design & estimation B&W

Design procedure of power supply system Single line of lighting / socket Single line of A/C, pump, fan, comp., chiller, lift, other… Single line of production machine Single line of LV m

PART I

ROUGH DESIGN

FOR FACTORY

Page: 2/198

1 Design procedure

1.1 Design procedure of power supply system

Single line of lighting / socket

Single line of A/C, pump, fan, comp., chiller, lift, other…

Single line of production machine

Single line of LV main panel

Main CB capacity

Transformer number, capacity

S/S type

A: outdoor type B: Outdoor cubicle C: Kiosk

D: indoor panel

MV single line

(MV system specification)

(G) Cabling route / size

(F) Short circuit current

A: PC trans Capacity, %Z B: Distance from PC S/S

(E) Meter position CT/PT

A: MV on pole B: MV in elec Room C: LV in kiosk / outdoor cubicle

(D) RMU

A: need

B: no need

(C) Wiring method A: U/G cabling

2.1.2 Procedure for lighting calculation

2.1.2.1 Make calculation from : refer to "example"

Example:

Make condition by you:

• Office -> FL40Wx2 Louver type / 500Lux

• Office area -> FL40Wx2 V type / 300Lux

2.1.2.2 Put in room name

2.1.2.3 Choose lighting type

- Incase have condition by Owner, follow requirement

- No requirement, choose VNKD standard

2.1.2.4 Illumination level E (Lux)

- Incase have condition by Owner, follow requirement

- No, requirement, choose VNKD standard

- Depend on lighting type

2.1.2.8 Measure room area

2.1.2.12 Calculate final illumination level

2.3 Illumination Factor (U)

Type Room (m2)

FL

V Type

FL Reflector

FL Louver

Mercury Metal halide Under 50 0,63 0,63 0,58

50 to 100 0,70 0,72 0,62

100 to 200 0,75 0,78 0,66

Over 200 0,80 0,82 0,68 0.75

2.4 Maintenance factor (M) : 70%

2.5 Illumination level and lighting fixture type

2.5.1 Follow Customer’s specification

2.5.2 If not requested, take under table

V type Other office

area Reflector 250lux

Factory

FL Reflector

200lux

Entrance DL PLC 18W 2m pitch

Exit EXIT FL10W w/ battery - Near entrance

- Top of door to outdoor - -

EMG (office) 3W x 2 w/ battery

- Near car park

- 1nos/40m for road light - -

Special room Estimated

Small fan (1PH) 1nos/1fan

4 Lighting / Socket distribution system

4.1 Make group

4.1.1 Separate to office and factory

4.1.2 Max Capacity / 1 group : 65kVA / 3PH(380-220)V

4.2 Circuit

15 nos FL40Wx2

6 nos HID (Mercury, Sodium, Metal halide) 150W

4 nos HID (Mercury, Sodium, Metal halide) 250W

3 nos HID (Mercury, Sodium, Metal halide) 400W

15 nos EXIT, EMG

1 nos Floor socket

5 nos wall socket

10 set small fan

4.4 Single line diagram

4.4.1 Typical drawing of distribution board

Page: 12/198 4.4.2 Standard D/B

1 no MCB3P 100AF/60AT

30 nos MCB1P15AT

1 set N – Bar 30 Point

1 set G – Bar 30 Point

4.5 Main MCB trip current (A)

)(3803

)(

V

kVA Capacity Total

DB

×

≥ x 0.8 (DF)

DF: Demand factor (Lighting = 1, socket = 0.5)

