UNIVERSIDAD DE CASTILLA - LA MANCHA

ESCUELA TÉCNICA SUPERIOR

DE INGENIEROS INDUSTRIALES

CIUDAD REAL

FACILITIES PLANNING

FACTORY OF ELECTRICAL MOTORS “MOTELEC”

Author:

(Group 2)
Carolina Aparicio Sanroma
Carlos Medina Arce
Juan Bosco Ramos Almada
Enrique Vélez Ayuso

Mayo 2014
Index
1. Introduction 1

2. Objectives 1

3. Product 1

4. Legislation 1

5. Location 2

6. Process 4

7. Layout 13

8. Detailed Design 15
8.1. Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.1.1. Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.2. Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.3. Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.4. Sewage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.5. Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.5.1. Indoor Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.5.2. Outdoor Lighting . . . . . . . . . . . . . . . . . . . . . . . . . 40

9. Work Distribution 44

10.Bibliography 45

I
Figures Index
1. Valdepeñas Location . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Facility Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Production process scheme . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Laminating machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Manufactured magnetic steel. . . . . . . . . . . . . . . . . . . . . . . 6
6. Stator shaped. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7. Manufacturing rotor machinery. . . . . . . . . . . . . . . . . . . . . . 8
8. Press for rotor manufacturing. . . . . . . . . . . . . . . . . . . . . . . 8
9. Rotor manufacturing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10. Balancing machine rotors. . . . . . . . . . . . . . . . . . . . . . . . . 9
11. Shield and frame manufactured. . . . . . . . . . . . . . . . . . . . . . 10
12. Motor winding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
13. Automatic winding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
14. Rotors in bolt conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . 11
15. Motors assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
16. Painting zone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
17. Motors ready to be dispached. . . . . . . . . . . . . . . . . . . . . . . 13
18. Relationship chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
19. Blocks diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
20. Final layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
21. X bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
22. Gussets 10 % . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
23. American lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
24. 3D design of facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
25. Structural hypothesis . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
26. Structural scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
27. Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
28. Envelopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
29. Foundation data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
30. Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
31. Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
32. General data and Protencions of the line diagram. . . . . . . . . . . . 23
33. Wires of the electrical installation. . . . . . . . . . . . . . . . . . . . . 23
34. Line Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
35. General data of water installation. . . . . . . . . . . . . . . . . . . . . 26
36. Parameters of the water installation. . . . . . . . . . . . . . . . . . . 26
37. Maximum velocity of the installation. . . . . . . . . . . . . . . . . . . 26
38. Coefficients of the installation and excavation. . . . . . . . . . . . . . 27
39. Water Supply system for MOTELEC Equipment Factory. . . . . . . . 27
40. Tubing sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
41. General data and materials of sewage installation. . . . . . . . . . . . 29
42. General data and materials of sewage installation. . . . . . . . . . . . 30
43. Maximum velocity of sewage installation. . . . . . . . . . . . . . . . . 30
44. Coefficients of the sewage installation and excavation. . . . . . . . . . 30
45. Water sewage system for MOTELEC Equipment factory. . . . . . . . 31

II
46. Tubing sizes (sewage). . . . . . . . . . . . . . . . . . . . . . . . . . . 32
47. Offices Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
48. Indoor luminaire 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
49. Indoor luminaire 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
50. Top View of the indoor lighting of facility . . . . . . . . . . . . . . . 35
51. Isolines map of indoor lighting . . . . . . . . . . . . . . . . . . . . . . 36
52. Isolines map of indoor lighting (Offices) . . . . . . . . . . . . . . . . . 36
53. Outdoor luminaire . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
54. Outdoor lighting scheme . . . . . . . . . . . . . . . . . . . . . . . . . 42
55. Curve for the utilization factor (outdoor) . . . . . . . . . . . . . . . . 42
56. Outdoor luminaires distribution . . . . . . . . . . . . . . . . . . . . . 43
57. Outdoor colour scale of lux . . . . . . . . . . . . . . . . . . . . . . . . 44
58. Work Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

