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BEF 44903 Chapter 1

BEF 44903 Industrial Power Systems Chapter 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

BEF 44903 Industrial Power Systems Chapter 1

1.1 Example of Plant Distribution System

Panelboard Feeding 240/415V Harmonic Loads

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1.1 Planning Distribution Systems 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.

BEF 44903 Industrial Power Systems Chapter 1

1.1 Planning Distribution Systems

Load survey of a particular area is carried out to find out the present load requirement as well as the expected load growth gro th over o er a period of 5 to 15 years. ears The following follo ing basic data should be collected for starting this work:
9 A detailed map of the area showing important features. 9 The existing number of houses, population and new construction anticipated in the area. 9 The expected number of shops shops, post offices offices, rural health centres, centres etc. 9 The type of industry and number of industries possible in the area. 9 Development programmes implemented in the area.
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1.1 Planning Distribution Systems

For the purpose of forecasting load, the prospective consumers may be categorized as under:
1. 1 Domestic D ti consumers, i.e. i residential id ti l houses. h 2. Commercial consumers, i.e. shops, schools, hospitals, hotels, and other commercial establishments. 3. Industrial consumers:
a. b. c. d. e. f. Small industries (up to 20 kW) Medium industries (up to 100 kW) Large industries (above 100 kW) Municipal consumers (i.e. street lighting, water works, parks, etc.) Agricultural consumers Mining industries

BEF 44903 Industrial Power Systems Chapter 1

1.1 Layout of Distribution Systems

Sub-transmission Line (66kV or 33kV) Primary Substation Secondary Substation

11kV Feeder 132kV/66kV 66kV Feeder 66kV/11kV 11kV Feeder

Distribution Substation
3 Phase Consumers (415V) 11kV/415V

Single Phase Consumers (240V)

Industrial Consumer

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1.1 Layout of Distribution Systems

The high voltage from transmission line (132 kV) is stepdown at the Primary Substation to 66 kV or 33 kV. From this primary substation, substation power at 66 kV or 33kV is carried through sub-transmission lines to different load centres. The length of a sub-transmission line is about 50 km and they carry about 50 MW of power. It has been found that sending power through subtransmission lines at 33 kV or 66 kV is economical in terms of losses (i.e. I2R) and the capital cost (i.e. cost of conductor, d i insulators l and d supports). ) Most domestic, commercial and small-scale industrial consumers receive power at low voltage, i.e. 240V or 415V. Large-scale consumers having load in excess of 100 kW buy bulk power at 11 kV and above.
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1.1 Planning for Connection Supplies at Low Voltages of 240V and 415V
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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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1.1 Planning for Connection Supplies at 275kV, 132kV, 33kV, 22 kV, 11kV and 6.6kV
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For all types of loads:

Maximum Active Power consumption in kW; Maximum Reactive Power consumption in kVAR.

For motor loads:

Types of control equipment; Methods of starting; g; Magnitude and duration of the starting current; Frequency of starting (number/hour); Under voltage setting and time; Negative phase sequence protection; Sub-transient and/or locked rotor reactance of the motor.
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1.1 Planning for Connection

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For nonlinear loads with harmonic current injections:

Harmonic current spectrum including harmonic number and the corresponding maximum current. current

For fluctuating loads:

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

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1.1 Planning for Connection

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For voltage sensitive loads:

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

For Shunt Connected Reactors and Capacitors p :

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

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1.2 Voltage and Frequency Considerations Voltage Criteria

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Steady-State Voltage Fluctuation (Normal Condition):

Voltage level 415V and 240V 6.6kV, 11 kV, 22kV,33kV 132kV and 275kV % variation -10% & +5% +/- 5% -5% & +10

Steady-State Voltage Fluctuation (Contingency Condition)

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

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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:

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Three-phase, three-wire and 11 kV for load of 1,000 kVA maximum demand and above Three-phase, three-wire, 22kV or 33kV for load of 5,000 kVA maximum demand and above Three-phase, three-wire, 66kV, 132kV and 275kV for exceptionally large load of above 25 MVA maximum demand

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1.2 Voltage and Frequency Considerations Frequency Criteria

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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. 1 According A di to t nature t of f construction t ti
a. Overhead distribution system (cheaper) b. Underground distribution system (in crowded area)

2. According to nature of current

a. DC distribution system b. AC distribution system

3. According to number of wires

2 wire DC system 2-wire system, 3-wire 3 wire DC system system, 1-phase 1 phase 2-wire 2 wire AC system system, 3-phase 3-wire AC system, 3-phase 4-wire AC system

4. According to the scheme of connections

(a) Radial system (b) Ring system (c) Inter-connected system
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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 normall a primary primar distribution distrib tion line is designed to carry carr a load of 1-2 MVA, the number of primary distribution lines emanating from a 33/11 kV secondary substation is about 4. When the load requirement increases and crosses about 8 MVA, the losses in the 33 kV sub-transmission line become large. large Thus, Thus power must fed from a 66 kV sub subtransmission line. The number of primary distribution lines emanating from a 66/11 kV secondary substation is six to ten.
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1.3 Primary Distribution Lines (Feeders) 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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1.3 Primary Distribution Lines (Feeders) 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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BEF 44903 Industrial Power Systems Chapter 1

1.3 Primary Distribution Lines (Feeders)

Advantages of Radial Feeders:
i. ii. ii iii. A heavy load very near the secondary substation. Isolated I l t d loads. l d 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 tail end to reach a value below the permissible limit. When a fault occurs at any point along the length of the feeder, supply to all the consumers beyond this point towards the tailend gets interrupted.

ii.

