JahangirThesis Final (27[1].04.10)

A PROJECT REPORT ON

THE ELECTRICAL SYSTEM DESIGN, DRAWING, ESTIMATING AND INSTALLATION SUPERVISION

OF A SPINNING MILL

PREPARED BY:

MD. JAHANGIR ALAM(ID. 0701068)

A project submitted to the Department of Electrical and Electronic Engineering

Of

GREEN UNIVERSITY OF BANGLADESH (GUB)In partial fulfillment of the requirements for the degree of

BACHELOR OF SCIENCE IN ELECTRICAL AND ELECTRONIC

ENGINEERING

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

GREEN UNIVERSITY OF BANGLADESH (GUB)May 2010

Declaration

It is hereby declared that this project or any part of it has not been submitted elsewhere for the award of any degree or diploma.

Signature of the candidates

……………………………………………………………(MD. JAHANGIR ALAM Student ID No: 0701068)

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Dedication

To our Country

The People’s Republic of Bangladesh

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Acknowledgements

We would like to express our acknowledgement and heartfelt gratitude to

our supervisor Prof. Dr. M. Shamsul Alam, Dean, Department of Electrical

and Electronic Engineering, Green University of Bangladesh (GUB), Dhaka,

for his constant guidance, invaluable suggestions and perpetual support

throughout the progress of my work.

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

of Electrical and Electronic Engineering, Green University of Bangladesh

(GUB), Dhaka, for his tremendous help and support. Without his

encouragement, this project would not come to a successful completion.

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

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LAYOUT OF THIS PROJECT

Organization of this project included seven chapters. Chapter one gives a general introduction followed by background and objective of the works.

Chapter two reviews different concepts that are needed for this project like that Fuse, Air circuit breaker (ACB), Moulded case circuit breaker (MCCB), Miniature Circuit Breaker (MCB), Pre fabricated bus bar, Power factor improvement plant (PFI),

In chapter three in a spinning mill using machine list, the machine layout plane, symbol of machine & electrical equipments and the machine load chart table.

Chapter four machine load calculation, selection of Generator capacity, single line diagram, selection of low tension switchgear circuit breaker, bus bar ratting and cable size, low tension switchgear panel design, Power factor improvement (PFI) plant design.

Details technical specifications and estimating the low tension switchgear, power factor improvement plant and pre fabricated bus bar trunking system in chapter five.

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http://simoncnc.en.made-in-china.com/product/WoxQLuKVvGcR/China-Moulded-Case-Circuit-Breaker-YCM1-.html

In chapter six low tension switchgear, power factor improvement plant panel layout plan, the pre fabricated bus bar trunking system installation process & shop drawing,

An Appendix is included at the end as chapter seven. And it describes as reference.

Contents

Declaration 1Dedication 2Acknowledgements

3Project Layout

4List of Figures

7List of Tables

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Chapter 1 1.1 Introduction 81.1.1 General 81.1.2 Importance of electrical energy 81.1.3 Necessity of electric power in a spinning mill

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5

1.2 Background information for the electricity 10

1.2.1 What is electricity? 101.2.2 Who discovered electricity?

111.2.3 What is static electricity? 11 1.2.4 What is current? 111.2.5 What is current electricity?

111.2.6 What is the difference between alternating and direct current

111.3 Objective of the work

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Chapter 2 2.1 Discussion of the using product 132.1.1 How does a fuse work? 132.1.2. Air Circuit Breaker (ACB) 132.1.3. Moulded Case Circuit Breaker (MCCB)

142.1.4 Miniature Circuit Breaker (MCB)

152.1.5 Bus bar Trunking System (BBT) 162.2 Power factor Improvement

182.2.1. Importance of Power Factor

182.2.2. Power Factor

182.2.3. Phase 182.2.4. Phasor Diagrams 19

Chapter 33.1 A spinning mills using machines list are bellows

203.2 A Spinning mills machine layout plan

213.3 A Spinning mill using machine & electrical equipments symbols

223.4 Machine load chart in a Spinning Mill (36636 Spindle)

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Chapter 4

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4.1 Total Load Calculation in a Spinning Mill (36636 Spindle)24

4.2 Generator Selection26

4.3 Single line diagram of low tension switchgear27

4.4 Single line diagram of distribution board28

4.5 Selection of Low Tension Switchgear Incoming Circuit Breaker29

4.6 Branch Load Calculation 304.6.1 Load calculation for BBT- 01

304.6.2 Load calculation for BBT- 02


344.6.4 Dreading function of an ambient temperature

354.7 Cable rating calculation 354.8 Correction factors to current rating for ambient temperature (a)

384.9 Correction factors for groups of cables

384.10 Current ratings and volt drops for single core p.v.c. insulated cable

394.11 Current ratings of mineral insulated cables clipped direct

394.12 Volt drops for mineral insulated cables

404.13 Cable volt drop 414.14 Cable Selection & length measurement

42 4.15 Design of low tension switchgear

46 4.16 Design of power factor improvement plant

474.17 Machine layout with bus bar layout plan

484.18 Bus bar layout plan with location of distribution board

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Chapter 5

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5.1 Cost of the Low voltage Switchgear50

