Planning Industrial Power Distribution Systems

11/09/2014
BEF 44903 Topic 1
BEF 44903 Industrial Power Systems Topic 1
Outlines
1.1 Plant Distribution Systems
1.2 Voltage and Frequency Considerations
1.3 Types of Plant Distribution Networks
1.4 Power Demand and Load Estimation
1.5 Transformer Sizing
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1.1 Overview of Electric Power Systems

Generation System
13.8 kV 15.6 kV
Transmission System
132 kV 500 kV
Distribution System
11 kV 66 kV
1.1 Example of Plant Distribution System
Panelboard
Feeding
240/415V
Harmonic Loads
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1.1 Planning Distribution Systems
Power system concept:

Analysis
Selection of the network
configuration
Type of connection to
ground
Technical features
Network calculation:
Load flow
Short-circuit calculation
Energy balance
Rating:
Transformers
Cables
Protective/ switching
devices
Provisions for redundant
supply
Power system planning

5
Source: Siemens
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Low
losses
High
reliability
of supply
Simple
structure
An optimum network configuration should

particularly meet the following requirements:
Favorable
and
flexible
expansion
options

Example of Industrial
Power Networks
11/09/2014

A distribution system deals with the distribution
of electrical energy to its specific loads.
The main purposes of planning are:
To make the system economical (cost effective).
To minimise power losses and maintain regulation
within permissible limits.
Load survey and load forecasting of the area are

necessary.

Load survey of a particular area is carried out to find out
the present load requirement as well as the expected
load growth
gro th over
o er a period of 5 to 15 years.
ears The follo
following
ing
basic data should be collected for starting this work:
A detailed map of the area showing important features.
The existing number of houses, population and new construction
anticipated in the area.
The expected number of shops
shops, post offices
offices, rural health centres,
centres
etc.
The type of industry and number of industries possible in the
area.
Development programmes implemented in the area.
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For the purpose of forecasting load, the prospective

consumers may be categorized as under:
1. D
1
Domestic
ti consumers, i.e.
i residential
id ti l h
houses.
2. Commercial consumers, i.e. shops, schools, hospitals, hotels,
and other commercial establishments.
3. Industrial consumers:
a.
b.
c.
d.
e.
f.
Small industries
Medium industries
Large industries
Municipal consumers (i.e. street lighting, water works, parks, etc.)
Agricultural consumers
Mining industries
11
1.1 Layout of Distribution Systems
Sub-transmission Line
(66kV or 33kV)
Primary
Substation
Distribution
Substation
Secondary
Substation
3 Phase
Consumers
(415V)
11kV Feeder
132kV/66kV
66kV/11kV
66kV Feeder
11kV/415V
11kV Feeder
Single Phase
Consumers
(240V)
Industrial
Consumer
12
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1.1 Layout of Distribution Systems

The high voltage from transmission line (132 kV) is stepdown at the Primary Substation to 66 kV or 33 kV.
From this primary substation
substation, power at 66 kV or 33kV is
carried through sub-transmission lines to different load
centres. The length of a sub-transmission line is about 50
km and they carry about 50 MW of power.
It has been found that sending power through subtransmission lines at 33 kV or 66 kV is economical in
terms of losses (i.e. I2R) and the capital cost (i.e. cost of
conductor,
d
iinsulators
l
and
d supports).
)
Most domestic, commercial and small-scale industrial
consumers receive power at low voltage, i.e. 240V or
415V. Large-scale consumers having load in excess of
100 kW buy bulk power at 11 kV and above.
13
1.1 Planning for Connection

Supplies at Low Voltages of 240V and 415V
Maximum power requirements in kVA

Types and number of equipment and its
corresponding connected capacity in kVA
Shunt connected reactors and capacitors in kVAr
For single-phase 240V motors with rating of greater
than 6kVA and/or three-phase 415V motors with
rating greater than 75kVA:
(i) Rating in HP or KVA, (ii) Types of control equipment, (iii)
Methods of starting and starting current, (iv) Frequency of
starting (number/hour), and (v) Rated power factor;
Voltage sensitive loads (indicating sensitivity)