4.6 Branch MCB: 1P15Ax3N, 3P20A

4.7 Neutral, grounding bar shall have termination point to be same number of circuit

4.8 Cable:

0.6kV/PVC/PVC/3C-2.5mm2 or 0.6kV/PVC wire 2.5 mm2x3

- Light

- Socket 0.6kV/PVC/PVC/3C-4mm2 MH in factory

4.9 Outdoor and Factory HID lighting system

4.9.1 Select system

Operation HID

light

Number/1 -circuit

1P20A 1P20A 1P20A

4mm2 4mm2 4mm2

3P20A 3P20A 3P20A

4mm2 4mm2 4mm2

O

O

O 150W

>1.6AxN/3

>2.6AxN/3

>4AxN/3

Depend on Voltage drop

4.9.1.1 Operation system type 1

Magnetic contactor (MC) and push button (PB)

4.9.1.1.1 0 / 100% operation by manual cut and auto start

• Street light

• Outdoor HID

• Factory HID, garden light

• Remote PB system should be installed by owner’s requirement 4.9.1.1.2 0 / 33% / 66% / 100% operation

Page: 14/198 4.9.1.2 Operation system type 2

Automatic operation 0 / 33% / 66% / 100%

• Road light

• Switch on by photocell

• Switch off by timer relay

• Grounding at each lighting position

• Cable shall be used for 0.6kV/XLPE/DSTA/PVC/4c- mm2

5 Power supply panel for Production machine

5.1.2 Rough calculate each total capacity (kW)

5.1.3 Check / compare with each max capacity

Capacity / 1 group:

Max: 100kW / 3PH380V Max: 50kW / 3PH200V Max: 30kW / 1PH100V

Note: If 1 set motor’s capacity is over 75kW/380V, 37kW/200V, 1 group shall be made

by 1 set motor

5.1.4 Check area / cable length, if some machine's position is far, separate group

5.1.5 Put in each machine's name and capacity to each typical dwg by Table 5.1.5.6~9

Page: 16/198

5.1.5.1 Typical drawing of local power supply panel (3PH380V)

5.1.5.2 Typical drawing of local power supply panel (3PH380V/220V)

5.1.5.3 Typical drawing of Power Supply Panel (3PH-200V)

THERMAL RELAY 1C

(mm2) 3C (mm2)

DIRECT START

STAR/DELTA STARTER kA

METER (A) GROUNDING WIRE (MM2)

Note: Motor capacity (kW) direct start on 600%

0.2 ~ 7.5 kW 10 sec 12 time 16 time

5.1.5.7 3PH400V MOTOR

CABLE & MCCB SELECTION FOR FEEDER (OVER 2 SETS OF MOTOR)

THERMAL RELAY (A) 1C (mm2) 3C (mm2) DIRECT START STAR/DELTA STARTER (kA)

METER (A) GROUNDING WIRE (MM2)

Note: Motor capacity (kW) direct start on 600% x

5.1.5.9 3PH200V MOTOR

CABLE & MCCB SELECTION FOR FEEDER (OVER 2 SETS OF MOTOR)

Page: 22/198 5.1.5.4 Typical drawing of Power Supply Panel (3PH-200V <50kW )

5.1.5.5 Typical drawing of power supply panel (3PH-173V/100V)

Page: 24/198

5.1.6 Choose MCCB's rating / cable, grounding size for motor load by 5.1.5.6 / 5.1.5.8

5.1.7 Choose main MCCB rating, cable, grounding size by 5.1.5.7 / 5.1.5.9

5.2 Make 400V single line (local panel) for each group

5.2.1 MCCB rating for motor (pump, fan)

Branch / main MCCB’s trip current shall be selected by 5.1.5.6 / 5.1.5.7

Note: Be careful for MCCB’s kA

5.2.2 If load is heater, calculate as follow:

)(13803

)()