5.2 Cost of power bas bar trunking system64

5.3 Cost of lighting bas bar trunking system66

5.4 Total cost of the Low voltage Switchgear & pre fabricated bus bar

675.5 Local cost of the connecting cable, installation, testing & commissioning 68

Chapter 66.1 Distribution switchboards

696.2 Three basic technologies are used in functional distribution switchboards

696.3 Panel Layout Plan 736.4 How do bus bars installations compare in terms of cost

746.5 Process of bus bars operate

756.6 Isometric drawing 76

Chapter 7Appendix 77Reference 78

List of Figure

Figure 1.1 Spinning mills (Ring Frame)9

Figure 1.2 Electric lamp10

Figure 1.3 Proton, neutron & electron10

Figure 2.1 Electrical circuit with fuse & bulb13

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Figure 2.2 Air Circuit Breaker (ACB) 14 Figure 2.3 Moulded Case Circuit Breaker 15 Figure 2.4 Electrical distribution network

15Figure 2.5 MCB (Miniature Circuit Breaker)

16 Figure 2.6 bus bar connections with M/C 17 Figure 2.7 bus bar connections with light 17Figure 2.8 Power out from bus bar 17Figure 2.9 Phase angle between voltage & current

19Figure 3.1 A Spinning mills machine layout plan

21Figure 4.1 Single line diagram of low tension switchgear

27Figure 4.2 Single line diagram of distribution board

28Figure 4.3 Design of low tension switchgear

46 Figure 4.4 Design of power factor improvement plant

47Figure 4.5 Machine layout with bus bar layout plan

48Figure 4.6 Bus bar layout plan with location of distribution board

49Figure 6.1 Assembly of a final distribution switch board

69Figure 6.2 Distribution switchboard with disconnect able functional units

70Figure 6.3 Distribution switchboard with withdraw able functional units

71 Figure 6.4 Panel layout plan 73Figure 6.5 Isometric drawing for installation

76

List of Table

Table 3.1 Machine load chart in a Spinning Mill23

Table 4.4.1 Load Calculation chart in a Spinning Mill24

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http://image.made-in-china.com/2f0j00dButgjnykroM/MCB-CYK13-.jpg


http://image.made-in-china.com/2f0j00jeBQDwCKQWkS/Air-Circuit-Breaker-DW15-Series.jpg


Table 4.6.1 Load calculation for BBT- 0130



Table 4.7.1 Dreading function of an ambient temperature35

Table 4.8.1 Correction factors to current rating for ambient temperature (a)38

Table 4.9.1 Correction factors for groups of cables38

Table 4.10.1 Current ratings and volt drops for single core p.v.c. insulated cable39

Table 4.11.1 Current ratings of mineral insulated cables clipped direct39

Table 4.12.1 Volt drops for mineral insulated cables40

Chapter 1

1.1 INTRODUCTION

1.1.1 General

Energy is the basic necessity for the economic development of a country. Many function necessary to present day living grind to halt when the supply of energy stops. It is practically impossible to estimate the actual magnitude of the part that energy has played in the building up of present day civilization. The availability of huge amount of energy in the modern times has resulted in a shorter working day, higher agricultural and industrial production, a healthier and more balanced diet and better transportation facilities. As a matter of fact, there is a close relationship between the energy used per person and his standard of living. The greater the per capita consumption of energy in a country the higher is the standard of living of its people.

1.1.2 Importance of electrical energy

Energy may be needed as heat as light as motive power etc. The present day advancement in science and technology has made it possible to convert electrical energy into any desired form. This has given electrical energy a

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place of pride in the modern world. The survival of industrial undertakings and our social structures depends primarily upon low cost and uninterrupted supply of electrical energy. In fact the advancement of a country is measured in terms of per capita consumption of electrical energy.

