Industrial Electrical Systems - I

Industrial Electrical Systems

High Tension (HT) Connections

• High Tension connections operate at voltages higher than 1,000 volts
• Used for transmitting electricity over long distances from power generation plants to substations
• High voltage reduces energy loss during transmission
• Involves specialized equipment and components, including:
  • Transformers
  • Circuit breakers
  • Isolators
  • Insulators
• Components are designed to handle high voltages safely and efficiently

Substations

• High Tension power lines are connected to electrical substations
• Voltage is stepped down through transformers before being distributed to lower-voltage networks
• Substations play a crucial role in ensuring a reliable and safe power supply

Safety Considerations

• Working with High Tension connections requires strict adherence to safety protocols and regulations
• Personnel involved in installation, maintenance, or repair tasks must have proper training and use appropriate personal protective equipment

Industrial Substations

• Receive high-voltage electricity from the power grid and distribute it to meet the electrical needs of an industrial facility
• Key components include:
  • Incoming High Voltage Lines
  • Isolators and Disconnect Switches
  • Circuit Breakers
  • Power Transformers
  • Bus bars
  • Switchgear
  • Control Room
  • Protection and Control Systems
  • Grounding System
  • Voltage and Current Transformers
  • Surge Arresters
  • Capacitor Banks (if needed)

Key Functions of Industrial Substations

• Voltage Transformation
• Distribution
• Protection
• Control and Monitoring
• Power Quality Improvement
• Transformer selection

Transformer Selection

• Considerations include:
  • KVA Rating
  • Voltage Ratings and Ratios
  • Voltage Taps
  • Type of Construction
  • Impedance
  • Single Phase or Three Phase Transformers

Industrial Loads

• Refers to the electrical demand and consumption associated with various manufacturing and industrial processes
• Diverse range of sectors, including manufacturing, chemical processing, mining, refining, and more
• Key points include:
  • Diversity of Industrial Loads
  • Types of Industrial Loads (Motor Loads, Heating Loads, Lighting Loads, etc.)
  • Power Demand Variability
  • Power Factor Considerations
  • Heavy Machinery and Equipment
  • Three-Phase Power
  • Harmonics and Disturbances
  • Energy Management Systems
  • Peak Demand and Load Shedding
  • Energy Efficiency Initiatives
  • Power Quality

Motors

• Starting of motors is a crucial aspect in the operation of electrical systems
• Key aspects include:
  • Motor Components (Stator, Rotor, Windings)
  • Starting Methods (DOL, Star-Delta, Autotransformer, Soft Starting)
  • Factors Affecting Motor Selection (Load Characteristics, Speed Requirements, Efficiency)
  • Motor Protection
  • Power Factor

Lightning Protection

• Aim is to provide a safe path for the lightning strike to follow, directing it away from critical areas and preventing potential fires, structural damage, and electrical system failures
• Key components include:
  • Air Terminals (Lightning Rods)
  • Conductors (Down Conductors)
  • Grounding System
  • Surge Protection Devices (SPDs)
  • Bonding
  • Transient Voltage Surge Suppressors (TVSS)

SLD, Cable and Switchgear selection

• Single Line Diagram (SLD):
  • Shows the main components of a power system, including generators, transformers, switchgear, and other equipment
  • Load Requirements
  • Safety Considerations
  • System Redundancy
  • Compliance
• Cable Selection:
  • Voltage Rating
  • Current-Carrying Capacity
  • Environmental Conditions
  • Installation Method### Switchgear Selection
• Consider voltage and current ratings, type of switchgear (air-insulated or gas-insulated), reliability, and safety features when selecting switchgear.
• Choose switchgear from reputable manufacturers known for producing reliable and durable products.
• Consider circuit breakers, protective relays, and interlocking mechanisms as safety features.

Earthing System Design

• Conduct soil resistivity analysis to determine the electrical resistivity of the soil.
• Choose appropriate earthing electrodes based on soil resistivity and fault current requirements.
• Install electrodes at suitable depths in the ground to achieve low resistance.
• Design an earthing grid or network that interconnects the various earthing electrodes.
• Ensure that all electrical equipment is properly grounded.
• Integrate the earthing system with the lightning protection system.
• Implement cross-bonding to interconnect metallic structures.
• Establish equipotential bonding between various conductive elements within a facility.
• Install monitoring systems to regularly measure the resistance of the earthing system.

Power Factor Correction

• Power factor correction involves improving the power factor of an electrical system by adding reactive power.
• Calculate the required kVAR for power factor correction by determining the existing power factor, desired power factor, and power factor improvement.
• Select or design power factor correction equipment such as capacitors based on the calculated reactive power.

PCC and MCC Panels

• Power Control Centre (PCC) is a centralized panel that serves as the main distribution point for electrical power in an industrial or commercial facility.
• Components of a PCC include main incoming switchgear or circuit breaker, bus bars, feeder breakers, control and protection devices, and metering devices.
• Applications of PCCs include large industrial plants, manufacturing units, and commercial buildings.
• Benefits of PCCs include centralized control and monitoring, efficient power distribution, and reduced downtime for maintenance.
• Motor Control Centre (MCC) is specifically designed to control and distribute electrical power to electric motors.
• Components of an MCC include motor starters or contactors, overload relays, control devices, bus bars, and communication and monitoring devices.
• Applications of MCCs include industrial settings where numerous motors need to be controlled and monitored.
• Benefits of MCCs include centralized control of motor operations, improved motor protection, and simplified maintenance and troubleshooting.

