JahangirThesis Final (27 (1) .04.10)

A PROJECT REPORT ON
THE ELECTRICAL SYSTEM DESIGN, DRAWING,

ESTIMATING AND INSTALLATION SUPERVISION OF A
SPINNING MILL
PREPARED BY:
MD. JAHANGIR ALAM

(ID. 0701068)
A project submitted to the Department of Electrical and Electronic

Engineering
Of
GREEN UNIVERSITY OF BANGLADESH (GUB)
In partial fulfillment of the requirements for the degree of
BACHELOR OF SCIENCE IN ELECTRICAL AND ELECTRONIC
ENGINEERING
DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
GREEN UNIVERSITY OF BANGLADESH (GUB)
May 2010
Declaration
It is hereby declared that this project or any part of it has not been submitted
elsewhere for the award of any degree or diploma.
Signature of the candidates
……………………………………………………………
(MD. JAHANGIR ALAM Student ID No: 0701068)
2
Dedication
To our Country
The People’s Republic of Bangladesh
3
Acknowledgements
We would like to express our acknowledgement and heartfelt gratitude to our

supervisor Prof. Dr. M. Shamsul Alam, Dean, Department of Electrical and
Electronic Engineering, Green University of Bangladesh (GUB), Dhaka, for his
constant guidance, invaluable suggestions and perpetual support throughout
the progress of my work.
We would also like to thanks A. H. M. Rezwanul Islam, Lecturer, Department

of Electrical and Electronic Engineering, Green University of Bangladesh
(GUB), Dhaka, for his tremendous help and support. Without his
encouragement, this project would not come to a successful completion.
Thanks to all of you whose names are not mentioned here.
4
LAYOUT OF THIS PROJECT
Organization of this project included seven chapters. Chapter one gives a

general introduction followed by background and objective of the works.
Chapter two reviews different concepts that are needed for this project like
that Fuse, Air circuit breaker (ACB), Moulded case circuit breaker (MCCB),
Miniature Circuit Breaker (MCB), Pre fabricated bus bar, Power factor
improvement plant (PFI),
In chapter three in a spinning mill using machine list, the machine layout
plane, symbol of machine & electrical equipments and the machine load
chart table.
Chapter four machine load calculation, selection of Generator capacity, single

line diagram, selection of low tension switchgear circuit breaker, bus bar
ratting and cable size, low tension switchgear panel design, Power factor
improvement (PFI) plant design.
Details technical specifications and estimating the low tension switchgear,

power factor improvement plant and pre fabricated bus bar trunking system
in chapter five.
In chapter six low tension switchgear, power factor improvement plant panel
layout plan, the pre fabricated bus bar trunking system installation process &
shop drawing,
5
An Appendix is included at the end as chapter seven. And it describes as
reference.
Contents
Declaration 1
Dedication 2
Acknowledgements 3
Project Layout
4
List of Figures
7
List of Tables
7
Chapter 1
1.1 Introduction 8
1.1.1 General 8
1.1.2 Importance of electrical energy 8
1.1.3 Necessity of electric power in a spinning mill
8
1.2 Background information for the electricity
10
1.2.1 What is electricity? 10
6
1.2.2 Who discovered electricity?
11
1.2.3 What is static electricity? 11
1.2.4 What is current? 11
1.2.5 What is current electricity?
11
1.2.6 What is the difference between alternating and direct current
11
1.3 Objective of the work
12
Chapter 2
2.1 Discussion of the using product 13
2.1.1 How does a fuse work? 13
2.1.2. Air Circuit Breaker (ACB) 13
2.1.3. Moulded Case Circuit Breaker (MCCB) 14
2.1.4 Miniature Circuit Breaker (MCB) 15
2.1.5 Bus bar Trunking System (BBT) 16
2.2 Power factor Improvement
18
2.2.1. Importance of Power Factor
18
2.2.2. Power Factor 18
2.2.3. Phase 18
2.2.4. Phasor Diagrams 19
Chapter 3
3.1 A spinning mills using machines list are bellows
20
3.2 A Spinning mills machine layout plan
21
3.3 A Spinning mill using machine & electrical equipments symbols
22
3.4 Machine load chart in a Spinning Mill (36636 Spindle)
23
Chapter 4
4.1 Total Load Calculation in a Spinning Mill (36636 Spindle)
24
4.2 Generator Selection
26
4.3 Single line diagram of low tension switchgear 27
4.4 Single line diagram of distribution board
28
7
4.5 Selection of Low Tension Switchgear Incoming Circuit Breaker
29
4.6 Branch Load Calculation 30
4.6.1 Load calculation for BBT- 01
30
32
34
4.6.4 Dreading function of an ambient temperature
35
4.7 Cable rating calculation 35
4.8 Correction factors to current rating for ambient temperature (a)
38
4.9 Correction factors for groups of cables 38
4.10 Current ratings and volt drops for single core p.v.c. insulated cable
39
4.11 Current ratings of mineral insulated cables clipped direct
39
4.12 Volt drops for mineral insulated cables 40
4.13 Cable volt drop 41
4.14 Cable Selection & length measurement
42
4.15 Design of low tension switchgear
46
4.16 Design of power factor improvement plant
47
4.17 Machine layout with bus bar layout plan
48
4.18 Bus bar layout plan with location of distribution board
49
Chapter 5
5.1 Cost of the Low voltage Switchgear
50
5.2 Cost of power bas bar trunking system 64
5.3 Cost of lighting bas bar trunking system
66
5.4 Total cost of the Low voltage Switchgear &
pre fabricated bus bar
67
5.5 Local cost of the connecting cable, installation,
testing & commissioning 68
8
Chapter 6
6.1 Distribution switchboards 69
6.2 Three basic technologies are used in functional distribution switchboards
69
6.3 Panel Layout Plan 73
6.4 How do bus bars installations compare in terms of cost
74
6.5 Process of bus bars operate
75
6.6 Isometric drawing 76
Chapter 7
Appendix 77
Reference 78
List of Figure
Figure 1.1 Spinning mills (Ring Frame)

9
Figure 1.2 Electric lamp 10
Figure 1.3 Proton, neutron & electron
10
Figure 2.1 Electrical circuit with fuse & bulb
13
Figure 2.2 Air Circuit Breaker (ACB) 14
Figure 2.3 Moulded Case Circuit Breaker 15
Figure 2.4 Electrical distribution network
15
Figure 2.5 MCB (Miniature Circuit Breaker) 16
Figure 2.6 bus bar connections with M/C 17
Figure 2.7 bus bar connections with light 17
Figure 2.8 Power out from bus bar 17
Figure 2.9 Phase angle between voltage & current
19
Figure 3.1 A Spinning mills machine layout plan
21
Figure 4.1 Single line diagram of low tension switchgear 27
9
Figure 4.2 Single line diagram of distribution board
28
Figure 4.3 Design of low tension switchgear
46
Figure 4.4 Design of power factor improvement plant
47
Figure 4.5 Machine layout with bus bar layout plan
48
Figure 4.6 Bus bar layout plan with location of distribution board
49
Figure 6.1 Assembly of a final distribution switch board 69
Figure 6.2 Distribution switchboard with disconnect able functional units
70
Figure 6.3 Distribution switchboard with withdraw able functional units
71
Figure 6.4 Panel layout plan 73
Figure 6.5 Isometric drawing for installation
76
List of Table
Table 3.1 Machine load chart in a Spinning Mill

23
Table 4.4.1 Load Calculation chart in a Spinning Mill
24
Table 4.6.1 Load calculation for BBT- 01
30
32
34
Table 4.7.1 Dreading function of an ambient temperature
35
Table 4.8.1 Correction factors to current rating for ambient temperature (a)
38
Table 4.9.1 Correction factors for groups of cables 38
Table 4.10.1 Current ratings and volt drops for single core p.v.c. insulated cable
39
Table 4.11.1 Current ratings of mineral insulated cables clipped direct
39
Table 4.12.1 Volt drops for mineral insulated cables 40
10
Chapter 1
1.1 INTRODUCTION
1.1.1 General
Energy is the basic necessity for the economic development of a country.

Many function necessary to present day living grind to halt when the supply
of energy stops. It is practically impossible to estimate the actual magnitude
of the part that energy has played in the building up of present day
civilization. The availability of huge amount of energy in the modern times
has resulted in a shorter working day, higher agricultural and industrial
production, a healthier and more balanced diet and better transportation
facilities. As a matter of fact, there is a close relationship between the energy
used per person and his standard of living. The greater the per capita
consumption of energy in a country the higher is the standard of living of its
people.
1.1.2 Importance of electrical energy
Energy may be needed as heat as light as motive power etc. The present day
advancement in science and technology has made it possible to convert
electrical energy into any desired form. This has given electrical energy a
place of pride in the modern world. The survival of industrial undertakings
and our social structures depends primarily upon low cost and uninterrupted
supply of electrical energy. In fact the advancement of a country is measured
in terms of per capita consumption of electrical energy.
1.1.3 Necessity of electric power in a spinning mill
In modern fashion technology, the demand for perfection begins right at the
birth of the raw material, permeates through every single process, till the
highly discerning customer dons the finished garment. It is this demand for
perfection that has spurred the growth of an organization and its corporate
philosophy. Those who can furnish clients with the best quality, competitive
price, and excellent customer services and prompt delivery can only survive
in the market. A Spinning Mills takes immense pride in perceiving its role as
the comprehensive architect of every single yarn and garment that its
produces. A multi-unit, multi-interest business group with a wide range of
industrial activity, an organization that has founded its evolution on value-
11
based commercial practice. 37000 spindles spinning mills per day production
18000 Kg yarn without electricity interruption.
Constant commitment to high quality standards and innovation has been the
secret of success ever since the company was founded. Superior Spinning
units ensure the supply of consistent quality yarn to manufacture the
garments. Superior spinning units leads the quality of yarn in the market.
Fig. 1.1 Spinning mills (Ring Frame)
Coupled with global standards of process manufacturing that turn out year of
superior quality in durability as well as finish. To produce superior quality
garments, ensure that every kilogram of yarn supplied from spinning unit
conforms to International standard and with zero complaint. Believe that
quality products are not only by promises but also by proven results.
Development of new textile products is done through - Innovation in defining
production processes of higher quality and making available modern
technologies and professionals with the highest level of competence.
The following advantages which have always a spinning mills are

goals: -
High Efficiency
The Most Competitive & Reasonable Price
Products Quality Guarantee
Prompt & Superior Service
Punctual Delivery
For the above goals are meet when the electricity without interruption.
Electrical power is a spinning mills are heard of a part, so good design of
electrical system are essential. Good design can save electricity and trouble
free running the system.
12
1.2 BACKGROUMD INFORMATION FOR ELECTRICITY
1.2.1 What is electricity?
Fig. 1.2 Electric lamp Fig. 1.3 Proton, neutron &

electron.
It is a form of energy, evident from the fact that it runs machinery and can be
transformed into other types of energy such as light and heat. It is invisible.
During an electrical storm, we do not see electricity. We observe the air being
ionized when the electricity travels through it. Electricity is created when
particles become charged. Some are negatively charged (electrons), some
are positively charged (protons). These opposite charges attract; whereas
particles with similar charges repel each other.
The nucleus of the atom contains protons (positively charged) and neutrons
(no charge) around which electrons (negatively charged) whirl. An electron is
two thousand times smaller in mass than a proton but its electrical charge is
equal to that of a proton. Electrons of many elements, particularly metals, are
easily knocked off from their parent atoms and can wander freely between
atoms. If a state of unbalanced charges exists, a necessary condition to
13
create an electric current also exists. However, the flow of electric current
cannot take place until the circuit is completed. When a battery or other
electrical source is attached to a wire, which is connected to some form of
resistance, (a light, a bell, a motor, etc.), and a circuit is completed back to
the source or to ground, free electrons are released into the wire, creating an
electrical potential or voltage. The electrons bounce against other electrons
in the wire which are repelled because they have the same electrical charge.
They go on bouncing against other free electrons down the wire, causing a
flow of electrons - an electrical current. Provided there is somewhere for the
electrons to go, such as a lamp or a motor, where the energy is converted to
another form of energy, the electrons flow out the far end.
1.2.2 Who discovered electricity?