III
Tables Index
1. Average price per square meter . . . . . . . . . . . . . . . . . . . . . 4
2. Datasheet of laminating machine . . . . . . . . . . . . . . . . . . . . 6
3. Powers (kW) consumed in MOTELEC. . . . . . . . . . . . . . . . . . 24
4. Water consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5. Collectors slope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6. Facility Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7. Lighting levels for indoor lighting . . . . . . . . . . . . . . . . . . . . 33
8. Utilization factor of local . . . . . . . . . . . . . . . . . . . . . . . . . 37
9. Comparison chart between methods . . . . . . . . . . . . . . . . . . . 40
10. Lighting levels for outdoor lighting . . . . . . . . . . . . . . . . . . . 41
11. Recommended height according to the luminous flux . . . . . . . . . 41

IV
1. Introduction
This project designs a factory of electrical motors.
This will include the location, layout, machinery and all necessary facilities as
metal structure, electrical installation, and lighting.

2. Objectives
We live in a world where there is much competition, especially from the Asian
market. Therefore we try to analyze the possibility of opening a new workshop and
storage in Central Europe in order to be so as closed as possible to our potentially
customers and Develop a new line of low cost products to be more competitive. The
actual level of exportation is near to 70We are determined to find solutions that fit
as perfectly as possible.
All the elements which make up the installations will be described in this project,
as well as the definition of the required solutions under all the established rules and
current regulations.

3. Product
The Features are the following:

Our motors can be provided from 0,25 kW up to 55 kW .

It is composed about Squirrel cage and cast iron motors.

Huge range of efficiency from IE1 and IE4.

Used for industrial processes.

It can be used in end-users in industry, tailored serial project OEM’s, pumps

and fans.

4. Legislation
The following existing legislation has been taken into account in order to write
up the present project:

Electrical Installation: Low-Voltage Electrotechnical Regulations and Comple-

mentary Instructions.

UNE-21123

UNE-EN 50.086-2-4

UNE-EN 60.598-2-3

UNE-20.324

1
 UNE-EN 50.102

UNE 20.324

UNE 12464.1

Emergency Installations: the 3rd of December Royal Decree 2267/2004

UNE-EN 671-1

UNE-EN 671-2

DIN 14675

UNE- 231102
Sanitation Installation:

UNE 43114
Foundations:

EHE-98-CTE
Steel Structure:

CTE DB SE-A

5. Location
To choose a specific location must consider multiple factors.
To choose the location of our facility we have to consider three criteria:

Price of the land where we locate our facility.

Level of existing communications.

Land knowledge, to avoid possible troubles.

Our choice is Valdepeñas (Ciudad Real):

2
 Figure 1: Valdepeñas Location

Located in the outskirts of the city, in the industrial area “Avenida del Vino”.

Figure 2: Facility Location

In the picture we can see the exact location on an empty plot to comply with

3
the dimensions that we need to install the facility.

Why have we chosen this location?

Has one of the lowest average price per square meter of industrial land of
Spain, and its annual trend is negative actually.

Chart 1: Average price per square meter

About communications, there is the A4 highway (one of the most used in

Spain), a RENFE train station for passengers and cargo, and another highway
in project CM-45.

The industrial area “Avenida del Vino” is adhered to convention with Castilla-
La Mancha govern, , which facilitates the arrival of companies with investment
grants and subsidized 75

Finally, components of the project group are locals.

6. Process
For the production of the various parts that form an electric motor, we need first
to estimate the necessary machinery and quantitative calculations give us a rough
idea of powers required both for consumption and for the correct dimensioning of
the electrical installation.
Moreover, this estimate is also useful for us to know the distribution plan as
efficient as possible.
To do this, based on the following scheme:

4
 Figure 3: Production process scheme

The magnetic plate will be manufactured through a rolling process, which will
require a laminator that allows the task.
This machine will consume approximately 220 kWh per unit and will be connec-
ted to a three-phase 400 VD. We will have 4 units. Below you can see a summary
of the technical features of the machine.

