AUXILIARY ELECTRICAL SYSTEM FOR INDUSTRIAL PLANTS

GENERAL
The electrical power distribution system of an industrial plant needs to be carefully planned to have the
required capacity to meet the load demand and sufficient degree of reliability such that the operation of
the plant is not unduly hampered.
MAIN POWER SUPPLY
a) The main power supply is usually from the concerned state Electricity Board (SEB) drawn from a
nearby substation
b) The power supply is made at the following voltages depending on the quantum of power required
and voltages available at the near by substation:-
i) Extra High Voltage (EHV) – Above 33 kV for very large plants.
ii) High voltages (HV) – 33, 22 or 11 kV for other plants.
c) The power supply is made over single circuit or double circuit (D/C) lines. D/C lines should
preferably be provided for large plants and for continuous process plants for maximum reliability.
Both lines should have the capacity to supply 100% load, such that when one line trips, other line can
carry full load.
d) The SEB power supply can be supplemented by in plant generation (captive power plant) wherever
required or feasible. Depending on the requirements, the captive power plant may run in isolated
mode or in parallel with grid supply.

IN PLANT GENERATION (Captive Power Plant)

Considerations for putting up captive power plant (CPP):-
a) Unreliable grid supply due to power cut, voltage and frequency variations beyond limits, frequent
outages which cause production loss particularly in continuous process plants and consequent
financial loss. The losses are more in continuous process plants where the raw materials under
processing usually gets wasted due to power failure and it may take hours to restart the process.
b) Low cost waste or by product fuel such as blast furnace gas in steel mill is available which can be
used in CPP.
c) The process requires large quantity of steam and a co-generation plant could supply both steam and
power at an economical cost.
d) To supply emergency power when the grid supply fails for safe shutdown of the plant or to run on
restricted load to avoid wastage of raw materials under processing.
e) CPP usually runs in isolated mode in case (a) to supply continuous process requirements. SEB
supply remains as stand by and may supply non essential loads.
f) In cases (b) & (c), CPP may run in isolated mode or in parallel with SEB supply, as required.
g) The loads in case (d) is usually supplied by in house Diesel Generator (DG) sets

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PLANT ELECTRICAL DISTRIBUTION SYSTEM

a) The electrical distribution system should be evolved keeping in mind reliability of supply required,
operational flexibility and cost. A less expensive scheme with sacrifices in reserve capacity, stand by
supply and consequent reliability can be adopted in case of simple process plants which can tolerate
short break in supply.
b) For small plants (Load demand wise and area wise) with 415volts drive motors only, the distribution
system would be at 415volts, 3 phases, and 4 wire.
c) Primary Distribution system (PDS) - For large plants where load demand is high and plant facilities
are distributed over large area, a primary distribution system at high voltage (3.3kv, 6.6kv or 11kv) is
adopted. This is referred to as HV system.
d) Unit substation (USS) - The primary distribution system supplies power to unit substations (Load
centers) located in different plant sections. In USS, the voltage is stepped down from HV to 415volts
for supply to loads within the area.
HV motors are usually supplied from HV bus of PDS.
The concept of USS is economical since it reduces cable costs, voltage drops in cables and power
losses. It also adds reliability to the system since trouble in one USS does not affect the rest of the
plant.

SYSTEM CONFIGURATION
a) The basic system configurations adopted are:-
i) Radial feed system – Only one radial feeder from HV bus to each USS with 1 x 100%
capacity unit service transformer (UST) and also one radial feeder from USS 415v bus to
each motor control centre (MCC)
ii) Duplicate feed system – Duplicate radial feeders from HV bus to each USS with 2 x 100%,
USTs. Similarly duplicate feeders from USS 415V bus to each MCC.
iii) Ring main system – All unit substations are connected by tie feeders from HV bus.
iv) Combination of all the above.
b) Configuration (i) is the cheapest but (ii) and (iii) offer flexibility and reliability since continuity of
power supply is maintained even when one of the feeders or transformers fails.
c) The enclosed figures show some of the basic configurations:-

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i) Figure 1 – Shows complete radial system with

 One incoming line from SEB substation
 1 x 100% capacity station transformer (ST) feeding HV primary distribution bus
 One radial feeder from HV bus to each USS
 1 x 100% capacity unit service transformer (UST) feeding 415 volt USS bus
 One radial feeder to each MCC from USS 415v bus
Emergency DG set, if provided, can be connected as shown.
ii) Figure 2- Shows complete duplicate system with duplicate feeders and 2 x 100% capacity
transformers for all the above services. The two feeds are usually sectionalized by bus section
breaker. The two transformers are not paralleled to reduce fault level of the respective LV side
system. When one of the feeders/transformers trip, the bus section breaker is closed manually
(locally or from remote point) to restore power to the dead section. Auto dead-bus transfer scheme
can also be adopted, if required, to quickly re establish the power. However auto transfer scheme is
complicated, costly and special stipulation are to be made for motor parameters and motor starter
circuit.

