with double
bus bar.
Connection to the power utility network (Contd)
Connection to the power utility network (Contd)
Connection to the power utility network Contd
Characteristics of service connections
High Voltage circuit configuration
• Can be configured in 3 different modes
• Single feeder, One or more transformers.
• Open ring with one HV connection.
• Open ring with two HV connections.
High Voltage circuit
configuration (Contd)

Single feeder,
One or more transformers.
High Voltage circuit
configuration (Contd)

Open ring
with one HV connection.
High Voltage circuit configuration (Contd)

• Open ring with two HV connections.

High Voltage circuit configuration (Contd)
Characteristics of H V Configurations.
High Voltage circuit configuration (Contd)
SELECTION CRITERIA FOR SUBSTATIONS
NUMBER OF DISTRIBUTION TRANSFORMERS
The following points need to be considered.
1. Surface area of the building site.
2. Total installed power capacity.
3. Sensitivity of circuits to power interruption.
4. Sensitivity of circuits to disturbances.
5. Installation scalability (future expansion).
The factors that lead to a choice of more than one transformer are
6. Large connected load.(>1250kVA)
7. Large surface area of the buildings.(>5000 Sq M).
8. Need for partial redundancy.
9. Separation of disturbing loads.
Stage 2. Choice of power distribution architecture details.
• Power distribution architecture is defined in this stage.
• Choice among the following is made.
Layout
Whether centralised or decentralised distribution.
Presence of backup generation.
Presence of Uninterrupted power supply.
Configuration of LV Circuits.
Architecture combination.
Stage 2. Choice of power distribution architecture details.(Contd)

LAYOUT
• Decided by the manufacturing process.
• Locate MV switch board as close to power consuming equipment.
• Locate Power source free of constraints like high temperature,
presence of dirt, vibration etc.
• Position all heavy equipment like transformer etc at a location with
ease of access and maintenance.
Stage 2. Choice of power distribution architecture details.(Contd)

CENTRALISED OR DECENTRALISED LAYOUT.

Centralised layout Decentralised layout

Stage 2. Choice of power distribution architecture details.(Contd)
Presence of backup generation.

Generator capacity – Part

load or full load.

Interlock – For selective

switching.
Stage 2. Choice of power distribution architecture details.(Contd)
Connection of critical loads through UPS.

• For modern sophisticated

loads
• Back up time varies from
a few minutes to several
hours.
 Stage 2. Choice of power distribution architecture details.(Contd)

Configuration of MV Circuits.(Last stage of finalising the distribution architecture.)

Radial Single feeder
Two pole configuration
Two Pole with two ½ MSBs
Sheddable switch board.
Interconnected switch boards.
Double ended power supply.
Configuration of MV Circuits (Contd)
Radial Single feeder

• Basic
Configuration
• Availability –
Minimum
• No redundancy
Configuration of MV Circuits (Contd)
Two pole configuration
HV

• Two
transformers
connected to the
same MSB
• When the
transformers are
located close to
each other , they
are operated in
parallel
Configuration of MV Circuits (Contd)
Two Pole with two ½ MSBs

• Variant of 2 pole
configuration
• Increases the power
availability in case of
a bus bar failure or
allows maintenance
on one of the
transformers.
• Needs proper
Bus
interlocking – 2 Key, Coupler
Configuration of MV Circuits (Contd)
Sheddable switch board.

Non critical load

shedding
possibility in case
of overload or
operating on
Generator.
 Configuration of MV Circuits (Contd)
Interconnected switch boards.
• If the substations are HV
physically distant from
each other , they can be
connected by a bus bar
trunking system.
• Critical load supply .
• Increased power
availability.
• Redundancy is partial if
each transformer is rated
to supply only part of
the loads.
•
 Configuration of MV Circuits (Contd)
Double ended power supply.
• Maximum power availability.
• Either 2 independent power G
sources by different H V Lines.
• Or one transformer and a back
up generator.
• Or one transformer and a UPS.
• Proper interlocking
arrangement or Automatic
transfer switch is required.
• Allows preventive and curative
maintenance without
interrupting the supply.
Selection of Transformer substations
• Most important component in the Transmission and distribution
network.
• Selection should be based on
• Economy.
• Technical suitability of the product.
• Cost.
• Short term gains and long term gains.
• Latest technology.
Factors deciding the selection of
transformers.
•Maximum Demand.
•Future expansion.
•Spare capacity.
•Statutory requirements.
•Site conditions.
Standard rated output of 11/0.433kV Transformers
• Standard ratings(In kVA)
50,63,80,100,160,200,250,315,400,500,630,800,1000,1250,1600,2000.

• Rated Impedance voltage – 4% (Used in Distribution networks)

- 6% (Used in industrial networks)
 Cooling
• Method of cooling is indicated on the name plate of the transformer.
• Total Four letters.
• First 2 Letters – Type of coolant and the manner of circulation of the
coolant for the windings.
• Last 2 Letters - Indicates the coolant and manner of circulation of
the coolant for cooling outside the transformer. Manner of circulating the
Sl.No Coolant Name Letter Cooling medium
• Symbol
cooling medium

1 Mineral Oil O
2 Clophen(Askarel) L Sl.No Coolant Letter Symbol
{polychlorinated
biphenyls (PCBs)}
Circulation
3 Gas G 1 Natural N
4 Water W 2 Forced F
5 Air A Circulation
Cooling (Contd) - ONAN
Cooling
(Contd) - ONAF
Cooling (Contd)
- ONAF
Cooling (Contd)

Example
• ONAN – Oil immersed self cooled. (Oil Natural Air Natural).
• ONAF – Oil immersed Forced air cooled. (Oil Natural, Air forced.).
Over loading capacity
Classification of sub stations based on the nature of duties

1. Step up or primary sub stations.

Associate with Generating stations
Generated 11kV or 33kV is stepped up for Transmission.
2. Primary Grid substations
Loated at Load centres.
Primary transmission voltage is stepped down to suitable secondary
voltages.
Further stepped down to sub transmission or primary distribution voltages.
3. Step down or distribution sub stations.
Located at load centres
Sub transmission/Primary distribution voltage is stepped down to secondary
distribution voltage (415/240V).
Consumer end power delivery through distribution network & service lines.
Classification of sub stations based on the basis of service rendered.

Transformer sub stations.

For Converting one voltage level to another voltage level.

Switching substations.
No transformation in voltage. Connects various transmission lines.

Converting substations.
AC to DC or vice versa or converting frequency.
Classification of sub stations
On the basis of operating voltage.
HV – 11kV to 66kV.
EHV – 132kV to 400kV.
UHV – Above 400kV.
On the basis of importance.
Grid Substations – Bulk power transmission across grid.
Town substations –
On the basis of design.
Indoor type – 11kV to 66kV.
Outdoor substations – Pole mounted (Single stout pole, H-pole or 4
Pole)and Foundation (above 250kVA)mounted.
Typical SLD of Transformer substation and MSB
Pole Mounted out door substation
Pole Mounted out door substation
Plinth mounted transformer with 4 pole structure
D O Fuse
11 kV isolator
HORN GAP FUSE
Indoor substation
Indoor substation (Contd)
SLD – Indoor S/S . 500kVA – 11kV/415 V
Installation of outdoor type transformer substation
Installation of indoor type transformer substation

(XLPE)
Installation of indoor type transformer substation (Contd)
Selection of switch gears
Selection of switch gears (Contd)
Selection of switch gears (Contd)
Switching Devices
Switching Devices (Contd)

another.