Figure 4: Laminating machine

5
 Chart 2: Datasheet of laminating machine

Then we can see from left to right, the different magnetic sheets for the .Air
Gap”to the 8-pole motor.

Figure 5: Manufactured magnetic steel.

6
 Regarding the manufacture of the shaft, by simplifying the process and technical
matters will be made by the auxiliary industry and will not be considered herein.
For the manufacture of the stator, it is necessary to have shapers, for which we
estimate a consumption of 50 kWh per unit addition of auxiliary machinery such as
lifts, tapes, etc ... for which a consumption of 50 kWh is estimated. We will have
suits for this process.

Figure 6: Stator shaped.

As for the rotor, need more shapers as we can see in the picture below.

7
 Figure 7: Manufacturing rotor machinery.

For this process, we estimate a consumption of 75 kWh per unit. We will have 4
units for this process also.
A pressing with an estimated consumption of 100 kWh per unit will also be
necessary. In this process will have 4 units.

Figure 8: Press for rotor manufacturing.

8
 Figure 9: Rotor manufacturing.

Finally, to complete the manufacture of the complete rotor, we need a balanced

machine as we can see below.

Figure 10: Balancing machine rotors.

9
 We estimate a consumption of 10 kWh for this section and 3 units will be needed.
The manufacture of the housing and shield are also made by molding, and in the
same way estimate consumption 75 kwh per unit. 4 Units will be needed.

Figure 11: Shield and frame manufactured.

Once we have the manufactured rotor through tape reaches the area of automatic
winding. Need for winding coils, about 150 kWh consumption per unit. In total, we
will have 2 automatic winders.

Figure 12: Motor winding.

10
 Figure 13: Automatic winding.

Figure 14: Rotors in bolt conveyor.

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 On insertion of rotor and stator with housing, we need the help of robots, which
will have a consumption of 60 kWh per line having 3 lines of assembly.

Figure 15: Motors assembly.

For impregnation and painting, we need auxiliary machine whose consumption

is estimated at 20 kWh per cabin. We have 3 booths.

Figure 16: Painting zone.

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 Finally for final assembly and testing, we need to have auxiliary machine, test-
beds and bridge crane with a total consumption of 600 kWh.

Figure 17: Motors ready to be dispached.

Finally conveyors also need to communicate the different workstations. To do

this we assume consumption 10kW per tape. We will have a total of 18 tapes.
In summary, if we take all the machines described and include lighting, auxiliary
lighting, plugs, etc ... need an electrical system capable of providing a power of 2600
kWh at full load.
Taking into account that this data should be oversized for future additional
applications, auxiliary equipment for higher yields, etc. .. 3200 installation kWh
would be more than enough for the entire factory.

7. Layout
For the plan distribution we must sort the main activities involved in the enter-
prise. For that reason you can have a look to the list and the matrix correlations
you can see in the picture.

Offices

Material reception

Laminate

Shaping

Pressing

Balancing

Winding

Assemble zone

13
 Painting
Tests
Expedition
The tablet shown in the right side indicates the level of proximity between acti-
vities.

Figure 18: Relationship chart.

The blocks diagram is the next one:

Figure 19: Blocks diagram.

14
 and the final layout:

Figure 20: Final layout.

8. Detailed Design
8.1. Structure
Calculations have been proceed with the program “New Metal 3D” in Cype.
The structure have been taken into account the following characteristics:

Dimensions:

− Pillar Height: 7 meters.

− Ridge Height: 9 meters.
− Beam:100
− Spans: 12
− Depth: 5
− Total area:

Actions:

− Indoor enclosures Wight: 10 kg/m2

− Overloading of the enclosure: 10 kg/m2

15
 − Lateral closing Wight: 10 kg/m2
− Snow Overload: Data for zone 3. (h=635 m)
− Policy: CTE-DB-SE-AE
− Snow overload: Data for zone B (Comercial)

Calculation of straps:

− Separation between belts: 1.5 meters

− Three or more openings.
− Arrow L/250 limit.
− Rigid fixation.
− All elements are calculated with steel building S-275.