(

PF

Kw city HeaterCapa AT

MCCB

×

×

>

5.2.3 Cable/Grounding wire for motor shall be selected from 5.1.5.6 / 5.1.5.7

5.2.4 Grounding bar, if need neutral (3PH400V-230V) neutral bar shall be set

5.2.5 Make single line diagram : write down capacity, MCCB rating, cable size, G size for

each circuit in 5.1.5.1 or 5.1.5.2

5.2.6 Demand factor for power supply panel (3PH200V, 3PH400V)

Voltage Max branch capacity Branch number Total DF

<10KW >10 sets 0.85

<10KW > 15 sets 0.8 3PH200V panel

<10KW >20 sets 0.7

<20KW >10 sets 0.85

<20KW > 15 sets 0.8 3PH400V panel

<20KW >20 sets 0.7

5.2.7 MCCB selection for big capacity production machine

5.2.7.1 If load capacity is over 20KW for 200V or 30KW for 380V shall request detail of load

to Owner Big capacity machine are almost following case

Case-1: combined by several motors

Case-2: including heater

In above case, MCCB selection shall be done by 5.2.7.2

5.2.7.2 MCCB selection for case-1 :

• Shall request detail motor capacity and operating condition for each motor to Owner and then decide DF

• MCCB rating and cable size shall be selected by5.1.5.7 for 380V or 5.1.5.9 for 200V

by 5.1.5.7

5.2.7.3 MCCB selection for case-2:

• Shall request detail capacity and number for motor, heater

• Calculate full load current (AH) for heater

• Select MCCB AT (AM) for motor by motor selection table

• Selected MCCB for total load = AH + AM

Example:

(1) Condition:

Production machine : 3PH200V-60KW

Detail: Motor 5KW x 2 sets

Motor20KW x 1 set Heater 30KW x 1 set Operation : same time operation for 3 loads (2) Selection :

AH = 30.000W/(1.73 x 200Vx 1 (PF)) = 86.7A

AM = total 30KW, max 20KW -> 150A by 5.1.7.9

Selected MCCB (AT) = 86.7A + 150A = 237A -> 250AT

5.3 Make 3PH200V single line diagram

)(2

.1)(

PF

kW capacity grouptotal

kVA capacity

(safety factor x demand factor = 1.2 x 1.0)

→ Main CB rating for transformer secondary:

- Calculated trip current Ac = Trans (KVA) x 1000 / (1.73 x 200V)

- Selected trip current As by 5.1.5.9

- Shall compare Ac with As, if Ac < As size up trans capacity up to Ac > As

)(75

.0

PF

kW ity totalcapac

×

≥

(safety factor x demand factor = 1.0 x 0.75)

→ Voltage 3PH- 400V/210V (Delta/Star) or 3PH-22kV/210V (delta/ delta)

→ Install at electrical room with 200V LV main panel

5.3.1.3 3PH200V total load (kW) > 400kW

→ Oil transformer

→ Trans capacity (kVA)

