Topic 1 Plant Planning and Power Demand

20/09/2017
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: Network calculation: Rating:

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

particularly meet the following requirements:
1
4
Simple High Low Favorable
structure reliability losses and
of supply flexible
expansion
options

Example of Industrial
Power Networks
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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 over a period of 5 to 15 years. The following
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, post offices, rural health 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 categorised as under:
1. Domestic consumers, i.e. residential houses.
2. Commercial consumers, i.e. shops, schools, hospitals, hotels,
and other commercial establishments.
3. Industrial consumers:
a. Small industries
b. Medium industries
c. Large industries
d. Municipal consumers (i.e. street lighting, water works, parks, etc.)
e. Agricultural consumers
f. Mining industries
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1.1 Layout of Distribution Systems
Sub-transmission Line
(66kV or 33kV) Distribution
Substation
Primary Secondary
Substation Substation 3 Phase
Consumers
11kV Feeder (415V)
132kV/66kV 66kV/11kV 11kV/415V Single Phase

66kV Feeder 11kV Feeder Consumers
(240V)
Industrial
Consumer
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1.1 Layout of Distribution Systems
The high voltage from transmission line (132 kV) is step-

down at the Primary Substation to 66 kV or 33 kV.
From this primary 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 sub-
transmission 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, insulators and 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.
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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;
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.
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For nonlinear loads with harmonic current injections:

Harmonic current spectrum including harmonic number and
the corresponding maximum 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:
configuration and sizes of individual banks;
types of switching and control equipment; and
types of harmonic filtering reactors.
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Voltage Criteria
Steady-State Voltage Fluctuation (Normal Condition):
Voltage level % variation
415 V and 240 V -10% & +5%
6.6 kV, 11 kV, 22 kV,33 kV +/- 5%
132 kV and 275 kV -5% & +10
Steady-State Voltage Fluctuation (Contingency Condition)

Voltage level % variation
415 V and 240 V +/- 10%
6.6 kV, 11 kV, 22 kV,33 kV +10 & -10%
132 kV and 275 kV +/- 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
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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, 22 kV or 33 kV for load of
5,000 kVA maximum demand and above
Three-phase, three-wire, 66 kV, 132 kV and 275 kV
for exceptionally large load of above 25 MVA
maximum demand
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Frequency Criteria
The supply frequency is 50 Hz 1%
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1.3 Classification of Distribution Systems
The distribution systems may be classified in

the following ways:
1. According to nature of construction
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, 3-wire DC system, 1-phase 2-wire AC 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
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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
normally a primary distribution line is designed to 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. Thus, power must fed from a 66 kV sub-
transmission line. The number of primary distribution
lines emanating from a 66/11 kV secondary substation is
six to ten.
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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)
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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
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Advantages of Radial Feeders:

i. A heavy load very near the secondary substation.
ii. Isolated loads.
iii. An area of low load density such as a village.
Limitations of Radial Feeders:

i. 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
to reach a value below the permissible limit.
ii. When a fault occurs at any point along the length of the feeder,
supply to all the consumers beyond this point towards the tail-
end gets interrupted.
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Loop Primary Circuits

To overcome the limitations of the radial feeders, the
loop primary circuit is taken to use.
Secondary
Substation
11 kV 11 kV
CB4 CB5
Distribution Distribution
Substation 2 Substation 3
CB3 CB6
A
CB2 CB1 Distribution
Substation 1
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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 and continues to be received from another
side.
This system is generally used in towns and cities.
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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
alternative supply, in case one side fails.
However, it must be realised 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.
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Ring Main or Network System

A more reliable system is the ring main system.
Secondary Secondary
Substation A Substation B
CB7 CB8 CB9 CB10

11 kV 11 kV
CB4 CB5
Distribution Distribution
Substation 2 Substation 3
CB3 CB6
CB2 CB1 Distribution

Substation 1
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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.
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 of supply. It gives a better voltage regulation
and less feeder losses.
Circuit breakers are used instead of fuses for protecting
the transformer in ring main system due to heavier loads.
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1.3 Secondary Distribution Lines (Distributors)
Distribution substations are a link between

feeders and distributors.
11 kV Feeders
Distribution 415 V Distributors
Substations
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%.
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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.
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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)
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Radial System
In this system, the LV distribution lines radiate out from
the distribution substation.
Radial Line 1
LV CB Switch-cum
Fuse Units
11 kV Line
220 kVA 11 Radial Line 2
kV/415V
In this system, the supply is from a single 11 kV feeder.