SELECTION OF VOLTAGES
a) The main power supply voltage is decided by SEB based on quantum of power required, voltages
available in the near by substation etc.
b) The utilization voltage for motor drives up to say 175 kW, lighting, air conditioning, ventilation
heating etc. is at 415 volts, 3 phases, 4 wire.
c) Motors above 175 kW are supplied at a higher voltage of 3.3 kV or 6.6 kV.
d) The primary distribution system voltage is decided on one of the following considerations:-
 At the SEB supply voltage of 11 kV or 22 kV if there are no HV motors.
 At 3.3 kV or 6.6 kV if there are HV motors of same voltage rating.
 At in plant generation voltage.

LOAD ESTIMATE
a) Type of loads include
i) Process loads
ii) Utility loads
b) Process loads – specific for the process.

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c) Utility/off-site facility loads comprise

i) Raw water/water treatment/cooling water system
ii) compressed air system
iii) Air conditioning and ventilation
iv) Material handling
v) Effluent treatment
vi) Fire protection system
vii) Auxiliaries for in plant generation
viii) Plant lighting
xi) Workshop, laboratory etc
x) Office building, stores, canteen etc.
d) Normal cum emergency loads - These loads are normally supplied from plant AC supply and
switchover to emergency AC supply whenever plant AC supply fails. Thus these loads are to be
included under both normal supply and emergency supply. These loads include:-
 Essential process loads
 Essential auxiliaries for in plant generation
 Battery charger
 Uninterrupted power supply (UPS) system
 Communication system
 Fire pumps
 Essential plant lightings
e) Area wise load estimate
i) Prepare list of individual connected loads and corresponding running loads of each USS or
load centre. The running load may be taken as 90% of the connected load, if actual data is not
available.
ii) For squirrel cage induction motors assume 85% efficiency and 0.85 power factor to arrive at
KVA ratings in case actual data are not available.
iii) The sum of all the running loads is the total load demand of the USS.

f) HV motor load
Prepare list of individual connected loads and running loads of HV motors. These will be connected
to either the PDS-HV bus or some USS – HV bus.
g) Total plant load estimate

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Total plant load= Sum of the USS loads x diversity factor + running load of HV motors.
h) A diversity factor is taken into account since maximum load demand of all USS may not happen
concurrently. Assume diversity factor as 0.9 (90%) if actual data is not available.

TRANSFORMER CAPACITIES
a) A 10% margin should be kept in transformer capacity over the load estimate and then rounded off to
the nearest standard rating as per IS 2026.
Rated UST capacity=1.10 x USS load in KVA
Rated ST capacity=1.10 x total plant load in KVA
b) For 1 x 100% and 2 x 100% transformer configuration, each transformer is to be rated for full
capacity as above. Sometime 3x50% transformer configuration is adopted in which case each
transformer is rated at 50% capacity. If one transformer fails, other two carry the full load.

OTHER TRANSFORMER PARTICULARS

No load voltage ratio of transformer
i) The no load voltage ratio of transformer is to be chosen to take care of internal voltage regulation, so
as to obtain rated voltage on the LV side when the transformer is fully loaded.
ii) For example UST no load voltage ratio should be HV voltage/433 volts to get 415 volts when the
transformer is fully loaded.

Transformer Impedance
i) Standard impedance as per IS 2026 should be chosen as far as possible.
ii) Higher impedance may be chosen if particularly required to limit LV side fault level but this will
increase voltage drops particularly at low power factor as in the case of induction motor starting.
iii) Lower impedance may be chosen to control voltage dips but this will increase LV side fault level.