1.1.3 Necessity of electric power in a spinning mill

In modern fashion technology, the demand for perfection begins right at the birth of the raw material, permeates through every single process, till the highly discerning customer dons the finished garment. It is this demand for perfection that has spurred the growth of an organization and its corporate philosophy. Those who can furnish clients with the best quality, competitive price, and excellent customer services and prompt delivery can only survive in the market. A Spinning Mills takes immense pride in perceiving its role as the comprehensive architect of every single yarn and garment that its produces. A multi-unit, multi-interest business group with a wide range of industrial activity, an organization that has founded its evolution on value-based commercial practice. 37000 spindles spinning mills per day production 18000 Kg yarn without electricity interruption.Constant commitment to high quality standards and innovation has been the secret of success ever since the company was founded. Superior Spinning units ensure the supply of consistent quality yarn to manufacture the garments. Superior spinning units leads the quality of yarn in the market.

Fig. 1.1 Spinning mills (Ring Frame)

Coupled with global standards of process manufacturing that turn out year of superior quality in durability as well as finish. To produce superior quality garments, ensure that every kilogram of yarn supplied from spinning unit conforms to International standard and with zero complaint. Believe that quality products are not only by promises but also by proven results. Development of new textile products is done through - Innovation in defining

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production processes of higher quality and making available modern technologies and professionals with the highest level of competence.

The following advantages which have always a spinning mills are goals: -

High EfficiencyThe Most Competitive & Reasonable PriceProducts Quality GuaranteePrompt & Superior ServicePunctual Delivery

For the above goals are meet when the electricity without interruption. Electrical power is a spinning mills are heard of a part, so good design of electrical system are essential. Good design can save electricity and trouble free running the system.

1.2 BACKGROUMD INFORMATION FOR ELECTRICITY

1.2.1 What is electricity?

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

It is a form of energy, evident from the fact that it runs machinery and can be transformed into other types of energy such as light and heat. It is invisible. During an electrical storm, we do not see electricity. We observe the air being ionized when the electricity travels through it. Electricity is created when particles become charged. Some are negatively charged (electrons), some are positively charged (protons). These opposite charges attract; whereas particles with similar charges repel each other.

The nucleus of the atom contains protons (positively charged) and neutrons (no charge) around which electrons (negatively charged) whirl. An electron is two thousand times smaller in mass than a proton but its electrical charge is equal to that of a proton. Electrons of many elements, particularly metals, are easily knocked off from their parent atoms and can wander freely between atoms. If a state of unbalanced charges exists, a necessary condition to create an electric current also exists. However, the flow of electric current cannot take place until the circuit is completed. When a battery or other electrical source is attached to a wire, which is connected to some form of resistance, (a light, a bell, a motor, etc.), and a circuit is completed back to the source or to ground, free electrons are released into the wire, creating an electrical potential or voltage. The electrons bounce against other electrons in the wire which are repelled because they have the same electrical charge. They go on bouncing against other free electrons down the wire, causing a flow of electrons - an electrical current. Provided there is somewhere for the electrons to go, such as a lamp or a motor, where the energy is converted to another form of energy, the electrons flow out the far end.

1.2.2 Who discovered electricity?

The Greeks had some idea of electricity. In the 18th century Franklin and other Europeans knew a great deal about it. Early in the century, Alessandro

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Volta invented the first source of continuous electric current - the battery. Later, Hans Christian Operated discovered that an electric current produced magnetism. But it was Michael Faraday who described the nature of the phenomena. In his electromagnetic induction theory he stated that an electric current flows in a conductor if that conductor is in a moving magnetic field and is part of a circuit.

1.2.3 What is static electricity?Static electricity is electricity at rest. It is produced by friction, by rubbing. All matter contains positively charged particles called protons and negatively charged particles called electrons. In an uncharged atom, the protons and electrons balance each other and the atom is neutral. If this neutral atom loses an electron, because it has an excess of protons, it is said to be positively charged. If the neutral atom gains an electron, it is said to be negatively charged. Rubbing can tear electrons loose from certain atoms. Some substances, because of the character of their atoms, tend to lose electrons and become positively charged; other substances gain electrons easily and become negatively charged.

1.2.4 What is current? Current is the rate of flow of electrons. It is produced by electrons "on the move", and it is measured in amperes. Unlike static electricity, current electricity must flow through a conductor, usually copper wire. Household current is usually no more than 30 amps.

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

1.2.6 What is the difference between alternating and direct current? A battery produces direct current (DC). The electrons are set in motion by a chemical reaction in a battery and flow only one way. A generator, on the other hand, produces alternating current (AC), because the wire coil core is

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influenced alternately by the North and South Poles of the magnets. The current is therefore constantly changing direction.

1.3 OBJECTIVE OF THE WORK

The objective of this project, I hope by this project I will learn more Engineering in the practical field that will be more helpful to our career. These projects objects are as follows:

In this project we know how to design the distribution system, low voltage switchgear design.

In this project we know how to draw the single line diagram of the electrical system.