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Supplies at 275kV, 132kV, 33kV, 22 kV, 11kV
and 6.6kV
For all types of loads:

Maximum Active Power consumption in kW;
Maximum Reactive Power consumption in kVAR.
For motor loads:
Types of control equipment;

Methods of starting;
g;
Magnitude and duration of the starting current;
Frequency of starting (number/hour);
Under voltage setting and time;
Negative phase sequence protection;
Sub-transient and/or locked rotor reactance of the motor.
15
For nonlinear loads with harmonic current injections:

Harmonic current spectrum including harmonic number and
the corresponding maximum current.
current
For fluctuating loads:

The rates of change of Active Power and Reactive Power
consumption in kW/minute and kVAR/minute ,respectively,
both increasing and decreasing;
The shortest repetitive time interval between fluctuations for
Active Power and Reactive Power in minutes; and
The magnitude of the largest step changes in Active Power
and Reactive Power in kW and kVAR respectively, both
increasing and decreasing.
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For voltage sensitive loads:

steady-state voltage tolerance limits of the equipment in
percentage of the nominal voltage;
intrinsic immunity limits to short duration voltage variation;
transient voltage tolerance limits of the equipment in
percentage of the nominal voltage and the corresponding
duration;
harmonic current emission limit for equipment.
For Shunt Connected Reactors and Capacitors:

p
configuration and sizes of individual banks;
types of switching and control equipment; and
types of harmonic filtering reactors.
17

Voltage Criteria
Steady-State Voltage Fluctuation (Normal Condition):

Voltage level
% variation
415V and 240V
-10% & +5%
6.6kV, 11 kV, 22kV,33kV

132kV and 275kV
+/- 5%
-5% & +10
Steady-State Voltage Fluctuation (Contingency Condition)

Voltage level
415V and 240V
6.6kV, 11 kV, 22kV,33kV
132kV and 275kV
% variation
+/- 10%
+10 & -10%
+/- 10%
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1.2 Supply Voltage Options

Low Voltage:
Single-phase, two-wire, 240V, up to 12 kVA maximum

demand
Three-phase, four-wire, 415V, up to 45 kVA maximum
demand
Three-phase, four-wire, C.T. metered, 415V, up to
1,000 kVA maximum demand
19
1.2 Supply Voltage Options

Medium and High Voltages:
Three-phase, three-wire and 11 kV for load of 1,000

kVA maximum demand and above
Three-phase, three-wire, 22kV or 33kV for load of
5,000 kVA maximum demand and above
Three-phase, three-wire, 66kV, 132kV and 275kV for
exceptionally large load of above 25 MVA maximum
demand
20
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Frequency Criteria
The supply frequency is 50 Hz 1%
21
1.3 Classification of Distribution Systems
The distribution systems may be classified in

the following ways:
1 According
1.
A
di tto nature
t
off construction
t ti
a. Overhead distribution system (cheaper)
b. Underground distribution system (in crowded area)
2. According to nature of current

a. DC distribution system
b. AC distribution system
3. According to number of wires

2 wire DC system
2-wire
system, 3-wire
3 wire DC system
system, 1-phase
1 phase 2-wire
2 wire AC system
system,
3-phase 3-wire AC system, 3-phase 4-wire AC system
4. According to the scheme of connections

(a) Radial system
(b) Ring system
(c) Inter-connected system
22
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1.3 Primary Distribution Lines (Feeders)

The 33/11 kV secondary substation is established where
the load requirement is approximately 5 MVA. Since
normall a primar
normally
primary distrib
distribution
tion line is designed to carr
carry a
load of 1-2 MVA, the number of primary distribution lines
emanating from a 33/11 kV secondary substation is
about 4.
When the load requirement increases and crosses about
8 MVA, the losses in the 33 kV sub-transmission line
become large.
large Thus,
Thus power must fed from a 66 kV sub
subtransmission line. The number of primary distribution
lines emanating from a 66/11 kV secondary substation is
six to ten.
23
There are 3 different ways in which the primary

distribution lines can be laid:
1. The radial primary circuit
2. The loop primary circuit
3. The ring main system (or primary network)
24
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Radial Primary Circuits
When each circuit coming out of a substation is separate
from the other circuits and has no inter-connection with
any other circuit, it is called a radial circuit.
Circuit 1 for Factory
Factory having load

of 1 MW at 11 kV
Circuit 2 feeding Substation in the city
Circuit 3 for Rural Areas
Secondary
Substation
25

Advantages of Radial Feeders:
i.
ii
ii.
iii.
A heavy load very near the secondary substation.