Structural element added:

− “Cruces de San Andrés”

Figure 21: X bracing

− Gussets 10 % at all nodes

16
 Figure 22: Gussets 10 %

− American lattice

Figure 23: American lattice

3D design of facility:
Having done all the checks, we obtain the following final design of the ship:

17
 Figure 24: 3D design of facility

Actions generated:
View all hypotheses:

Figure 25: Structural hypothesis

Profiles:

− HEB 200 (H)

18
 − IPE 270 (I)
− IPE 200 (Is)
− L 150x150x10 (L)

Figure 26: Structural scheme

− HEB 120 (Hl)

Figure 27: Structure

Envelopes:

19
 Figure 28: Envelopes

8.1.1. Foundation
All foundations are done through the “New Metal3D”.
Data:

Figure 29: Foundation data

20
Distribution of the shoes and tie beans:

Figure 30: Foundation

3D Vision:

Figure 31: Foundation

21
 Verification and dimension.
Then proceed to the grouping of all the shoes in terms of size and dimensioning are
assigned by the program. All shoes are sized according to the maximum value of the
efforts of the column produced by the situation of the bridge crane.

8.2. Electrical Installation

In this section, it is explained everything referent to the electrical installation of
the factory.

Background
On particular request, the following memory is written in which, according to the
current legislation, it is explained how is the electrical installation of the factory is
built.

Objective
Design and describe every element of the electrical installation of the factory.

Regulations
The norms applied are the ITC-BT:
ITC-BT – 1. Terminology
ITC-BT – 6. Implementation of the facilities
ITC-BT – 7. Permissible maximum current
ITC-BT – 10. Estimate of changes
ITC-BT – 20. Protection against over voltages and currents
ITC-BT – 21. Protection against direct and indirect contacts
ITC-BT – 25. Specific Requirements

Description
The electrical installation of the factory consist of an underground connection of
copper in a three-phase system. The supply voltage is 400V, and the maxmimum
allowable voltage drop is fixed at 5

Line Diagram
This is the notation that represents the three-phase power system for MOTELEC
Electrical equipment factory. All the machinery needed to carry out the production
process is represented in the following figures, with a simultaneity coefficient of 0.43.

22
 Figure 32: General data and Protencions of the line diagram.

The following figure shows the wires that are used in the electrical installation
of the plant. As explained before, the material of the wires is copper.

Figure 33: Wires of the electrical installation.

And finally, the next figure shows the line diagram of the electrical installation,
including all the machinery used in the production process and lighting.

23
 Figure 34: Line Diagram.

The following table shows the powers consumed by each of the machinery and
lighting.

Chart 3: Powers (kW) consumed in MOTELEC.

The total energy consumed in the electrical installation multiplied by the simul-
taneity coefficient is 1442 kW.
Because of the energy consumption in all the facilities is high, some checks could
not meet the dimensioned CYPELEC.

8.3. Water Supply

In this section, it is described in detail the water supply system of the factory. For
the design of water supply network as a whole, the quality of service provision was
considered, the limitations of supply pressure, the water supply flow, the minimum
diameters to respect and appropriate for distribution speeds.
For service provision, the following criteria showing the equivalence of the capacity
and population was used.

24
 Chart 4: Water consumption.

Limitations in the supply pressures

It is required to establish maximum and minimum limits in the supply pressures for
guaranteeing the supply network performance and good service to every consuming
nodes.
The maximum pressure must be established in order to favor the network mainte-
nance, since it decreases the breakage of the pipes and leakage are minimized. The
minimum pressure in the network depends on the point of consumption, it has to
be a remnant or residual pressure in each one.

The water supply flow

The water flows to supply in the network depend on the consumes on the supply
points. The following formula was used to calculate the flow of water on the points.

Dot · P ob
Q=
24 · 3600
Where:

Q = thef lowof waterinl/sec

Dot = Endowmentof waterinl/hab/day
P ob = P opulationtosupply
T he resultingf lowof waterwasapproximately2,5l/sec

Minimum diameters
By calculating the minimum diameters in the supply network, problems are avoi-
ded by the reduction of usable diameter due to deposits of water, also increases
consumption or network extensions in their final stages are favored.