Also we can know how to calculate the load of the different type machine in a Spinning mills

We can know selection of cable size for each machine connection and also know the pre fabricated Bus bar trunking system selection design.

While doing this project, we come to know the price of each electrical equipment by market study and how to estimate the price of this project.

We come to know the installation procedure by visiting each and every past of the site & installation direction to the site engineer.

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Chapter 2

2.1 DISCUSSATION OF THE USING PRODUCT

2.1.1 How does a fuse work?

A fuse is connected directly into an electrical circuit. If the electric current surges to a dangerous level, the metal in the fuse melts and the circuit is broken, preventing overheated wires in the walls of the house from starting a fire. Never substitute a fuse of greater capacity than that specified for a particular circuit. If the fuse has the ability to carry more current than originally designed, the wires will heat up before the fuse melts, and this could start a fire.

Fig. 2.1 Electrical circuit with fuse & bulb

2.1.2 Air Circuit Breaker (ACB)

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Product Description 1. Standard: IEC60947-2 2. Function: Overload & short-circuit & under-voltage protection 3. Rated voltage: 380V4. Rated current: 630A to 5000A5. Frequency: 50Hz

Air circuit breakers (hereinafter called circuit breaker) are rated 630A to 5000A in current (up to 630A for limiting current open circuit) and AC 50HZ 380V in voltage. The breaker is mainly used to distribute electric energy in the power distribution network and to prevent the circuit and power source equipment from overload, under voltage and short circuit. It can also be used in AC 50Hz 380V electric network to protect the motor from over load, under voltage or short circuit, Or in 660V or 1140V power distribution network to offer above protections. Under the normal conditions, the breaker can be used to switch the circuit and start the motor infrequently. With the current limiting characteristics, the current-limiting breaker is especially suitable for the network where large short-circuit current is likely to occur.

Fig. 2.2 Air Circuit Breaker (ACB)

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2.1.3 Moulded Case Circuit Breaker (MCCB)

A circuit breaker is an electrical device used in an electrical panel that monitors and controls the amount of amperes (amps) being sent through the electrical wiring. Circuit breakers come in a variety of sizes. For instance 6, 10, 15 and 20 amp breakers are used for most power and lighting needs in the typical home. Some appliances and specialty items (washers, dryers, freezers, whirlpools, etc.) will require a larger circuit breaker to handle the electrical load required to run that appliance.

Fig. 2.3 Moulded Case Circuit Breaker

Fig. 2.4 Electrical distribution network

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http://engineering.electrical-equipment.org/wp-content/uploads/2009/03/cb-cb1.jpg

2.1.4 Miniature Circuit Breaker (MCB)

Product Description: Circuit breaker is used in lighting distribution system or motor distribution system for protection.* Capable of switch electric circuit with load * Capable of quickly releasing stored energy operation * Adaptable to padlock device * Contact position indication * High short-circuit current withstand capacity * Highlighted of high making and breaking capacity * Used as main switch for household and similar installation

Fig. 2.5 MCB (Miniature Circuit Breaker)

TECHNICAL DATA

* Pole No: 1, 2, 3, 4 * Rated current(A): 1, 2, 3, 4, 6, 10, 20, 25, 32, 40, 50, 63 * Rated frequency: 50/60hz * Rated voltage: 230/400V AC * Rated withstand current: 1000A within 1 sec * Electro-mechanical endurance: 10000 cycles * Rated short-circuit making capacity: 10000A * Connection capacity: Rigid conductor 25mm2 * Connection terminal: * Screw terminal * Pillar terminal with clamp * Installation: * Panel mounting

2.1.5 Bus bar Trunking System (BBT):

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Bus bar Trunking is a prefabricated, modular system, designed to transmit and distribute electricity. General construction is of, insulated aluminium or copper conductors which complies with relevant standards, covered by a steel housing.Bus bar makes it possible to supply power at the Tap-off points. It also provides a simple for changes in machinery lines or any kind of extensions which will be required at the early stages of installation and even during the operation. So there is no need for lengthy delays to the line.The electrical energy is carried by means of the conductors which are placed into the metal housing using the plug in tap-off box provides a safe method of connection without interruption of supply.Using large cables for power distribution with in factories, high rise buildings etc can incur difficulties when running the cables into the cable trays or when there is a need for changes or extensions. These problems are easily overcome using Bus bar Systems instead of cables. Bus bar Systems allow you to "Tap" power at convenient locations, reducing the expense of changes to cable systems.