The Greeks had some idea of electricity. In the 18th century Franklin and
other Europeans knew a great deal about it. Early in the century, Alessandro
Volta invented the first source of continuous electric current - the battery.
Later, Hans Christian Operated discovered that an electric current produced
magnetism. But it was Michael Faraday who described the nature of the
phenomena. In his electromagnetic induction theory he stated that an electric
current flows in a conductor if that conductor is in a moving magnetic field
and is part of a circuit.
1.2.3 What is static electricity?

Static electricity is electricity at rest. It is produced by friction, by rubbing. All
matter contains positively charged particles called protons and negatively
charged particles called electrons. In an uncharged atom, the protons and
electrons balance each other and the atom is neutral. If this neutral atom
loses an electron, because it has an excess of protons, it is said to be
positively charged. If the neutral atom gains an electron, it is said to be
negatively charged. Rubbing can tear electrons loose from certain atoms.
Some substances, because of the character of their atoms, tend to lose
electrons and become positively charged; other substances gain electrons
easily and become negatively charged.
14
1.2.4 What is current?
Current is the rate of flow of electrons. It is produced by electrons "on the
move", and it is measured in amperes. Unlike static electricity, current
electricity must flow through a conductor, usually copper wire. Household
current is usually no more than 30 amps.
1.2.5 What is current electricity?

Current electricity is a stream of electrons flowing through a conductor. There
are different sources of current electricity including the chemical reactions
taking place in a battery and the application of pressure on quartz crystals.
However, the most significant source is the generator. A simple magneto, or
generator, produces electricity when a coil of copper turns inside a magnetic
field. In a power plant, electromagnets spinning inside an armature of many
coils of copper wire generate vast quantities of current electricity.
1.2.6 What is the difference between alternating and direct current?

A battery produces direct current (DC). The electrons are set in motion by a
chemical reaction in a battery and flow only one way. A generator, on the
other hand, produces alternating current (AC), because the wire coil core is
influenced alternately by the North and South Poles of the magnets. The
current is therefore constantly changing direction.
1.3 OBJECTIVE OF THE WORK
The objective of this project, I hope by this project I will learn more
Engineering in the practical field that will be more helpful to our career.
These projects objects are as follows:
In this project we know how to design the distribution system, low voltage
switchgear design.
In this project we know how to draw the single line diagram of the electrical
system.
15
Also we can know how to calculate the load of the different type machine in a
Spinning mills
We can know selection of cable size for each machine connection and also
know the pre fabricated Bus bar trunking system selection design.
While doing this project, we come to know the price of each electrical
equipment by market study and how to estimate the price of this project.
We come to know the installation procedure by visiting each and every past
of the site & installation direction to the site engineer.
Chapter 2
2.1 DISCUSSATION OF THE USING PRODUCT
2.1.1 How does a fuse work?
16
A fuse is connected directly into an electrical circuit. If the electric current
surges to a dangerous level, the metal in the fuse melts and the circuit is
broken, preventing overheated wires in the walls of the house from starting a
fire. Never substitute a fuse of greater capacity than that specified for a
particular circuit. If the fuse has the ability to carry more current than
originally designed, the wires will heat up before the fuse melts, and this
could start a fire.
Fig. 2.1 Electrical circuit with fuse & bulb
2.1.2 Air Circuit Breaker (ACB)
Product Description
1. Standard: IEC60947-2
2. Function: Overload & short-circuit & under-voltage protection
3. Rated voltage: 380V
4. Rated current: 630A to 5000A
5. Frequency: 50Hz
Air circuit breakers (hereinafter called circuit breaker) are rated 630A to
5000A in current (up to 630A for limiting current open circuit) and AC 50HZ
380V in voltage. The breaker is mainly used to distribute electric energy in
the power distribution network and to prevent the circuit and power source
equipment from overload, under voltage and short circuit. It can also be used
in AC 50Hz 380V electric network to protect the motor from over load, under
voltage or short circuit, Or in 660V or 1140V power distribution network to
offer above protections. Under the normal conditions, the breaker can be
used to switch the circuit and start the motor infrequently. With the current
limiting characteristics, the current-limiting breaker is especially suitable for
the network where large short-circuit current is likely to occur.
17
Fig. 2.2 Air Circuit Breaker (ACB)
2.1.3 Moulded Case Circuit Breaker (MCCB)
A circuit breaker is an electrical device used in an electrical panel that

monitors and controls the amount of amperes (amps) being sent through the
electrical wiring. Circuit breakers come in a variety of sizes. For instance 6,
10, 15 and 20 amp breakers are used for most power and lighting needs in
the typical home. Some appliances and specialty items (washers, dryers,
freezers, whirlpools, etc.) will require a larger circuit breaker to handle the
electrical load required to run that appliance.
18
Fig. 2.3 Moulded Case Circuit Breaker
Fig. 2.4 Electrical distribution network
2.1.4 Miniature Circuit Breaker (MCB)
Product Description:
Circuit breaker is used in lighting distribution system or motor distribution
system for protection.
* Capable of switch electric circuit with load
* Capable of quickly releasing stored energy operation
* Adaptable to padlock device
* Contact position indication
* High short-circuit current withstand capacity
* Highlighted of high making and breaking capacity
* Used as main switch for household and similar installation
19
Fig. 2.5 MCB (Miniature Circuit Breaker)
TECHNICAL DATA
* Pole No: 1, 2, 3, 4
* Rated current(A): 1, 2, 3, 4, 6, 10, 20, 25, 32, 40, 50, 63
* Rated frequency: 50/60hz
* Rated voltage: 230/400V AC
* Rated withstand current: 1000A within 1 sec
* Electro-mechanical endurance: 10000 cycles
* Rated short-circuit making capacity: 10000A
* Connection capacity: Rigid conductor 25mm2
* Connection terminal:
* Screw terminal
* Pillar terminal with clamp
* Installation:
* Panel mounting
2.1.5 Bus bar Trunking System (BBT):
Bus bar Trunking is a prefabricated, modular system, designed to transmit

and distribute electricity. General construction is of, insulated aluminium or
copper conductors which complies with relevant standards, covered by a
steel housing.
Bus bar makes it possible to supply power at the Tap-off points. It also
provides a simple for changes in machinery lines or any kind of extensions
which will be required at the early stages of installation and even during the
operation. So there is no need for lengthy delays to the line.
The electrical energy is carried by means of the conductors which are placed
into the metal housing using the plug in tap-off box provides a safe method of
connection without interruption of supply.
Using large cables for power distribution with in factories, high rise buildings
etc can incur difficulties when running the cables into the cable trays or when
20
there is a need for changes or extensions. These problems are easily
overcome using Bus bar Systems instead of cables. Bus bar Systems allow
you to "Tap" power at convenient locations, reducing the expense of changes
to cable systems.
Fig. 2.6 Bus bar connection with M/C Fig. 2.7 Bus bar connection with
light
System Advantages:
Long Life:
Bus bar Systems don't need special maintenance because of the structural
specifications. All parts of the installation can easily be mounted and
demented due to the modular structure of our system. The installation can
easily be changed or the system can be used again in another location if
required.
Modern Outlook:
Other than its functional advantages Bus bar system also creates a modern
view in buildings where it is used.
System Modification:
Because of the modular and flexible specifications Bus bar systems quickly
and easily accommodate changes in machinery lines or any kind of
extensions. The Bus bar system provides economic and quick solutions which
give us the opportunity to change during the operation.
21
Fig. 2.8 Power out from bus bar
2.2 POWER FACTOR IMPROVEMENT
2.2.1. Importance of Power Factor
A power factor of one or "unity power factor" is the goal of any electric utility
company since if the power factor is less than one, they have to supply more
current to the user for a given amount of power use. In so doing, they incur
more line losses. They also must have larger capacity equipment in place
than would be otherwise necessary. As a result, an industrial facility will be
charged a penalty if its power factor is much different from 1.
Industrial facilities tend to have a "lagging power factor", where the current
lags the voltage (like an inductor). This is primarily the result of having a lot
of electric induction motors - the windings of motors act as inductors as seen
by the power supply. Capacitors have the opposite effect and can
compensate for the inductive motor windings. Some industrial sites will have
large banks of capacitors strictly for the purpose of correcting the power
factor back toward one to save on utility company charges.
2.2.2. Power Factor
For a DC circuit the power is P = VI and this relationship also holds for the
instantaneous power in an AC circuit. However, the average power in an AC
circuit expressed in terms of the rms voltage and current is
22
where is the phase angle between the voltage and current. The additional
term is called the power factor
From the phasor diagram for AC impedance, it can be seen that the power
factor is R/Z. For a purely resistive AC circuit, R=Z and the power factor = 1.
2.2.3. Phase
When capacitors or inductors are involved in an AC circuit, the current and

voltage do not peak at the same time. The fraction of a period difference
between the peaks expressed in degrees is said to be the phase difference.
The phase difference is <= 90 degrees. It is customary to use the angle by
which the voltage leads the current. This leads to a positive phase for
inductive circuits since current lags the voltage in an inductive circuit. The
phase is negative for a capacitive circuit since the current leads the voltage.
The phase relation is often depicted graphically in a phasor diagram.
Fig. 2.9 Phase angle between voltage & current
2.2.4. Phasor Diagrams

It is sometimes helpful to treat the phase as if it defined a vector in a plane.
The usual reference for zero phases is taken to be the positive x-axis and is
associated with the resistor since the voltage and current associated with the
resistor are in phase. The length of the phasor is proportional to the
magnitude of the quantity represented, and its angle represents its phase
relative to that of the current through the resistor. The phasor diagram for
the RLC series circuit shows the main features.
23
Note that the phase angle, the difference in phase between the voltage and
the current in an AC circuit, is the phase angle associated with the impedance
Z of the circuit. The low power factor is mainly due to the fact that most of
the power leads are inductive and therefore take lagging current. In order to
improve the power factor. Same device taking leading power should de
connected in parallel with the load. One of such device can be a capacitor.
Normally the power factor of the whole load a large generating station is in
the region of 0.8 to 0.9 However sometimes whole load and such ease is it
generally desirable to take special steps to improve the power factor. This
can be archived by the following equipment.
i Synchronous condenser.
ii Phase advancers.
Chapter 3
3.1 A SPINNING MILLS USING MACHINE LIST ARE BELOWS
Blow Room
Draw frame
i) Breaker Drawing
ii) Finisher Drawing
Carding
Comber
Simplex
Ring frames
24
Auto cone
Uni lap
Yarn Conditioning/ West Collection
Compressor
Humidification Plant/ Air Filter
------------ Etc.
3.2 A Spinning mills machine layout plan
Figure 3.1
25
3.3 A Spinning mill using machine & electrical equipments symbols
26
3.4 Machine load chart in a Spinning Mill (36636 Spindle)
Table – 3.1
Connecting load per M/C

