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Developed and Compiled by
Engineering Ministries International Revised October 2016
Electrical Design Guide for the developing world
EMI Electrical Design Guide
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1. Table of Contents 2. Introduction ................................................................................................................................ 2
3. Questions To Consider Before & During an EMI Trip ..................................................................... 3
4. Typical Electrical Design............................................................................................................... 4
4.1 Electrical Symbols ......................................................................................................................... 4
4.2 Single line Diagram ....................................................................................................................... 4
4.3 Electrical Load Study .................................................................................................................... 4
4.4 Site Electrical Plan and Panel Schedules ...................................................................................... 5
4.5 Building Wiring Diagrams ............................................................................................................. 7
4.6 Panel Schedules ............................................................................................................................ 7
4.7 Circuit Breaker and Wire Size Determination .............................................................................. 7
4.8 Voltage Drop Calculation .............................................................................................................. 8
4.9 Grounding and Bonding ............................................................................................................... 9
4.10 Written Report ............................................................................................................................. 9
5. Solar Design .............................................................................................................................. 10
5.1 Solar Sizing Concepts .................................................................................................................. 10
5.2 Rough Cost for Solar Equipment ................................................................................................ 10
6. Hospital Electrical Design ........................................................................................................... 13
6.1 Equipment List ............................................................................................................................ 13
6.2 Equipment Frequency Considerations ....................................................................................... 13
6.3 Air Conditioning and Heating ..................................................................................................... 13
6.4 Code Requirements .................................................................................................................... 13
6.5 Transfer Switches ....................................................................................................................... 14
6.6 Other Systems ............................................................................................................................ 14
Reference Documents EMI Pre-Trip and During Trip Questions (p.15) EMI Wire Chart (p.24) EMI Electrical Power Density and Load Demand Factors (p.25) EMI Site Electrical Load Study Example (p.26) Electrical Panel Worksheet (p.27) EMI Electrical Report Example (p.28) EMI Solar vs Generator vs Utility Cost Comparison (p.29) World Solar Isolation Maps (p.31) Grounding Electrode Conductor Sizing (p.46) Electrical Voltage & Output Worldwide Standards (p.47) EMI Diesel Generators Overview (p.49)
Reference Drawings Electrical Symbols (p.56) Electrical Single Line Diagram (p.57) Electrical Site Plan (p.58) Site Grounding Diagram (p.59) Ground Rod Detail (p.60) Generator Room Electrical Plans (p.61) Basement Lighting Wiring Diagram (p.62) Basement Power Wiring Diagram (p.63) Ground Floor Lighting Wiring Diagram (p.64) Ground Floor Power Wiring Diagram (p.65) Panel Schedules - MDP, PPG, 120-240 (p.66) Panel Schedules - PPA, SPAG (p.67)
2. Introduction
Electrical Engineers on an EMI trip can expect to encounter a variety of unique design challenges that will require creativity, flexibility and good engineering judgment. EMI projects are all different and it would be impossible to try and address every design challenge that could be encountered. Therefore, this design guide is created to give the designer an idea of the general format of an EMI electrical design. This design guide will provide a lot of helpful information, but the designer must do their own research prior to the trip and while on the field and use their best judgment based on the information gathered during the trip. Data collected in the field that is different from this design guide shall take priority so long as safety of the public is maintained. Numerous supplemental documents and drawings are referenced throughout this design guide (see ‘Reference Documents (p.15)’ and ‘Reference Drawings (p.56)’). EMI uses AutoCAD to create its drawings. DraftSight is a free software that volunteers can use for creating, viewing and editing AutoCAD drawings. The software can be downloaded at: http://www.3ds.com/products-services/draftsight-cad-software/free-download/ Some countries have no established electrical code, so many of the design principles presented in this document are adapted from the NFPA 70 National Electrical Code and are believed to be in accordance with sound design. However, if there is any variance from any governing codes applicable to the site location, the governing codes take priority and the installation shall follow the latest edition of those codes regardless of any and all specifications explicitly or implicitly set forth in this document.
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3. Questions To Consider Before &
During an EMI Trip Prior to embarking on an EMI trip the electrical designer should become familiar with the resources in this design guide. The document labeled ‘EMI Pre-Trip and During-Trip Electrical Engineer Questions (p.15)’ is a list of questions that will help the designer understand and gather the pertinent information prior to and during the time in-country.
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4. Typical Electrical Design The example design in this design guide describes the basic elements of an EMI electrical design and includes drawings and calculations. 4.1 Electrical Symbols
The drawing labeled ‘Electrical Symbols (p.56)’ shows the typical symbols that are used to represent electrical devices. This is not an exhaustive list, so the designer may need to research the appropriate symbol if it is not included on this drawing. Also, if the designer is able to acquire a local electrical drawing and the symbols are different than shown on the EMI drawing, the symbols on the local drawing should be used.
4.2 Single line Diagram
The drawing labeled ‘Electrical Single line Diagram (p.57)’ shows a typical graphical representation of an entire electrical system. A Single line is usually one of the first drawings created in a design as it captures the information on an existing system and helps the designer quickly see how a system can be modified. Power sources are shown at the top of the page and the loads are at the bottom. The two power sources in this example are the public utility and a backup generator. A manual transfer switch is used to transfer between the two sources. The public utility through a transformer is the primary power source for the site. The transformer is sized to accommodate the loads for the Phase 1 and Phase 2 buildings (see ‘EMI Site Electrical Load Study Example (p.26)’ for a description of the loads). Although the generator is the backup power source for the entire site, it is only large enough to handle the Phase 1 loads. The client will need to upgrade the generator and the feeders to the transfer switch, or select the loads for which the generator will provide backup power (up to 100kW) when Phase 2 is built. If the client had requested that only certain loads be included on the backup generator, separate circuits and panels would need to be designed for the loads on back-up power. Wire and breaker sizes to the Main Distribution Panel (MDP) and the main building panels (PPA and PPPH) are shown on the single line diagram. The panels and sub-panels in each building are labeled and shown in more detail on the ‘Wiring Diagram (61-65)’ and ‘Panel Schedules (p.66-67)’ drawings.
4.3 Electrical Load Study Early in the design cycle a site electrical load study should be created to give the designer and the client an idea of the overall size of the electrical system. The ‘EMI Electrical Load Study Example (p.26)’ summarizes the loads for the facility being used as an example in this design guide. The design is separated into Phase 1 and Phase 2. Phase 1 includes the first two levels (basement and ground levels) of the accommodations building and all the site lighting and soccer field lights. Two additional floors will be added to the accommodations building in Phase 2. The general load for the building is calculated by multiplying the area of the building by the power density for lights and outlets for a particular facility (see ‘EMI Electrical Power Density and Load Demand Factors (p.25)’ for power densities). These load densities are general guidelines and may
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not be appropriate in some countries. The designer should try to measure lighting densities for similar facilities in the area and match the design to these. The “special loads” for each building are specified in the last column and are calculated by multiplying the number of “special loads” (indicated in parentheses) by their respective power consumption found in the ‘Device Power Consumption’ table at the bottom of the spreadsheet. The maximum demand is the sum of the “general” and “special loads”. Once all the loads have been calculated, a demand factor must be applied. Referring again to the ‘EMI Electrical Power Density and Load Demand Factors (p.25)’, a 50% demand factor should be applied to all “general loads”) and the demand factors for special loads must be determined by the engineer based on input from the ministry and observed patterns of use. In less developed countries the general load demand factor may be around 25%. In this example, a 75% demand factor is applied to the special loads because the client specified that no more than 75% of the air conditioners (which are classified as “special load” devices) would be used simultaneously. Pumps are listed below the demand factor and 100% of their load is added to the total demand.
4.4 Site Electrical Plan and Panel Schedules The drawing labeled ‘Site Electrical Plan p.58)’ shows all the main feeder cables and their routing on the site in addition to all the site lighting. The names and locations of the main panels (MDP, PPG, PPA) are also specified on the ‘Site Electrical Plan (p.58)’.
The drawing labeled ‘Generator Room Electrical Plans (p.61)’ is a basic layout for the generator building and shows the location of the MDP, PPG and Transfer Switch. The drawing labeled ‘Panel Schedules – MDP, PPG, 120-240V (p.66)’ shows the layout of the main distribution panel (MDP) and the Generator power panel (PPG). The 120-240V panel is only added as an example for volunteers to use. The MDP specifies all the main breakers feeding the subpanels. Figure 1 shows an example of a main distribution panel layout.
Figure 1: MDP Layout
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PPG is a single phase panel schedule called a consumer unit (see Figure 2 below). Consumer units are common in countries that have had European influence. The breakers mount to a din rail and the main breaker feeds power to the branch circuit breakers through jumper wires or jumper bars.
PPA is a three phase panel schedule. Picture 3 shows a three phase panel with the main breaker at the bottom of the panel. Three phase panels can either contain bus bar like the one below, or they may look more like the consumer unit with jumper wires or jumper bars connecting the main breaker to the branch circuit breakers. The load calculations for individual panels are described in section 3.6 ‘Panel Schedules’
Figure 3: PPA
Figure 2: PPG
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4.5 Building Wiring Diagrams The building wiring diagrams (see drawings ‘Basement Wiring Diagram (p.62-63)’ and ‘Ground Floor Wiring Diagram (p.64-65)’) show the general location of all the electrical devices and how they are connected together. The home runs to the panel board are also shown on the wiring diagrams. Each floor plan will have two sheet of electrical wiring to avoid overcrowding the drawing. One sheet shows the lighting wiring and the second shows the power wiring.
4.6 Panel Schedules The drawing labeled ‘Panel Schedules - PPA, SPAG (p.67)’ shows two typical three-phase panel schedules and PPG is a typical single-phase panel schedule. PPA is the main panel schedule for the building and is located in the Basement Worker’s Room. SPAG is the ground floor subpanel and is located in the ground floor janitor room as shown on the building wiring diagrams. At the top of the panel schedule all the pertinent information about the panel is displayed (Mark, Location, Main Breaker etc.). The middle of the panel is a graphical representation of the 3-Phase bus bars and their connection to each circuit breaker. Circuits #1, 3, 5 on panel PPA are shown with a line connecting them together to represent a 3-phase circuit breaker. The total power consumption of the 3-Phase loads is evenly distributed across the three phases. For example the total load on SPAG is 27.498kVA, or 9.166kVA per phase. The wire size, circuit breaker size (CB Trip), load size (Wattage) and a description of the equipment being served by that circuit are all shown on the panel layout. The load on each circuit is calculated by summing up the power consumption of all the electrical devices connected to that circuit. For example, circuit #2 on panel PPA is feeding two single phase air conditioners for the small classrooms in the basement of the Accommodations. Each air conditioner is rated at 1,232VA and they are connected to phase A, so 2,464VA is the value placed for phase A on circuit #2. The ‘Summary’ table shows the total load (kVA) and current (Amps) on each phase. The primary purpose of the ‘Summary’ table is to ensure that each phase has a similar amount of load on it, thus creating a balanced load.
4.7 Circuit Breaker and Wire Size Determination In order to demonstrate how to determine the circuit breaker and wire sizes, circuit #2 on panel PPA will be used as an example. The total load for circuit #2 on panel PPA in the drawing labeled ‘Panel Schedules – PPA, SPAG (p.67)’ is 2,464VA. The circuit breaker size and wire size can now be determined by calculating the maximum current through the circuit:
𝐼(𝑐𝑢𝑟𝑟𝑒𝑛𝑡) =𝑃(𝑝𝑜𝑤𝑒𝑟)
𝑉(𝑣𝑜𝑙𝑡𝑎𝑔𝑒)
𝐼 =2464𝑉𝐴
220𝑉= 11.2𝐴𝑚𝑝𝑠
Before selecting a breaker size, a safety factor of 25% should be applied to the maximum current to avoid nuisance tripping:
11.2𝐴𝑚𝑝𝑠 𝑥 1.25 = 14𝐴𝑚𝑝𝑠
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The next standard breaker size larger than the final current calculated is then selected for the circuit. In this case a 15Amp breaker would suffice. Circuit breakers generally come in standard sizes, so during the trip the designer should determine the standard sizes available in the area. With the breaker size selected, the wire size for the circuit must now be determined by referencing the ‘EMI Wire Chart (p.24)’. The circuit breaker is protecting the wire, so wire that is able to carry 15Amps of current or more should be used on this circuit. In this example, 2.5mm2 wire was selected because column 3 of the ‘EMI Wire Chart (p.24)’ shows that 2.5mm2 copper wire is capable of carrying 22 amps. The same calculation above can be followed for the three-phase loads except the voltage would be the phase to phase voltage (380V) and the current is calculated as follows:
𝐼 =𝑃
𝑉√3
The remainder of the ‘EMI Wire Chart (p.24)’ is explained as follows: Column 1 shows the American Wire Gauge (AWG) sizes. Most countries use mm2 for wire sizes as shown in column 2. Column 3 shows the current rating of copper wire that has an insulation rating of 75 since this is the most commonly used wire internationally. Column 4 shows the current rating of aluminum wire with a 75 insulation rating. The resistance factor used to calculate voltage drop is listed in column 5 and the physical characteristics of the wire are shown in columns 6-10.