Fig. 2.6 Bus bar connection with M/C Fig. 2.7 Bus bar connection with light

System Advantages:Long Life:Bus bar Systems don't need special maintenance because of the structural specifications. All parts of the installation can easily be mounted and demented due to the modular structure of our system. The installation can easily be changed or the system can be used again in another location if required.Modern Outlook:

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Other than its functional advantages Bus bar system also creates a modern view in buildings where it is used.System Modification:Because of the modular and flexible specifications Bus bar systems quickly and easily accommodate changes in machinery lines or any kind of extensions. The Bus bar system provides economic and quick solutions which give us the opportunity to change during the operation.

Fig. 2.8 Power out from bus bar

2.2 POWER FACTOR IMPROVEMENT

2.2.1. Importance of Power Factor

A power factor of one or "unity power factor" is the goal of any electric utility company since if the power factor is less than one, they have to supply more current to the user for a given amount of power use. In so doing, they incur more line losses. They also must have larger capacity equipment in place than would be otherwise necessary. As a result, an industrial facility will be charged a penalty if its power factor is much different from 1. Industrial facilities tend to have a "lagging power factor", where the current lags the voltage (like an inductor). This is primarily the result of having a lot of electric induction motors - the windings of motors act as inductors as seen by the power supply. Capacitors have the opposite effect and can compensate for the inductive motor windings. Some industrial sites will have

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large banks of capacitors strictly for the purpose of correcting the power factor back toward one to save on utility company charges.

2.2.2. Power Factor

For a DC circuit the power is P = VI and this relationship also holds for the instantaneous power in an AC circuit. However, the average power in an AC circuit expressed in terms of the rms voltage and current is

where is the phase angle between the voltage and current. The additional term is called the power factor

From the phasor diagram for AC impedance, it can be seen that the power factor is R/Z. For a purely resistive AC circuit, R=Z and the power factor = 1.

2.2.3. Phase

When capacitors or inductors are involved in an AC circuit, the current and voltage do not peak at the same time. The fraction of a period difference between the peaks expressed in degrees is said to be the phase difference. The phase difference is <= 90 degrees. It is customary to use the angle by which the voltage leads the current. This leads to a positive phase for inductive circuits since current lags the voltage in an inductive circuit. The phase is negative for a capacitive circuit since the current leads the voltage. The phase relation is often depicted graphically in a phasor diagram.

Fig. 2.9 Phase angle between voltage & current

2.2.4. Phasor Diagrams

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It is sometimes helpful to treat the phase as if it defined a vector in a plane. The usual reference for zero phases is taken to be the positive x-axis and is associated with the resistor since the voltage and current associated with the resistor are in phase. The length of the phasor is proportional to the magnitude of the quantity represented, and its angle represents its phase relative to that of the current through the resistor. The phasor diagram for the RLC series circuit shows the main features.

Note that the phase angle, the difference in phase between the voltage and the current in an AC circuit, is the phase angle associated with the impedance Z of the circuit. The low power factor is mainly due to the fact that most of the power leads are inductive and therefore take lagging current. In order to improve the power factor. Same device taking leading power should de connected in parallel with the load. One of such device can be a capacitor. Normally the power factor of the whole load a large generating station is in the region of 0.8 to 0.9 However sometimes whole load and such ease is it generally desirable to take special steps to improve the power factor. This can be archived by the following equipment.i Synchronous condenser.ii Phase advancers.

Chapter 3

3.1 A SPINNING MILLS USING MACHINE LIST ARE BELOWS

Blow Room

Draw frame

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i) Breaker Drawing

ii) Finisher Drawing

Carding

Comber

Simplex

Ring frames

Auto cone

Uni lap

Yarn Conditioning/ West Collection

Compressor

Humidification Plant/ Air Filter

------------ Etc.

3.2 A Spinning mills machine layout plan

Figure 3.1

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3.3 A Spinning mill using machine & electrical equipments symbols

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3.4 Machine load chart in a Spinning Mill (36636 Spindle)

Table – 3.1

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SL # Name of M/CConnecting load per M/C

(KW)

A B D1 Auto Cone 35

2 Ring M/C 28

3 Simplex M/C 28

4 Breaker Drawing 7.01

5 Finisher Drawing 11.11

6 Card M/C 24.68

7 Comber 6.7

8 Uni Lap 12

9 Pump Motor 22

10 Cooling Motor 5.5

11 West Collection 95

12 Air Filter -01 120



15 Compressor 37.5

16 Yarn Conditioning 256

17 Blow Room M/C 110

18 Lighting Load 160

Chapter 427

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

A spinning mill is run by some machine are 60% to 75% of connected load and some machine are 100% connected load like Air Filter, West Collection, Compressor, Blow Room M/C, Yarn Conditioning etc. The load calculation is given by the table -4.1.1 as below: Running load calculation 75% of connecting load is below machines.

Table – 4.1.1

SL # Name of M/C

Qty.