Industrial Electrical Systems

High Tension (HT) Connections

• High Tension connections operate at voltages higher than 1,000 volts
• Used for transmitting electricity over long distances from power generation plants to substations
• High voltage reduces energy loss during transmission
• Involves specialized equipment and components, including:
  • Transformers
  • Circuit breakers
  • Isolators
  • Insulators
• Components are designed to handle high voltages safely and efficiently

Substations

• High Tension power lines are connected to electrical substations
• Voltage is stepped down through transformers before being distributed to lower-voltage networks
• Substations play a crucial role in ensuring a reliable and safe power supply

Safety Considerations

• Working with High Tension connections requires strict adherence to safety protocols and regulations
• Personnel involved in installation, maintenance, or repair tasks must have proper training and use appropriate personal protective equipment

Industrial Substations

• Receive high-voltage electricity from the power grid and distribute it to meet the electrical needs of an industrial facility
• Key components include:
  • Incoming High Voltage Lines
  • Isolators and Disconnect Switches
  • Circuit Breakers
  • Power Transformers
  • Bus bars
  • Switchgear
  • Control Room
  • Protection and Control Systems
  • Grounding System
  • Voltage and Current Transformers
  • Surge Arresters
  • Capacitor Banks (if needed)

Key Functions of Industrial Substations

• Voltage Transformation
• Distribution
• Protection
• Control and Monitoring
• Power Quality Improvement
• Transformer selection

Transformer Selection

• Considerations include:
  • KVA Rating
  • Voltage Ratings and Ratios
  • Voltage Taps
  • Type of Construction
  • Impedance
  • Single Phase or Three Phase Transformers

Industrial Loads

• Refers to the electrical demand and consumption associated with various manufacturing and industrial processes
• Diverse range of sectors, including manufacturing, chemical processing, mining, refining, and more
• Key points include:
  • Diversity of Industrial Loads
  • Types of Industrial Loads (Motor Loads, Heating Loads, Lighting Loads, etc.)
  • Power Demand Variability
  • Power Factor Considerations
  • Heavy Machinery and Equipment
  • Three-Phase Power
  • Harmonics and Disturbances
  • Energy Management Systems
  • Peak Demand and Load Shedding
  • Energy Efficiency Initiatives
  • Power Quality

Motors

• Starting of motors is a crucial aspect in the operation of electrical systems
• Key aspects include:
  • Motor Components (Stator, Rotor, Windings)
  • Starting Methods (DOL, Star-Delta, Autotransformer, Soft Starting)
  • Factors Affecting Motor Selection (Load Characteristics, Speed Requirements, Efficiency)
  • Motor Protection
  • Power Factor

Lightning Protection

• Aim is to provide a safe path for the lightning strike to follow, directing it away from critical areas and preventing potential fires, structural damage, and electrical system failures
• Key components include:
  • Air Terminals (Lightning Rods)
  • Conductors (Down Conductors)
  • Grounding System
  • Surge Protection Devices (SPDs)
  • Bonding
  • Transient Voltage Surge Suppressors (TVSS)

SLD, Cable and Switchgear selection

• Single Line Diagram (SLD):
  • Shows the main components of a power system, including generators, transformers, switchgear, and other equipment
  • Load Requirements
  • Safety Considerations
  • System Redundancy
  • Compliance
• Cable Selection:
  • Voltage Rating
  • Current-Carrying Capacity
  • Environmental Conditions
  • Installation Method### Switchgear Selection
• Consider voltage and current ratings, type of switchgear (air-insulated or gas-insulated), reliability, and safety features when selecting switchgear.
• Choose switchgear from reputable manufacturers known for producing reliable and durable products.
• Consider circuit breakers, protective relays, and interlocking mechanisms as safety features.

Earthing System Design

• Conduct soil resistivity analysis to determine the electrical resistivity of the soil.
• Choose appropriate earthing electrodes based on soil resistivity and fault current requirements.
• Install electrodes at suitable depths in the ground to achieve low resistance.
• Design an earthing grid or network that interconnects the various earthing electrodes.
• Ensure that all electrical equipment is properly grounded.
• Integrate the earthing system with the lightning protection system.
• Implement cross-bonding to interconnect metallic structures.
• Establish equipotential bonding between various conductive elements within a facility.
• Install monitoring systems to regularly measure the resistance of the earthing system.

Power Factor Correction

• Power factor correction involves improving the power factor of an electrical system by adding reactive power.
• Calculate the required kVAR for power factor correction by determining the existing power factor, desired power factor, and power factor improvement.
• Select or design power factor correction equipment such as capacitors based on the calculated reactive power.

PCC and MCC Panels

• Power Control Centre (PCC) is a centralized panel that serves as the main distribution point for electrical power in an industrial or commercial facility.
• Components of a PCC include main incoming switchgear or circuit breaker, bus bars, feeder breakers, control and protection devices, and metering devices.
• Applications of PCCs include large industrial plants, manufacturing units, and commercial buildings.
• Benefits of PCCs include centralized control and monitoring, efficient power distribution, and reduced downtime for maintenance.
• Motor Control Centre (MCC) is specifically designed to control and distribute electrical power to electric motors.
• Components of an MCC include motor starters or contactors, overload relays, control devices, bus bars, and communication and monitoring devices.
• Applications of MCCs include industrial settings where numerous motors need to be controlled and monitored.
• Benefits of MCCs include centralized control of motor operations, improved motor protection, and simplified maintenance and troubleshooting.

Learn about High Tension connections, a type of electrical connection used for transmitting electricity at high voltage levels, and its applications in electrical power distribution.