4.8 Voltage Drop Calculation Voltage drop must be calculated in situations where the circuit conductors span large distances. If the voltage drop is too great (greater than 4%), the conductor size must be increased to maintain the voltage and current between the points. The calculations for a single-phase circuit and a three-phase circuit are slightly different. Single-phase voltage drop calculation:
𝑉D =2 × 𝐿 × 𝑅 × 𝐼
1000
𝑉D% =𝑉D
𝑉SOURCE × 100
Three-phase voltage drop calculation:
𝑉D =2 × 𝐿 × 𝑅 × 𝐼
1000× 0.866
𝑉D% =𝑉D
𝑉SOURCE × 100
VD = Voltage drop in Volts VD% = Percentage of voltage drop, but is commonly called “voltage drop” L = One way length of the circuits feeder (in meters) R = Resistance factor of the wire in ohms/kilometer (see ‘EMI Wire Chart (p.24)’) I = Current in Amps VSOURCE = Voltage of the circuit at the source of power (i.e. 110, 220, 380 V …)
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If we continue with the example above using circuit #2 in panel PPA on drawing ‘Panel Schedules - PPA, SPAG (p.67)’ and assume a distance of 40 meters from the panel to the air conditioners and a 2.5mm2 wire, the voltage drop would be:
𝑉D% = [(2 × 40𝑚 × 8.99Ω km⁄ × 11.2𝐴𝑚𝑝𝑠
1000𝑚/𝑘𝑚) /(220𝑉)] × 100 = 3.6%
Since the voltage drop is less than 4% on this branch circuit the wire size chosen is adequate.
4.9 Grounding and Bonding The Reference Document ‘Grounding Electrode Conductor Sizing (p.46)’ shows the size of the ground conductor needed for the corresponding feeder conductors. The ‘Panel Grounding & Bonding Diagram (p.46)’ (below the table) identifies the components of a properly grounded panel and building. The ‘Site Grounding Diagram (p.59)’ shows how a typical site in the developing world is grounded. Most sites in the developing world do not have a ground wire running from the main distribution panel. Each individual building will have its own grounding electrode (ie. ground rod) and grounding electrode conductor which runs into the main building panel where the neutral and ground are tied together. This type of grounding is TN-C-S which is also known as Multiple Earthed Neutral (MEN) or Protective Multiple Earthing (PME). This method of grounding does not require a ground wire to be run from the main distribution panel to the main building panels of each individual building. It also provides an easy transition from an ungrounded system because grounds can be added at each building one at a time without having to add a fifth wire (ground wire) to all the distribution lines. In addition, this ensures that the ground and conductive surfaces in each building are as close as possible in electrical potential to the ground a person would be standing on. The ‘Ground Rod Detail (p.60)’ shows a typical ground rod installation.
4.10 Written Report The document ‘EMI Electrical Report Example (p.28)’ is an example of the electrical section of an EMI report. Typically, the electrical section of the report is around 1-3 pages in length and should be a high-level summary of the designers intent. The report should not include technical details, but should only reference drawings and spreadsheets for the technical details. A copy of the ‘EMI Site Electrical Load Study (p.26)’ should also be included in the report as an Appendix.
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5. Solar Design 5.1 Solar Sizing Concepts
When sizing solar panels for a system, one must first determine the total system energy needs (Et = Watts x Time) per day. This energy must be harvested during the window of usable sunlight (about 7.5 hours at a latitude of less than +/-15 degrees). The Reference Document labeled ‘World Solar Insolation Maps (p.31)’ shows the equivalent sun hours on the surface of the earth. The system efficiency is about 70%, so the solar panel wattage (P) is estimated as:
P = Et / (7.5 x 0.7) Charge controllers must be sized to match the solar panel wattage, P. Inverters must be sized to match the maximum power demand expected at any point during the day. Batteries must be sized to store the total energy (Eb = watts x time) required outside the solar harvest window. Since a battery efficiency of about 80% is typical, and since a deep cycle battery can be safely cycled to about 50% depth of discharge (DOD), the battery bank W-h rating is estimated as:
W-h = Eb / (0.8 x 0.5) A 100 A-h, 12V battery is a 1200 W-h battery.
5.2 Rough Cost for Solar Equipment The following table is a rough estimate of the cost associated with a typical solar system (Year 2015 Values). These costs are for the USA and may be higher in some developing countries due to a longer supply chain. These costs should be checked with a local distributor while in country. Residential Scale (Less than 10kW):
Item Cost
Solar modules (panels) 1120 $/kW (in US) 600 $/kW ( in India/China)
Charge Controller 350 $/kW
Inverter (grid tied only) 400 $/kW
Inverter (with off-grid capability) 550 $/kW
Batteries (Lithium Ion: Tesla Powerwall)
350 $/kW-h [5000 cycle, 15 yr lifespan]
Batteries (Deep Cycle Lead Acid AGM: Trojan 31-AGM)
225 $/kWh [1000 cycle, 2.7 yr lifespan]
Batteries (Deep Cycle Flooded Lead Acid: Trojan T-145)
134 $/kWh [1200 cycle, 3.3 yr lifespan]
Solar Module Racking 250 $/kW
Installation costs 650 $/kW
Other hardware: wiring/switch gear 200 $/kW
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Commercial Scale (Greater than 10kW):
Item Cost
Solar modules (panels) 690 $/kW (in US) 560 $/kW (in India/China)
Charge Controller 350 $/kW
Inverter 250 $/kW
Batteries (Lithium Ion: Tesla Powerpack)
250 $/kW-h [5000 cycle, 15 yr lifespan]
Batteries (Vanadium Flow: Imagery) 500 $/kWh (projected to be 300 $/kWh in 2017), [5,475 to
10,950 cycles, 15-30 yr lifespan]
Solar Module Racking 250$/kW
Installation costs 200 to 400 $/kW
Other hardware: wiring/switch gear 200 $/kW
Note: Lifespan is based on the assumption that recommended depth of discharge for the battery is not exceeded and that the battery is cycled one time a day. Sources: http://cleantechnica.com/2015/05/09/tesla-powerwall-powerblocks-per-kwh-lifetime-prices-vs-aquion-energy-eos-energy-imergy/ http://www.greentechmedia.com/research/report/global-pv-pricing-outlook-2015 http://www.powertechsystems.eu/home/tech-corner/lithium-ion-vs-lead-acid-cost-analysis/ http://www.trojanbattery.com http://www.nrel.gov/docs/fy14osti/60412.pdf Below is a summary of the unsubsidized levelized cost of sources of energy for reference. This does not take into account the subsidies on utility power in many developing countries.
Energy Source $/ MWh (value in parenthesis is projection for 2017)
Residential Scale PV $180-265
Commercial and Industrial Scale PV $126-177
Utility Scale PV $72-86 ($60)
Wind $37-81
Battery Storage $265-324 ($168)
Diesel Generator $297-332
Natural Gas Generator $179-230
Coal $66-151
Nuclear $92-132 ($124)
Source: Version 8.0 of Lazard’s Levelized Cost of Energy Analysis
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The average total cost of an installed solar system in California as of October of 2015 was $5.35/watt for systems <10kW and $4.56/watt for systems >10kW. (https://www.californiasolarstatistics.ca.gov/) Energy storage is becoming more common in solar systems in the United States, but the majority of these systems are still grid tied without battery backup. Many Ministries would like to know how much a solar system would cost compared to the utility or using a generator. The document called ‘EMI Solar vs Generator vs Utility Cost Comparison (p.29)’ can be used to calculate a rough estimate of the initial and on-going cost of each system. The cells highlighted in yellow are the variables the designer must input for the specific project. The graph shows the cost of each system over 25 years.
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6. Hospital Electrical Design 6.1 Equipment List
A major part of hospital/clinic design deals with providing the correct voltage, phase, ampacity, frequency, and location for each piece of equipment. An equipment list and specifications from the client are extremely important. This list usually requires some research, consulting, and guessing by the owner but it must be part of the design and documentation. The equipment list is also needed by the other design team members for A/C requirements, plumbing requirements, architectural space needs, structural considerations, etc. Specialized equipment in hospitals and clinics is much more extensive than any other type of facility design. In addition to the equipment, special room layouts, lighting and accessories will be required. Equipment suppliers should be contacted for these special pieces of equipment and wiring layouts. Examples of equipment in this category are: CAT Scans, X-Rays, MRI’s, O.R. Exam Lights, O.R. special equipment (ie. portable x-ray), Laboratory Equipment, and Intensive Care Suite special equipment (ie. monitoring equipment).
6.2 Equipment Frequency Considerations Equipment frequency (50Hz vs. 60Hz) must be clarified before design can proceed. Equipment is often donated from the US with 60Hz requirements but at the same time the client will also want to use local 50Hz equipment. If the utility service frequency is 50Hz, motor-driven 60Hz equipment will not work unless a 50 to 60Hz converter is used. The equipment list should indicate where the equipment is to be obtained to force a decision on frequency. In addition, equipment designed by the team must specify the correct frequency depending on where it will be purchased/donated.
6.3 Air Conditioning Air Conditioning is often the largest load requirement in a hospital or clinic, so it is important to determine which areas specifically will be air conditioned and ventilated and what type of equipment will be used (window units, split systems, central systems, ceiling fans, etc.).
6.4 Code Requirements NEC (NFPA 70), Article 517 – Health Care Facilities should be reviewed before the site visit. It may not be possible, or desirable, to follow this code exactly, but it should be used as a basis of design. Any downgrades from the code should be discussed with the client. For instance, providing only one or two emergency branches instead of three may make sense for a small rural hospital, or the use of fewer outlets per patient bed may make sense if minimal patient support equipment will be available for plug-in. Another standard that should be reviewed prior to the site visit is NFPA 110 – Standard for Emergency and Standby Emergency Systems. When designing a generator for a site, this standard should be followed as much as possible. In addition, a wealth of information is available on the internet from generator manufactures regarding physical sizes, air supply requirement, clearances,
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heat dissipation, etc. Caterpillar, Kohler and Cummins are all good sources. The generator voltage, phase and frequency must match the system design parameters.
6.5 Transfer Switches Transfer switches for a hospital should be of the automatic type in lieu of manual if the cost will allow. Upon loss of power, which may be quite often in some locations, a generator can start and be on-line within 10 seconds with an automatic transfer switch. This may be critical to some patients and medical procedures. In some cases the generator will need to be used as “Base Power” and the utility as backup due to totally unreliable utility power. In this case automatic switching will definitely be required.
6.6 Other Systems Several other systems may be requested by the client and will need to be addressed in some manner by the engineer. These include: automatic or manual fire alarm system; nurse call systems; security systems (usually cameras and door controls); data network and server systems; telecom systems; satellite transmitting and receiving systems; electronic record-keeping systems; exit lighting; doctor’s paging and others. Usually EMI Engineers do not have the time or, in some instances, the knowledge to design these types of systems, but if the client requests any of the systems, they should be dealt with in the project report in some manner. The most efficient way to handle these designs is to send the floor plans to a manufacturer’s representative and ask for a design layout and cost to include in the report (except possibly for the exit lighting which the engineer should be able to design). If a local manufacture’s representative can be found for any of these systems, they should be given preference to help and encouraged to be involved. Local service of these systems will be critical to their operational longevity.