Connecting load per

M/C (KW)

Running load per

M/C (KW)Running

75%

Total Connecting Load

(KW)

Total Running

Load (KW)

A B C D E F=C x D G = C x E

1 Auto Cone 12 35 26.25 420 315

2 Ring M/C 71 28 21 1988 1491

3 Simplex M/C 7 28 21 196 147

4Breaker Drawing 5 7.01 5.26 35.05 26.3

5Finisher Drawing 5 11.11 8.33 55.55 41.65

6 Card M/C 15 24.68 18.51 370.2 277.65

7 Comber 5 6.7 5.03 33.5 25.15

8 Uni Lap 1 12 9 12 9

9 Pump Motor 5 22 16.5 110 82.5

10Cooling Motor 5 5.5 4.13 27.5 20.65

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SUB TOTAL LOAD (KW) 3247.8 2435.85

Running load calculation 100% of connecting load is below machines

SL # Name of M/C

Qty.

Connecting load per

M/C (KW)

Running load per

M/C (KW)Running

100%

Total Connecting Load

(KW)

Total Running

Load (KW)

A B C D E F= C x D G = C x E

11West Collection 1 95 95 95 95

12 Air Filter -01 1 120 120 120 120

13 Air Filter -02 1 240 240 240 240

14 Air Filter -03 1 189 189 189 189

15 Compressor 3 37.5 37.5 112.5 112.5

16Yarn Conditioning 1 256 256 256 256

17Blow Room M/C 1 110 110 110 110

18 Lighting Load 1 160 160 160 160

SUB TOTAL

LOAD (in KW) 1282.5 1282.5

Sub Total Running Load in KW (Table -1) = 2435.85Sub Total Running Load in KW (Table -2) = 1282.50 Grand Total Running Load in KW = 3718.35

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4.2 Generator Selection

Generator need for a 36636 Spindle spinning mill

Total Running Load in KW = 3718.35

Each Generator =

= 929.59 KW

Suppose, Generator ratting is 1038 KW & efficiency 90%

Efficiency =

Or, Output = Efficiency x input = 0.9 x 1038

= 934.2 KW

So that, our running load is 929.59 KW & also generator output is 934.2KW

We need 4 nos. 1038 KW Gas Generator for this project

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4.3 Single line diagram of low tension switchgear

Fig. 4.1

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4.4 Single line diagram of distribution board

Fig. 4.2

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4.5 Selection of Low Tension Switchgear Incoming Circuit Breaker

Calculation for L.T Panel incoming Circuit Breaker Power [ P ] = VIcosø

Current [ I ] = Here, Power [ P ] =

Power in KW Cosø = Power factor Current [ I ] = Current in Amps

Current ( I ) = 1498.27 at, Cosø = 0.9 and Temperature = 35 º CCurrent ( I ) = 1498.27A / 0.91

= 1646.45A Here, Dreading factor 0.91 at 50 º C [From table 4.7.1]Safety Factor = 0.9For circuit breaker ratting = 1646.45 / 0.9 = 1829.40A

Selected Incoming Circuit Breaker = 2000A

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4.6 Branch load calculation


Table – 4.6.1

SL # Name of M/C

Qty.

Running load per M/C (KW)

Total Running Load (KW)

A B C D E = C x D

1Blow Room M/C 1 110 110

2 Carding M/C 15 18.51 277.65

3Breaker Drawing 5 5.26 26.3

4Finisher Drawing 5 8.33 41.65

5 Comber 5 5.03 25.15

6 Uni Lap 1 9 9

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7 Ring M/C 7 21 147

8 Simplex M/C 7 21 147

9West Collection 1 95 95

10 Air Filter -01 1 120 120

TOTAL LOAD (in KW) 998.75

Branch BBT Load Calculation

SL #

Name of M/C

Qty.



A B C D E = C x D

1Blow Room M/C 1 110 110

2 Carding M/C 15 18.51 277.65

Branch BBT- A, Load (KW)

387.65 = 624A BBT =800A

3Breaker Drawing 5 5.26 26.3

4Finisher Drawing 5 8.33 41.65

5 Comber 5 5.03 25.15

6Uni Lap 1 9 9

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7 Ring M/C 7 21 147


9West Collection 1 95 95

10Air Filter -01 1 120 120

Branch BBT- B, Load (KW)

611.1 = 984A BBT =1250A

7 Ring M/C 7 21 147


9Air Filter -01 1 120

120

Branch BBT- C, Load (KW)

414 = 667A BBT =800A

Power [ P ] = VIcosø

Current [ I ] = Here, Power [ P ] = Power in KW

Cosø = Power factor Current [ I ] = Current in Amps

Current ( I ) = 1601.79A at, Cosø = 0.9 and Temperature = 35 º C

Current ( I ) = 1601.79A / 0.91 = 1760.21A Here, Dreading factor 0.91 at 50 º C [From

table 4.7.1]Safety Factor = 0.9

Pre Fabricated Bus Bar ratting = 1760.21 / 0.9 = 1956A

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Selected Pre Fabricated Bus Bar = 2000A,

Low tension switchgear incoming breaker also = 2000A


Table – 4.6.2

SL # Name of M/C

Qty.