SL # Name of M/C (KW)
A B D
1 Auto Cone 35
2 Ring M/C 28
27
3 Simplex M/C 28
4 Breaker Drawing 7.01
5 Finisher Drawing 11.11
6 Card M/C 24.68
7 Comber 6.7
8 Uni Lap 12
9 Pump Motor 22
10 Cooling Motor 5.5
11 West Collection 95
12 Air Filter -01 120
15 Compressor 37.5
16 Yarn Conditioning 256
17 Blow Room M/C 110
18 Lighting Load 160
Chapter 4
4.1 Total Load Calculation chart in a Spinning Mill (36636 Spindle)
A spinning mill is run by some machine are 60% to 75% of connected load
and some machine are 100% connected load like Air Filter, West Collection,
Compressor, Blow Room M/C, Yarn Conditioning etc. The load calculation is
given by the table -4.1.1 as below: Running load calculation 75% of
connecting load is below machines.
28
Table – 4.1.1
Running load
per M/C Total Total
SL Qty Connecting (KW) Connectin Running
# Name of M/C . load per Running g Load Load
M/C (KW) 75% (KW) (KW)
A B C D E F=C x D G=CxE
1 Auto Cone 12 35 26.25 420 315
2 Ring M/C 71 28 21 1988 1491
3 Simplex M/C 7 28 21 196 147
Breaker
4 Drawing 5 7.01 5.26 35.05 26.3
Finisher
5 Drawing 5 11.11 8.33 55.55 41.65
6 Card M/C 15 24.68 18.51 370.2 277.65
7 Comber 5 6.7 5.03 33.5 25.15
8 Uni Lap 1 12 9 12 9
9 Pump Motor 5 22 16.5 110 82.5
10 Cooling Motor 5 5.5 4.13 27.5 20.65
SUB TOTAL LOAD (KW) 3247.8 2435.85
Running load calculation 100% of connecting load is below machines
SL Qty Connecting Running load Total Total

# Name of M/C . load per per M/C Connecti Running
29
(KW)
Running ng Load Load
M/C (KW) 100% (KW) (KW)
A B C D E F= C x D G=CxE
West
11 Collection 1 95 95 95 95
12 Air Filter -01 1 120 120 120 120
13 Air Filter -02 1 240 240 240 240
14 Air Filter -03 1 189 189 189 189
15 Compressor 3 37.5 37.5 112.5 112.5
Yarn
16 Conditioning 1 256 256 256 256
Blow Room
17 M/C 1 110 110 110 110
18 Lighting Load 1 160 160 160 160
LOAD (in
SUB TOTAL KW) 1282.5 1282.5
Sub Total Running Load in KW (Table -1) = 2435.85

Sub Total Running Load in KW (Table -2) = 1282.50
Grand Total Running Load in KW = 3718.35
30
4.2 Generator Selection
Generator need for a 36636 Spindle spinning mill
Total Running Load in KW = 3718.35
Each Generator = 3718.35 4

= 929.59 KW
Suppose, Generator ratting is 1038 KW & efficiency 90%
Output Input
Efficiency =
Or, Output = Efficiency x input
= 0.9 x 1038
= 934.2 KW
So that, our running load is 929.59 KW & also generator output is 934.2KW
We need 4 nos. 1038 KW Gas Generator for this project
31
4.3 Single line diagram of low tension switchgear
Fig. 4.1
32
4.4 Single line diagram of distribution board
Fig. 4.2
33
4.5 Selection of Low Tension Switchgear Incoming Circuit Breaker
Calculation for L.T Panel incoming Circuit Breaker

Power [ P ] = 3 VIcosø
Current [ I ] = 934.2 x1000 3 x 400 x0.9 Here, Power [ P ] = Power in

KW
Cosø = Power
factor
Current [ I ] =
Current in Amps
Current ( I ) = 1498.27 at, Cosø = 0.9 and Temperature = 35 º C

Current ( I ) = 1498.27A / 0.91
= 1646.45A Here, Dreading factor 0.91 at 50 º C [From
table 4.7.1]
Safety Factor = 0.9
For circuit breaker ratting = 1646.45 / 0.9
= 1829.40A
Selected Incoming Circuit Breaker = 2000A
34
4.6 Branch load calculation
Table – 4.6.1
SL Running load per M/C Total Running Load

# Name of M/C Qty. (KW) (KW)
A B C D E=CxD
Blow Room
1 M/C 1 110 110
2 Carding M/C 15 18.51 277.65
Breaker
3 Drawing 5 5.26 26.3
Finisher
4 Drawing 5 8.33 41.65
5 Comber 5 5.03 25.15
6 Uni Lap 1 9 9
7 Ring M/C 7 21 147
8 Simplex M/C 7 21 147
West 1 95 95
9 Collection
35
10 Air Filter -01 1 120 120
TOTAL LOAD (in KW) 998.75
Branch BBT Load Calculation

A B C D E=CxD
Blow Room
1 M/C 1 110 110
2 Carding M/C 15 18.51 277.65
Branch BBT- A, Load 387.65 = 624A BBT

(KW) =800A
Breaker
3 Drawing 5 5.26 26.3
Finisher
4 Drawing 5 8.33 41.65
5 Comber 5 5.03 25.15
6 Uni Lap 1 9 9
7 Ring M/C 7 21 147
West 1 95 95
9 Collection
36
10 Air Filter -01 1 120 120
Branch BBT- B, Load 611.1 = 984A BBT

(KW) =1250A
7 Ring M/C 7 21 147

120
9 Air Filter -01 1 120
Branch BBT- C, Load
(KW) 414 = 667A BBT =800A
Current [ I ] = 998.75 x1000 3 x 400 x 0.9 Here, Power [ P ] = Power in KW

Cosø = Power factor
Current [ I ] = Current in
Amps
Current ( I ) = 1601.79A at, Cosø = 0.9 and Temperature = 35 º C
Current ( I ) = 1601.79A / 0.91

= 1760.21A Here, Dreading factor 0.91 at 50 º C [From
table 4.7.1]
Safety Factor = 0.9
Pre Fabricated Bus Bar ratting = 1760.21 / 0.9

= 1956A
Selected Pre Fabricated Bus Bar = 2000A,
Low tension switchgear incoming breaker also = 2000A
Table – 4.6.2
SL Qty. Running load per M/C Total Running Load

37
# Name of M/C (KW) (KW)
A B C D E=CxD
1 Ring M/C 64 21 1344
2 Compressor 3 37.5 112.5
TOTAL LOAD (in KW) 1456.5

A B C D E=CxD
1 Ring M/C 64 21 1344
Branch BBT- A, Load 1457=2344A BBT

(KW) 3000A
1 Ring M/C 32 21 672
Branch BBT- B, Load 785=1264A BBT

(KW) =1600A
1 Ring M/C 21 21 441
Branch BBT- C, Load 441=710A BBT

(KW) =1000A
38
Current [ I ] = 1456.5 x1000 3 x 400 x0.9 Here, Power [ P ] = Power in KW

Amps
Current ( I ) = 2338.63A at, Cosø = 0.9 Temperature = 35 º C
Current ( I ) = 2338.63A / 0.91

= 2570A Here, Dreading factor 0.91 at 50 º C [From
table 4.7.1]
Safety Factor = 0.9
Pre Fabricated Bus Bar ratting = 2570/0.9

= 2856A
Selected Pre Fabricated Bus Bar =3000A

Table – 4.6.3

A B C D E=CxD
1 Air Filter -02 1 240 240
2 Air Filter -03 1 189 189
Yarn
3 Conditioning 1 256 256
4 Auto Cone 12 26.25 315
TOTAL LOAD (in KW) 1000
39

A B C D E=CxD
2 Air Filter -03 1 189 189
Yarn
4 Auto Cone 12 26.25 315
Branch BBT- B, Load 760=1224A BBT

(KW) =1600A
Yarn
4 Auto Cone 12 26.25 315
Branch BBT- C, Load 572=921A BBT

(KW) =1250A
Current [ I ] = 1000 x1000 3 x 400 x 0.9 Here, Power [ P ] = Power in KW

Amps
Current ( I ) = 1605A at, Cosø = 0.9 and Temperature = 35 º C

Current ( I ) = 1605A / 0.91
= 1764A Here, Dreading factor 0.91 at 50 º C [From
table 4.7.1]
Safety Factor = 0.9
Pre Fabricated Bus Bar ratting = 1764/0.9

= 1960A
40
Selected Pre Fabricated Bus Bar = 2000A
4.6.4 Dreading function of an ambient temperature
Table – 4.7.1
Ambient temperature 35 º C 40 º C 45 º C 50 º C 55 º C
Coefficient K 1 1 0.97 0.94 0.91 0.87
4.7 Cable rating calculation
The Regulations indicate the following symbols for use when selecting cables:
is the current carrying capacity of the cable in the situation where it is

Iz
installed
is the tabulated current for a single circuit at an ambient temperature of

It
30°C
Ib is the design current, the actual current to be carried by the cable
In is the rating of the protecting fuse or circuit breaker
is the operating current for the fuse or circuit breaker (the current at
I2
which the fuse blows or the circuit breaker opens)
Ca is the correction factor for ambient temperature
Cg is the correction factor for grouping
Ci is the correction factor for thermal insulation.
The correction factor for protection by a semi-enclosed (rewritable)

fuse/circuit breaker is not given a symbol but has a fixed value of 0.725.
Under all circumstances, the cable current carrying capacity must be equal to
or greater than the circuit design current and the rating of the fuse or circuit
breaker must be at least as big as the circuit design current. These
requirements are common sense, because otherwise the cable would be
overloaded or the fuse/circuit breaker would blow when the load is switched
on.
41
To ensure correct protection from overload, it is important that the protective
device operating current (Iz) is not bigger than 1.45 times the current
carrying capacity of the cable (Iz). Additionally, the rating of the fuse or
circuit breaker (In) must not be greater than the the cable current carrying
capacity (Iz) It is important to appreciate that the operating current of a
protective device is always larger than its rated value. In the case of a back-
up fuse, which is not intended to provide overload protection, neither of these
requirements applies.
To select a cable for a particular application, take the following steps: (note
that to save time it may be better first to ensure that the expected cable for
the required length of circuit will] not result in the maximum permitted volt
drop being exceeded 4.13.
1. Calculate the expected (design) current in the circuit (Ib)
2. Choose the type and rating of protective device (fuse or circuit breaker) to
be used (In)
3. Divide the protective device rated current by the ambient temperature