Tap changer of transformer

i) To be provided to take care of grid voltage variation. Two types of tap changer are available:
 Off circuit tap changer
 On load tap changer (OLTC)
ii) Off circuit tap changer - Suitable for operation manually when the transformer is de energized.
Available range is + 5% in steps of 2.5%. UST is usually provided with off circuit tap changer.
ii) On load tap changer (OLTC) - Suitable for operation when the transformer is on load. Operated
electrically from local and remote panels. Available range +10% in steps of 1.25%. ST could be

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provided with OLTC or off circuit tap changer depending of frequency of grid supply variation and
requirement of process plant.

FAULT LEVELS
a) SEB supply system
The fault level of the supply system should be obtained from the SEB. All equipment connected to
the supply system should be designed for this fault level.
b) PDS and USS system
The fault levels of PDS –HV systems USS – 415 volts systems need to be calculated to specify the
fault level of all the equipments connected to the respective system.
c) Contribution to fault current
On the occurrence of fault (short circuit or earth fault) all the lines, transformer(s), in plant
generator(s) and motors connected to the bus contribute to the fault current.
d) Contribution by transformer(s).
Contribution to fault current by a transformer depends on its impedance and the fault level of supply
source behind it.
e) Contribution by in plant generator
Contribution to fault current by a generator depends on its sub transient reactance (Xd”)
f) Contribution by motors
The initial contribution to the fault current by a motor depends on the sub transient reactance. For
induction motors this is taken as locked rotor reactance. However, the motor contribution dies down
very quickly. Hence, the following reactances are taken for short circuit calculations.

Sl No Equipment Symmetrical Short Circuit Current

a. Induction Motors: At time of trip (above 2 During first one

cycles) cycle

i. Above 175Kw 1.5 XLR XLR

ii. 40-175KW 3.0XLR XLR

iii. Below 40KW Neglected

b. Synchronous Motors 1.5Xd” Xd”

Where XLR is locked rotor reactance and Xd” is sub transient reactance.

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g) Case study for induction motor contribution to fault at the time of trip

Motor capacity………….. above 175kw

Locked rotor current………6 times full load current

Full load current
XLR = -------------------- = 1/6 p.u
Locked rotor current

Motor capacity in MVA Motor capacity in MVA

Motor fault MVA = ----------------------------- = ----------------------------
1.5 XLR 1.5 x 1/6

= Motor capacity in MVA

0.25

= 4 x Motor capacity inMVA

For the case study, motor contribution to fault during first one cycle of fault will be:

Motor fault MVA = 6 x Motor capacity in MVA

SHORT CIRCUIT DUTIES

a) Symmetrical short circuit duty

This is symmetrical short circuit current (rms) say If (rms) after 2 cycles from inception of fault as
mentioned above.

b) Momentary symmetrical short circuit duty.

This is symmetrical short circuit current (rms) say Im (rms) during the first one cycles of the fault.
This will be higher than If due to increased contribution to faults by motors as explained above.

When no motors are involved, the fault current will be same as If.

c) Making duty

i) This is the peak current in kilo Amps at the inception of fault. At the inception of fault the
current is asymmetrical with a DC component added to Im (rms), The DC component dies
down quickly in about 0.5 cycle.

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ii) The initial magnitude of DC component and its rate of decay depends on X/R ratio of the
complete system from source of supply to fault point

iii) Making current Im (peak) = √2 x k x Im (rms)

iv) k is a factor depending on X/R ratio of the system and a value of 1.8 may be used based on
typical X/R ratio

Hence Im (Peak) = √2 x 1.8 x Im (rms) = 2.5 Im (rms) approximately

d) Short time with stand capacity

Circuit breakers, isolators, bus bars and other switchgear components will have to carry the short
circuit current If (rms) for a short time in case of through faults and stuck breaker. Generally one (1)
second withstand time is specified but sometime 3 second is also specified.

SHORT CIRCUIT DUTIES OF SWITCHGEAR

a) Circuit breakers shall be rated to:-

i) Interrupt If (rms) in about 3 cycles (60 ms) or faster

ii) Carry Im(rms)

iii) Close on to a fault (making duty) with current Im (peak)

iv) Carry If (rms) for one second or 3 second as specified.

b) Bus bars and other components of the switchgear shall be rated to:-

i) Carry If (rms) for the specified time

ii) With stand Im (rms) and Im (peak)

SWITCHGEAR PARTICULARS

Selection, sizing, design, and construction features of HV and MV switchgears and motor control are
covered in separate lecture.