A B C D E = C x D

1 Ring M/C 64 21 1344

2 Compressor 3 37.5 112.5

TOTAL LOAD (in KW) 1456.5


SL # Name of M/C

Qty.



A B C D E = C x D

1 Ring M/C 64 21 1344


Branch BBT- A, Load (KW)

1457=2344A BBT 3000A

Ring M/C 32 21 672

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1



785=1264A BBT =1600A

1 Ring M/C 21 21 441


441=710A BBT =1000A




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

Current ( I ) = 2338.63A / 0.91 = 2570A Here, Dreading factor 0.91 at 50 º C [From

table 4.7.1]

Safety Factor = 0.9

Pre Fabricated Bus Bar ratting = 2570/0.9 = 2856A

Selected Pre Fabricated Bus Bar =3000A



Table – 4.6.3

SL # Name of M/C

Qty.



A B C D E = C x D

1Air Filter -02 1 240 240

38

2 Air Filter -03 1 189 189

3Yarn Conditioning 1 256 256

4 Auto Cone 12 26.25 315

TOTAL LOAD (in KW) 1000


SL # Name of M/C

Qty.



A B C D E = C x D

2 Air Filter -03 1 189 189


4 Auto Cone 12 26.25 315


760=1224A BBT =1600A


4 Auto Cone 12 26.25 315


572=921A BBT =1250A




39

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

Current ( I ) = 1605A / 0.91 = 1764A Here, Dreading factor 0.91 at 50 º C [From

table 4.7.1]

Safety Factor = 0.9

Pre Fabricated Bus Bar ratting = 1764/0.9 = 1960A

Selected Pre Fabricated Bus Bar = 2000A


4.6.4 Dreading function of an ambient temperature

Table – 4.7.1

Ambient temperature 35 º C 40 º C 45 º C 50 º C 55 º CCoefficient K 1 1 0.97 0.94 0.91 0.87

4.7 Cable rating calculation

The Regulations indicate the following symbols for use when selecting cables:

Izis the current carrying capacity of the cable in the situation where it is installed

Itis the tabulated current for a single circuit at an ambient temperature of 30°C

Ib is the design current, the actual current to be carried by the cable

In is the rating of the protecting fuse or circuit breaker

I2is the operating current for the fuse or circuit breaker (the current at which the fuse blows or the circuit breaker opens)

Ca is the correction factor for ambient temperature

Cg is the correction factor for grouping

Ci is the correction factor for thermal insulation.

40

The correction factor for protection by a semi-enclosed (rewritable) fuse/circuit breaker is not given a symbol but has a fixed value of 0.725.

Under all circumstances, the cable current carrying capacity must be equal to or greater than the circuit design current and the rating of the fuse or circuit breaker must be at least as big as the circuit design current. These requirements are common sense, because otherwise the cable would be overloaded or the fuse/circuit breaker would blow when the load is switched on.

To ensure correct protection from overload, it is important that the protective device operating current (Iz) is not bigger than 1.45 times the current carrying capacity of the cable (Iz). Additionally, the rating of the fuse or circuit breaker (In) must not be greater than the the cable current carrying capacity (Iz) It is important to appreciate that the operating current of a protective device is always larger than its rated value. In the case of a back-up fuse, which is not intended to provide overload protection, neither of these requirements applies.

To select a cable for a particular application, take the following steps: (note that to save time it may be better first to ensure that the expected cable for the required length of circuit will] not result in the maximum permitted volt drop being exceeded 4.13.

1. Calculate the expected (design) current in the circuit (Ib)

2. Choose the type and rating of protective device (fuse or circuit breaker) to be used (In)

3. Divide the protective device rated current by the ambient temperature ----correction factor (Ca) if ambient temperature differs from 30°C

4. Further divide by the grouping correction factor (Cg)

5. Divide again by the thermal insulation correction factor (CI)

6. Divide by the semi-enclosed fuse/circuit breaker factor of 0.725 where applicable

7. The result is the rated current of the cable required, which must be chosen ----from the appropriate tables 4.10.1 to 4.12.1.