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.
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1.3 Expanded Radial Scheme
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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.
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Primary Selective Scheme
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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
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Transformers are said to be banked when two or more

supplied from the same primary circuit are paralleled to
feed into the same secondary 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.
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This system is mostly used in areas of low load

densities, where a multiple primary and secondary
network is not justified.
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.
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1.3 Secondary Selective Scheme
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1.3 Sparing Transformer Scheme
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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
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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 non-
retail 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/ industry
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.
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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.
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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%
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1.4 Example: Max. Loading for MCC (SB)

Load 3 Duty Motor Ope- PF x Motor Heater 3 1 1 1
description / N or rating rating =K input load load load load
1 S (kW) motor power (kVA) R Y B
power phase phase phase
(kW) (kVA) (kVA) (kVA)
Cooling
3 N 15 12 0.7 17.1 17.1
tower 1 fan
Cooling
3 S 15 12 0.7 17.1 -
tower 2 fan
Heater 3 N 5 - - - 5 5
Fan coil 1 N 1.5 1.3 0.6 2.2 2.2
Water pump 3 N 11 9 0.68 13.2 13.2
Extract fan 1 N 1 0.8 0.6 1.3 1.3
Compressor 1 N 1.5 1 0.6 1.6 1.6
Future pump 3 N 5.5 4 0.6 6.7 6.7
Total load 42.0 2.2 1.3 1.6
Total load on the MCC = 47.1 kVA

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1.4 Example: Max. Loading for LV Switchboard
Load Duty (N/ S) Connected Operating K kVA

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

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1.4 Old Supply Schemes for various M.D
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1.4 New Supply Schemes for various M.D
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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), K = 0.78.
Ten (10), 50 HP motors (8 motors are running at the same time),
K = 0.68.
500 kW of heating and process loads.
Two (2), 50 kVA lighting transformers, PF = 0.92, = 95%
100 HP of small (mostly fractional HP, only 85% are running at
any given time) motors, K = 0.72
TASK
Decide the proper supply voltage from local utility
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1.5 Common Connection for Transformer
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1.5 Why Delta Grounded Star
Delta at primary
Free of 3rd harmonics of the magnetising 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.
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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.
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1.5 Basic Installation of Industrial Plant
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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.
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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
incoming MV line (IGMV), it is
advisable to provide a
switching, isolation and
protection device on the
individual MV risers of the
two transformers (IMV1 and
IMV2) as well.
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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.
When coordinating the
protections, the fact that
the overcurrent on the LV
side is divided between the
two transformers must be
taken into consideration.
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which operate simultaneously on two separate
half-busbars
Providing a CLV bus-tie
and an I interlock
which prevents the bus-
tie from being closed
when both the incoming
circuit-breakers from the
transformer are closed.
This management
method allows a lower
value of the short-circuit
current on the busbar.
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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)
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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
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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, 460V, 0.8 power 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?
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Code Letter (KVA per HP) -Locked Rotor Current
Motor Code Min Max
A 3.15 -
B 3.16 3.55
C 3.56 4
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 -
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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.
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Short circuit capacity with infinite source
Infinite source
FLA = ?
What is %Z?
1000 kVA
ISCmax = ?
11kV 415 V
kVASC = ?
%Z = 5%
kVASC = ?
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Short circuit capacity with finite source
500 MVASC
MVASC(TX) = ?
1000 kVA MVASC(SEC) = ?
11kV 415 V ISCmax = ?
%Z = 5%
kVASC = ?
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Simple transformer-load connection
FLA = ?
1000 kVA ISCmax = ?
11kV 415 V kVASC = ?
%Z = 5.0%
kVASC = ? Is the given size (1000
kVA) suitable to serve
the motor load?
80% Full load

M Inrush current = 6 times
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Topic 1 Plant Planning and Power Demand

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20/09/2017

BEF 44903 Topic 1

BEF 44903 Industrial Power Systems Topic 1

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

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: Network calculation: Rating:

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

A distribution system deals with the distribution

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning Distribution Systems

Load survey of a particular area is carried out to find out

A detailed map of the area showing important features.

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

132kV/66kV 66kV/11kV 11kV/415V Single Phase

BEF 44903 Industrial Power Systems Topic 1

1.1 Layout of Distribution Systems

The high voltage from transmission line (132 kV) is step-

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning for Connection

Supplies at Low Voltages of 240V and 415V

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning for Connection

Supplies at 275kV, 132kV, 33kV, 22 kV, 11kV

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning for Connection

For nonlinear loads with harmonic current injections:

BEF 44903 Industrial Power Systems Topic 1

1.1 Planning for Connection

For voltage sensitive loads:

BEF 44903 Industrial Power Systems Topic 1

1.2 Voltage and Frequency Considerations

Steady-State Voltage Fluctuation (Contingency Condition)

BEF 44903 Industrial Power Systems Topic 1

1.2 Supply Voltage Options

BEF 44903 Industrial Power Systems Topic 1

1.2 Supply Voltage Options

Medium and High Voltages:

BEF 44903 Industrial Power Systems Topic 1

1.2 Voltage and Frequency Considerations

BEF 44903 Industrial Power Systems Topic 1

1.3 Classification of Distribution Systems

The distribution systems may be classified in