REFERENCE DOCUMENTS
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EMI Pre-Trip and During-Trip Electrical Engineer Questions
Table of Contents 1. Before Trip ............................................................................................................................ 16
1.1. Power Requirements ...................................................................................................... 16 1.2. Solar Data....................................................................................................................... 16 1.3. Wind Data ...................................................................................................................... 16 1.4. Equipment and Materials to Bring ................................................................................. 16
1.5 Equipment Available for Loan.......................................................................................... 16
2. During Trip............................................................................................................................ 17 2.1. Sites with Existing Electric Infrastructure ..................................................................... 17
2.2. Sites to Add Local Electric Service ............................................................................... 19 2.3. Sites to Add a Generator ................................................................................................ 20 2.4. Planned Electrical Load Information ............................................................................. 20
3. Project Specific Information ................................................................................................ 22 4. Alternative Energy System Planning .................................................................................. 22
4.1. Solar Question List ........................................................................................................ 22
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1. Before Trip
1.1. Power Requirements
If building drawings are available prior to the trip the EMI Electrical Power Density
and Load Demand Factors (p.25) can be used as a guide for making a rough estimate of
the total electric service power requirement for your project.
1.2. Solar Data
Collect solar data for location (see World Solar Insolation Maps (p.31)).
1.3. Wind Data
Collect wind data for location
1.4. Equipment and Materials to Bring
a) Clamp on Ammeter with voltage testing capability (if possible with min, max, and
avg. recording capabilities)
b) Live Wire Circuit Tracer
c) For large facilities a 3 phase power analyzer is recommended
d) 3-point ground tester
e) Clamp on ground tester (optional)
f) Infrared Camera to look for hot spots (optional)
g) Camera to document transformers, generators, panel locations, etc.
h) Calipers to measure wire diameter
i) Multi-Bit screwdriver set
j) Multi-purpose tool (i.e. Leatherman)
k) Set of mini screwdrivers for working on electronics
l) Electrically Insulated rubber gloves rated for the voltage you will be working on
with a set of thin fabric glove liners to absorb moisture and a set of leather outer
gloves to prevent holes in the rubber. Class 0 is sufficient for most trips.
m) Headlamp
n) Ear plugs for working around active diesel generators
o) A few sheets of Labels
p) Roll of electrical tape
q) Safety glasses
1.5 Equipment Available for Loan
The following equipment is available for loan from EMI. Contact your project leader to
reserve a piece of equipment for your project and to make arrangements for transporting the
equipment to the site. Larger projects will be given higher priority.
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a) Clamp on Ammeter with voltage testing capability and min, max, and avg.
recording capability.
b) Live Wire Circuit Tracer
c) 3-point ground tester
d) 3 phase power analyzer
e) Infrared Camera
2. During Trip
Find out the cost of electricity per kW-hr. If you can get any costs per kW-hr for energy
supplied from the local utility, this information might be useful if there is any need to make
any kind of economic tradeoff comparison.
2.1. Sites with Existing Electric Infrastructure
If there is any existing electrical infrastructure, the tedious task of documentation is
necessary.
a) While on site the document labeled Electrical Panel Worksheet (p.27) should be
filled out as completely as possible for every electrical panel. By doing so all of the
information required for creating the one-line diagram and doing the load study will
be available. It is wise to bring plenty of blank paper copies of the worksheet to the
site even if there is an existing one-line diagram.
b) The power at the main panel(s) should be recorded. At a minimum a clamp on
ammeter with maximum/minimum recording capability should be used to capture
the maximum and minimum current draw on each of the phases coming into the
main panel over a 24 hour period. If possible these same values should be recorded
on the main breakers or main subpanels being fed by the main distribution panel.
The voltage should also be observed at the main panel to determine its
characteristics; including maximum, minimum, frequency, and harmonics over a
period of time, ideally 24 hours. The best option is to use a 3 phase power analyzer
at the main distribution panel over a 24 hour period and at the main subpanels for
the same duration. This piece of equipment allows you to record all of the
parameters needed on all 3 phases at the same time so it saves a lot of time. Note: In
order to run a 3-phase power analyzer overnight it may need to be plugged in to a
nearby receptacle.
c) A rough sketch of the electrical site plan should be created showing the electrical
distribution for the facility. This should include power poles and specify when the
lines are running under ground and overhead. This should also include the location
of all the electrical panels documented by each Electrical Panel Worksheet using
the identification assigned in the worksheets. Although this may be a challenge,
documentation of the electrical distribution scheme for the existing buildings is
needed. If an electrician familiar with the site can be found, he would be an
invaluable friend who could make this task simple. A feed from the electric utility
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probably runs to a power panel in one of the buildings, and then is distributed from
that panel to the other existing buildings. A crude sketch documenting the electrical
feed entry point and its interconnection to buildings is the goal.
d) A rough sketch of existing buildings is needed - not architectural quality. Show
doors, but windows are not necessary. Only major room dimensions are needed.
Somewhere in each room sketch, jot down the number of lights with wattage, the
number of outlets and the number of fans (if any). The locations of these items are
not needed.
e) As is mentioned in the Electrical Panel Worksheet (p.27) all special loads fed by an
electric panel should be documented. At a minimum the name of the equipment, the
power it draws in VA, and the required input voltage should be recorded. It is also
recommended that a photo of the piece of equipment and any nameplates be taken.
Loads with higher power draw are the most important. Some examples are the
following:
Refrigerators, freezers, electric water heaters, electric stoves, electric washing
machines, electric dryers, electric irons, air conditioning units, electric
heating, autoclaves, pumps, and other electrical motor loads.
f) Document the earthing (grounding) method for the main power panel. Earth rod?
Wire size? Check on any panels beyond the main power panel to document how
earthing is handled.
g) Is the service drop overhead or underground?
h) Information on the incoming electrical feed is needed. It probably runs to a
transformer mounted in a pole along a road somewhere in the vicinity of the site. If
at all possible, determine the rating (kVA) of that transformer. Also, try to
determine the size of the electrical cable used for this feed. Make a reasonable
estimate of the length of this cable run from the transformer to the site connected
building.
i) Ask the ministry to give you copies or allow you to photograph any electrical
drawings that they have for the site. If you can obtain any such information, it
would be of great value.
j) Ask the ministry for copies of any electric bills, generator logs, or any other
documentation available on the electric usage for different sources over the last 12
months.
k) If possible, a design goal should be to feed the existing electrical system from a
panel that is part of the new electrical system design.
EMI Electrical Design Guide
19
l) If there is a generator, get complete nameplate data on it - voltage, kVA or kW
rating, power factor, three-phase or single-phase and primary or standby rating.
m) If there is an existing bore-hole pump, try to get name plate data.
2.2. Sites to Add Local Electric Service
If the site presently has no electrical service, but plans to request service, there are
several issues to explore.
a) Where is the closest utility power line?
b) Where will the electrical service enter the site?
c) Is a transformer already installed from which the service would be supplied? If it is
already installed, obtain Voltage and kVA rating on the transformer.
d) If there is no transformer, will the electric utility company pay for the new
transformer and to run the lines to the property?
i. If the ministry has to purchase the transformer, prices may range from $US
40-70 per kVA. (Year 2011 values).
e) Will the ministry quickly need any preliminary electrical plan to initiate the
application for electrical service? If so, determine the level of detail.
f) Does the local utility just offer service to certain customers for certain hours during
the day – in other words, rolling blackouts?
g) Is the local utility supplied service single-phase or three-phase? Determine the
voltage (see Electrical Voltages & Outlets Worldwide (p.47)).
h) Find out if the local utility has rules, limits, or price breaks on levels of service per
service drop. It might be possible that multiple utility service drops are advisable.
i) Are there any national or local electrical codes to be satisfied? Are there any
government inspections to be made? If so on either count, find out all the
information available about the processes.
j) Is site electrical power distribution to be underground or overhead?
k) If underground distribution is to be used, ask if they use metallic shielded cable or
PVC conduit for direct burial.
l) Find out what standard circuit breaker sizes are readily available.
EMI Electrical Design Guide
20
2.3. Sites to Add a Generator
a) Is there already a generator on the site? If so, record complete nameplate data and
photo document the generator unit and the associated generator house.
b) If a new generator is to be installed, identify a suitable spot for a generator house
(see EMI Diesel Generators Overview (p.49)). Ideally it needs to be 200 ft or less
from the most distant point of electric service to minimize voltage drop problems.
The building would need truck access to deliver diesel fuel. Noise emissions are
principally from one side of generator house, but it could be irritating to those on all
sides if sound-proofing is not used.
c) If the purpose of the generator is for backup power, will it be used for total site
backup or will it be used for certain loads deemed to be critical loads? If the latter,
get a clear definition of these critical loads.
d) The cost of an installed generation will probably be in the range of US$ 250-400
per kW plus an additional US$ 5000 -10000 for control panels. (Year 2011 values)
e) If any information on the cost of any recently delivered multi-kW diesel generator
set in the area can be found, this would be good information to know.
f) The fuel consumption for the diesel engine will be about 0.07 gallons per kW-hr.
Thus, a 50 kW load for 12 hrs per day with $5 per gallon diesel fuel costs $210 per
day.
g) In addition to fuel, the engine will require an oil change (maybe 2-3 gal) and a filter
change each 100-150 hours of operation. A major engine overhaul will be required
every 25-30,000 hours of operation. There will be other expenses for operating an
engine – a mechanic on site would reduce these expenses.
h) Will there be a person on site with primary responsibility to keep the generator and
electric system properly functioning?
2.4. Planned Electrical Load Information
a) Obtain best estimates of walled square footages for the purpose of electrical load
planning.
b) Local practice on illumination power density needs to be determined and compared
to the EMI Electrical Power Density and Load Demand Factors (p.25). Observe the
installed lighting wattage and roughly measure the floor area to determine the
W/sq-m illumination power density for some typical existing building in the site
EMI Electrical Design Guide
21
neighborhood that has a living or dining area. Similarly, determine the illumination
power density for an office or library area.
c) What types of light bulbs will be used? Fluorescent tubes (length and wattage)?
Compact fluorescent lights (wattage)? Incandescent bulbs (wattage)?
d) Is there any air conditioning, electric heating (direct or furnace), or electric water
heating planned? If so, document specific locations. Get best description possible
of the power these devices consume.
e) Is a kitchen planned? If so, get all the information possible on the electric
appliances to be installed - quantities and sizes.
f) Will there be any pumping loads for fresh water or for sewage treatment facilities?
g) For a medical clinic, identify electrical medical equipment planned - especially such
items as X-ray machines and sterilization equipment.
h) If a water well is to be drilled on the site, find out the expected depth of the well,
the height of the storage tank above the well head, and the total daily water usage
anticipated for the purposes of sizing a pump. This information is needed to
determine the power requirement for the pump.
i) If laundry facilities are planned, document the number of any electric washing
machines, electric dryers, or electric irons anticipated?
j) If there are some administrative offices planned, identify anticipated types and
quantities of the electrical office equipment - PCs, printers, copiers, etc.
k) Determine the nature of desired security lighting around the site. Do they plan to
use street lights? Do they want motion activated lights around the entrance areas of
buildings?
l) If you are able to talk with an electrician or electrical contractor, ask if they wire
with Ring Circuits or with Radial Feeds in building wiring. Also, ask if they
specify their electrical wiring by the standard European sq mm sizes?
m) If possible, take some close-up photos of electrical plug receptacles (they may call
them outlets). It would be nice to know their particular plug pattern. Although that
information does not have to be specified on the wiring diagram, it is a clue as to
how close to they hold to the British standard (see Electrical Voltages & Outlets
Worldwide (p.47)).
n) If possible, take some close-up photos of power panels in the area, both three-phase
and single-phase. Of special concern is the single-phase power panel. If there is
British influence, they may use what is called a Consumer Unit – breakers mounted
EMI Electrical Design Guide
22
horizontally on a DIN rail. This information will allow use of the appropriate panel
template in the design work.
o) Assuming that there is to be indoor bath rooms in the project, check on a couple of
things that would be British practice related.
i. Are the plug receptacles inside the bathroom required to be special receptacles
called “Shaver Outlets” with transformer isolation?
ii. Are lights in the bathroom required to be either controlled by a switch located
outside the door or by an insulated pull-cord?
3. Project Specific Information
All eMi projects are different, thus a general question list will not address all the issues. For
example, there might be light manufacturing facilities, a hospital, or other operations that
have electrical service requirements beyond the scope covered by this document. In such
cases, the EE volunteer should do appropriate research in advance of the project trip to
prepare questions to properly gather information for the design phase.
4. Alternative Energy System Planning
Discussion might arise concerning the use of photovoltaic (PV) generation or wind
generation for backup electrical power since these two methods have low operating costs. PV
generation has a fairly prohibitive initial cost - say around US$ 6-7000 per KW (Year 2011
Values). Rarely will a site have the average wind speed to make wind generation feasible.