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FAULT LEVEL CALCULATION

Symmetrical short circuit duty

a) - Select a base MVA

- Calculate per unit (p.u) reactance on base MVA for all equipment

- Prepare a reactance one line diagram with reactances arranged in series/parallel configuration as
applicable.

- Calculate the single equivalent p.u reactances from the sources up to the fault point (X eq)
Fault MVA = Base MVA
X eq in p.u

Fault current = Fault MVA kA (rms)

√3 x kv
b) Case study

A fault level calculation for a simple hypothetical system is shown in Appendix-1 .

c) Momentary symmetrical short circuit duty calculations are similar to above but with lower
impedances of motors taken into account.

d) For fault level calculation in large networks, use computer programmes.

VOLTAGE DROPS

a) As mentioned, voltage drops due to transformer regulation and grid voltage variations are taken care
of by selecting proper no load voltage ratio of transformer and tap changer. Thus LV side voltage is
maintained close to rated voltage under load conditions.

b) The bus voltages should be close to rated voltage. The voltage drop from transformer LV terminal to
the corresponding switchgear bus should be limited to less than 2%. This is done by sizing the power
cable appropriately

c) Voltage drop during motor starting

i) Direct-on-line (DOL) starting of squirrel cage induction motors produce starting current up to 6
times full load current and with +20% allowable tolerance the starting current can go up to 7.2
times full load current.

ii) With reduced voltage starting (Star-delta or auto transformer) the starting current will reduce
proportional to the reduced voltage applied. For star-delta mode of starting, the starting current
will be 7.2 /√3 (i.e. 4.16) times full load current.

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iii) HV motors usually have DOL starting.

iv) In case SEB power is drawn at HV voltage (11 kv to 33kv), the supply Authorities usually put
restrictions on DOL starting of 415 volt motors above a certain kw rating

v) Standard motors built to IS 325 can start and accelerate at lower voltages up to 85% of rated
voltage. Hence voltage drop at motor terminals during DOL starting should be limited to 15%
of rated voltage. This could be less for reduced voltage starting. Further, the supply authorities
or project authorities may put further restrictions on allowable voltage drop during starting.

vi) The voltage drop can be limited by using higher size of cable and maintaining higher bus
voltage by tap changing.

VOLTAGE DROP CALCULATIONS

Voltage drop at motor terminals during starting

Zm
Vdrop = 1- ---------------------------- per unit of bus voltage
Zm+Zs+Zt+Zc
Where Zm = p.u motor impedance during starting = Base MVA
Starting MVA of motor

Starting MVA= 7.2 x motor capacity in MVA for DOL starting

Or = 4.16 x motor capacity in MVA for star-delta starting

Zs= p.u system impedance = Base MVA

System fault MVA

Zt = p.u transformer impedance = Base MVA

Fault MVA of transformer

Zc = p.u impedance of cable from bus to motor = Zactual

Z.Base
= Z actual x Base MVA
kv^2
b) In case the voltage drop calculated as above is beyond the limit, the same can be cross checked as
follows:

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- The starting current is highly inductive, say at 0.2 power factor where as in the cables the
resistance is much more than the reactance cos ø =0.2. Hence sinø =0.97.

- Voltage drop in the cables during starting = √3x I start x √( (cosø x Rc)2 + ( sinø x Xc)2)volts

Where Rc and Xc are resistance and reactance in ohms for the length of cable from bus to motor.
Since the calculated bus voltage at full load is known, the actual voltage at the motor terminal can
be worked out.

c) For critical computation of voltage drops, computer programs should be used.

SYSTEM EARTHING:

a) HV System (3.3KV, 6.6KV, 11KV)

The Transformer neutral is earthed through a low resistance to limit the earth fault current to full load
current or even less. This reduces risk of damage to HV equipment and allows better relay co-
ordination for selective tripping of the faulty circuit.

The grounding resistor is usually rated for 10second duty.

b) 415Volts system

The Transformer neutral is solidly earthed.

POWER FACTOR IMPROVEMENT:

a) The Supply authorities usually stipulate the minimum power factor to be maintained. The minimum
Power factor usually stipulated is 0.9 lag.

b) It is otherwise also good practice to operate the plant at a higher power factor to reduce power losses
and improve the voltage profile of the system.

c) The Power Factor improvement is done by adding shunt capacitors to HV bus or 415v buses as
required. The shunt capacitors can be manually controlled or automatically controlled depending on
whether the plant load is steady or vary frequently.

d) The selection, sizing and design parameters of shunt capacitors are covered in a separate lecture.