General Information
The following figures shows the definition of the elements of the water supply system,
as the materials and the landing of the plant.

25
 Figure 35: General data of water installation.

The materials used in the installation is 1A PN2O TUBO FNCGL, in cohesi-

ve soil. The parameters, limits, coefficients and excavations are shown in the next
figures.

Figure 36: Parameters of the water installation.

Figure 37: Maximum velocity of the installation.

26
 Figure 38: Coefficients of the installation and excavation.

The water supply system for the electrical equipment factory consists of 6 con-
suming points, which 4 are in the corners and are the restrooms of the factory. The
other consuming point is located at the bottom (NC6) which is the dining room.
The general supply node is located at the top as SG1. The following figure shows in
detail the water supply system made in CYPE.

Figure 39: Water Supply system for MOTELEC Equipment Factory.

27
 By making the calculations in CYPE, the diameters of the supply network re-
sulted as shown in the previous figure.

Tubing sizes
The following figures shows the sizing of the tubes in the installation.

Figure 40: Tubing sizes.

8.4. Sewage
In this section it is described everything related to the sewage system of the
factory. For the design of the sewage system, it is recommended to follow a series of
considerations, such as the layout of the network, diameters and types of sections,
the depth of the ditches, and slope of the collectors. The design of the layout of
the water sewage system must consider that the collectors must be located under
the sidewalks in order to avoid the loads due to traffic. In any case, the design of
the own sidewalks and roadway with a proper slope should allow the evacuation of
pluvial water.

Diameters and types of sections

A minimum diameter must be established for the collectors. The diameters of the
sections in the sewage system are shown in the next figures.

Depth of the trenches

Collectors should be housed in trenches the depth should be sufficient to make them
both protected from the effects of external loads, such as variations in temperature.

Slope of the collectors

The slope of the collectors should be established as a function of its diameter, so

28
that the flow rate at which the water is within a range of values. It is shown in the
following table:

Chart 5: Collectors slope.

The procedure of designing the sewage system in CYPE is next.

General Information
The following figures shows the definition of the elements of the sewage system, as
the materials and the landing of the plant.

Figure 41: General data and materials of sewage installation.

The materials used in the installation is A 4000 TUBO FIB, in cohesive soil.
The parameters, limits, coefficients and excavations are shown in the next figures.

29
 Figure 42: General data and materials of sewage installation.

Figure 43: Maximum velocity of sewage installation.

Figure 44: Coefficients of the sewage installation and excavation.

30
 The water sewage system for MOTELEC consist of 5 evacuation points, which
the four in the corners are restrooms and the fifth one is the dining room. The drain
system is located at the very bottom of the plant. The following figure shows in
detail the water sewage system made in CYPE.

Figure 45: Water sewage system for MOTELEC Equipment factory.

Tubing sizes
The following figures shows the sizing of the tubes in the installation.

31
 Figure 46: Tubing sizes (sewage).

8.5. Lighting
Lighting is an important factor in a facility, and we should have to make a study
in order to create optimal lighting conditions of industrial production processes.
These optimal conditions are going to depend on the process that we are going to
develop in the different rooms of our facility.
The industrial lighting has different characteristics than conventional or residen-
tial lighting, as higher power, brightness, flow and increased tolerance to voltage
changes.
We can use two methods to realize the lighting project, using the manual methods
of lumens and with the computer software Dialux.
Divide the lighting study in two parts: indoor and outdoor lighting.

8.5.1. Indoor Lighting

First we must consider the different areas of the facility:

32
 Chart 6: Facility Areas

Figure 47: Offices Area

Here we can see the lighting levels for indoor lighting.