----correction factor (Ca) if ambient temperature differs from 30°C
4. Further divide by the grouping correction factor (Cg)
5. Divide again by the thermal insulation correction factor (CI)
6. Divide by the semi-enclosed fuse/circuit breaker factor of 0.725 where

applicable
7. The result is the rated current of the cable required, which must be chosen
----from the appropriate tables 4.10.1 to 4.12.1.
42
Example(a)
A 415 V 50 Hz three-phase ring m/c motor with an output of 28 kW, power
factor 0.9 and efficiency 90% is the be wired using 415 V light duty three-
core mineral insulated p.v.c. sheathed cable. The length of run from the HBC
protecting fuses is 10 m, and for about half this run the cable is clipped to
wall surfaces. For the remainder it shares a cable tray, touching two similar
cables across the top of a boiler room where the ambient temperature is
50°C. Calculate the rating and size of the correct cable. The first step is to
calculate the line current of the motor.
Output Input
Efficiency =
Output efficiency
Or, Input =
= 28 0.9
= 31.11 KW
Line Current [ Ib ] = 31.11x1000 3 x 415 x0.9

= 48.12 A
We must now select a suitable fuse/circuit breaker 50A size to be the most
suitable. Part of the run is subject to an ambient temperature of 50°C, where
the cable is also part of a group of three, so the appropriate correction factors
must be applied from Table 4.8.1 and 4.9.1
Line Current [ Iz ] = Ib CgxCa
= 48.12 0.79 x0.71
= 85.8 A
Note that the grouping factor of 0.70 has been selected because where the
cable is grouped it is clipped to a metallic cable tray, and not to a non-
metallic surface. Next the cable must be chosen from table 4.11.1. Whilst the
current rating would be 48.12A if all of the cable run were clipped to the wall,
part of the run is subject to the two correction factors, so a rating of 85.8A
must be used. For the clipped section of the cable (48.12A), reference
method I could be used which gives a size of 6.0 mm² (current rating 51A).
43
However, since part of the cable is on the tray (method 3) the correct size for
85.8 A will be 16.0 mm², with a rating of 92 A.
4.8 Correction factors to current rating for ambient temperature (a)
Table 4.8.1
Ambient
Type of insulation
temperature
(°C) 70°C p.v.c 85°C rubber 70°C m.i 105°C m.i
25 1.03 (1.03) 1.02 (1.02) 1.03 (1.03) 1.02 (1.02)
30 1.00 (1.00) 1.00 (1.00) 1.00 (1.00) 1.00 (1.00)
35 0.94 (0.97) 0.95 (0.97) 0.93 (0.96) 0.96 (0.98)
40 0.87 (0.94) 0.90 (0.95) 0.85 (0.93) 0.92 (0.96)
45 0.79 (0.91) 0.85 (0.93) 0.77 (0.89) 0.88 (0.93)
50 0.71 (0.97) 0.80 (0.91) 0.67 (0.86) 0.84 (0.91)
55 0.61 (0.84) 0.74 (0.88) 0.57 (0.79) 0.80 (0.89)
4.9 Correction factors for groups of cables
Table 4.9.1
Number
of Correction factor Cg
circuits
Enclosed or
- Clipped to non-metallic surface
clipped
- - Touching Spaced*
2 0.80 0.85 0.94
3 0.70 0.79 0.90
4 0.65 0.75 0.90
5 0.60 0.73 0.90
6 0.57 0.72 0.90
44
7 0.54 0.72 0.90
8 0.52 0.71 0.90
9 0.50 0.70 0.90
10 0.48 ---------- 0.90
4.10 Current ratings and volt drops for single core p.v.c. insulated
cable
Table 4.10.1
In In
conduit conduit In In
Cross Clippe Clippe
in in condu condu
section d d Volt drop Volt drop
thermal thermal it on it on
al area direct direct
insulati insulati wall wall
on on
(mV/A/m
(mm²) (A) (A) (A) (A) (A) (A) (mV/A/m)
)
2 3 or 4 2 3 or 4 2 3 or 4 3 or 4
- 2 cables
cables cables cables cables cables cables cables
1.0 11.0 10.5 13.5 12.0 15.5 14.0 44.0 38.0
1.5 14.5 13.5 17.5 15.5 20.0 18.0 29.0 25.0
2.5 19.5 18.0 24.0 21.0 27.0 25.0 18..0 15.0
4.0 26.0 24.0 32.0 28.0 37.0 33.0 11.0 9.5
6.0 34.0 31.0 41.0 36.0 47.0 43.0 7.3 6.4
10.0 46.0 42.0 57.0 50.0 65.0 59.0 4.4 3.8
16.0 61.0 56.0 76.0 68.0 87.0 79.0 2.8 2.4
4.11 Current ratings of mineral insulated cables clipped direct
Table 4.11.1
Cross- Volt p.v.c. p.v.c. p.v.c. Bare Bare

sectional sheath Sheath Sheath 3 sheath sheath
area 2x 3 core x single 2x 3x
45
single or
or twin single single
twin
(mm²) (A) (A) (A) (A) (A)
1.0 500v 18.5 16.5 16.5 22.0 21.0
1.5 500v 24.0 21.0 21.0 28.0 27.0
2.5 500v 31.0 28.0 28.0 38.0 36.0
4.0 500v 42.0 37.0 37.0 51.0 47.0
1.0 750v 20.0 17.5 17.5 24.0 24.0
1.5 750v 25.0 22.0 22.0 31.0 30.0
2.5 750v 34.0 30.0 30.0 42.0 41.0
4.0 750v 45.0 40.0 40.0 55.0 53.0
6.0 750v 57.0 51.0 51.0 70.0 67.0
10.0 750v 78.0 69.0 69.0 96.0 91.0
16.0 750v 104.0 92.0 92.0 127.0 119.0
Note that in (Table 4.11.1 and 4.12.1) 'P.V.C. Sheath means bare and
exposed to touch or having an over-all covering of p.v.c. and 'Bare' means
bare and neither exposed to touch nor in contact with combustible materials.
4.12 Volt drops for mineral insulated cables
Table 4.12.1
Cross-sectional Single-phase Single- Three-phase Three-phase

area p.v.c. Sheath phase bare p.v.c. Sheath bare
(mm²) (mV/A/m) (mV/A/m) (mV/A/m) (mV/A/m)
1.0 42.0 47.0 36.0 40.0
1.5 28.0 31.0 24.0 27.0
2.5 17.0 19.0 14.0 16.0
4.0 10.0 12.0 9.1 10.0
6.0 7.0 7.8 6.0 6.8
46
10.0 4.2 4.7 3.6 4.1
16.0 2.6 3.0 2.3 2.6
4.13 Cable volt drop
All cables have resistance, and when current flows in them this result in a volt
drop. Hence, the voltage at the load is lower than the supply voltage by the
amount of this volt drop.
The volt drop may be calculated using the basic Ohm's law
formula
U=IxR
where U is the cable volt drop (V)
I is the circuit current (A) and
R is the circuit resistance (Ohms)


Unfortunately, this simple formula is seldom of use in this case, because the
cable resistance under load conditions is not easy to calculate.
Indicates that the voltage at any load must never fall so low as to impair the
safe working of that load, or fall below the level indicated by the relevant
British Standard where one applies.
Indicates that these requirements will he met if the voltage drop does not
exceed 4% of the declared supply voltage. If the supply is single-phase at the
usual level of 240 V, this means a maximum volt drop of 4% of 240 V which is
9.6 V, giving (in simple terms) a load voltage as low as 230.4 V. For a 415 V
47
three-phase system, allowable volt drop will be 16.6 V with a line load voltage
as low as 398.4 V.
It should be borne in mind that European Agreement RD 472 S2 allows the

declared supply voltage of 230 V to vary by +10% or -6%. Assuming that the
supply voltage of 240 V is 6% low, and allowing a 4% volt drop, this gives
permissible load voltages of 216.6 V for a single-phase supply, or 374.5 V
(line) for a 415 V three-phase supply.
Each cable rating has a corresponding volt drop figure in mill volts per
ampere per meter of run (mV/A/m). Strictly this should be mV/ (A m), but
here we shall follow the pattern adopted by BS 7671: 1992. To calculate the
cable volt drop:
1. Take the value from the volt drop table (mV/A/m)

2. Multiply by the actual current in the cable (NOT the current rating)
3. Multiply by the length of run in meters
4. Divide the result by one thousand (to convert mill volts to volts).
Example (b)
Calculate the volt drop and maximum length of run for the motor circuit of
Exam. (a)
This time we have a mineral insulated p.v.c. sheathed cable, so volt drop
figures will come from table 4.12.1.This shows 6 mV/A/m for the 6 mm² cable
selected, which must be used with the circuit current of 48.12 A and the
length of run which is 10 m.
[6 x 48.12 x10 ] 1000

Voltage drop =
=1.92V
[4 x 415] 100
Maximum permissible volt drop is 4% of 415V =
= 16.6V
48
Maximum length of run for this circuit
[48 .12 x10 ] 1.92
with the same cable size and type will be =
= 250m
The 'length of run' calculations carried out in these examples are often useful
to the electrician when installing equipment at greater distances from the
mains position.
4.14 Cable Selection & length measurement
Load (in Length(

Description KW) Amp Cable selection m)
TO BBT DB-1 148.1 267 4x1c-150 rm NYY 16

TO BBT DB-2 148.1 267 4x1c-150 rm NYY 16
TO BBT DB-3 124.1 224 4x1c-150 rm NYY 132
TO BBT DB-4 196 353 4x1c-240 rm NYY 152
TO BBT DB-5 196 353 4x1c-240 rm NYY 52
TO BBT DB-6 280 504 4x1c-300 rm NYY 56
TO BBT DB-7 280 504 4x1c-300 rm NYY 156
TO BBT DB-8 280 504 4x1c-300 rm NYY 252
TO BBT DB-9 308 554 4x1c-300 rm NYY 16
TO BBT DB-10 308 554 4x1c-300 rm NYY 20
TO BBT DB-11 308 554 4x1c-300 rm NYY 20
TO BBT DB-12 315 567 4x1c-300 rm NYY 20
2x4x1c-150rm
TO BBT DB-13 361 650 NYY 56
TO BBT DB-14 113 203 4x1c-150 rm NYY 144
TO BBT Blow 110 198 4x1c-150 rm NYY 40
W/C
TO BBT Room 95 171 4x1c-95 rm NYY 24
TO BBT A/C-01 120 216 4x1c-150 rm NYY 24
TO BBT A/C-02 240 432 4x1c-300 rm NYY 32
TO BBT A/C-03 189 340 4x1c-240 rm NYY 96
DB-1 Card-1 24.68 44.4 4x1c-10 rm NYY 120