8.0)(

)(7

.0

PF

kW ity totalcapac

Page: 28/198

5.3.2 3PH200V single line (local panel) for each group

5.3.2.1 MCCB rating for motor shall be selected from 5.1.5.8 / 5.1.5.9

5.3.2.2 If load is heater, calculate as follow

MCCB (AT) >

)(12003

)(

PF V

kW city Heatercapa

×

×

5.3.2.3 Cable / Grounding wire for motor shall be selected from 5.1.5.8 / 5.1.5.9

5.3.2.4 Grounding bar only

5.3.3 Make single line diagram : write down capacity, MCCB rating, cable size, G size for

each circuit in 5.1.5.3 or 5.1.5.4

5.3.4 3PH200V LV Main panel : refer to item 7

5.4 Make 1PH100V single line (local panel)

5.4.1 Select transformer

5.4.1.1 One set dry transformer shall be selected for each group

5.4.1.2 Transformer Capacity (kVA)

8.0)(

)(

PF

kW capacity Grouptotal

≥

5.4.1.3 Rating: 3PH400V/182-105 V (Delta/Star)

5.4.1.4 Install at local with panel

5.4.2 1PH 100V single line (local panel) for each group

5.4.2.1 Primary trans MCCB trip current <

V

kVA Trans

3803

).(

9.0

1733

)(9

.0

×

×

5.4.2.3 Branch: MCB 1P(15A~20A)

Max load / 1 circuit : ≤ 1.5kVA

if bigger than 1.5kVA, MCB trip ampere ≥ 1.2 x load(VA)/100V

5.4.2.4 Cable size: 0.6kV/PVC/PVC/3Cx2.5mm 2

5.4.2.5 Grounding bar

5.4.2.6 Socket outlet shall be estimated for each load

5.4.3 Make single line diagram : write down capacity, MCCB rating, cable size, G size for

each circuit in 5.1.5.5

6.3.1 MCCB rating: same as 5.2.1 with note

6.3.2 Heater: same as 5.2.2 tem

6.3.3 Make single line diagram : put main/branch MCCB's trip current, cable size,

grounding size by 5.1.5.6 / 5.1.5.7 in 5.1.5.1 / 5.1.5.2

6.3.4 Neutral :

• Use for control circuit or small load

• If use for big load with small N-load, shall consider which system is better ( 4 core cable or small transformer with fuse)

• If choose 4 core cable system, N-phase cable size shall not be used for smaller than 50% of phase cable

• 1-N-cable shall be used for per 1 circuit

6.3.5 Demand factor for power supply panel (3PH380V) : Same as 5.2.6

6.3.6 MCB, cable selection / calculation for 1PH220V load

6.3.6.1 System

for mixed with 3PH380V and 1PH220V load, shall select one of following 2 system

3PH4W system (4 core cable + G) 3PH3W + small trans

1PH220V total capacity (KW) > panel total (KW) x 5% < panel total (KW) x 5% Branch MCB MCB + fuse MCB

MCB for over current, fuse for short circuit

6.3.6.2 Calculation for single 1PH220V load

• Full load current Af = KW x 1.5 / (220V x 0.8 (PF))

(1.5 is starting current factor)

Load : 1PH220V Air-con 1.5kW and 3.5 kW

• 1.5kW AC MCB trip A = 1.5kWx10000x1.5 / (220Vx0.8PF) = 12.7A -> 15AT

• Cable size = 2.5mm2

• 3.5kW AC MCB trip A = 3.5kWx1000x1.5 / (220Vx0.8PF) = 29.8A -> 30AT

• Cable size = 6mm2

6.4 Control

6.4.1 One set magnetic contactor (MC) with thermal relay shall be set per 1-circuit,

MC’s capacity (kW) = motor capacity

6.4.2 One set relay / 1 circuit

6.4.3 Two set push button / 1 circuit

6.4.4 Three set pilot lamp / 1 circuit

6.4.5 One set select switch / 1 circuit

6.4.6 If request remote switch, control cable and push button shall be indicated on dwg 6.1.4.7 Neutral and grounding bar

Page: 32/198

7 LV main panel

7.1 Single line diagram

7.1.1 Put each panel capacity, cable size and MCCB rating in typical drawing

(3PH4W-400/230V)

7.1.2 Put each panel capacity, cable size and MCCB rating in typical drawing

(3PH-200V, < 400KVA)

Page: 34/198

7.1.3 Put each panel capacity, cable size and MCCB rating in typical drawing

(3PH-200V, > 400KVA)

kVA Trans

2103

)(

×

≤

V

kVA Trans

4003

)(

×

≤

7.1.4 Trip current: same as local main MCCB or MCB

Note: never use MCB

7.1.5 Interrupting current: refer to (12.1.1)

7.2 Capacitor with MCCB, MC, PF controller, PB, PL

7.2.1 - Total capacitor’s capacity (kVAR) = 3PH motor load (kW) (exclude heater,

lighting) x 0.7(DF) x 0.4 / 0.8(PF) ≈ trans.(kVA) x (0.25< ….<0.3) for LV main panel