Chart 7: Lighting levels for indoor lighting

We present the two types of lighting that we have chosen for indoor lighting:

PHILIPS BY151P 1xCDM-TMW210W/942 EB P-WB +BY150G

33
This luminaire is special because it’s situated very high and requires more
power and luminous flux.

Figure 48: Indoor luminaire 1

Total Lamp Flux: 23100 lm

System Flux: 17094 lm
System power: 227 W
Light Output Ratio: 0.88
HxD: 0.59x0.43 m

PHILIPS TBS460 SQR 3xTL5-24W HFP D8-VH

Figure 49: Indoor luminaire 2

Total Lamp Flux: 5250 lm

System Flux: 4987 lm

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 System power: 80 W
Light Output Ratio: 0,95
LxBxH: 0.6x0.6x0.05

Dialux Software

In the following picture we see a top view of the indoor facility where all lumi-
naires appear.

Figure 50: Top View of the indoor lighting of facility

After realize the calculation with the software we get the following isolines map
where we can see lighting level (in lux):

35
 Figure 51: Isolines map of indoor lighting

The overall area has a number of lux approximately 700 as regulation says us.

Figure 52: Isolines map of indoor lighting (Offices)

The offices also complies the regulation says about 500 lux.

Lumens Method

Follow the step by step method is to calculate the lumens needed to obtain the
desired lighting level. First we define the height of the warehouse and the reflectance
of ceiling, walls and floor.

36
 Heigth of overall zone: 7 m.
Heigth of offices zone: 3.5 m.
Ceiling Reflectance: 0.8; Walls Reflectance: 0.5; Floor Reflectance: 0.2;
Knowing that we want a general lighting system and intensive.

Entrance Hall
Determine the room cavity ratio:
a·b 6 · 10
K= = = 1,415
h · (a + b) 2,65 · (6 + 10)
Where
h = htotal − hworkplane = 3,5 − 0,85 = 2,65

Using the following table and get the reflection data we obtain the utilization
factor:

Chart 8: Utilization factor of local

Cu = 1,08
Em · a · b 500 · 60
φT = = = 39682,54
F m · Cu 0,7 · 1,08

37
Where we assume maintenance factor equal to 0.7.
And finally:
φT 39682,54
N= = = 7,63 ≈ 8
φ1 5200
Distribution of the luminaires is not done because it was done in Dialux software.
Business Office
Determine the number of luminaires:

a·b 5 · 5,65
K = = =1
h · (a + b) 2,65 · (5 + 5,65)
Cu = 1,015
Em · a · b 500 · 28,25
φT = = = 19880,36
F m · Cu 0,7 · 1,015
φT 19880,36
N = = = 3,82 ≈ 4 (x2)
φ1 5200
Dining room
Determine the number of luminaires:

a·b 7 · 10
K = = = 1,55
h · (a + b) 2,65 · (7 + 10)
Cu = 1,08
Em · a · b 400 · 70
φT = = = 37037,03
F m · Cu 0,7 · 1,08
φT 37037,03
N = = = 7,12 ≈ 7
φ1 5200

Meeting room
Determine the number of luminaires:

a·b 5 · 8,20
K = = = 1,17
h · (a + b) 2,65 · (5 + 8,20)
Cu = 1,055
Em · a · b 500 · 41
φT = = = 27758,97
F m · Cu 0,7 · 1,055
φT 27758,97
N = = = 5,34 ≈ 6
φ1 5200

Office toilets
Determine the number of luminaires:

38
 a·b 5 · 8,20
K = = = 1,17
h · (a + b) 2,65 · (5 + 8,20)
Cu = 1,055
Em · a · b 400 · 41
φT = = = 22207,18
F m · Cu 0,7 · 1,055
φT 22207,18
N = = = 4,27 ≈ 5
φ1 5200

Corridor
Determine the number of luminaires:

a·b 1,5 · 27,9

K = = = 0,53
h · (a + b) 2,65 · (1,5 + 27,9)
Cu = 0,91
Em · a · b 400 · 41,85
φT = = = 26279,43
F m · Cu 0,7 · 0,91
φT 26279,43
N = = = 5,05 ≈ 5
φ1 5200

Toilets
Determine the number of luminaires:

a·b 5·4
K = = = 0,84
h · (a + b) 2,65 · (5 + 4)
Cu = 0,975
Em · a · b 400 · 20
φT = = = 11721,61
F m · Cu 0,7 · 0,975
φT 11721,61
N = = = 2,25 ≈ 3 (x3)
φ1 5200