DB-1 Card-2 24.68 44.4 4x1c-10 rm NYY 112
DB-1 Card-3 24.68 44.4 4x1c-10 rm NYY 104
DB-1 Card-4 24.68 44.4 4x1c-10 rm NYY 96
DB-1 Card-5 24.68 44.4 4x1c-10 rm NYY 88
DB-1 Card-6 24.68 44.4 4x1c-10 rm NYY 36
DB-1 Card-7 24.68 44.4 4x1c-10 rm NYY 20
DB-1 Card-8 24.68 44.4 4x1c-10 rm NYY 48
49
DB-2 Card-9 24.68 44.4 4x1c-10 rm NYY 24
DB-2 Card-10 24.68 44.4 4x1c-10 rm NYY 32
DB-2 Card-11 24.68 44.4 4x1c-10 rm NYY 48
DB-2 Card-12 24.68 44.4 4x1c-10 rm NYY 64
DB-2 Card-13 24.68 44.4 4x1c-10 rm NYY 80
DB-2 Card-14 24.68 44.4 4x1c-10 rm NYY 96
DB-2 Card-15 24.68 44.4 4x1c-10 rm NYY 112
DB-3 Draw-1 11.11 20 4x1c-6 rm NYY 176
DB-3 Draw-2 11.11 20 4x1c-6 rm NYY 148
DB-3 Draw-3 11.11 20 4x1c-6 rm NYY 120
DB-3 Draw-4 11.11 20 4x1c-6 rm NYY 92
DB-3 Draw-5 11.11 20 4x1c-6 rm NYY 64
DB-3 Draw-6 11.11 20 4x1c-6 rm NYY 184
DB-3 Draw-7 11.11 20 4x1c-6 rm NYY 160
DB-3 Draw-8 11.11 20 4x1c-6 rm NYY 136
DB-3 Draw-9 11.11 20 4x1c-6 rm NYY 112
DB-3 Draw-10 11.11 20 4x1c-6 rm NYY 88
DB-3 Lab-1 12 22 4x1c-6 rm NYY 40
DB-3 Com-1 6.7 12.06 4x1c-4 rm NYY 32
DB-3 Com-2 6.7 12.06 4x1c-4 rm NYY 48
DB-3 Com-3 6.7 12.06 4x1c-4 rm NYY 64
DB-3 Com-4 6.7 12.06 4x1c-4 rm NYY 80
DB-3 Com-5 6.7 12.06 4x1c-4 rm NYY 96
DB-4 Simp-1 28 50.4 4x1c-16 rm NYY 112

DB-4 Simp-2 28 50.4 4x1c-16 rm NYY 80
DB-4 Simp-3 28 50.4 4x1c-16 rm NYY 80
DB-4 Simp-4 28 50.4 4x1c-16 rm NYY 100
DB-4 Simp-5 28 50.4 4x1c-16 rm NYY 112
DB-4 Simp-6 28 50.4 4x1c-16 rm NYY 128
DB-4 Simp-7 28 50.4 4x1c-16 rm NYY 160
DB-5 Ring-1 28 50.4 4x1c-16 rm NYY 48

DB-5 Ring-2 28 50.4 4x1c-16 rm NYY 44
DB-5 Ring-3 28 50.4 4x1c-16 rm NYY 40
DB-5 Ring-4 28 50.4 4x1c-16 rm NYY 36
DB-5 Ring-5 28 50.4 4x1c-16 rm NYY 40
DB-5 Ring-6 28 50.4 4x1c-16 rm NYY 44
DB-5 Ring-7 28 50.4 4x1c-16 rm NYY 48
DB-6 Ring-1 28 50.4 4x1c-16 rm NYY 48

DB-6 Ring-2 28 50.4 4x1c-16 rm NYY 44
DB-6 Ring-3 28 50.4 4x1c-16 rm NYY 40
DB-6 Ring-4 28 50.4 4x1c-16 rm NYY 36
DB-6 Ring-5 28 50.4 4x1c-16 rm NYY 36
DB-6 Ring-6 28 50.4 4x1c-16 rm NYY 44
DB-6 Ring-7 28 50.4 4x1c-16 rm NYY 48
50
DB-6 Ring-8 28 50.4 4x1c-16 rm NYY 52
DB-6 Ring-9 28 50.4 4x1c-16 rm NYY 56
DB-6 Ring-10 28 50.4 4x1c-16 rm NYY 60
DB-6 Ring-11 28 50.4 4x1c-16 rm NYY 64
DB-7 Ring-12 28 50.4 4x1c-16 rm NYY 48

DB-7 Ring-13 28 50.4 4x1c-16 rm NYY 44
DB-7 Ring-14 28 50.4 4x1c-16 rm NYY 40
DB-7 Ring-15 28 50.4 4x1c-16 rm NYY 36
DB-7 Ring-16 28 50.4 4x1c-16 rm NYY 36
DB-7 Ring-17 28 50.4 4x1c-16 rm NYY 40
DB-7 Ring-18 28 50.4 4x1c-16 rm NYY 44
DB-7 Ring-19 28 50.4 4x1c-16 rm NYY 48
DB-7 Ring-20 28 50.4 4x1c-16 rm NYY 52
DB-7 Ring-21 28 50.4 4x1c-16 rm NYY 56
DB-8 Ring-22 28 50.4 4x1c-16 rm NYY 56

DB-8 Ring-23 28 50.4 4x1c-16 rm NYY 52
DB-8 Ring-24 28 50.4 4x1c-16 rm NYY 48
DB-8 Ring-25 28 50.4 4x1c-16 rm NYY 44
DB-8 Ring-26 28 50.4 4x1c-16 rm NYY 40
DB-8 Ring-27 28 50.4 4x1c-16 rm NYY 36
DB-8 Ring-28 28 50.4 4x1c-16 rm NYY 40
DB-8 Ring-29 28 50.4 4x1c-16 rm NYY 44
DB-8 Ring-30 28 50.4 4x1c-16 rm NYY 48
DB-8 Ring-31 28 50.4 4x1c-16 rm NYY 52
DB-8 Ring-32 28 50.4 4x1c-16 rm NYY 56
DB-9 Ring-1 28 50.4 4x1c-16 rm NYY 56

DB-9 Ring-2 28 50.4 4x1c-16 rm NYY 52
DB-9 Ring-3 28 50.4 4x1c-16 rm NYY 48
DB-9 Ring-4 28 50.4 4x1c-16 rm NYY 44
DB-9 Ring-5 28 50.4 4x1c-16 rm NYY 40
DB-9 Ring-6 28 50.4 4x1c-16 rm NYY 36
DB-9 Ring-7 28 50.4 4x1c-16 rm NYY 40
DB-9 Ring-8 28 50.4 4x1c-16 rm NYY 44
DB-9 Ring-9 28 50.4 4x1c-16 rm NYY 48
DB-9 Ring-10 28 50.4 4x1c-16 rm NYY 52
DB-9 Ring-11 28 50.4 4x1c-16 rm NYY 56
DB-10 Ring-12 28 50.4 4x1c-16 rm NYY 56

DB-10 Ring-13 28 50.4 4x1c-16 rm NYY 52
DB-10 Ring-14 28 50.4 4x1c-16 rm NYY 48
DB-10 Ring-15 28 50.4 4x1c-16 rm NYY 44
DB-10 Ring-16 28 50.4 4x1c-16 rm NYY 40
DB-10 Ring-17 28 50.4 4x1c-16 rm NYY 36
DB-10 Ring-18 28 50.4 4x1c-16 rm NYY 40
51
DB-10 Ring-19 28 50.4 4x1c-16 rm NYY 44
DB-10 Ring-20 28 50.4 4x1c-16 rm NYY 48
DB-10 Ring-21 28 50.4 4x1c-16 rm NYY 52
DB-11 Ring-22 28 50.4 4x1c-16 rm NYY 56

DB-11 Ring-23 28 50.4 4x1c-16 rm NYY 52
DB-11 Ring-24 28 50.4 4x1c-16 rm NYY 48
DB-11 Ring-25 28 50.4 4x1c-16 rm NYY 44
DB-11 Ring-26 28 50.4 4x1c-16 rm NYY 40
DB-11 Ring-27 28 50.4 4x1c-16 rm NYY 36
DB-11 Ring-28 28 50.4 4x1c-16 rm NYY 40
DB-11 Ring-29 28 50.4 4x1c-16 rm NYY 44
DB-11 Ring-30 28 50.4 4x1c-16 rm NYY 48
DB-11 Ring-31 28 50.4 4x1c-16 rm NYY 52
DB-11 Ring-32 28 50.4 4x1c-16 rm NYY 56
DB-12 Auto-1 35 63 4x1c-25 rm NYY 56

DB-12 Auto-2 35 63 4x1c-25 rm NYY 52
DB-12 Auto -3 35 63 4x1c-25 rm NYY 48
DB-12 Auto -4 35 63 4x1c-25 rm NYY 44
DB-12 Auto -5 35 63 4x1c-25 rm NYY 40
DB-12 Auto -6 35 63 4x1c-25 rm NYY 36
DB-12 Auto -7 35 63 4x1c-25 rm NYY 40
DB-12 Auto -8 35 63 4x1c-25 rm NYY 44
DB-12 Auto -9 35 63 4x1c-25 rm NYY 48
DB-13 Auto -10 35 63 4x1c-25 rm NYY 48

DB-13 Auto -11 35 63 4x1c-25 rm NYY 44
DB-13 Auto -12 35 63 4x1c-25 rm NYY 40
DB-13 Y/C 256 63 4x1c-240 rm NYY 200
DB-14 Comp -1 37.5 67.5 4x1c-25 rm NYY 20

DB-14 Comp -2 37.5 67.5 4x1c-25 rm NYY 24
DB-14 Comp -3 37.5 67.5 4x1c-25 rm NYY 28
52
4.15 Design of low tension switchgear
Fig: 4.3 (1&2)
53
4.16 Design of power factor improvement plant
Fig: 4.4
4.17 Machine layout with bus bar layout plan
Fig: 4.5
54
4.18 Bus bar layout plan with location of distribution board
55
Fig: 4.6
56
Chapter 5
Details technical specifications and estimating the low tension switchgear,

power factor improvement plant and pre fabricated bus bar trunking system.
5.1 Cost of the Low voltage Switchgear
5.1.1 MAIN LT SWITCHGEAR PANEL-1:
16 SWG Sheet steel fabricated, floor mounting, tropicalized

design, indoor type, low tension switchgear for 3 phase, 4
wire, 50 Hz, 380/415V AC system & shall be supplied
complete TP + N+ PE bus bars sized & properly insulated
arrange to withstand & short current of 50KA for 1 sec.
Origin: France / UK / Germany / Japan
S/L TECHNICAL SPECIFICATIONS: Qty Unit U/P in $ T/P in $
INCOMING :
0,73
1 2000A, 3P, 65KA, 415V, 50Hz, (ACB) 4 Nos. 2,684 7
With electronics Micro process
based protection unit having
adjustable over current and short
circuit protection with shunt trip.
OUTGOING :
5,36
2 2000A, 3P, 65KA, 415V, 50Hz, (ACB) 2 Nos. 2,684 8
With electronics micro process
3 3200A, 3P, 85KA, 415V, 50Hz, (ACB) 1 No. 3,595 3,595

With electronics micro process
OUTGOING : (BBT- 01 & 03)

4 C.T ratio 2000/5A 6 Nos. 50 300
5 Ammeter scaled (0-2000A) with 2 Nos. 35 70

57
selector
Switch.
Voltmeter scaled (0 - 500V) with

6 selector 2 Nos. 35 70
Switch.
3
7 Phase indicating lamp 6 Nos. 5 2
RED/YELLOW/BLUE.
8 Control Fuse for protection circuit. 2 Sets 5 10

OUTGOING : (BBT- 02)
9 C.T ratio 3200/5A 3 Nos. 50 150

10 Ammeter scaled (0-3200A) with 1 No. 35 35
Selector switch.
3
11 Voltmeter scaled (0 - 500V) with 1 No. 35 5
Selector switch.