- Trans (kVA) x 0.3 for 3PH200V main panel

7.2.2 Standard: 100kVAR/set, 50kVAR/set, 25kVAR/set

7.2.3 Number of 50(kVAR) capacitor =

)(50

)('

kVAR

kVAR sCapacity itor

TotalCapac

7.2.4 Reactor : 6% (kVA) with each capacitor (kVAR)

7.2.5 Power factor controller : 6-step, 12-step

7.2.6 Branch MCCB, MC

Capacitor

(kVAR)

MCCB 3P (AT)

MC 3P (A)

Reactor

(kVA) 400V 210V 400V 210V

Page: 36/198

7.3.2 Switch

Trip current ≤ 800(A) MCCB

Trip current > 800(A) ACB (max 4000A)

7.4 Interrupting current : refer to 12.1.1

7.5 Meter

7.5.1 Ampere, Volt meter with select switch

7.5.2 kW meter

7.5.3 PF controller: meter and controller

7.5.4 Current trans (CT) for above

7.5.5 Other meter if request by Owner

7.6 Protection relay

7.6.1 Over current relay (OCR): MCCB, ACB has internally

7.6.2 Ground fault relay (GFR): ACB has internally, MCCB don’t has internally

3PH3W 3 sets 1 set 3PH4W

w/ shunt trip coil

4 sets 1 set

Setting under 100A

7.6.3 Earth leakage relay (ELR)

• Should be used only by Owner’s request

MCCB - 3PH3W ZCT+ELR

MCCB w/ shunt strip ELCB ELCB

MCCB - Feeder

MCCB - 3PH4W

ZCT ELR

MCCB w/ shunt strip Main

Page: 38/198 System:

7.7 Secondary (feeder) cable / grounding wire :

7.7.1 For power supply panel (production, AC, pump) shall be selected from (CAL-)

7.7.2 For light DB, for heater: shall be selected as cable’s allowable current (A) x 0.8 > main

MCCB’s trip current

7.7.3 0.6kV/XLPE/PVC cable shall be used

7.8 Branch cable from feeder cable

• The joining directly from main feeder to branch cable, MCCB shall be installed by following condition:

MTL<1000kVA 0.8 ≥ MTL

x0.8kVA

I(A) = T/√3x400V

I(A) = T/√3x22000V

MTL>1000kVA 0.75 ≥ MTL

x0.75kVA

I(A) = T/√3x400V

I(A) = T/√3x22000V

I(A) = T/√3x22000V

MTL<400kVA 0.75 ≥ MTL

x0.75kVA

I(A) = T/√3x210V

I(A) = T/√3x220003PH

210V

MTL>400kVA 0.7 ≥ MTL

x0.7kVA

I(A) = T/√3x210V

I(A) = T/√3x22000V

Note:

Max capacity of trans : - Depend on secondary CB capacity

- 2500kVA (3600A secondary current) at 400V

- 1300kVA (3600A secondary current) at 210V

8.2 Secondary cable

• Main CB trip current ≤ selected cable allowance current (A)x1.0

• 0.6kV/XLPE/PVC/1C for over 240mm2 shall be used

9 Voltage drop

9.1 Calculation

Max Vd (total 5%) Voltage drop (V)

Main feeder Branch 1PH2W Vd = 35.6xL(m)xI(A) / S(mm2) x 1000 ≤ 2%

3PH3W

3PH4W

Vd = 30.8xL(m)xI(A) / S(mm2) x 1000 ≤ 3%

If direct to load = 5%

≤ 2%

L: cable length (m), I: rated current, S: Cable size

Page: 40/198 9.2 I(A) rated current

3PH 380V, 3PH 200V 1PH 220V

Feeder for motor panel I = panel(kW) x 0.8 / √3 x 400V x 0.8 -

Feeder for lighting panel I = panel (kVA) x 0.8 / √3 x 400V -

Each motor I = Motor(kW) / √3 x 380V x 0.8 -

10.1 Grounding for substation

10.1.1 Resistance max = 4 ohm

10.1.2 Mesh connection system