I l t d loads.
Isolated
l d
An area of low load density such as a village.
Limitations of Radial Feeders:

i.
ii.
When the load demand on the radial feeder increases, the

length of the feeder has to be extended. This results in a greater
voltage drop which may cause the voltage towards the tail-end
tail end
to reach a value below the permissible limit.
When a fault occurs at any point along the length of the feeder,
supply to all the consumers beyond this point towards the tailend gets interrupted.
26
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Loop Primary Circuits
To overcome the limitations of the radial feeders,, the
loop primary circuit is taken to use.
11 kV
Secondary
Substation
11 kV
CB4
CB5
Distribution
Substation 2
Distribution
Substation 3
CB3
CB6
A
CB2
CB1 Distribution
Substation 1
27

Two 11 kV feeders emanate from the secondary
substation.
In this system, every distribution substation receives
supply from two sides.
In case of fault, say at point A, the circuit breaker 1 at
distribution substation 1 and circuit breaker 6 at
distribution substation 3 will open, thus isolating the
faulty section. The supply to the substation 1 and 3 is still
uninterrupted
i
d and
d continues
i
to b
be received
i d ffrom another
h
side.
This system is generally used in towns and cities.
28
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The reliability of supply in this system has improved in
comparison with that in the radial system as it has an
alternati e ssupply,
alternative
ppl in case one side fails
fails.
However, it must be realized that the source of supply for
the whole loop system is a single secondary substation.
If a fault occur in the secondary substation causing a
failure of the 11 kV supply source, the whole of the
system will suffer power interruption.
29

Ring Main or Network System
A more reliable system
y
is the ring
g main system.
y
Secondary
Substation A
CB7
Secondary
Substation B
CB8
CB9
11 kV
CB10
11 kV
CB4
CB5
Distribution
Substation 2
Distribution
Substation 3
CB3
CB6
CB2
CB1 Distribution
Substation 1
30
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In the ring main system, there are two different sources
of supply which are indicated as secondary substation A
and B.
B
The ring system has the added advantage from loop
system is that should one of the sources of supply fail,
say A, the whole system continues to get supply from the
other source B.
The ring main system is by far the most reliable for
continuity
i i off supply.
l IIt gives
i
a better
b
voltage
l
regulation
l i
and less feeder losses.
Circuit breakers are used instead of fuses for protecting
the transformer in ring main system due to heavier loads.
31
1.3 Secondary Distribution Lines (Distributors)

Distribution substations are a link between
feeders and distributors.
11 kV Feeders
Distribution
Substations
415 V Distributors
The standard voltage transformation at a

distribution substation is 11 kV/415V. The
declared consumer voltage as per Malaysian
Nasional Grid is 415 V between phases and 240
V between phase and neutral with a permissible
voltage variation of 5%.
32
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A consumer at the near-end of the distribution
substation may have a voltage as high as 436 V
(3-phase) and 252 V (single-phase) during light
load hours whereas a consumer at the far-end
may have a voltage as low as 395 kV (3-phase)
and 228 V (single-phase) at peak load hours.
The circuits for the secondary distribution
system are essentially the same as those for
primary distribution except that they are on a
smaller scale.
33
When power is supplied to the consumers