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1.3 Primary Distribution Lines (Feeders) Loop Primary Circuits

, the To overcome the limitations of the radial feeders, loop primary circuit is taken to use.
Secondary Substation

11 kV CB4 Distribution Substation 2 CB3

11 kV CB5 Distribution Substation 3 CB6 A

CB2

CB1 Distribution Substation 1

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BEF 44903 Industrial Power Systems Chapter 1

1.3 Primary Distribution Lines (Feeders)

Two 11 kV feeders emanate from the secondary substation. In this system, every distribution substation receives supply from two sides. In case of fault, say at point A, the circuit breaker 1 at distribution substation 1 and circuit breaker 6 at distribution substation 3 will open, thus isolating the faulty section. The supply to the substation 1 and 3 is still uninterrupted i d and d continues i to b be received i df from another h side. This system is generally used in towns and cities.

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1.3 Primary Distribution Lines (Feeders)

The reliability of supply in this system has improved in comparison with that in the radial system as it has an alternative alternati e supply, s ppl in case one side fails. fails However, it must be realized that the source of supply for the whole loop system is a single secondary substation. If a fault occur in the secondary substation causing a failure of the 11 kV supply source, the whole of the system will suffer power interruption.

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BEF 44903 Industrial Power Systems Chapter 1

1.3 Primary Distribution Lines (Feeders) Ring Main or Network System

A more reliable system y is the ring g main system. y
Secondary Substation A
CB7 CB4 Distribution Substation 2 CB3 CB6 CB8 11 kV

Secondary Substation B
CB9 11 kV CB5 Distribution Substation 3 CB10

CB2

CB1 Distribution Substation 1

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1.3 Primary Distribution Lines (Feeders)

In the ring main system, there are two different sources of supply which are indicated as secondary substation A and B. B The ring system has the added advantage from loop system is that should one of the sources of supply fail, say A, the whole system continues to get supply from the other source B. The ring main system is by far the most reliable for continuity i i of f supply. l I It gives i a better b voltage l regulation l i and less feeder losses. Circuit breakers are used instead of fuses for protecting the transformer in ring main system due to heavier loads.
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BEF 44903 Industrial Power Systems Chapter 1

1.3 Secondary Distribution Lines (Distributors) Distribution substations are a link between feeders and distributors.
11 kV Feeders

Distribution Substations

415 V Distributors

The standard voltage transformation at a distribution substation is 11 kV/415V. The declared consumer voltage as per Malaysian Nasional Grid is 415 V between phases and 240 V between phase and neutral with a permissible voltage variation of 5%.
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1.3 Secondary Distribution Lines (Distributors) 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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BEF 44903 Industrial Power Systems Chapter 1

1.3 Secondary Distribution Lines (Distributors) 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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1.3 Secondary Distribution Lines (Distributors) Radial System

In this system, the LV distribution lines radiate out from the distribution substation.
LV CB 11 kV Line 220 kVA 11 kV/415V Switch-cum Fuse Units Radial Line 1

Radial Line 2

In this I thi system, t the th supply l is i f from a single i l 11 kV feeder. f d A fault in the feeder will cause the interruption of supply to all consumers. Circuit breaker and switch-cum fuse units are used for protection purpose.
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1.3 Expanded Radial Scheme

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1.3 Secondary Distribution Lines (Distributors) 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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1.3 Secondary Distribution Lines (Distributors) 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 35

BEF 44903 Industrial Power Systems Chapter 1

1.3 Secondary Distribution Lines (Distributors)

Transformers are said to be banked when two or more supplied from the same primary circuit are paralleled to feed into the same secondary secondar mains. mains By this arrangement more than one path is provided over which high currents can flow. This results in lowering the extent to which the voltage fluctuates on the line. Further advantages of this system:
i. More reliable, have alternative supply from other transformer. ii. Better load distribution on each transformer. iii. The voltage drop in the system is reduced.
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1.3 Secondary Distribution Lines (Distributors)

This system is mostly used in areas of low load densities, where a multiple primary and secondary network net ork is not justified. j stified If a fault occurs within one of the transformers, it will be automatically disconnected from the line by blowing the two secondary line fuses and the primary transformer fuse without interrupting service to any consumer.