Unless the trees list at about 15 degrees from withstanding sustained winds, wind generation
probably will not be feasible. The annual average wind speed for the site should exceed 15
mph before wind generation should be considered.
Since PV generation is the more common alternate energy consideration for eMi projects, the
following planning guide may be found useful in explaining the costs associated with a solar
system. If the ministry definitely wants a solar system, then the items on the Solar Question
List should be addressed during the project trip.
4.1. Solar Question List
a) Get a clear definition of the loads to be operated during the solar harvest window
from about 8:30 am to 4 pm (the harvest window may be shorter for latitudes
greater +/- 15 degrees). This is a power-time profile – specific loads and time of day
for which each load exists (see World Solar Insolation Maps. (p.31)).
b) Get a clear definition of the loads to be operated outside of the solar harvest
window from about 4 pm to 8:30 am. This is a power-time profile – specific loads
and time of day for which each load exists.
EMI Electrical Design Guide
23
c) Water pumps can be a challenge for operation on a solar system. The best approach
will be to use a small DC pump especially designed for solar power operation and
to operate the pump only during the solar harvest window. Otherwise, batteries will
have to be sized to handle the pump operation, thus significantly increasing the
capital outlay.
d) How would the ministry choose to handle cloudy days? If electrical service is to be
provided on cloudy days, then sufficient batteries would have to be installed to
provide the energy needs for the span of sunless days. Also, sufficient solar panels
would have to be installed to harvest the extra energy to be stored. Provision for
electric service for a single cloudy day could easily double the system cost; a two-
consecutive cloudy day contingency could easily triple the system costs, etc.
e) Batteries have approximately a 5 year life, thus this ongoing operational cost should
be understood. Also, battery terminals need to be cleaned about every 6 months.
Battery voltages need to be checked periodically – say once per month. Panel tilt
angles need to be seasonally adjusted for maximum efficiency.
f) A location for solar panels must be identified wherein there will be no blockage of
incident sunlight during the solar harvest window. Solar panels may need to be
washed down after dusty conditions. Keeping the solar arrays near the Power
Center is best as voltage drop in connection cabling can be a design issue.
EMI Electrical Design Guide
24
Copper
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EMI Electrical Design Guide
25
EMI Electrical Power Density and Load Demand Factors For loads serviced by Electric Utility or Generator Churches, Auditoriums, Dining Halls, Large Open Spaces Illumination power density 7 VA/m2 (0.6 VA/ft2) General Outlet Loads No additional load added for outlets Air Conditioners and Audio/Visual equipment are
included in special loads Fans 6 VA/m2 (0.56 VA/ft2) Demand factors* 50% for General loads
See * below for Special Loads Demand Factor Dwellings, Offices, Schools, Dormitories, Small Clinics Illumination power density 7 VA/m2 (0.6 VA/ft2) General Outlet Loads 3 VA/m2 (0.28 VA/ft2)
Fans 6 VA/m2 (0.56 VA/ft2) Demand factors* 50% for General loads
See * below for Special Loads Demand Factor Hospitals, Large Clinics Illumination power density Operating and Procedure 27 VA/m2(2.5 VA/ft2)
General Purpose 7 VA/m2 (0.6 VA/ft2) General Outlet Loads 6 VA/m2 (0.56 VA/ft2)
Fans 6 VA/m2 (0.56 VA/ft2) Demand factors* 50% for General loads
See * below for Special Loads Demand Factor * The demand factors for special loads must be determined by the engineer based on input from
the ministry and observed patterns of use. In less developed countries the general load demand factor may be around 25%. Note: Alternate energy systems must be handled by a more carefully formed power-time profile.
EMI Electrical Design Guide
26
SUMMARY
1 98.33
1 35.97
134.30
150.00
89.5%
PHASE 1
Accommodations (2 levels) 2 528 7 9 16896 40780 57676 88 *A/Cs (29), Washers(4) Dryers(4)
Site Lighting 46 4600 4600 7 *Site Lights (46)
Soccer Field Lights 10 2000 2000 3 *Field Lights (10)
64276
43983
42629
1066
10657
98
PHASE 2
VA/m2
Outlets +
Special Loads
(VA)Outlets+Fan
sLoads (VA)
Accommodations (2 levels) 2 528 7 9 16896 36696 53592 81 *A/Cs (29)
53592
35970
36
200
1000
500
400
5000
1000
500
280
150
750
200
100
1232
1716
2310
150
600
Air Conditioner (Small)
Air Conditioner (Medium)
Air Conditioner (Large)
Ceiling Fan
Data Projector
Coffee Maker
PC
Printer
Copier
Field Lights
Site Lights
Device
Freezer
Microwave
Washing Machine
Gas Dryer (motor)
Electric Dryer
Iron
Special LoadsLoad Description Qty Area (m2)
Phase 2 Max Demand (VA)
General Load
(VA)
Special Loads
(VA)
Maximum
Demand (VA)Phase Currents Special LoadsLoad Description Qty Area (m2)
VA/m2
Lights
VA/m2
Outlets +
Fans
Demand Factor: 50% General Loads + 75% Special
40 hp Well Pump with 0.7 power factor(VA)
Total Phase 1 Demand (kVA)
10 hp Booster Pump (VA)
1 hp Filtration Pump (VA)
General Load
(VA)
Maximum
Demand (VA)Phase Currents
*Device Power Consumption
VA/m2
Lights
*Device Power Consumption
Power (VA)
EMI Site Electrical Load Study Example
Demand Factor: 50% General Load + 75% Special
Phase 1 Max Demand (VA)
Total Phase 2 Demand (kVA)
EMI Site Electrical Load Study Example
Property Loads Qty Total (kVA)
Phase 1
Phase 2
Loads Total (kVA)
Xfmer Size (kVA)
Power Percentage Used
EMI Electrical Design Guide
27
EMI Electrical Panel Worsheet
Name
Panel location
Panel photo #(s)
Special loads
Infrared Photo #(s) (description,
quantity,
How many floors device photo,
receive power nameplate
from this panel? photo, and
Incoming ground breaker &
current [A] conductor
Incoming ground sizes
resistance [Ω]
Draw a panel diagram below and include the following:
Main breaker rating Size & material of incoming phase conductor
Distance from last panel Size & material of incoming ground wire
ID of panel
feeding this
panel
Panel ID ["PXX-YY" where
XX=building number,
YY=A,B,C identifier
where "A" is first panel
in the building]
EMI Electrical Design Guide
28
EMI Electrical Report Example
1.1 Existing Electrical
The existing site presently has a 100 kW, 50 Hz, 380/220 VAC generator that is being used to run the well pump. No utility electrical service comes onto the site; however, a three-phase distribution line does exist across the road on the south side of the property. There will be line and transformer expenses required to extend the electrical service onto the site.
1.2 Proposed Electrical System
The national electric utility grid will be the primary source of power for the Site. The government utility will need to provide the site with high voltage power lines from the existing power lines across the street from the property to the generator shed (see drawing ‘Site Electrical Plan’). The ‘EMI Electrical Load Study Example’ shows the complete load planning for the site electrical grid – Phase 1 and Phase 2. A 150kVA transformer will be needed for all future phases of this project, but a 100kVA transformer would be sufficient for the first phase. The 100kW generator will be used as a back-up for the site but it will not be able to power the whole site when the future phases are added. Loads will have to be reduced or the backup loads separated when the future phases are added. Air conditioners contribute to the majority of the electrical load on this site. The new generator building will be located relatively close to the accommodations as they have the largest power demands. The generator building is also centrally located on the site to minimize voltage drop concerns if future buildings are added in the agriculture area. In addition to housing the generator, the building will also contain the main distribution panel, and the manual transfer switch to select between the utility as the primary power source, and the generator as the backup power source (see drawing ‘Generator Room Electrical Plans’). The ‘Electrical One Line Diagram’ shows a drawing of the proposed site electrical system wherein cable sizes are specified and electrical panels and switch gear are identified. Since some electrical cable runs exceed 60 m in length, several cables have been sized larger than necessary based on ampacity to keep voltage drop within the standard practice of 4% or less. Also, all panels, breakers and cables have been sized to accommodate all future expansion on the conference facility, so that new cables and panels do not have to be installed when the buildings are expanded. The ‘Site Electrical Plan’ suggests a viable plan for buried distribution cable routing for the site. Electrical power panels are also associated with each building on this drawing. Perimeter security lights are activated by a switch in the generator room with power supplied from panel PPG.
1.2.1 Accommodations
Drawings ‘Wiring Diagram - Basement’ and ‘Wiring Diagram - Ground Floor’ show the wiring diagrams for the accommodations. Electrical service to the building feeds through one main power panel located in the worker’s room in the basement - PPA. Subpanels, fed from this main power panel, are distributed to each floor to provide convenient access to breakers for isolation of building sectors. As floors are added to the building a sub-panel for that floor can easily be connected in to the main panel in the basement. The main panel has been sized to account for all the future floors of the accommodations building. Calculations for the electrical loads serviced by each main power panel are shown below the respective panel drawings.
EMI Electrical Design Guide
29
Yello
w-h
ighlig
hte
d c
ells
are
input va
lues
Tim
e of
Day
(am
firs
t row
, pm
sec
ond
row
)12
-11-
22-
33-
44-
55-
66-
77-
88-
99-
1010
-11
11-1
2LO
ADEN
ERG
Y (W
)(W
)(W
)(W
)(W
)(W
)(W
)(W
)(W
)(W
)(W
)(W
)(k
W-h
)
Tota
l Site
Hou
rly (
AM)
4000
4000
4000
4000
4000
4000
4000
4000
19000
29000
29000
29000
Pow
er D
eman
d
(PM
)29000
29000
29000
19000
19000
29000
29000
19000
19000
19000
19000
4000
Site
Dai
ly E
nerg
y U
sage
401.0
0
Util
ity A
vaila
bili
ty a
s %
of
tota
l pow
er
dem
and
80.0
0%
Sola
r S
yste
m A
ssum
ptions:
Inve
rter
eff
icie
ncy (
ηI )
= 9
0%
Syste
m e
ffic
iency (
ηS)
= 7
0%
Charg
e C
ontr
olle
r eff
icie
ncy (
ηC)
= 9
5%
Depth
of
Battery
Dis
charg
e (
DO
D)
=
50%
Battery
eff
icie
ncy (
ηB)
=95%
Battery
repla
cem
ent eve
ry3
years
4.5
(kW
h/m
^2/d
ay) 7
0%
Syste
m S
ize:
50%
63.6
508
kW
260
Watts
245
1.6
0m
^2548.8
m^2
Genera
tor
Assum
ptions:
Fuel u
sage r
ate
= 0
.07 g
al/k
W-h
Genera
tor
repla
cem
ent eve
ry3
years
3.5
0 U
S$/g
al
Util
ity A
ssum
ptio
ns
Ele
ct. C
ost per
kW
-h0.1
5U
S$/k
W-h
Dis
tance to S
ite100
Mete
rs
Equip
ment
costs
:S
ola
r M
odule
s1100
US
$/k
W70016
US
$
Charg
e C
ontr
olle
r372
US
$/k
WC
ost =
17447
US
$
Inve
rter
(Off
-Gri
d B
attery
)235
US
$/k
WC
ost =
7572
US
$
235
US
$/k
WC
ost =
10471
US
$
Cost =
5000
US
$
Batteri
es
269
US
$/k
W-h
Cost =
53517
US
$
Genera
tor
300
US
$/k
VA
Cost =
9667
US
$
Genera
tor
annual f
uel c
ost =
Cost =
35859
US
$
Tra
nsfo
rmer
35
US
$/k
VA
Cost =
1128
US
$
Cost fo
r 3-p
hase to s
ite39
US
$/m
ete
rC
ost =
3900
US
$
Util
ity e
lectr
icity
usage a
nnual c
ost =
21955
US
$
Cost =
Tota
l PV
syste
m e
ffic
iency
(not in
clu
din
g b
atteri
es)
=
Daily
insola
tion
Note
: U
se low
est
valu
e if
com
ple
tely
off
-gri
d
batt
ery
based.
Use a
nnual avera
ge if
utilit
y
inte
ractive.
Note
: G
enera
tors
typic
ally
need a
majo
r overh
aul or
repla
cem
ent
every
20,0
00 h
ours
. M
ust
round t
o w
hole
year.