RED/YELLOW/BLUE.
13 Control Fuse for protection circuit. 1 Set 5 5
14 4000A TPN+E bus bar 1 Lot 6,200 6,200

Sized (100 x20) mm Cable, Cable
Socket, Cable Tie & other
accessories.
Enclosure (L700x D800 x H 2000)

15 mm. 6 Nos. 500 3,000
------------- ----------
- -
Total in
Sub $ 9,624
5.1. LT SWITCHGEAR PANEL-02 with
2 COS
Qt
S/L TECHNICAL SPECIFICATIONS: y Unit U/P in $ T/P in $
INCOMING :
83
1 1000A, 3P, 85KA, 415V, 50Hz, MCCB 1 No. 832 2
58
Adjustable with thermal & magnetic
standard protection trip unit.
31
2 630A, 3P, 36KA, 415V, 50Hz, MCCB 1 No. 313 3
15
3 C.T ratio 1000/5A 3 Nos. 50 0

selector switch
5 Voltmeter scaled (0 - 500V) with 1 Nos. 35 35
Selector switch.
1
RED/YELLOW/BLUE.
OUTGOING :
8 400A, 3P, 30KA, 415V, 50Hz, MCCB 1 No. 170 170

38
9 160A, 3P, 30KA, 415V, 50Hz, MCCB 4 Nos. 95 0
10 100A, 3P, 30KA, 415V, 50Hz, MCCB 7 Nos. 55 385

1250A TPN+E bus bar sized (100 x 6) 80

11 mm 1 Lot 800 0
Cable Socket, Cable Tie & other
accessories.
Enclosure (L700 x D800 x H 2000) 1,00

12 mm. 2 Nos. 500 0
------------- ----------
- -
59
Total in 4,12
Sub $ 1
5.1. 800KVAR AUTO/MANUAL PFI

3 PLANT-1 1 SET
Automatic power factor improvement plant of 800Kvar.

Sheet steel fabricated, floor mounting, tropicalized design,
indoor type, for 3 phase, 4 wire, 50 Hz 380/415V AC system
and shall be supplied complete TP + N bus bars suitably
sized & properly insulated arrange to withstand and short
current of 50KA for 1 sec.
The panel shall comprise of

Qt
S/L. TECHNICAL SPECIFICATIONS: y Unit U/P in $ T/P in $
1 1600A, 3P, 65KA, 415V, 50Hz, (ACB) 1 No. 1,694 1,694

With electronics Micro process based
protection unit having adjustable
Over current and short circuit
protection with shunt trip.
25KVAR , 415V, 50 Hz, 3 phase, dry

2 type, 1 No. 98 98
Self healing compact PF capacitors
bank with discharge resistor. (Fixed)
25KVAR , 415V, 50 Hz, 3 phase, dry

3 type, 2 Nos. 98 196
bank with discharge resistor.
(25X2) = 50KVAR, 415V, 50 Hz, 3
4 phase , 4 Nos. 196 783
Dry type, self healing compact PF
capacitors bank with discharge
resistor.
(25X3)=75KVAR, 415V, 50 Hz , 3
5 phase , 3 Nos. 294 881
resistor.
(25X4)=100KVAR, 415V, 50 Hz , 3
6 phase , 3 Nos. 392 1176
60
resistor.
7 TP Magnetic contactor Operation 40A, 2 Nos. 35 70

For 25Kvar capacitor.

TP Magnetic contactor Operation

9 105A, 3 Nos. 124 372

10 150A, 3 Nos. 177 531
11 Start pushbutton. 12 Nos. 2.71 33
12 Stop pushbutton. 12 Nos. 2.71 33
13 Auto manual selector switch with 1 No. 5 5

Adder block.

RED/YELLOW/BLUE.
HRC Fuse with fuse base of suitably

16 sized, 39 Nos. 6 234
17 C.T ratio 1600/5A 3 Nos. 50 150
12 Steps reactive power regulator

18 which 1 No. 318 318
Performs the switching of capacity
bank in automatic power factor
correction equip-ments depending on
changes of reactive power complete
with p. f. Luminescent indicators and
digital power factor meter.
19 2000A TPN+E bus bar (100 x 10) mm 1 Lot 800 800

accessories.
61
Enclosure (L 700 x D 800 x H 2000) 1,00
20 mm. 2 Nos. 500 0
------------- ----------
- -
Total in 8,7
Sub $ 53

4 PLANT: 2 2 SET

Qt
S/L. TECHNICAL SPECIFICATIONS: y Unit U/P in $ T/P in $
1 1000A, 3P, 85KA, 415V, 50Hz, MCCB 1 No. 832 832

25KVAR , 415V, 50 Hz , 3 phase , dry

2 type, 1 No. 98 98
25KVAR , 415V, 50 Hz , 3 phase , dry

3 type, 5 Nos. 98 490
(25X2) = 50KVAR, 415V, 50 Hz , 3

4 phase , 7 Nos. 196 1,371
resistor.


Adder block.
62
RED/YELLOW/BLUE.
HRC Fuse with fuse base of suitably

12 sized, 39 Nos. 6 234
13 C.T ratio 1250/5A 3 Nos. 50 150
14 which 1 No. 318 318
correction equip-ments depending on
changes of reactive power complete
with p. f. Luminescent indicators and
digital power factor meter.
1250A TPN+E bus bar sized (100 x 6)

15 mm 1 Lot 800 800
accessories.
Enclosure (L 700 x D 800 x H 2000)

16 mm. 2 Nos. 500 1,000
Country of Origin: Bangladesh
------------- ----------
- -
Total in
Sub $ 6,151

5 PLANT-3 1 SET
Automatic power factor improvement plant of 250Kvar.

Sheet steel fabricated, floor mounting, tropicalized design,
indoor type, for 3 phase, 4 wire, 50 Hz 380/415V AC system
and shall be supplied complete TP + N bus bars suitably
sized & properly insulated arrange to withstand and short
current of 50KA for 1 sec.

S/L. TECHNICAL SPECIFICATIONS: Qty Unit U/P in $ T/P in $
1 400A, 3P, 30KA, 415V, 50Hz, MCCB 1 No. 170 170

63
25KVAR, 415V, 50 Hz, 3 phase, dry
2 type, 1 No. 98 98
25KVAR, 415V, 50 Hz, 3 phase, dry

3 type, 3 Nos. 98 294
(25X2)= 50KVAR, 415V, 50 Hz, 3

4 phase, 3 Nos. 196 587
resistor.

5 40A, 3 Nos. 35 106

6 80A, 3 Nos. 78 233

Adder block.

RED/YELLOW/BLUE.
HRC Fuse with fuse base suitably

12 sized 21 Nos. 6 126
13 C.T ratio 500/5A 3 Nos. 35 105

14 which 1 No. 275 275
correction equip-ments depending
on changes of reactive power
complete with p. f. Lumin-escent
64
indicators and digital power factor
meter.

15 mm 1 Lot 600 600
accessories.

16 mm. 1 No 550 550
------------- ----------
- -
Total in 3,2
Sub $ 18
5.1.
6 DISTRIBUTION BOARD 01 & 02: 2 SET
16 SWG Sheet steel fabricated, floor mounting, tropicalized

design, indoor type, low tension switchgear for 3 phase, 4
wire, 50 Hz, 380/415V AC system & shall be supplied
complete TP + N+ PE bus bars sized & properly insulated
arrange to withstand & short current of 50KA for 1 sec.
INCOMING :
17
1 400A, 3P, 30KA, 415V, 50Hz, MCCB 1 No. 170 0
15
2 C.T ratio 400/5A 3 Nos. 50 0
3
Selector switch.
3
Selector switch.
1
RED/YELLOW/BLUE.
65
OUTGOING :
49
7 100A, 3P, 30KA, 415V, 50Hz, MCCB 9 Nos. 55 5

8 mm 1 Lot 600 0
accessories.
Enclosure (L 700 x D 500 x H 1600) 40

9 mm. 1 No. 400 0
------------- ----------
- -
Total in 1,9
Sub $ 06
5.1.
7 DISTRIBUTION BOARD -03 2 SET

INCOMING :
17
1 400A, 3P, 30KA, 415V, 50Hz, MCCB 1 No. 170 0
15
2 C.T ratio 400/5A 3 Nos. 50 0
3
Selector switch.
3
Selector switch.
1
66
RED/YELLOW/BLUE.
OUTGOING :
7 63A, 3P, 30KA, 415V, 50Hz, MCCB 12 Nos. 55 660
8 32A, 3P, 18KA, 415V, 50Hz, MCCB 6 Nos. 55 330


9 mm 1 Lot 600 0
accessories.
Enclosure (L 800 x D 500 x H 1600) 45

10 mm 1 No. 450 0
------------- ----------
- -
Total in 2,4
Sub $ 51
5.1.
8 DISTRIBUTION BOARD 04 & 05: 2 SET
INCOMING :
31
1 630A, 3P, 36KA, 415V, 50Hz, MCCB 1 No. 313 3
15
2 C.T ratio 630/5A 3 Nos. 50 0
3
Selector switch.
67
5
Selector switch.
1
RED/YELLOW/BLUE.
OUTGOING :
44
7 100A, 3P, 30KA, 415V, 50Hz, MCCB 8 Nos. 55 0
Adjustable thermal & magnetic
8 mm 1 Lot 650 0
accessories.
Enclosure (L 700 x D 500 x H 1600) 40

9 mm. 1 No, 400 0
------------- ----------
- -
Total in 2,0
Sub $ 44
5.1. DISTRIBUTION BOARD 06 to 10

9 5 SET
S/L TECHNICAL SPECIFICATIONS: Qty Unit U/P in $ T/P in $

INCOMING :
31
1 630A, 3P, 36KA, 415V, 50Hz, MCCB 1 No. 313 3
15
2 C.T ratio 630/5A 3 Nos. 50 0
3
Selector switch.
3
Selector switch.
68
1
RED/YELLOW/BLUE
OUTGOING :
66
7 100A, 3P, 30KA, 415V, 50Hz, MCCB 12 Nos. 55 0

8 mm 1 Lot 750 0
accessories.
Enclosure (L 800 x D 500 x H 1600) 45

9 mm. 1 No. 450 0
------------- ----------
- -
Total in 2,4
Sub $ 14
5.1.
10 DISTRIBUTION BOARD 12 1 SET
INCOMING :
1 630A, 3P, 36KA, 415V, 50Hz, MCCB 1 No. 313 313
15
2 C.T ratio 630/5A 3 Nos. 50 0
69
5
Selector switch.
3
Selector switch.
1
RED/YELLOW/BLUE.
OUTGOING :
55
7 100A, 3P, 30KA, 415V, 50Hz, MCCB 10 Nos. 55 0
750A TPN+E bus bar sized (75 x 75

8 5)mm 1 Lot 750 0
accessories.
Enclosure (L 800 x D 500 x H 1600) 45

9 mm. 1 No. 450 0
------------- ----------
- -
Total in 2,3
Sub $ 04
5.1.
INCOMING :
31
1 630A, 3P, 36KA, 415V, 50Hz, MCCB 1 No. 313 3
15
2 C.T ratio 630/5A 3 Nos. 50 0
70
3
Selector switch.
3
Selector switch.
1
RED/YELLOW/BLUE.

