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The document provides a 7 step solution to design an electrical installation with a connected load of 550kW including a 150HP motor load and 200kW essential load. Step 1 sizes a 630kVA transformer to power the load. Step 2 selects 150mm2 XLPE cable for the high voltage connection. Step 3 chooses a 630A HT breaker and control switch. Step 4 selects a 1250A low voltage breaker. Step 5 specifies 400mm2 cables from the transformer. Step 6 sizes busbars and selects various MCCBs for branch circuits. Step 7 determines a 200kVA generator is needed for the essential 200kW load.

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Joshua Cm
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117 views

Note1 PDF

The document provides a 7 step solution to design an electrical installation with a connected load of 550kW including a 150HP motor load and 200kW essential load. Step 1 sizes a 630kVA transformer to power the load. Step 2 selects 150mm2 XLPE cable for the high voltage connection. Step 3 chooses a 630A HT breaker and control switch. Step 4 selects a 1250A low voltage breaker. Step 5 specifies 400mm2 cables from the transformer. Step 6 sizes busbars and selects various MCCBs for branch circuits. Step 7 determines a 200kVA generator is needed for the essential 200kW load.

Uploaded by

Joshua Cm
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Electrical Design 1

Q: Design an installation with the following details


I. Connected load 550 kW of which the maximum motor load is 150 Hp and essential
load is 200 KW
II. Earth Resistivity 90 ohm-meter

Solution

Step – 1: Transformer Sizing

Total connected load = 550 kW


Motor Load = 150 Hp
Motor Load in kW = 150 X 0.746 = 111.9 kW
Total connected load in kW = 111.9+200+238.1 KW
Total connected load in KVA = 550 / 0.8 = 687.5 KVA
Let take diversity factor as 1.5
Maximum demand load = connected load / diversity factor
= 687.5 / 1.5 = 458.33 KVA
Let Consider additional 20 % for future need then:
Maximum demand load in KVA = 458.33 X 1.2 = 550 KVA
Hence we select next higher size of transformer 630 KVA

Let check 630 KVA transformer is sufficient for starting the highest motor 150 Hp
= 139.875 kW X 2.5 = 349.68 KVA
Hence the transformer 630KVA is sufficient.

Step – 2: HT Cable Selection.


Let consider fault level at HT side as 250MVA
Fault current (Is) = 250,000 / (1.73 X 11)
= 13.13 KA
Duration of fault current = 1 sec
Cross section of AL XLPE HT Cable = 10.64 X Is X Root T
= 10.64 X 13.13 X 1 = 139.78 mm2
Hence 150 Sq.mm XLPE Al Cable Selected

Step – 3: HT Breaker Selection.


Primary side current = 630 / (1.73 X 11) = 33.10 A
HT HRC fuse selection = 35 A
C.T for HT side = 35 / 5A, 15 VA, Class 0.5
P.T for HT side is = 11 / 110 V, 100 VA, Class 0.5
HT side Control Switch = 11 KV, 630A, 250 MVA, HTABSFU (High Tension Air Break Switch Fuse
Unit)
Step – 4: LT Breaker Selection.
Full Load Current of Transformer LT Side = 630 / (1.73 X 0.433) = 841.02 A
Let add 150 % for safest design = 841.02 X 1.5 = 1261.53 A
Let consider Transformer % impedance as 5% then short circuit current becomes
= 841.02 / (5/100) = 16820.4 A
= 16.82 KA
Total Load Current = 550 KVA / (1.73 X 0.433) = 734.224 A
Electrical Design 2

Hence select 1250A, 4P, 36 KA, Mechanical or Electrical draw out ACB with 3O/C + 1E/F in built release
and low set E/F protection using neutral C.T set at 800A

Step – 5: LT Cable Selection.


For 630 KVA transformer select 4 X 3.5 X 400 Sq.mm AFYF cable (X mtr) from Cable Chart.

Step – 5: MDB Busbar Selection.


LT side of Transformer Protection Beaker Size = 1250 A
Let consider bus bar is aluminum and current density is 0.8 A/Sq.mm
Current density = Current / Area of the busbar
Area of Bus bar = 1250 /0.8 = 1562.5 Sq.mm
Hence select 1 X 150 X 12 bus bar for 3 Phases and 1 X 75 X 12 for Neutral bus bar

Step – 6: MDB Branch Breaker Selection.


Branch load-1
150 Hp Motor operate with Star Delta Starter Power Factor 0.8 and efficiency 85% and voltage 415V,
Three Phase
Motor Load = 150 Hp
Motor Load in kW = 150 X 0.746 = 111.9 kW

Motor Full load Current A = 111.9 / (1.73 X 0.415 X 0.8 X 0.85)


= 229.20 A
Maximum Size of Inverse Trip Circuit Breaker = 250% X Full Load Current (as per. NEC 430-52)
= 229.20 X (250 / 100)
= 573 A
As a Thump Rule If MDB incomer is ACB and Branch Circuits are MCCB, The rating of Branch Circuit
Breakers Shall be In a limit (1/3 X Is <> 0.8 X Is)
Where Is is MDB incomer Set Current i.e. 800A
Then Range becomes = (800 / 3 <> 800 X 0.3)
= 266.66 A <> 640 A

Then select 800A MCCB, set at 640A for Motor load

Branch load-2
Let take 238 KW as load – Mech. & Elect. Work Shop.
Connected Load in kW = 238 kW
Let take diversity factor 1.5

Maximum Demand = 238 / 1.5 = 158.66 KW


Maximum Demand Current = 158.66 / (1.73 X 0.433 X 0.8)
= 264.76 A
Maximum Size of Inverse Trip Circuit Breaker = 125% X Full Load Current
= 264.76 X (125 / 100)
= 330.95 A

Then select 500A MCCB, set at 350A

Branch load-3
Take 1 No 500A MCCB as Spare Breaker
Electrical Design 3

Branch load-4
Take 1 No 630A MCCB as Spare Breaker

Under essential load

Branch load-5
Let take 100 KW as load – Electrical Dept.
Connected Load in kW = 100 kW
Let take diversity factor 1.5

Maximum Demand = 100 / 1.5 = 66.66 KW


Maximum Demand Current = 66 / (1.73 X 0.433 X 0.8)
= 111.23 A
Maximum Size of Inverse Trip Circuit Breaker = 125% X Full Load Current
= 111.23 X (125 / 100)
= 139.04 A

Then select 315A MCCB, set at 157A

Branch load-6
Let take 100 KW as load – Mechanical Dept.
Connected Load in kW = 100 kW
Let take diversity factor 1.5

Maximum Demand = 100 / 1.5 = 66.66 KW


Maximum Demand Current = 66 / (1.73 X 0.433 X 0.8)
= 111.23 A
Maximum Size of Inverse Trip Circuit Breaker = 125% X Full Load Current
= 111.23 X (125 / 100)
= 139.04 A

Then select 315A MCCB, set at 157A

Branch load-7
Take 1 No 315A MCCB as Spare Breaker

Step – 7: Generator Sizing


Connected Load in KW = 200 KW
Let consider Diversity 1.5 same as transformer case
Maximum Demand Load in KW = 200 / 1.5 = 133.33 KW
Maximum Demand Load in KVA = 133.33 / 0.8 = 166.66 KVA
Let Consider additional 25 % for future need then:
Maximum demand load in KVA = 166.66 X 1.25 = 208.325 KVA
Hence select 200 KVA Generator for feeding power to 200KW essential load.
Electrical Design 4

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