Perc
ent of
Curr
ent D
aily
Pow
er
Usage to b
e c
ove
red b
y s
ola
r (X
%)
=
Sin
gle
Module
Ratin
g =
Sin
gle
Module
Are
a =
Fuel S
ave
r C
ontr
ols
to P
ara
llel S
ola
r w
ith G
enset
Num
ber
of
Module
s =
Estim
ate
of
Tota
l Are
a a
t 10
° til
t =
Sola
r A
rray S
ize =
EMI S
olar
vs.
Gen
erat
or v
s. U
tility
Cos
t Com
pari
son
Note
: # o
f cycle
s t
he b
att
ery
is r
ate
d f
or
div
ided b
y
365 (
days in a
year)
is a
good r
ough e
stim
ate
of
how
oft
en b
att
ery
will
need t
o b
e r
epla
ced.
Must
round t
o
whole
year.
In
the table
belo
w,
ente
r estim
ate
d h
ourly p
ow
er
dem
and v
alu
es f
or
the s
ite in W
. If
siz
ing f
or
battery
based o
ff-g
rid u
se w
ors
t case d
ay w
hen
loads a
re h
ighest. I
f siz
ing f
or
a g
rid inte
ractiv
e s
yste
m u
se the a
vera
ge d
aily
use o
ver
a 1
year
peri
od.
Inve
rter
(Genera
tor/
Util
ity
Inte
ractiv
e)
Die
sel f
uel i
nclu
din
g
transport
to s
ite =
EMI Electrical Design Guide
30
World Design Insolation Map
Solarex’s World Design Insolation map plots design insolation—to the extent it has been reliablyrecorded—on the surface of the earth. On this map, design insolation is expressed as the average value ofthe total solar energy received each day on an optimally tilted surface during the month with the lowestsolar radiation. This worst-month data is commonly accepted as a valid solar energy index for designingsystems which must support a load 12 months per year, rather than seasonally. The unit of measurementis kilowatt-hours/m²/day, often referred to as equivalent sun-hours, or ESH.
The map presents color-coded areas of essentially equal insolation (see key at bottom right) in addition topoint values recorded at selected monitoring stations. From the main map, you can access detailedinsolation maps of any area by clicking on that area. Consult the Adobe Acrobat Reader Help menu forinstructions on moving around on the map.
Select the site design insolation from the map, and enter it on line 9 of the Array Sizing Procedure form.Particularly if the site is at a latitude higher than 45°, be aware that the ESH number represents averagedaily insolation during the worst month of the year. It is not indicative of how much solar energy isavailable during other months, which--particularly at high latitudes--may be substantial. Contact anauthorized Solarex representative for assistance in designing systems for such sites.
EMI Electrical Design Guide
46
CopperAluminum or Copper-
Clad AluminumCopper
Aluminum or Copper-
Clad Aluminum
2 (35) or smaller 1/0 (50) or smaller 8 (10) 6 (10)
1 or 1/0 (50) 2/0 or 3/0 (70) 6 (16) 4 (25)
2/0 or 3/0 (70) 4/0 or 250 (120) 4 (25) 2 (35)
Over 3/0 through 350
(95-185)
Over 250 through 500
(120-240) 2 (35) 1/0 (50)
Over 350 through 600
(185-300)
Over 500 through 900
(300-500) 1/0 (70) 3/0 (95)
1Referenced from NEC 2008 Table 250.66
Minimum Size of Equipment
Grounding Conductor -
AWG/kcmil(mm2)
Size of Largest Ungrounded Service-Entrance
Conductor or Equivalent Area for Parallel
Conductors - AWG/kcmil(mm2)
Grounding Electrode Conductor Size1
Panel Grounding and Bonding Diagram
Magellan's Adaptor Plugs:
Electrical Standards by Country:
Country
Voltage/F
reqSock
etNon-
Grounded
Adap
torsGro
unded
Adaptors
Notes
Country
Voltage/F
reqSock
etNon-
Grounded
Adap
torsGro
unded
Adaptors
Notes
Country
Voltage/F
reqSock
et
Non-Gro
unded
Adaptors
Grounded
Adap
tors
Notes
Afghanistan 220/50 F EA23MFG EA23MFG Guyana 120/50 C EA351C EA23MCG Poland 220/50 D EA351D EA23MDG 1D EA351D EA23MDG 240/50 A EA351A EA23MAG Portugal 220/50 D EA351D EA23MDG
Albania 220/50 D EA351D EA23MDG F EA23MFG EA23MFG F EA23MFG EA23MFGHaiti 110/60 A EA351A EA23MAG Puerto Rico 120/60 A EA351A EA23MAG
Algeria 220/50 F EA23MFG EA23MFG Honduras 110/60 A EA351A EA23MAG Qatar 240/50 C EA351C EA23MCGD EA351D EA23MDG Hong Kong 230/50 C EA351C EA23MCG F EA23MFG EA23MFG
Andorra 220/50 D EA351D EA23MDG F EA23MFG EA23MFG Romania 220/50 D EA351D EA23MDG 1Angola 220/50 D EA351D 1 Hungary 220/50 D EA351D EA23MDG Russia 220/50 D EA351D EA23MDG 1Antigua 230/60 C EA351C EA23MCG Iceland 220/50 D EA351D EA23MDG Rwanda 220/50 D EA351D EA23MDG 1
110/60 A EA351A EA23MAG India 230/50 F EA23MFG EA23MFG 1 St. Kitts-Nevis 220/60 C EA351C EA23MCGArgentina 220/50 E EA351E EA23MEG 1 C EA351C EA23MCG F EA23MFG EA23MFG
D EA351D EA23MDG D EA351D St. Lucia 240/50 C EA351C EA23MCGArmenia 220/50 D EA351D EA23MDG Indonesia 220/50 D EA351D EA23MDG 1 St. Maarten 220/50 D EA351D EA23MDGAustralia 240/50 E EA351E EA23MEG 110/50 St.Vincent/Grenadines 220/50 C EA351C EA23MCGAustria 220/50 D EA351D EA23MDG 1 Iran 220/50 D EA351D EA23MDG 1 A EA351A EA23MAGAzerbaijan 220/50 D EA351D EA23MDG Iraq 220/50 C EA351C EA23MCG Samoa, American 120/60 A EA351A EA23MAG 1
F EA23MFG EA23MFG D EA351D EA23MDG 220/50 E EA351E EA23MEGBahamas 120/60 A EA351A EA23MAG F EA23MFG EA23MFG D EA351D EA23MDGBahrain 220/50 C EA351C EA23MCG Ireland, Northern 220/50 C EA351C EA23MCG Samoa, Western 220/50 E EA351E EA23MEG
F EA23MFG EA23MFG Ireland, Republic of 230/50 C EA351C EA23MCG San Marino 220/50 D EA351D EA23MIGBangladesh 220/50 F EA23MFG EA23MFG Israel 230/50 D EA351D EA23MJG 1 Sao Tome and Principe 220/50 D EA351D EA23MDG
D EA351D EA23MDG Italy 220/50 D EA351D EA23MIG Saudi Arabia 110/60 A EA351A EA23MAGC EA351C EA23MCG EA23MDG 220/50 D EA351D EA23MDGA EA351A Ivory Coast 220/50 D EA351D EA23MDG 1 C EA351C EA23MCG
Barbados 115/50 A EA351A EA23MAG Jamaica 110/50 A EA351A EA23MAG Scotland 220/50 C EA351C EA23MCGBelarus 220/50 D EA351D EA23MDG Japan 100/60 A EA351A EA23MAG 1 Senegal 220/50 D EA351D EA23MDGBelgium 230/50 D EA351D EA23MDG 1 Okinawa Prefectorate 100/60 A EA351A EA23MAG F EA23MFG EA23MFGBelize 110/60 A EA351A EA23MAG E EA351E EA23MEG EA23MKG
220/60 C EA351C EA23MCG Jordan 220/50 C EA351C EA23MCG Serbia/Montenegro 220/50 D EA351D EA23MDG 1Benin 220/50 F EA23MFG EA23MFG D EA351D EA23MDG Seychelles 220/50 C EA351C EA23MCG
D EA351D EA23MDG F EA23MFG EA23MFG F EA23MFG EA23MFGBermuda 120/60 C EA351C EA23MCG Kampuchea 220/50 D EA351D EA23MDG 1 Sierra Leone 220/50 C EA351C EA23MCG
A EA351A EA23MAG 110/60 A EA351A F EA23MFG EA23MFGBhutan 220/50 F EA23MFG EA23MFG C EA351C EA23MCG Singapore 230/50 C EA351C EA23MCG 1
C EA351C EA23MCG Kazakhstan 220/50 D EA351D EA23MDG Slovak Republic 220/50 D EA351D EA23MDGD EA351D EA23MDG Kenya 220/50 C EA351C EA23MCG Slovenia 220/50 D EA351D EA23MDG
Bolivia 110/50 A EA351A EA23MAG 1 F EA23MFG EA23MFG Solomon Islands 220/50 E EA351E EA23MEG220/50 D EA351D Kiribati 220/50 E EA351E EA23MEG Somalia 220/50 D EA351D EA23MDG 1
Bosnia/Herzegovina 220/50 D EA351D EA23MDG 1 110/60 A EA351A EA23MAG South Africa, Republic of 220/50 H EA23MHG EA23MHGBotswana 220/50 C EA351C EA23MCG Korea, Dem. 220/50 D EA351D EA23MDG C EA351C EA23MCG
F EA23MFG EA23MFG 110/60 A EA351A EA23MAG Spain 220/50 D EA351D EA23MDG 1Brazil 110/60 A EA351A EA23MAG 1 Korea, Rep. 110/60 A EA351A EA23MAG 110/50
220/60 D EA351D EA23MDG 220/60 D EA351D EA23MDG Sri Lanka 230/50 F EA23MFG EA23MFGBrunei 240/50 C EA351C EA23MCG Kuwait 240/50 C EA351C EA23MCG D EA351D EA23MDGBulgaria 220/50 D EA351D EA23MDG D EA351D EA23MDG Sudan 240/50 C EA351C EA23MCGBurkina Faso 220/50 D EA351D EA23MDG F EA23MFG EA23MFG D EA351D EA23MDGBurma 220/50 C EA351C EA23MCG 1 Kyrgyz Rep. 220/50 D EA351D EA23MDG Surinam 120/60 D EA351D EA23MDG 1
D EA351D EA23MDG Laos 220/50 A EA351A EA23MAG Swaziland 220/50 H EA23MHG EA23MHGF EA23MFG EA23MFG D EA351D EA23MDG D EA351D EA23MDG
Burundi 220/50 D EA351D EA23MDG Latvia 220/50 D EA351D EA23MDG 1 Sweden 230/50 D EA351D EA23MDG
Cambodia 220/50 D EA351D EA23MDG 1 Lebanon 220/50 D EA351D EA23MDG 1 Switzerland 230/50 D EA351D EA23MSG 110/60 A EA351A 110/50 A EA351A Syria 220/50 D EA351D EA23MDG 1
C EA351C EA23MCG Lesotho 220/50 H EA23MHG EA23MHG Taiwan 110/60 A EA351A EA23MAGCameroon 220/50 D EA351D EA23MDG 1 D EA351D EA23MDG Tajikistan 220/50 D EA351D EA23MDGCanada 110/60 A EA351A EA23MAG Liberia 120/60 C EA351C EA23MCG Tanzania 230/50 C EA351C EA23MCGCanary Islands 220/50 D EA351D EA23MDG 220/50 A EA351A F EA23MFG EA23MFGCape Verde,Republic of 220/50 D EA351D EA23MDG Libya 127/50 D EA351D EA23MDG Thailand 220/50 D EA351D EA23MDG 1Cayman Islands 120/60 A EA351A EA23MAG 230/50 F EA23MFG EA23MFG A EA351A EA23MAGCentral African Republic220/50 D EA351D EA23MDG 1 Liechtenstein 220/50 D EA351D EA23MSG Tibet 220/50 D EA351D EA23MDG 1Chad 220/50 D EA351D EA23MDG Lithuania 220/50 D EA351D EA23MDG 1 E EA351E EA23MEG
F EA23MFG EA23MFG Luxembourg 220/50 D EA351D EA23MDG 1 Togo 220/50 D EA351D EA23MDG 1Chile 220/50 D EA351D EA23MIG 1 Macao 200/50 F EA23MFG EA23MFG Tonga 240/50 E EA351E EA23MEGChina 220/50 E EA351E EA23MEG C EA351C EA23MCG F EA23MFG EA23MFG
C EA351C EA23MCG Macedonia 220/50 D EA351D EA23MDG D EA351D EA23MDGD EA351D EA23MDG Madagascar 220/50 D EA351D EA23MDG 1 Trinidad & Tobago 110/60 A EA351A EA23MAGA EA351A F EA23MFG EA23MFG 220/50 C EA351C EA23MCG
Hong Kong Region 230/50 C EA351C EA23MCG Madeira 220/50 F EA23MFG EA23MFG F EA23MFG EA23MFGF EA23MFG EA23MFG D EA351D EA23MDG Tunisia 220/50 D EA351D EA23MDG 1
Colombia 110/60 A EA351A EA23MAG 1 Malawi 230/50 C EA351C EA23MCG Turkey 220/50 D EA351D EA23MDG 1Comoros 220/50 D EA351D EA23MDG Malaysia 240/50 C EA351C EA23MCG Turkmenistan 220/50 D EA351D EA23MDGCongo 220/50 D EA351D EA23MDG 1 Maldives 220/50 F EA23MFG EA23MFG A EA351A EA23MAGCongo, Dem. Rep. 220/50 D EA351D EA23MDG D EA351D EA23MDG Turks & Caicos Islands 120/60 A EA351A EA23MAGCook Islands 240/50 E EA351E EA23MEG A EA351A Tuvalu 220/50 E EA351E EA23MEGCosta Rica 120/60 A EA351A EA23MAG Mali 220/50 D EA351D EA23MDG 1 Uganda 220/50 C EA351C EA23MCGCroatia 220/50 D EA351D EA23MDG Malta 220/50 C EA351C EA23MCG F EA23MFG EA23MFG
Martinique 220/50 D EA351D EA23MDG 1 Ukraine 220/50 D EA351D EA23MDGCuba 110/60 A EA351A EA23MAG 1 F EA23MFG EA23MFG United Arab Emirates 220/50 C EA351C EA23MCG