OUTGOING :
17
7 400A, 3P, 30KA, 415V, 50Hz, MCCB 1 No. 170 0
8 100A, 3P, 30KA, 415V, 50Hz, MCCB 4 Nos. 55 220
9 mm 1 Lot 750 0
accessories.
10 mm. 1 No. 450 50
------------- ----------
- -
Total in 2,1
Sub $ 44
5.1.
INCOMING :
1 400A, 3P, 30KA, 415V, 50Hz, MCCB 1 No. 170 170

2 C.T ratio 400/5A 3 Nos. 50 150
71
selector switch
3
selector switch
1
RED/YELLOW/BLUE.
OUTGOING :
28
7 160A, 3P, 30KA, 415V, 50Hz, MCCB 3 Nos. 95 5
22
8 32A, 3P, 18KA, 415V, 50Hz, MCCB 4 Nos. 55 0

9 mm 1 Lot 600 0
accessories.
Enclosure (L 800 x D 500 x H 1600) 45

10 mm. 1 No. 450 0
------------- ----------
- -
Total in 1,9
Sub $ 66
5.1. Motor Control Panel(Star Delta

13 & DOL) 1 SET
Star Delta Starter - 22KW : 05

Sets
27
1 63A, 3P, 30KA, 415V, 50Hz, MCCB 5 Nos. 55 5
72
37
2 C.T ratio 400/5A 15 Nos. 25 5
17
selector switch
17
selector switch
5
RED/YELLOW/BLUE.
80
6 Magnetic Contactor 10 Nos. 80 0
22KW, Operation Current: 50A,
Ith:80A
Coil Voltage: 220VAC
7 Magnetic Contactor
18.5KW, Operation Current: 40A, 33
Ith:60A 5 Nos. 67 5
8 Thermal Overload Relay (18-26)

15
With Open Phase Protective device 5 Nos. 31 5
9 Super Timer
Operating Voltage=100-240VAC 5 Nos. 35 175
10 Push Button (Start) 5 Nos. 4 19
1
11 Push Button (Stop) 5 Nos. 4 9
5
12 Signal Lamp(Start, Stop, Trip) 10 Nos. 5 0
Direct On Line Starter: 5.5KW :

05Sets
73
10
13 25A, 3P, MCB 5 Nos. 20 0
415V, 50Hz, MCB
11
14 Magnetic Contactor 5 Nos. 22 0
5.5KW, Opp. Current: 12A, Ith:20A
9
15 Thermal Overload Relay (7-11) 5 Nos. 18 0
With Open Phase Protective device
2
16 Push Button (Start) 5 Nos. 4 0
2
17 Push Button (Stop) 5 Nos. 4 0
5
18 Signal Lamp(Start, Stop, Trip) 10 Nos. 5 0
4
19 Connector Terminal 10 Set 4 0

20 mm 1 Lot 500 500
accessories.
Enclosure (L 800 x D 500 x H 1600) 45

21 mm. 1 No. 450 0
----------
-
Sub total cost of above goods 3,9
in USD 87
74
5.2 Cost of power bus bar trunking system
Power Bas bar trunking system 1 Lot
Uni T/P in
SL # Description Qty.
t U/P in $ $
2000A AL BUSWAY - 4w (IP54)

GEN-1 TO GP-1
72
1 2000A 4P+PE Flanged end Pcs 360
2 0
1,42
2 2000A 4P+PE elbow Pcs 357
4 9
3,02
3 2000A 4P+PE straight length m 260
12 7
Set 4,69
4 2000A 4P+PE Connection Unit 2347
2 s 4
GEN-2 TO GP-2
72
2 0
1,42
4 9
4,01
15 5
Set 4,69
2 s 4
GEN-3 TO GP-3
72
2 0
1,42
4 9
6,56
25 1
Set 4,69
2 s 4
GEN-4 TO GP-4
72
2 0
1,42
4 9
8,32
32 2
Set 4,69
2 s 4
GP-1 TO L.T-1
1 2000A 4P+PE Flanged end 2 Pcs 360 72
75
0
1,07
3 1
2,66
10 0
Set 4,69
2 s 4
GP-2 TO L.T-2
72
2 0
1,07
3 1
2,25
9 5
Set 4,69
2 s 4
GP-3 TO L.T-3
72
2 0
1,07
3 1
1,66
6 4
Set 4,69
2 s 4
BBT-01
MAIN BRANCH 2000A AL BUSWAY -
4w (IP54)
36
1 0
1,07
3 1
2,08
8 0
29
4 2000A/800A 4P+PE Reduction Unit Pcs 290
1 0
29
1 0
BRANCH -A, 800A AL BUSWAY-4W
(IP54)
18
1 7
6,52
45 5
5
8 End Cover Pcs 51
1 1
BRANCH -B, 1250A AL BUSWAY-4W
76
(IP54)
4,22
20 0
27
1 1
BRANCH-C, 800A AL BUSWAY-
4W(IP54)
2,90
20 0
5
12 End Cover Pcs 51
1 1
Tap Off Box With MCCB
19
13 Plug in hole Pcs 13
15 5
3,92
14 630A Tap off Box with MCCB Pcs 1309
3 7
3,98
6 4
66
1 4
92
3 1
BBT-02
4w (IP54)
56
1 6
2,31
5 0
24,94
61 9
45
1 0
BRANCH A, 1600A AL BUSWAY-4W
(IP54)
15,84
60 0
25
1 0
BRANCH B, 1000A AL BUSWAY-4W
(IP54)
7,64
40 0
5
8 End Cover Pcs 51
1 1
9 Plug in hole 15 Pcs 13 19
77
5
7,85
6 4
66
1 4
61
2 4
BBT-03
4w (IP54)
36
1 0
1,78
5 6
24,70
95 5
29
1 0
BRANCH -A, 1600A AL BUSWAY-4W
(IP54)
3,43
13 2
25
1 0
BRANCH -B, 1250A AL BUSWAY-4W
(IP54)
7,17
34 4
31
1 5
5
9 End Cover Pcs 51
1 1
19
10 Plug in hole Pcs 13
15 5
1,65
1 0
3,92
3 7
66
1 4
92
3 1
--------
--
Sub total cost of above goods in 210,4
USD 24
78
5.3 Cost of lighting bus bar trunking system
Lighting BBT 1 Lot
SL # Description Qty. Unit U/P in $ T/P in $

1 250A TPN+PE feed unit 2 Pcs 195 390
2 250A TPN+PE centre feed unit 1 Pcs 215 215
3 250A TPN+PE straight length L=3m 26 Pcs 149 3874
4 160A TPN+PE straight length L=3m 24 Pcs 120 2880
5 Fixing bracket 82 Pcs 4.48 367
6 32A, Tap off box 46 Pcs 36 1656
7 25A 4P+PE feed unit 46 Pcs 19.38 891
101
8 25A 2PN+PE straight length L=3m Pcs 26.27 26585
2
9 End cover 46 Pcs 2.98 137
151
10 Fixing bracket (For BBT) Pcs 2 3036
8
11 Tap off connector (For light) 830 Pcs 2.5 2075
166
12 Fixing bracket (For Light ) Pcs 1.9 3154
0
13 DOUBLE TUBE LIGHT SHADE 830 Pcs 16 13280
2X36W Industrial Light with Ballast,
Starter Reflector & 2 Nos. Tube
Light
---------
---
Sub total cost of above goods in 58,5
USD 41
5.4 Total cost of the Low voltage Switchgear & pre fabricated bus
bar
29,62 29,62
01) MAIN LT SWITCHGEAR PANEL-1 1 Set 4 4
4,12 4,12
02) LT SWITCHGEAR PANEL-02 with COS 1 Set 1 1
8,75 8,75
03) 800KVAR AUTO/MANUAL PFI PLANT 1 Set 3 3
79
6,15 12,30
04) 500KVAR AUTO/MANUAL PFI PLANT 2 Sets 1 2
3,21 3,21
05) 250KVAR AUTO/MANUAL PFI PLANT 1 Set 8 8
1,90 3,81
06) DISTRIBUTION BOARD 01 & 02 2 Sets 6 2
2,45 2,45
07) DISTRIBUTION BOARD -03 1 Set 1 1
2,04 4,08
08) DISTRIBUTION BOARD 04 & 05 2 Sets 4 8
DISTRIBUTION BOARD 06, 07, 08, 09, 10 & 2,41 14,48

09) 11 6 Sets 4 4
2,30 2,30
10) DISTRIBUTION BOARD 12 1 Set 4 4
2,14 2,14
11) DISTRIBUTION BOARD 13 1 Set 4 4
1,96 1,96
12) DISTRIBUTION BOARD -14 1 Set 6 6
Motor Control Panel (Star Delta & 3,98

13) DOL) 1 Set 7 3,987
2,10,42 2,10,42
14) Pre Fabricated Power Bus Bar 1 Lot 4 4
15) Pre Fabricated Lighting Bus Bar 1 Lot 58,541 58,541
Transportation cost of 3x40’

16) container 3 Nos 2,400 7200
----------
-
Total cost of above goods in 3,69,41
USD 9
80
5.5 Local cost of the connecting cable, installation, testing &
commissioning
U/P in
S/L. TECHNICAL SPECIFICATIONS Qty Unit $ T/P in $
17,13,
01 1c - 300 rm NYY 572 m 2995 140
11,83,
02 1c - 240 rm NYY 500 m 2366 000
6,33,4
03 1c - 150 rm NYY 428 m 1480 40
04 1c - 95 rm NYY 24 m 945 22,680
1,62,2
05 1c - 25 rm NYY 617 m 263 71
6,75,3
06 1c - 16 rm NYY 3904 m 173 92
1,19,8
07 1c - 10 rm NYY 1080 m 111 80
08 1c - 6 rm NYY 1320 m 71 93,720
09 1c - 4 rm NYY 320 m 50 16,000
Cable Socket, cable tai, & other 100,00 500,00
10 accessories 1 Lot 00 0
Installation, testing & 750,00 750,00
11 commissioning 1 Job 0 0
---------
---
Grand total for local work in 63,69,
Taka. 523
81
Chapter: 6
Low tension switchgear, power factor improvement plant panel design and
panel layout plan. The pre fabricated bus bar trunking system installation
process & shop drawing,
6.1 Distribution switchboards