through the secondary distribution system, one
of the following arrangements is used:
1. Radial system
2. Looped system
3. Network system (Banked secondary system)
34
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Radial System
In this system, the LV distribution lines radiate out from
the distribution substation.
LV CB
11 kV Line
Switch-cum
Fuse Units
Radial Line 1
Radial Line 2
220 kVA 11
kV/415V
IIn this
thi system,
t
the
th supply
l is
i ffrom a single
i l 11 kV feeder.
f d
A fault in the feeder will cause the interruption of supply
to all consumers. Circuit breaker and switch-cum fuse
units are used for protection purpose.
35
1.3 Expanded Radial Scheme
36
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Looped System
In this case, the reliability of supply is better than in the
radial system. In the case of fault on one line, the load
can be fed from the other by connecting switch S.
415/240 V
CB
S
11 kV Line
220 kVA 11
kV/415V
415/240 V
However, a fault in the 11 kV feeder will cause the

interruption of supply to all consumers. Circuit breaker
and the fuse unit provide a protection for the transformer
and line respectively.
37
Primary Selective Scheme
38
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Banked Secondary System
When radial secondary circuits are supplied by a single
transformer, high starting currents of motors may cause
objectionable voltage drops. One of the most effective
and economical means of controlling such a voltage drop
is the banking of distribution transformers.
11 kV Primary Distribution Line
T1
T2
T3
Fuse
415/240 V Secondary Distribution Line

39

Transformers are said to be banked when two or more
supplied from the same primary circuit are paralleled to
feed into the same secondar
secondary mains
mains.
By this arrangement more than one path is provided
over which high currents can flow. This results in
lowering the extent to which the voltage fluctuates on
the line.
Further advantages of this system:
i. More reliable, have alternative supply from other transformer.
ii. Better load distribution on each transformer.
iii. The voltage drop in the system is reduced.
40
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This system is mostly used in areas of low load
densities, where a multiple primary and secondary
net ork is not jjustified.
network
stified
If a fault occurs within one of the transformers, it will be
automatically disconnected from the line by blowing the
two secondary line fuses and the primary transformer
fuse without interrupting service to any consumer.
41
1.3 Secondary Selective Scheme
42
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1.3 Sparing Transformer Scheme
43
1.4 Load Data

Typical range of Industrial Loads:
Light Industry 50 kVA to 7000 kVA

Heavy Industry 1,000 kVA to 200,000 kVA
Typical Industrial Loads:
HVAC
Process equipment, pumps, compressors and fans
Industrial services such as boiler, water treatment
Workshop and laboratory equipment
Motor control centre
44
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1.4 Initial Maximum Demand Estimation

2 methods to estimate the maximum power
demand in feasibility/ conceptual design stage:
VA/m2 or W/ ft2 This is normally apply to commercial

building where the typical loads are lighting, general
power, and HVAC. Example: 50 100 VA/m2 for nonretail buildings, 60 150 VA/m2 for retail buildings.
0.9 W/ft2 for lighting and 4.7 W/ft2 for Air Condition.
Maximum demand of a similar building/
g industry
y
Applicable for residential, commercial, and industrial
buildings. Example: Plant A having maximum demand
of 2 MVA then this figure can be used for a plant of
similar capacity.
45
1.4 Detailed Load Estimation

Comprehensive load estimate based on actual
load information.
Can be calculated either in kVA or amperes. If
the output is given in kW, the kVA can be
obtained using following formula:
kVA kW ( PF )
Future load should be considered as given in

spare circuits for future use.
46
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1.4 Diversity Factor (DF)

For better load estimation, a proper diversity
factor should be considered as not all
equipment/ load operate simultaneously.
Definition of diversity factor:
DF Max. Demand Connected Load
Typical diversity factor values:

Types of load/ circuit
Recommended DF
Lighting load
100%
General purpose power circuit
40% - 50%
Main switchboard
80% - 90%
Intermittent duty loads
50%
47
1.4 Example: Max. Loading for MCC (SB)