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1.3 Secondary Selective Scheme

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1.3 Sparing Transformer Scheme

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BEF 44903 Industrial Power Systems Chapter 1

1.4 Load Data Typical range of Industrial Loads:

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Light Industry 50 kVA to 7000 kVA Heavy Industry 1,000 kVA to 200,000 kVA HVAC Process equipment, pumps, compressors and fans Industrial services such as boiler, water treatment Workshop and laboratory equipment Motor control centre

Typical Industrial Loads:

} } } } }

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1.4 Initial Maximum Demand Estimation 2 methods to estimate the maximum power demand in feasibility/ conceptual design stage:
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VA/m2 or W/ ft2 This is normally apply to commercial building where the typical loads are lighting, general power, and HVAC. Example: 50 100 VA/m2 for nonretail buildings, 60 150 VA/m2 for retail buildings. 0.9 W/ft2 for lighting and 4.7 W/ft2 for Air Condition. Maximum demand of a similar building/ g industry y Applicable for residential, commercial, and industrial buildings. Example: Plant A having maximum demand of 2 MVA then this figure can be used for a plant of similar capacity.
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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 Lighting load General purpose power circuit Main switchboard Intermittent duty loads Recommended DF 100% 40% - 50% 80% - 90% 50%
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1.4 Example: Max. Loading for MCC (SB)

Load description 3 / 1 Duty N or S Motor rating (kW) Operating motor power (kW) 12 12 1.3 9 0.8 1 4 PF x =K Motor input power Heater 3 load (kVA) 1 load R phase (kVA) 1 load Y phase (kVA) 1 load B phase (kVA)

Cooling tower 1 fan Cooling tower 2 fan Heater Fan coil Water pump Extract fan Compressor Future pump Total load

3 3 3 1 3 1 1 3

N S N N N N N N

15 15 5 1.5 11 1 1.5 5.5

0.7 0.7 0.6 0.68 0.6 0.6 0.6

17.1 17.1 2.2 13.2 1.3 1.6 6.7 5

17.1 5 2.2 13.2 1.3 1.6 6.7 42.0 2.2 1.3 1.6

Total load on the MCC = 47.1 kVA

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1.4 Example: Max. Loading for LV Switchboard

Load description
DB 1 DB 2 MCC 1 MCC 2 Packaging machine CO2 compressor W t pump 1 Water Water pump 2 Welder Future

Duty (N/ S)
N N S N

Connected (kW)
37 75 30 30 18

Operating load (kW)

31 68 25 25 -

K
0.7 0.765 0.68 0.68 0.5

kVA
30 78 47.1 50 44.3 88.9 36.8 36 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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1.5 Common Connection for Transformer

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1.5 Why Delta Grounded Star Delta at primary

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Free of 3rd harmonics of the magnetizing currents and any possible homopolar current are free to circulate through the sides of the delta, without flowing into the network; thus, the magnetic fluxes remain sinusoidal at the secondary. in case of unbalanced loads at the secondary winding, the reaction current absorbed by the primary flows only through the corresponding winding (as shown in the figure) without affecting the other two.

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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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1.5 Methods of Transformer Installation Method 2 Substation with two transformers with one as a spare for the other
The circuit-breakers on the LV side must be connected with an I interlock whose function is to prevent the transformers from operating in parallel. Apart from the switching and isolation device on the i incoming i MV li line (IGMV), ) it is i advisable to provide a switching, isolation and protection device on the individual MV risers of the two transformers (IMV1 and IMV2) as well.
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1.5 Methods of Transformer Installation Method 3 Substation with two transformers which operate in parallel on the same busbar
Possible to use two transformers with lower rated power. Operation in parallel of the transformers could cause greater problems in management of the network network. When coordinating the protections, the fact that the overcurrent on the LV side is divided between the two transformers must be taken into consideration.
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1.5 Methods of Transformer Installation Method 4 Substation with two transformers which operate simultaneously on two separate half-busbars
Providing a CLV bus-tie and an I interlock which prevents the bustie from being closed when both the incoming circuit-breakers from the transformer are closed closed. This management method allows a lower value of the short-circuit current on the busbar.

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1.5 Transformer Sizing Transformer sizing is generally based on:

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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 Transformer Sizing Short circuit capacity with infinite source

Infinite source FLA = ? What is %Z? ISCmax = ? kVASC = ?

1000 kVA 11kV 415 V %Z = 5% kVASC = ?

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BEF 44903 Industrial Power Systems Chapter 1

1.5 Transformer Sizing Short circuit capacity with finite source

500 MVASC MVASC(TX) = ? MVASC(SEC) = ? ISCmax = ?

1000 kVA 11kV 415 V %Z = 5% kVASC = ?

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1.5 Transformer Sizing Simple transformer-load connection

FLA = ? ISCmax = ? kVASC = ? Is the given size (1000 kVA) suitable to serve the motor load?

1000 kVA 11kV 415 V %Z = 5.0% kVASC = ?

80% Full load Inrush current = 6 times

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