220/60 D EA351D EA23MIG Mauritania 220/50 D EA351D EA23MDG 1 F EA23MFG EA23MFGCyprus 220/50 C EA351C EA23MCG 1 Mauritius 220/50 C EA351C EA23MCG USA 110/60 A EA351A EA23MAGCzech Rep. 220/50 D EA351D EA23MDG D EA351D EA23MDG Uruguay 220/50 E EA351E EA23MEG 1Denmark 230/50 D EA351D EA23MKG 1 Mexico 120/60 A EA351A EA23MAG D EA351D EA23MIGDjibouti 220/50 D EA351D EA23MDG Micronesia 120/60 A EA351A EA23MAG Uzbekistan 220/50 D EA351D EA23MDGDominica 230/50 C EA351C EA23MCG Moldova 220/50 D EA351D EA23MDG Vanuatu 220/50 E EA351E EA23MEG 1
F EA23MFG EA23MFG Monaco 220/50 D EA351D EA23MDG 1 C EA351C EA23MCGDominican Republic 110/60 A EA351A EA23MAG F EA23MFG EA23MFG D EA351DEcuador 120/60 A EA351A EA23MAG 1 Mongolia 220/50 D EA351D EA23MDG 1 Venezuela 120/60 A EA351A EA23MAG 1Egypt 220/50 D EA351D EA23MDG 1 Montserrat 230/60 A EA351A EA23MAG 1 Vietnam 220/50 D EA351D EA23MDG 1El Salvador 115/60 A EA351A EA23MAG Morocco 220/50 D EA351D EA23MDG 110/60 A EA351A
D EA351D EA23MDG F EA23MFG EA23MFG C EA351C EA23MCGEngland 220/50 C EA351C EA23MCG Mozambique 220/50 D EA351D EA23MDG 1 Virgin Islands (British) 110/60 A EA351A EA23MAGEquatorial Guinea 220/50 D EA351D EA23MDG 1 H EA23MHG EA23MHG C EA351C EA23MCGEritrea 220/50 D EA351D EA23MIG 1 Myanmar 220/50 C EA351C EA23MCG 1 Virg. Isl.(US) 110/60 A EA351A EA23MAGEstonia 220/50 D EA351D EA23MDG 1 D EA351D EA23MDG Wales 220/50 C EA351C EA23MCGEthiopia 220/50 D EA351D EA23MIG F EA23MFG EA23MFG Yemen 220/50 C EA351C EA23MCG
F EA23MFG EA23MFG Namibia 220/50 D EA351D EA23MDG F EA23MFG EA23MFGFiji 240/50 E EA351E EA23MEG H EA23MHG EA23MHG A EA351AFinland 220/50 D EA351D EA23MDG Nauru 220/50 E EA351E EA23MEG Zambia 220/50 C EA351C EA23MCG 1France 230/50 D EA351D EA23MDG Nepal 220/50 F EA23MFG EA23MFG D EA351DFrench Guiana 220/50 D EA351D EA23MDG 1 D EA351D EA23MDG Zimbabwe 220/50 C EA351C EA23MCGFrench Polynesia 220/60 D EA351D EA23MDG Netherlands 230/50 D EA351D EA23MDG 1 F EA23MFG EA23MFG
110/60 A EA351A EA23MAG Neth. Antilles 220/50 D EA351D EA23MDG 1Gabon 220/50 D EA351D EA23MDG 1 110/50 A EA351A EA23MAGGambia 220/50 C EA351C EA23MCG New Caledonia 220/50 D EA351D EA23MDG 1Georgia 220/50 D EA351D EA23MDG New Zealand 230/50 E EA351E EA23MEG Notes:Germany 230/50 D EA351D EA23MDG Nicaragua 120/60 A EA351A EA23MAG In countries where multiple adaptors are listed, the most commonGhana 220/50 C EA351C EA23MCG Niger 220/50 D EA351D EA23MDG 1 configuration is listed first. Wise travelers prepare for all possibilities.
D EA351D EA23MDG Nigeria 230/50 C EA351C EA23MCGF EA23MFG EA23MFG F EA23MFG EA23MFG (1) Not all electrical sockets in these countries provide grounding.
Gibraltar 240/50 C EA351C EA23MCG Norway 230/50 D EA351D EA23MDG 1D EA351D EA23MDG Oman 240/50 C EA351C EA23MCG 1 Please Note: Electrical adaptor plugs do not change voltage (e.g. from 220 volts
Greece 220/50 D EA351D EA23MDG 1 D EA351D to 110 volts for North American appliances). If your appliance is not designed to Greenland 220/50 D EA351D EA23MDG Pakistan 230/50 F EA23MFG EA23MFG operate on 220 volt systems found overseas, you will need a step-down transformer.
EA23MKG D EA351D EA23MDG If your appliance has three pins we recommend that you use a grounded adaptorGrenada 220/50 C EA351C EA23MCG Panama 120/60 A EA351A EA23MAG plug. Grounding helps protect you from shock if your appliance is damaged and
D EA351D EA23MDG E EA351E EA23MEG an electrical short occurs. In areas where grounded sockets are not availableF EA23MFG EA23MFG Papua New Guinea 240/50 E EA351E EA23MEG you may choose to bypass the grounding pin and use your appliance without the
Guadeloupe 220/50 D EA351D EA23MDG 1 Paraguay 220/50 D EA351D EA23MDG 1 protection of a grounded socket.Guam 110/60 A EA351A EA23MAG Peru 110/60 A EA351A EA23MAG 1Guatemala 120/60 A EA351A EA23MAG 220/60 D EA351DGuinea 220/50 D EA351D EA23MDG 1 Philippines 220/60 A EA351A EA23MAGGuinea-Bissau 220/50 D EA351D EA23MDG D EA351D
© 2008 Magellan's Travel Supplies. All Rights Reserved.
EMI Electrical Design Guide
49
EMI Diesel Generators Overview
When considering a design where generators will be used a prime power for remote and small
operations (<1MW) there are several factors that need to be considered and known.
1. Terminology:
Technically “Generators” produce DC voltage and current, and “Alternators” produce AC
voltages and current, the same that we see from utility sources. While there are design
differences in the internal connections of the electrical side of things that make that
difference, it is common practice to call the entire system of engine driven alternators as
"generators", and we will use that term here. We will use the term “alternator” only to
describe design issues that impact the electrical portion of the overall generating system.
DC systems have current flowing in a single constant direction with typically steady voltages
and are commonly seen in battery powered systems. AC systems have current directional
flow alternating, typically many times a second; the voltage also varies in a sine wave
pattern, from zero to a positive peak then back down to zero and down to a negative peak
then rising back to zero in each cycle. Since the voltage is constantly varying, the output is
rated by an “RMS” (root mean square) voltage that is a mathematical calculation of the sine
wave that give the same power as a DC current at that same voltage would. Peak voltages
are higher than the RMS value by a factor of about 1.41 (the square root of 2). So a 120 volt
AC system will have peak voltages of about 170 volts, and 220 volt AC system peak voltages
of about 308 volts.
2. Ratings:
Generators are typically sold by KW capacity with a kVA rating also provided. Generator
sets (Gensets) are typically rated for Prime or continuous duty rating and at higher rating for
Standby or limited run hours. It is wise to buy the unit based on the lower kVA Prime or
continuous duty rating if it is to take to place of utility power and run all day or over 12-14
hours a day.
The KW capacity is controlled by available engine horsepower (work), while the alternator's
winding kVA rating (current) is limited due to temperature rise from windings resistance. At
higher altitude and hotter inlet air the engine will deliver less horsepower than at sea level
and standard temperature. Likewise hotter ambient air will also limit the acceptable
temperature of the windings in the alternator thus limiting kVA. Since almost all 3 phase
generators are rated with a 0.8 power factor, expect to see typical ratings like 80KW /
100kVA.
While power factor is more complicated than we will deal with here, it is the effect when the
current flow of an AC system doesn’t match exactly the voltage sine wave. Incandescent
EMI Electrical Design Guide
50
lights and resistance heaters have a power factor of 1.0 and induction motors typically have
power factors closer to 0.8, lagging while capacitive loads such as UPS input filters tend to
have leading power factors. The voltage regulators in the alternators generally have
problems responding to leading power factor loads and loads with very low leading power
factors can result in loss of voltage stability. Using a generator to feed a normal mix of loads
this is not a problem but if you are feeding loads where a UPS kVA rating is over about 50%
of the load the generator will be carrying, special attention to getting an engineer’s review
would be wise.
At cooler temperatures and for short periods the genset can deliver slightly above its rating.
This allows for motor starting loads and brief load transitions. How well it will perform
during this overload varies with the ambient air temperature, amount of overload and
duration. You are at the edge or outside the envelope here so anything you get be grateful
for. Planning under normal conditions not to exceed 80% of the engines rating is wise.
3. Frequency:
The frequency of the output voltage is directly related to the engine speed. Thus with typical
4 pole armatures, a 50Hz machine will run at 1500 RPM and a 60 Hz machine will run at
1800 RPM. Engine speed is controlled by the governor. If you are having frequency and
engine speed problems that is where to look, not the alternator or voltage regulator.
So, yes some 60 hertz machines can be dialed back to run at the lower speed, but you will
lose some horsepower and torque, so it will not deliver full original KW/kVA ratings at the
lower speed. Likewise, some 50Hz machines could be adjusted upward in speed to provide
60Hz, where they would have more available engine horsepower but also might have
tendency for the engine to overheat if the radiator system was sized closely at the 50 Hz
rating, likewise fuel consumption will increase.
Other than motor loads, many loads such as lighting, resistance heaters (stove, ovens, toasters
etc), and many electronic devices are not frequency sensitive, they can work on either 50 or
60 hertz. Check the nameplate of the device to be sure.
4. Voltage:
The voltage regulator controls output voltage. Engine speed and operation would only
impact voltage if the engine is at the end of its performance range and can't hold any more
power OR if a large load is suddenly applied to the engine. This block loading (adding or
removing a large say >=25% fraction of the generator's rating) will briefly impact both speed
(frequency) and voltage output but in general the engine should recover within about 3-5
seconds.
Try to specify permanent magnet excited alternators, if they are available, other types can,
when out of service for some time, (maintenance issues) have to have the field windings
'flashed' to get the unit generating voltage again. While this is a fairly simple procedure, it is
EMI Electrical Design Guide
51
easy for the procedure to be forgotten or trained personnel to leave before it is needed again.