Load
description
3
/
1
Duty
N or
S
Motor
rating
(kW)
Operating
motor
power
(kW)
PF x
=K
Motor
input
power
Cooling
tower 1 fan
15
12
0.7
17.1
17.1
Cooling
tower 2 fan
15
12
0.7
17.1
Heater
Fan coil
1.5
1.3
0.6
2.2
Water pump
11
0.68
13.2
Extract fan
0.8
0.6
1.3
Compressor
1.5
0.6
1.6
Future pump
5.5
0.6
6.7
Total load
Heater
3
load
(kVA)
1
load
R
phase
(kVA)
1
load
Y
phase
(kVA)
1
load
B
phase
(kVA)
5
2.2
13.2
1.3
1.6
6.7
42.0
2.2
1.3
1.6
Total load on the MCC = 47.1 kVA

48
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11/09/2014
1.4 Example: Max. Loading for LV Switchboard

Load
description
Duty (N/ S)
Connected
(kW)
Operating
load (kW)
kVA
DB 1
30
DB 2
78
MCC 1
47.1
MCC 2
50
Packaging
machine
37
31
0.7
44.3
CO2
compressor
75
68
0.765
88.9
W t pump 1
Water
30
25
0.68
36.8
Water pump 2
30
25
0.68
Welder
18
0.5
36
Future
50
Total load on LV Switchboard = 461.1 kVA

49
1.4 Old Supply Schemes for various M.D
50
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1.4 New Supply Schemes for various M.D
51
1.4 In-Class Practise (1)

A small industrial plant has the following loads:
Twenty (20), 200HP motors (only half of them are

running at any given time).
Ten (10), 50 HP motors (8 motors are running at the
same time).
500 kW of heating and process loads.
Two (2), 50 kVA lighting transformers, and
100 HP of small (mostly fractional HP) motors
motors.
TASKS
Decide the proper supply voltage (from local utility)
52
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1.5 Common Connection for Transformer
53
1.5 Why Delta Grounded Star

Delta at primary
Free of 3rd harmonics of the magnetizing currents and

any possible homopolar current are free to circulate
through the sides of the delta, without flowing into the
network; thus, the magnetic fluxes remain sinusoidal
at the secondary.
In case of unbalanced loads at the secondary
winding, the reaction current absorbed by the primary
flows only through the corresponding winding (as
shown in the figure) without affecting the other two.
54
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1.5 Why Delta Grounded Star

Grounded Star at secondary
To make line and phase voltages easily available.

For safety reasons, since, in the event of a fault
between the MV and LV sides, the voltage at the
secondary remains close to the phase value, thus
guaranteeing higher safety for people and maintaining
the insulation.
55
1.5 Basic Installation of Industrial Plant
56
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1.5 Methods of Transformer Installation

Method 1 Substation with a single transformer
In the case where the
protection device also
carries out switching and
isolation functions, an
interlock must be provided
which allows access to the
transformer only when the
power supply line of the
substation has been
isolated.
Installation of the SMV
switching and isolation
device positioned
immediately to the supply
side of the transformer.
57

Method 2 Substation with two transformers
with one as a spare for the other
The circuit-breakers on the
LV side must be connected
with an I interlock whose
function is to prevent the
transformers from operating
in parallel.
Apart from the switching and
isolation device on the
i
incoming
i MV liline (IGMV),
) it is
i
advisable to provide a
switching, isolation and
protection device on the
individual MV risers of the
two transformers (IMV1 and
IMV2) as well.
58
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11/09/2014

which operate in parallel on the same busbar
Possible to use two
transformers with lower
rated power.
Operation in parallel of the
transformers could cause
greater problems in
management of the
network
network.
When coordinating the
protections, the fact that
the overcurrent on the LV
side is divided between the
two transformers must be
taken into consideration.
59

which operate simultaneously on two separate
half-busbars
Providing a CLV bus-tie
and an I interlock
which prevents the bustie from being closed
when both the incoming
circuit-breakers from the
transformer are closed
closed.
This management
method allows a lower
value of the short-circuit
current on the busbar.
60
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1.5 In-Class Practise (2)

Refer again the problem given in In-Class
Practise (1).
TASK
Design a simple power system (one-line diagram)
61

Transformer sizing is generally based on:
Total max. demand of individual/group consumer