A distribution switchboard is the point at which an incoming-power supply
divides into separate circuits, each of which is controlled and protected by
the fuses or switchgear of the switchboard. A distribution switchboard is
divided into a number of functional units, each comprising all the electrical
and mechanical elements that contribute to the fulfillment of a given
function. It represents a key link in the dependability chain.
Consequently, the type of distribution switchboard must be perfectly adapted
to its application. Its design and construction must comply with applicable
standards and working practices.
The distribution switchboard enclosure provides dual protection:
Protection of switchgear, indicating instruments, relays, etc. against
mechanical impacts, vibrations and other external influences likely to
interfere with operational integrity (dust, moisture, vermin, etc.)
The protection of human life against the possibility of direct and indirect
electric shock
6.2 Three basic technologies are used in functional distribution

switchboards.
Fixed functional units
82
These units cannot be isolated from the supply so that any intervention for
maintenance, modifications and so on, requires the shutdown of the entire
distribution switchboard. Plug-in or withdraw able devices can however be
used to minimize shutdown times and improve the availability of the rest of
the installation.
Fig 6.1 Assembly of a final distribution switchboard with fixed functional units
Disconnect able functional units
Each functional unit is mounted on a removable mounting plate and provided

with a means of isolation on the upstream side (bus bars) and disconnecting
facilities on the downstream (outgoing circuit) side. The complete unit can
therefore be removed for servicing, without requiring a general shutdown.
83
Fig 6.2 Distribution switchboard with disconnect able functional units
Drawer-type withdraw able functional units
The switchgear and associated accessories for a complete function are

mounted on a drawer-type horizontally withdraw able chassis. The function is
generally complex and often concerns motor control. Isolation is possible on
both the upstream and downstream sides by the complete withdrawal of the
drawer, allowing fast replacement of a faulty unit without de-energizing the
rest of the distribution switchboard.
84
Fig 6.3 Distribution switchboard with withdraw able functional units in
drawers
Different standards
Certain types of distribution switchboards (in particular, functional

distribution switchboards) must comply with specific standards according to
the application or environment involved. The reference international standard
is IEC 60439-1 type-tested and partially type-tested assemblies
Standard IEC 60439-1
Three elements of standard IEC 60439-1 contribute significantly to

dependability:
- Clear definition of functional units
- Forms of separation between adjacent functional units in accordance with
user
requirements
- Clearly defined routine tests and type tests
- Categories of assemblies
Standard IEC 60439-1 distinguishes between two categories of assemblies:
Type-tested LV switchgear and control gear assemblies (TTA), which do not
diverge significantly from an established type or system for which
conformity is ensured by the
85
Type tests provided in the standard.
- Partially type-tested LV switchgear and control gear assemblies (PTTA),
which may contain non-type-tested arrangements provided that the
latter are derived from type-tested arrangements. When implemented
in compliance with professional work standards and manufacturer
instructions by qualified personnel, they offer the same level of safety
and quality.
Functional units
The same standard defines functional units:
Part of an assembly comprising all the electrical and mechanical elements
that contribute to the fulfillment of the same function.
The distribution switchboard includes an incoming functional unit and one or
more functional units for outgoing circuits, depending on the operating
requirements of the installation. What is more, distribution switchboard
technologies use functional units that may be fixed, disconnect able or
withdraw able.
86
6.3 Panel Layout Plan
Fig 6.4 Panel layout plan
87
6.4 How do bus bar installations compare in terms of cost
Most favorably, historically, the material cost of bus bar has been a point of
concern for electrical contractors. However, it is short sighted to compare the
cost of bus bar against that of cable - and not the real cost of a cable
installation to include multiple runs of cable, cable tray and fixing, let alone
the protracted time and effort of the cable pulling operation. (A comparative
study between a traditional system (cables) and one realized with bus bar
trunking systems. The cost of bus bar systems has fallen in real terms over
recent years. Add to this, the cost saving in installation time - up to 50% less
than cable. The reality is that electrical contractors can offer a more
competitive bid, at the same time as offering his client a "state of the art"
power distribution installation which is infinitely more flexible in use. The
installation time for bus bar is virtually the same as for installing cable tray -
before the installation of the cables; this is obviously a very important
consideration in these days of ever tightening completion deadlines.
With its inherent properties of strong dielectric strength and wide
temperature range
(-70°C to +150°C), polyester film was the perfect choice for insulating our
bus ducts. One important distinction between our products and competitors is
that we apply 4 layers of polyester film in 125 micron layers. This causes the
layers to overlap, resulting in an airtight seal that is sufficient to guard
against any moisture that might make its way through the bus duct housing.
Not surprisingly, the insulation on our bus ducts is capable of withstanding at

least 155KV of dielectric strength at any point of contact.
88
6.5 Process of bus bars operate
Bus bar trunking falls into two categories - distribution and feeder bus bar.
Distribution bus bar distributes power through tap-offs points along the
length of the bus bar at typically a 0.5 or 1.0 metre centres. Tap-off units are
simply plugged in along the length of the bus bar to supply a load, (this could
be a sub distribution board or in the case of a factory, to individual
machines). Each individual tap-off can normally be added to or removed with
the bus bar live, thus eliminating production down time.
Used vertically the same systems can be used for rising-mains applications,
with tap-offs feeding individual floors. (Certified fire barriers are available at
points where the bus bar passes through a floor slab). The fact that the
protection devices (fuses, switch-fuses or circuit breakers) are located along
the bus bar run, reduces the need for large quantities of distribution cables
running to and from installed equipment.
High power feeder bus bar takes power directly from A to B. Usually from a
power transformer or switchboard to switchboard. This basic configuration is
often referred to as "a goal post configuration". However, if a power source is
89
required to be tapped off then it is possible to do this at a joint along the run -
another example of the flexibility of bus bar.
Both feeder and distribution bus bar systems in the medium and high power
ranges are available in two forms: (a) the flat spaced configuration where the
conductors are either air insulated or have PVC insulated conductors all
within an earthed metal enclosure, (b) the sandwich configuration which is
becoming the norm at these ratings. Sandwich construction means that the
conductors are individually insulated and mounted to form a sandwich of
conductors and insulation within the bus bar casing. The sandwich
construction bus bar has very good mechanical strength, gives higher fault
level withstand characteristics and has lower volt drop characteristics. This
type of bus bar is very compact making it ideal for installing into the ever
reducing available space which is allowed in the modern building services
When used for rising main applications, the sandwich configuration negates
the need for fire-barriers because there is no air gap within the casing to give
a chimney effect, which would allow the passage of smoke and fire.
6.6 Isometric drawing for installation
Fig 6.5 (a) Isometric drawing
90
Fig 6.5 (b) Isometric drawing
Fig 6.5 (c) Installation measurement drawing
Chapter 7
Appendix
In this project I describe the electrical power system in a spinning mill. This
project work done we observed different type of electrical concept like that
fuse, air circuit breaker (ACB), moulded case circuit breaker (MCCB),
miniature circuit breaker (MCB) power factor improvement and pre fabricate
bus bar which is modern technology of electrical distribution systems. Pre
fabricate bus bar it is short sighted to compare the cost of bus bar against
that of cable - and not the real cost of a cable installation to include multiple
runs of cable, cable tray and fixing, let alone the protracted time and effort of
91
the cable pulling operation. A comparative study between a traditional
system (cables) and one realized with bus bar trunking systems.
The cost of bus bar systems has fallen in real terms over recent years. Add to
this, the cost saving in installation time - up to 50% less than cable. The
reality is that electrical contractors can offer a more competitive bid, at the
same time as offering his client a "state of the art" power distribution
installation which is infinitely more flexible in use. The installation time for
bus bar is virtually the same as for installing cable tray - before the
installation of the cables; this is obviously a very important consideration in
these days of ever tightening completion deadlines.
Work this project I study various type of electrical Power Distribution

Company like that Adex Corporation Ltd. (Sold distributor of world famous
Schenider Electric of France), Automation Engineering & Controls Ltd. (Sold
distributor of Fuji Electric Company Ltd., Japan), Energy Pac and also help
from internet some data are collect from reference books and discussion with
our teacher about this project.
During the work I have tried our best, especially in giving a more organized
shape to follow the instructions that provided which gave us viewpoint of the
whole task. The project was a challenging experience to us and I firmly
believe that this assignment would be able to provide the details about the
Electrical Installation of a spinning mills.
I have to work as how to do load calculation, electrical estimating of a

spinning mills and how to installation of the electrical equipments I have
gathered new experience from this project. I will utilize the experience in our
future life.
References
i) Adex Corporation Ltd.
92
(Sold distributor of world famous Schenider Electric of France),
ii) Automation Engineering & Controls Ltd.
(Sold distributor Fuji Electric Company Ltd., Japan),
iii) Energy Pac Power generation Ltd.
iv) BRB Cable industries Ltd. &
v) Internet
93

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A PROJECT REPORT ON

THE ELECTRICAL SYSTEM DESIGN, DRAWING,

MD. JAHANGIR ALAM

A project submitted to the Department of Electrical and Electronic

Signature of the candidates

We would like to express our acknowledgement and heartfelt gratitude to our

We would also like to thanks A. H. M. Rezwanul Islam, Lecturer, Department

Thanks to all of you whose names are not mentioned here.

Organization of this project included seven chapters. Chapter one gives a

Chapter four machine load calculation, selection of Generator capacity, single

Details technical specifications and estimating the low tension switchgear,

Figure 1.1 Spinning mills (Ring Frame)

Table 3.1 Machine load chart in a Spinning Mill

Energy is the basic necessity for the economic development of a country.

1.1.2 Importance of electrical energy

1.1.3 Necessity of electric power in a spinning mill

Fig. 1.1 Spinning mills (Ring Frame)

The following advantages which have always a spinning mills are

1.2.1 What is electricity?

Fig. 1.2 Electric lamp Fig. 1.3 Proton, neutron &

1.2.2 Who discovered electricity?

1.2.3 What is static electricity?

1.2.5 What is current electricity?

1.2.6 What is the difference between alternating and direct current?

1.3 OBJECTIVE OF THE WORK

2.1 DISCUSSATION OF THE USING PRODUCT

2.1.1 How does a fuse work?

Fig. 2.1 Electrical circuit with fuse & bulb

2.1.2 Air Circuit Breaker (ACB)

2.1.3 Moulded Case Circuit Breaker (MCCB)

A circuit breaker is an electrical device used in an electrical panel that

Fig. 2.4 Electrical distribution network

2.1.4 Miniature Circuit Breaker (MCB)

2.1.5 Bus bar Trunking System (BBT):

Bus bar Trunking is a prefabricated, modular system, designed to transmit

2.2 POWER FACTOR IMPROVEMENT

2.2.1. Importance of Power Factor

2.2.2. Power Factor

When capacitors or inductors are involved in an AC circuit, the current and

Fig. 2.9 Phase angle between voltage & current

2.2.4. Phasor Diagrams

3.1 A SPINNING MILLS USING MACHINE LIST ARE BELOWS

3.2 A Spinning mills machine layout plan

Connecting load per M/C

4 Breaker Drawing 7.01

5 Finisher Drawing 11.11

6 Card M/C 24.68

10 Cooling Motor 5.5

12 Air Filter -01 120

13 Air Filter -02 240

14 Air Filter -03 189

16 Yarn Conditioning 256

17 Blow Room M/C 110

18 Lighting Load 160

4.1 Total Load Calculation chart in a Spinning Mill (36636 Spindle)

1 Auto Cone 12 35 26.25 420 315

2 Ring M/C 71 28 21 1988 1491

3 Simplex M/C 7 28 21 196 147

6 Card M/C 15 24.68 18.51 370.2 277.65

7 Comber 5 6.7 5.03 33.5 25.15

9 Pump Motor 5 22 16.5 110 82.5

10 Cooling Motor 5 5.5 4.13 27.5 20.65