Thus, getting written manufacturers troubleshooting and basic maintenance procedures
should be a part of the purchase if at all possible.
Some 277/480 VAC units could be dialed down at the voltage regulator to provide 230/416
or possibly 220/400 VAC power for overseas systems. If the voltage regulator won't adjust
that low possibly a replacement one can be obtained that will allow for the lower voltage.
3 Phase alternators are available in 6 lead and 12 lead winding arrangements, the leads are
typically marked T1- T12. The 12 lead machines can be connected to provide two or more
voltage levels across the three phases (120/208 or 277/480VAC). 6 lead machines have the
two ends of each of the three windings available to be connected as a delta or star (WYE)
arrangement. Be sure the connection is made as needed to match the electrical system design
you are working with. The delta arrangement has a single voltage between any two phase
connections and such will give only a single voltage, 120, 208, 240, 400, 480. While a star
or WYE connected arrangement ties one end of each phase winding to a common point and
then grounds them. This provides two voltage ranges, with the phase to ground voltage 120
in a 120/208 system, 220 in a 220/400 system and 277 in a 277/480 system. While the phase
to phase voltage gives the higher level in each of those pairings. If the machine is
reconnectable there will be a diagram in the owner’s manual and often a wiring diagram on
the alternator cover. Reconnecting to get a different voltage arrangement may require
changes in the sensing leads landed on the voltage regulator, watch closely if you have to
make a reconnection.
5. Single or 3 Phase:
A single phase unit can be connected to a 3 phase panel with each of 3 single phases wired to
each hot phase, but of course it will not support true 3 phase loads, still all those single phase
loads can be powered. The KW and kVA ratings will still apply since the three connections
each add load. It is possible to use a 3 phase unit and wire to a single phase panel but the
windings in the alternator will be heating unevenly and you need to reduce the loading to 1/3
of kVA rating if you only connect 1 phase. If you connect 2 legs to a US standard 120/240
panel you can use about 2/3 of the kVA rating of the unit.
6. Fuel choices:
Engine generators in smaller sizes are generally available in gasoline from under 1KW to
about 150KW, with natural gas (propane) and diesel units available in the whole range of 20-
1000+ KW. In most majority world settings, diesel is the best choice for the following
reasons. Diesel is less flammable (listed as combustible) than gasoline. Liquid fuels are
categorized based on flash point, the temperature where the fuel gives off enough vapor to
ignite. Combustible fuels (kerosene, D-2, Jet A etc) have flashpoints above 100F, while
flammable fuels gasoline, alcohol have flashpoints under 100F (~37.7C). Thus combustible
fuels are safer to transport and store. Diesel fuel should not be stored or piped with
EMI Electrical Design Guide
52
galvanized iron pipe. Black iron pipe is fine and the interior is preserved by the oily nature
of the fuel. Diesel tends to strip the zinc galvanizing off the pipe and it causes problems for
the engine injectors.
In general, diesel fuel stores pretty well, as least compared with gasoline, and so it is more
widely available in the more rural areas. Exceptions to this would be areas served by small
boats with gasoline outboard engines. Diesel engines are also generally considered longer
lived and to require less maintenance since they do not have points, spark plugs and electric
ignition systems.
While natural gas and propane are also scarce in the more rural areas due to transportation
issues, gaseous fueled engines also have slightly slower responses to varying loads, and
require spark ignition systems. There are some dual fueled engine that use some diesel fuel
as an ignition source and mix the intake air with gaseous fuel for the rest of the power
requirements but these are generally larger than the sizes reviewed here. So in general, diesel
is the preferred fuel for this application.
Many diesel engines are rated by their manufacturers to run on alternate fuels. Some fuels
have slighter lower energy per volume and so reduce the generator KW capacity, these rarely
require more than 5-10% de-rate. The key issue is often the fuel pump needing a certain
level of lubricity. Telephone companies in the US often operate diesel engine generators on
K-1 kerosene and D-1 (lighter weight or winter diesel) since they are more stable in storage.
Most diesel engine vendors also have recommendations on use of so called bio-diesel fuels,
while long term storage of bio fuels is generally not recommended many engine vendors
have approved these fuels for operation with little if any KW derating. Always check with
the engine manufacturer for their recommendations. Likewise many diesel operators blend
used and filtered motor oil back into diesel fuel at ratios under 10% of used motor oil with
satisfactory results.
Bio fuels are not recommended for longer term storage (.>~45 days) since they tend to
degrade and or grow out microbial bugs. If bio fuels are to be used be sure there is no water
contamination as any water (even in standard diesel fuel) increases fuel microbial growth that
can lead to filter plugging and fuel deterioration. High storage temperatures are also very
bad for bio-diesel blends. Higher ratio blends of bio-diesel also can have greater than 12%
de-rate for horsepower and increased fuel quantity consumption values above 15%. If
biodiesel fuels are to be used, seriously consider use of fuel stabilizers. Biodiesel blends may
also tend to clean the tanks of any accumulations of sludge or other sediments and can result
in more frequent filter plugging than straight diesel.
If you are located in extremely cold climates be aware that diesel fuel has a paraffin point or
cloud point, a temperature where small crystals of waxy particulate condense out of the fuel.
To avoid plugging the fuel filter or even having the fuel gel in the tank, the fuel must be kept
above the paraffin point temperature. Your local fuel supplier should be able to provide you
info on the cloud point of their winter fuel. Be aware that fuel blends can change summer to
EMI Electrical Design Guide
53
winter, so take that info account.
Underground storage is often recommended since it reduces the temperature swings of
aboveground tanks and so reduces moisture condensation that mixes into the fuel and tends
to promote microbial growth. A nearly full tank has less air space and so less moisture
condensation problems, but a large tank reduces fuel turnover so there is a greater change of
the fuel having some deterioration due to longer storage times. It is best to try to use the tank
down to very low level before refueling, as just mixing a little fresh fuel into a near full tank
gives a longer average life of the fuel being stored and so a higher risk of deterioration.
Environmental concerns recommend enclosing the diesel storage tank with a secondary
containment able to prevent release of the fuel into watercourses if the tank leaks or is
spilled. Since water is heavier than diesel fuel, be sure and pump any water or sediment laden
fuel off the bottom of the tank at least annually. You can use a rigid small diameter pipe to
get the water or fuel off the bottom of the tank, if there is no sump drain. For the same
reason, make sure the fuel pickup piping is installed at least a couple of inches (5cm) or so
off the bottom of the tank, so any water isn’t picked up and distributed to the fuel injectors as
they can be damaged by this. On larger tanks, the pickup point can be 4-6" off the bottom of
cylindrical tanks.
7. Fuel Consumption:
At least for planning and budgetary reasons, the designer needs to be aware of fuel
consumption requirements. Until a specific generator is selected and purchased, how do you
estimate fuel consumption and thus fuel storage requirements? Rule of thumb - For each
10KW of load being operated, a diesel generator will use about 1 GPH (~4 LPH) of diesel
fuel. This gets somewhat better with larger engines fully loaded and a little worse with
smaller engines or engines under small partial load, but gives you a starting point for
planning purposes.
Many larger capacity diesel engines have fuel return lines. Excess fuel is pumped by the fuel
pump to the injector pump and circulates in the fuel rail, cooling the injectors, the fuel that
isn't needed at the existing engine loading is returned via the fuel return line. Some
manufacturers have optional fuel coolers, small radiators for this fuel to pass thru before it is
returned to the fuel tank. For planning purposed only the fuel consumed by the engine per
hour is needed, but be aware that the fuel returned to the tank will tend to warm the fuel up
and thin it out somewhat.
8. Fuel Security:
Security of your fuel supply is a critical item. Loss by theft is all too common and a source of
unneeded expense. For critical applications (hospitals etc.) having a separate concealed
reserve can be helpful not only for emergencies requiring more fuel consumption than
normal but as a bridge to cover delays in fuel delivery, or in emergencies due to theft.
Locking and frequent inventory of fuel storage by principals to verify that (even otherwise
EMI Electrical Design Guide
54
trusted) staff is faithfully managing the expensive fuel supply is a wise management control
item. While this seems harsh, such measures can also serve to reduce temptations to divert
what seems to be such a plentiful and valuable liquid commodity. Initial planning for fuel
storage should take these measures into consideration.
9. Radiator Cooled units:
The rule of thumb for radiator cooled units says you need at a clear open inlet area least 1 ½
to 2 times the area of the radiator. Since many units in majority world installations don't have
enclosed engine rooms or ducted air exhaust and inlet, this may not impact your design. But
it is wise to make arrangements so the air flow from the radiator is not easily recycled into
the inlet side of the radiator. The effect of such re-circulated air is to reduce engine cooling
capacity and if the hotter air is entrained into the diesel engine inlet filters, the reduced
density gives the effect of higher altitude operation and reduces available engine horsepower
and thus KW. Thus pay attention to prevailing wind directions, radiator discharge into
prevailing winds should be avoided or else use scoops or diverters to direct off radiator air
upwards or sideways to allow normal airflow to help dissipate radiator exhaust hot air plume.
If you have use for large quantities of hot water (hospitals) consider design of a heat
exchanger to use waste engine heat to provide domestic hot water.
10. Noise:
Remember the noise factor when designing placement of a diesel generator. Will it need to
run at nighttime? While voltage drop issues force the unit to be located close to higher amp
draw uses, look at orientation of the unit to minimize noise impact to sensitive areas.
Pointing the engine exhaust and radiator fan away from those areas is a basic starting point.
Scoops to divert radiator exhaust upwards can make significant noise reduction, as can
baffling of air inlets around the sides of the generator.
11. Operating an Engine genset at reduced loads:
While diesel engines can and do operate in wide range of loads, be aware that prolonged use
under about 30% of rated loading can result in "wet stacking" where the engine tends to ooze
a black tarry viscous liquid that is a mix of unburned diesel fuel, soot and carbon particles.
This can cause the engine problems over time and is cured by running the engine for several
hours at higher loads (50-75% of rating), before the problem gets too serious. Wet stacking
can reduce the ability of a generator to supply its full rated load and cause other maintenance
issues, so don't oversize a generator if the future load growth is several years off. Better to
buy a more closely right sized unit now and trade when the load exceeds 90% or so of rated
capacity. This problem is common with the older 2 cycle designs from Detroit diesel.
12. Trouble Shooting:
While operational costs will depend on the local staff skills of the facility, distance from a
EMI Electrical Design Guide
55
service provider and cost of parts for that brand of unit in the country where it is located.
Preference should be given to using manufacturers with good support in the region or at least
the country. Importing the "finest" make in the world into an area where parts are simply
hard to get, or unobtainable will result in an out of service unit all too soon. Air freight and
import duties for specially imported parts will cost more than similar parts that are imported
in greater quantity due to wider use of that make and model of engine. Consider specifying a
fuel/water separator unit, and provide for spare fuel, oil and air filters. Try to get
manufacture’s training for the local service staff to at least be able to change oil and all
filters. The recommended service intervals will depend on how clean the air is at the
generator, windblown dust and dirt will shorten service intervals and increase costs as air
filters will have to be replace more often and oil changes made more frequently. Labor costs
will of course vary so investigate those costs and make sure the owner is aware of them.
REFERENCE DRAWINGS
CEILING MOUNTED INCANDESCENT LIGHT
PATIO LIGHT (WALL MOUNTED)
TRANSFORMER
DOUBLE POLE, DOUBLE THROW - FOR 4-WAY SWITCH
DUPLEX OUTLET W/EARTH, GFCI, CURRENT RATING AS INDICATED
SINGLE CEILING MOUNT FLUORESCENT LAMP, 40W BULB
DUAL CEILING MOUNT FLUORESCENT LAMP, 40W BULBS
JUNCTION BOX
WATER HEATER
LIGHT BAR OR OTHER SUITABLE FIXTURE FOR MIRROR ILLUMINATION
SINGLE POLE SWITCH WITH WATER PROOF COVER
SMOKE DETECTOR
POWER PANEL (PP) OR SUBPANEL (SP)
WIRE - PROPOSED POWER WIRING
HOME RUN TO POWER PANEL PPA, CONNECTING TO BREAKER # 1
SINGLE POLE SWITCH
SINGLE POLE, DOUBLE THROW - FOR 3-WAY SWITCH
CEILING MOUNT LAMP, COMPACT FLUORESCENT BULB
SINGLE OUTLET W/ EARTH, CURRENT RATING AS INDICATED
SECURITY LIGHT WITH MOTION DETECTOR, WEATHER PROOF, 100 WINCANDESCENT FLOOD LAMP. ALL SECURITY LIGHTS MUST BEMOUNTED AT A MINIMUM HEIGHT OF 2.5m. UNDER ROOF OVERHANG.WHERE POSSIBLE, THE HEIGHT SHOULD BE 3m.