Expedition zone
Determine the number of luminaires:

a·b 6 · 5,5
K = = = 1,083
h · (a + b) 2,65 · (6 + 5,5)
Cu = 1,015
Em · a · b 500 · 33
φT = = = 23223,08
F m · Cu 0,7 · 1,015
φT 23223,08
N = = = 4,46 ≈ 5
φ1 5200

Overall zone

39
 Determine the number of luminaires:

a·b 5400
K = = = 7,56
h · (a + b) 4,706 · (94,87 + 56,92)
h = htotal − hworkplane = 5,556 − 0,85 = 4,706
Cu = 1,17
Em · a · b 750 · 5400
φT = = = 494505,94
F m · Cu 0,7 · 1,17
φT 494505,94
N = = = 214,07 ≈ 215
φ1 23100

We make a comparison chart between the two methods performed about the
number of luminaires:

Chart 9: Comparison chart between methods

8.5.2. Outdoor Lighting

The special luminaire used for the outdoor lighting is:
PHILIPS BGP431 T35 1XGRN94-2S/657 DW

Figure 53: Outdoor luminaire

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 Total Lamp Flux: 8237 lm
System Flux: 9360 lm
System power: 82.3 W
Light Output Ratio: 0.88
LxBxH: 0.75x0.48x0.20

Regulation marks us the following levels of outdoor lighting:

Chart 10: Lighting levels for outdoor lighting

Outside our facility can be assumed as an “Area of transport and storage of

material”
Lumens Method

Follow the method of lumens for outdoor step by step:

A value of average lighting level is set according to the space to be lit (see the
table), 25 lux.
Mounting height of the luminaires is defined so that the flow is not exceeded
maximum recommended (see Table). We choose 7 m.

Chart 11: Recommended height according to the luminous flux

Distribution of the luminaires will unilaterally because we just want to enlighten

our warehouse.
We see the height of the luminaire and the road width (6 m) in the next picture.

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 Figure 54: Outdoor lighting scheme

a1 = 5; a2 = 1; h = 7
a1 5
= = 0,72
h 7
a2 1
= = 0,14
h 7
Given these relationships, and the curves of Figure shows that the utilization
factor is:

Figure 55: Curve for the utilization factor (outdoor)

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 Fu = Furoad + Fusidewalk = 0,35 + 0,02 = 0,37

Maintenance factor estimates it at 0.7.

Once calculated these data we calculate the separation distance of luminaires
using:

φ · Fm · Fu 8237 · 0,7 · 0,37

d= = = 14,22m ≈ 14m
a · Em 6 · 25
Our facility width is 60 m and the length is 100 m, so that on the part of the
width have 60/14 = 4,28 ≈ 5, and the length part is 100/14 = 7,14 ≈ 8
We have doubled the lighting in the loading dock because we need for higher
level of illumination there.
Dialux Software

Now with data of lumens method we realize the project in Dialux Software.
We see the distribution of luminaires around the facility and can see that at the
end where the loading dock is, lighting has been strengthened.

Figure 56: Outdoor luminaires distribution

In this picture we see a color scale that indicates the amount of lux and how
comply with the regulation.

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 Figure 57: Outdoor colour scale of lux

9. Work Distribution
The distribution of work for the realization of this project can be seen in the
following illustration.

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 Figure 58: Work Distribution

10. Bibliography
References
[1] Universidad de Zaragoza. Curso de Introducción al Urbanismo Industrial. Cen-
tro Politécnico Superior de Ingenieros.

[2] Instituto Nacional de Seguridad e Higiene (2011). Iluminación en el puesto de

trabajo. Ministerio de Empleo y Seguridad Social

[3] PHILIPS, (2004). Manual de alumbrado. Madrid. Ed. Paraninfo

[4] Javier Contreras Sanz (2014). Notes of Facilities Planning.. ETSII Ciudad Real.
UCLM

[5] James A. Tompkins (2010). Facilities Planning, 4th Edition. Wiley

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