Installed voltage level (kV)
Method of installation or arrangement
Short circuit capacity
62
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1.5 In-Class Practise (3):Transformer Sizing

Lets calculate voltage drop in transformer 1000
KVA, 11/0.480 kV, impedance 5.75% due to starting
of 300 kW
kW, 460V
460V, 0
0.8
8 po
power
er factor
factor, motor code D
(kVA/HP). Motor starts 2 times per hour and the
allowable voltage drop at transformer secondary terminal
is 10%. Is the transformer size suitable?
63

Code Letter (KVA per HP) -Locked Rotor Current
Motor Code
Min Max
A
3.15
B
3.16 3.55
C
3 56 4
3.56
D
4.1 4.5
E
4.6
5
F
5.1 5.6
G
5.7 6.3
H
6.4 7.1
J
7.2
8
K
8.1
9
L
9.1 10
M
10.1 11.2
N
11.3 12.5
P
12.6 14
R
14.1 16
S
16.1 18
T
18.1 20
U
20.1 22.4
V
22.5
64
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If the previous motor load is changed to the following:
Total KW of Three Phase Motors: 300 kW
Total KW of Single Phase Motors: 10 kW
Volt (L-L) : 460 Volt
Power Factor: 0.8
Locked Rotor Current: 450% (Max)
Analyse again the suitability of the transformer size
used.
65

Short circuit capacity with infinite source
Infinite source
1000 kVA
11kV 415 V
%Z = 5%
kVASC = ?
FLA = ?
What is %Z?
ISCmax = ?
kVASC = ?
66
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Short circuit capacity with finite source
500 MVASC
1000 kVA
11kV 415 V
%Z = 5%
kVASC = ?
MVASC(TX) = ?
MVASC(SEC) = ?
ISCmax = ?
67

Simple transformer-load connection
1000 kVA
11kV 415 V
%Z = 5.0%
kVASC = ?
FLA = ?
ISCmax = ?
kVASC = ?
Is the given size (1000
kVA)) suitable to serve
the motor load?
80% Full load

Inrush current = 6 times
68
34

Planning Industrial Power Distribution Systems

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11/09/2014

BEF 44903 Topic 1

BEF 44903 Industrial Power Systems Topic 1

BEF 44903 Industrial Power Systems Topic 1

1.1 Overview of Electric Power Systems

BEF 44903 Industrial Power Systems Topic 1

1.1 Example of Plant Distribution System

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning Distribution Systems

Power system concept:

Power system planning

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning Distribution Systems

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning Distribution Systems

An optimum network configuration should

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning Distribution Systems

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning Distribution Systems

Load survey and load forecasting of the area are

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning Distribution Systems

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning Distribution Systems

For the purpose of forecasting load, the prospective

BEF 44903 Industrial Power Systems Topic 1

1.1 Layout of Distribution Systems

BEF 44903 Industrial Power Systems Topic 1

1.1 Layout of Distribution Systems

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning for Connection

Maximum power requirements in kVA

Voltage sensitive loads (indicating sensitivity)

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning for Connection

For all types of loads:

For motor loads:

Types of control equipment;

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning for Connection

For nonlinear loads with harmonic current injections:

For fluctuating loads:

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning for Connection

For voltage sensitive loads:

For Shunt Connected Reactors and Capacitors:

BEF 44903 Industrial Power Systems Topic 1

1.2 Voltage and Frequency Considerations

Steady-State Voltage Fluctuation (Normal Condition):

415V and 240V

-10% & +5%

6.6kV, 11 kV, 22kV,33kV

Steady-State Voltage Fluctuation (Contingency Condition)

BEF 44903 Industrial Power Systems Topic 1

1.2 Supply Voltage Options

Single-phase, two-wire, 240V, up to 12 kVA maximum

BEF 44903 Industrial Power Systems Topic 1

1.2 Supply Voltage Options

Three-phase, three-wire and 11 kV for load of 1,000

BEF 44903 Industrial Power Systems Topic 1

1.2 Voltage and Frequency Considerations

The supply frequency is 50 Hz 1%