POLE MOUNTED STREET LIGHT, FOR SITE OR ROADWAY LIGHTING
AIR CONDITIONER
DUPLEX OUTLET W/ EARTH, CURRENT RATING AS INDICATED
MULTI-POSITION SWITCH
FLOOD LIGHT, WEATHER PROOF, 100 W
PENDENT MOUNTED FAN, NO LIGHT
2-POLE DISCONNECT, CURRENT RATING AS INDICATED
PPA - 1
PPA
ELECTRIC MOTOR
WIRE - SWITCHED WIRING
PENDENT MOUNTED FAN, WITH LIGHT
3
4
WP
EXHAUST FAN WITH LIGHT
VENT HOOD
AC
M
J
WH
10A
10A
50 A
EXHAUST FAN NO LIGHT
1. ALL ELECTRICAL CABLES ARE INSULATED (MINIMUM 75° C RATING) WITH COPPERCONDUCTORS.
2. ALL SWITCHES, RECEPTACLES, AND CEILING MOUNTED LIGHTS MUST BE PLACEDIN METAL BOXES THAT ARE BONDED TO THE GROUND CONDUCTOR.
3. UNLESS EMBEDDED IN WALLS, ALL CONDUCTORS ROUTED TO SWITCHES ANDRECEPTACLES MOUNTED ON INSIDE WALLS MUST BE PLACED IN EITHER METALRACEWAY (TRUNKING) OR METAL CONDUIT WHEN BELOW THE CEILING LEVEL.
4. ALL CONDUCTORS ROUTED ALONG OUTSIDE WALLS MUST BE IN METAL CONDUITWITH APPROPRIATE WEATHER PROOF TERMINATION INTO WEATHER PROOFBOXES.
5. INSTALL RECEPTACLES ALONG WALLS AT A MINIMUM HEIGHT OF 300 mm FROMFINISHED FLOOR (FFF).
6. INSTALL ALL WALL MOUNTED SWITCHES AT A MAXIMUM HEIGHT OF 1200 mm FFF.
CIRCUIT BREAKER
FUSE
FUSED DISCONNECT
GENERATORG
GFCI
FLOOR DUPLEX OUTLET W/ EARTH, CURRENT RATING AS INDICATED10A
QUADRUPLEX OUTLET W/ EARTH, CURRENT RATING AS INDICATED10A
10A
INVT INVERTER
CC BATTERY CHARGE CONTROLLER
PV SOLAR PANNEL
B BATTERIES
ELECTRICITY POLE
CONTACTOR
TRANSFER SWITCH
UTILITY METERM
OCT 2016
ELE
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RIC
AL
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MB
OLS
SHEET NUMBER
LOCAL REGULATIONS MAYREQUIRE DRAWINGS TO
BE FINALIZED BY ANARCHITECT/ENGINEER
LICENSED TO PRACTICEIN COUNTRY
REVISIONS:
DATE ISSUED:
PROJECT:
PR
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CT
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#5XXX
GENERATOR
MAIN DISTRIBUTION PANEL (MDP)
100 KW, 50 HZ, 380/220 V, 3PH
ACCOMODATION POWER PANEL (PPA) [80kVA]
G
HIGHVOLTAGEELECTRIC
UTILITYFEED
11KV : 380/220 V150 KVA3P, 4W 225 A, 3ɸ
150 A3ɸ
225 AMANUAL
TRANSFERSWITCH
225 A3ɸ
100 A3ɸ
150 A3ɸ40 A
GENERATORROOM(PPG)
[7.4 kVA]
50A
150A
50A
GROUND FLOORSUB PANEL (SPAG)
[27.5 kVA]
FUTURE 1STFLOOR SUB
PANEL (SPA1)[25 kVA]
PUMP HOUSEPOWER PANEL
(PPPH)[42.6 kVA]
A-PHASE
METER
1 4 X 120 mm², 1 X 35 mm² GND
1
2 4 X 70 mm², 1 X 25 mm² GND
3 4 X 50 mm²
4 2 X 6 mm², 1 X 6 mm² GND
2
4
3 1
[<1 m]
1
[<5 m]
[<1 m]
[227.2 m]VD = 2.9%
NOTE(S):1. ALL WIRE IS COPPER UNLESS OTHERWISE NOTED
[<1 m]
118.8 m]VD = 1.2%
M
OCT 2016
SIT
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SHEET NUMBERL
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PROJECT/CLIENT NAME
CITY, COUNTRY#5XXX
SHEET NUMBER
LOCAL REGULATIONS MAYREQUIRE DRAWINGS TO
BE FINALIZED BY ANARCHITECT/ENGINEER
LICENSED TO PRACTICEIN COUNTRY
REVISIONS:
DATE ISSUED:
PROJECT:
PR
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#5XXX
250
250
250
250
250
250
250
250
250
250
HIGH VOLTAGE LINEFROM UTILITY
PPA
POLE MOUNTEDTRANSFORMER
NOTES:
1. ALL CABLES MUST BE BURIED A MINIMUM OF 0.5m BELOW GRADE. CABLERUNS SHOULD BE MARKED WITH A WARNING OF "BURIED ELECTRICAL CABLE"AND INDICATION OF RUN DIRECTION APPROXIMATELY 25CM ABOVE THECABLE.
2. CABLES OF EACH RUN ARE TO BE ENCLOSED IN PVC CONDUIT.
3. CABLE RUNS MUST NOT SHARE TRENCHES WITH WATER OF SEWAGE LINES. IFA CABLE RUN CROSSES A WATER OR SEWAGE LINE, THE CABLE RUN SHOULDPASS UNDERNEATH WITH A CLEARANCE OF APPROXIMATELY 25cm.
PPGMDP
PPPH
PPG - 4
PPG - 6 PPG - 5PPG - 3
SPORTS FIELD
PA
RK
ING
AGRICULTURALSHED
PUMP HOUSE
489
127
423
103
58
52
ACCOM
MO
DATIONS
GENERATORBUILDING
AGRICULTURAL FIELD
AGRICULTURAL FIELD
EX
IST
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RO
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64
100
20
48
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L P
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1
N
SHEET NUMBER
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BE FINALIZED BY ANARCHITECT/ENGINEER
LICENSED TO PRACTICEIN COUNTRY
REVISIONS:
DATE ISSUED:
PROJECT:
PR
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#5XXX
GENERATOR ORTRANSFORMER
3P, 4W
EARTH
MAIN PANELBUILDING A
L1L2L3N
GROUNDINGELECTRODECONDUCTOR
MAIN PANELBUILDING Z
L1L2L3N
LOAD LOAD
EARTH
EARTH EARTH
GROUNDINGELECTRODECONDUCTOR
OCT 2016
SIT
EG
RO
UN
DIN
G D
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1
SHEET NUMBER
LOCAL REGULATIONS MAYREQUIRE DRAWINGS TO
BE FINALIZED BY ANARCHITECT/ENGINEER
LICENSED TO PRACTICEIN COUNTRY
REVISIONS:
DATE ISSUED:
PROJECT:
PR
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#5XXX
300m
m25
00m
m
500X500x500mmINSPECTION HOLE
COPPER WIRE TOGROUND BAR ONMAIN PANEL
16mm DIA.COPPER ROD
OCT 2016
GR
OU
ND
RO
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AIL
1
SHEET NUMBER
LOCAL REGULATIONS MAYREQUIRE DRAWINGS TO
BE FINALIZED BY ANARCHITECT/ENGINEER
LICENSED TO PRACTICEIN COUNTRY
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DATE ISSUED:
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#5XXX
GENERATOR
ELECTRICAL ROOM
61
GENERATOR ROOM ELECTRICAL PLAN
CONCEPTUALDRAWINGSNOT FOR
CONSTRUCTION
PR
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/C
LIE
NT
N
AM
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FUTUREELEVATOR
J
3 3 33
TO FLOOR ABOVE TO FLOOR ABOVE
J
3 3 33 3 3 33
3 3
PPA - 10 PPA - 14
3
TO FLOOR ABOVE
3
TO FLOOR ABOVE
EXPANSION JOINT
OCT 2016
BU
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NA
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BA
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LIG
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WIR
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PLA
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1
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SHEET NUMBER
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BE FINALIZED BY ANARCHITECT/ENGINEER
LICENSED TO PRACTICEIN COUNTRY
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#5XXX
FUTUREELEVATOR
PPA
AC40 A
AC40 A
AC40 A
AC40 A
AC40 A
AC40 A
AC40 A
AC40 A
AC40 A
AC40 A
AC40 A
AC40 A
AC40 A
JJJ
PPA-2PPA-4PPA-6
J J
J
PPA-8
PPA - 12
PPA - 16
PPA-20
PPA-22
PPA-24
PPA-18
GFCI
10A
10A
10A
10A
10A
10A
10A
10A10A
10A 10A 10A
10A
10A
10A
10A 10A 10A 10A
10A
10A
10A 10A 10A 10A 10A 10A
10A
10A 10A 10A 10A 10A 10A 10A 10A
10A 10A 10A 10A
10A
OCT 2016
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PO
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BE FINALIZED BY ANARCHITECT/ENGINEER
LICENSED TO PRACTICEIN COUNTRY
REVISIONS:
DATE ISSUED:
PROJECT:
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#5XXX
JANITOR
OFFICE(FUTURE
ELEVATOR)
BOOKSTORE
J
SPAG-1
J J
SPAG-5
SPAG-7
33
TO FLOORBELOW
TO FLOORBELOW
3 3
OCT 2016
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FLO
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WIR
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PLA
N
1
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LOCAL REGULATIONS MAYREQUIRE DRAWINGS TO
BE FINALIZED BY ANARCHITECT/ENGINEER
LICENSED TO PRACTICEIN COUNTRY
REVISIONS:
DATE ISSUED:
PROJECT:
PR
OJE
CT
/C
LIE
NT
N
AM
EC
ITY
, CO
UN
TR
Y
#5XXX
JANITOR
OFFICE(FUTURE
ELEVATOR)
BOOKSTORE
AC AC40 A 40 A
AC AC40 A 40 A
AC AC40 A 40 A
AC AC40 A 40 A
AC AC40 A 40 A
AC AC40 A 40 A
SPAG
AC
40 A
AC AC40 A 40 A
JJJ
SPAG-3SPAG-6
SPAG-4
SPAG-10
J
SPAG-12
SPAG-9
SPAG-2
J
10A
10A
10A
10A
10A 10A
10A
10A
10A 10A
10A 10A
10A10A
10A
10A
10A
10A
10A
10A 10A
10A 10A
10A 10A
10A
10A 10A
10A
10A 10A
10A GFCI10A
10A 10A
GFCI10A
10A 10A
GFCI10A
10A 10A
GFCI10A
10A 10A
GFCI10A
10A 10A
GFCI10A
OCT 2016
BU
ILD
ING
NA
ME
GR
OU
ND
FLO
OR
PO
WE
R W
IRIN
G P
LAN
1
N
SHEET NUMBER
LOCAL REGULATIONS MAYREQUIRE DRAWINGS TO
BE FINALIZED BY ANARCHITECT/ENGINEER
LICENSED TO PRACTICEIN COUNTRY
REVISIONS:
DATE ISSUED:
PROJECT:
PR
OJE
CT
/C
LIE
NT
N
AM
EC
ITY
, CO
UN
TR
Y
#5XXX
66
PANEL SCHEDULE - MDP
PANEL SCHEDULE - PPG PANEL SCHEDULE - 120-240V SAMPLE
CONCEPTUALDRAWINGSNOT FOR
CONSTRUCTION
PR
OJE
CT
/C
LIE
NT
N
AM
E
67
PANEL SCHEDULE - PPA PANEL SCHEDULE - SPAGCONCEPTUAL
DRAWINGSNOT FOR
CONSTRUCTION
PR
OJE
CT
/C
LIE
NT
N
AM
E
![[] PCB Design Guidelines for Reduced EMI(BookZZ.org)](https://img.pdfslide.us/doc/110x75/55cf94f0550346f57ba57086/-pcb-design-guidelines-for-reduced-emibookzzorg.jpg)