SHORT BREAK EMERGENCY SUPPLY

a) The normal cum emergency loads mentioned under ‘load estimate’ is usually supplied by diesel-
generator set(s). On the failure of plant AC supply the DG set is started to restore power to the
essential auxiliaries.

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b) The quick autostart DG set is known as AMF set.

c) The DG set is sized to carry the emergency loads plus 10% margin.

d) The normal cum emergency loads are either supplied from a separate switchgear / MCC or from a
separate section of the main switchgear which gets supply from both the normal supply and the DG
set (see Fig 1)

ONE LINE DIAGRAM

a) An one line diagram should be prepared to show the complete distribution system together with
major equipment parameters , motor ratings, CTs , VTs, Instruments , Meters, Protection relays etc.,

b) The one line diagram should be evolved in stages starting with the distribution system and adding
details as the design progresses.

DC SUPPLY

a) A DC supply from batteries and battery chargers are provided for controls, Interlocks, indications,
annunciation, emergency lighting at strategic locations and DC motor drives for essential auxiliaries.

b) The DC voltage is selected from 24/48/110/220V depending on the requirement.

c) The selection, sizing and design parameters of battery and charger are covered in a separate lecture.

UNINTERRUPTED POWER SUPPLY (UPS)

a) Computer based technology used for process control, instrumentation and data logging requires
uninterrupted voltage and frequency stabilized A.C supply.

b) The UPS requirement is provided by a rectifier-inverter system with battery back up. The rectifier
will normally supply the inverter and trickle charge the battery. On power failure, the battery
continues to supply the inverter.

c) Usually a separate dedicated battery is provided for the UPS.

d) The selection sizing and design parameters of UPS are covered in a separate lecture.

PROTECTION:

Protection scheme and relay particulars for the distribution system and associated equipment are covered
in a separate lecture.

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STATUARY APPROVALS:

a) The following drawings require approval of the electrical inspector of the concerned state
government.

i. One line diagram.

ii. Layout drawings of outdoor switchyard/ substation and indoor switchgear rooms.

iii. Earthing layout drawings for the plant and switchyard / substation

b) The approvals should be taken as early as possible to allow for design changes if required.

HAZARDOUS AND CORROSIVE AREAS

a) Due care should be taken in planning the distribution system and selection of electrical equipment for
hazardous areas classified as per IS5572 and corrosive areas.

b) Locating a switchgear or MCC is these areas should be avoided.

APPENDIX 1
TYPICAL FAULT LEVEL CALCULATION
SYSTEM DIAGRAM
IMPEDANCE DIAGRAM (VALUES IN P.U.)
Where XG = Xd’’ = Generator sub transient reactance.
Xs = System reactance (resistance neglected)
XT = ZT (Tansformer imedance, Resitance neglected)
XM= Motor Reactance = 1.5 XLR
Assume: Base MVA as 100 and 33KV System Fault level as 2500MVA,
 Calculate Xs
Base MVA 100
Xs = ---------------- = ------- = 0.04 PU
System fault MVA 2500

 Calculate XT,

6.3
Transformer fault MVA = -------- = 70MVA

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0.9 x 1
(Assume 10% negative
tolerance on Impedance)

Base MVA 100

XT = ------------------------------ = ------- = 1.43 PU
Transformer fault MVA 70

 Calculate XG
6.25
Generator fault MVA = -------- = 52MVA
0.12

100
XG = --------- = 1.92 PU
52

 Calculate XM

Motor Fault level = 4 x 10.416 = 41.66 MVA

100
XM = -------- = 2.40 PU
41.66

I 1 1 1
-------- = ---------- + -------------------- + -----------
Xeq 1.92 (0.04+1.43) 2.4

Xeq = 1.92 x 1.47 x 2.4

---------------------------------------------------------
1.92 x 1.47 +1.47 x 2.4 + 2.4 x 1.92

6.77
= -------- = 0.617 PU
10.96

100
Symmetrical Short Circuit MVA = ----- = 162MVA
0.617

162
Symmetrical Short Circuit Current = ------- = 14.19KA
√3 x 6.6

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