41

Example(a)A 415 V 50 Hz three-phase ring m/c motor with an output of 28 kW, power factor 0.9 and efficiency 90% is the be wired using 415 V light duty three-core mineral insulated p.v.c. sheathed cable. The length of run from the HBC protecting fuses is 10 m, and for about half this run the cable is clipped to wall surfaces. For the remainder it shares a cable tray, touching two similar cables across the top of a boiler room where the ambient temperature is 50°C. Calculate the rating and size of the correct cable. The first step is to calculate the line current of the motor.

Efficiency =

Or, Input =

=

= 31.11 KW


Line Current [ Ib ] =

= 48.12 A

We must now select a suitable fuse/circuit breaker 50A size to be the most suitable. Part of the run is subject to an ambient temperature of 50°C, where the cable is also part of a group of three, so the appropriate correction factors must be applied from Table 4.8.1 and 4.9.1

Line Current [ Iz ] =

=

42

http://www.tlc-direct.co.uk/Figures/Tab4.3.htm

= 85.8 A

Note that the grouping factor of 0.70 has been selected because where the cable is grouped it is clipped to a metallic cable tray, and not to a non-metallic surface. Next the cable must be chosen from table 4.11.1. Whilst the current rating would be 48.12A if all of the cable run were clipped to the wall, part of the run is subject to the two correction factors, so a rating of 85.8A must be used. For the clipped section of the cable (48.12A), reference method I could be used which gives a size of 6.0 mm² (current rating 51A). However, since part of the cable is on the tray (method 3) the correct size for 85.8 A will be 16.0 mm², with a rating of 92 A.

4.8 Correction factors to current rating for ambient temperature (a)

Table 4.8.1

Ambient temperature

Type of insulation

(°C) 70°C p.v.c85°C

rubber70°C m.i 105°C m.i

25 1.03 (1.03) 1.02 (1.02) 1.03 (1.03) 1.02 (1.02)

30 1.00 (1.00) 1.00 (1.00) 1.00 (1.00) 1.00 (1.00)

35 0.94 (0.97) 0.95 (0.97) 0.93 (0.96) 0.96 (0.98)

40 0.87 (0.94) 0.90 (0.95) 0.85 (0.93) 0.92 (0.96)

45 0.79 (0.91) 0.85 (0.93) 0.77 (0.89) 0.88 (0.93)

50 0.71 (0.97) 0.80 (0.91) 0.67 (0.86) 0.84 (0.91)

55 0.61 (0.84) 0.74 (0.88) 0.57 (0.79) 0.80 (0.89)

4.9 Correction factors for groups of cables

Table 4.9.1

Number of

circuitsCorrection factor Cg

43

-Enclosed or

clippedClipped to non-metallic surface

- - Touching Spaced*

2 0.80 0.85 0.94

3 0.70 0.79 0.90

4 0.65 0.75 0.90

5 0.60 0.73 0.90

6 0.57 0.72 0.90

7 0.54 0.72 0.90

8 0.52 0.71 0.90

9 0.50 0.70 0.90

10 0.48 ---------- 0.90

4.10 Current ratings and volt drops for single core p.v.c. insulated cable

Table 4.10.1

Cross sectio

nal area

In conduit

in thermal insulati

on

In conduit

in thermal insulati

on

In conduit on wall

In conduit on wall

Clipped

direct

Clipped

direct

Volt drop

Volt drop

(mm²) (A) (A) (A) (A) (A) (A)(mV/A/

m)(mV/A/m)

-2

cables3 or 4 cables

2 cable

s

3 or 4 cable

s

2 cable

s

3 or 4 cable

s2 cables

3 or 4 cables

1.0 11.0 10.5 13.5 12.0 15.5 14.0 44.0 38.0

1.5 14.5 13.5 17.5 15.5 20.0 18.0 29.0 25.0

2.5 19.5 18.0 24.0 21.0 27.0 25.0 18..0 15.0

4.0 26.0 24.0 32.0 28.0 37.0 33.0 11.0 9.5

44

6.0 34.0 31.0 41.0 36.0 47.0 43.0 7.3 6.4

10.0 46.0 42.0 57.0 50.0 65.0 59.0 4.4 3.8

16.0 61.0 56.0 76.0 68.0 87.0 79.0 2.8 2.4

4.11 Current ratings of mineral insulated cables clipped direct

Table 4.11.1

Cross-sectional

areaVolt

p.v.c. sheath

2 x single or twin

p.v.c. Sheath 3 core

p.v.c. Sheath 3 x single or twin

Bare sheath

2 x single

Bare sheath

3 x single

(mm²) (A) (A) (A) (A) (A)

1.0 500v 18.5 16.5 16.5 22.0 21.0

1.5 500v 24.0 21.0 21.0 28.0 27.0

2.5 500v 31.0 28.0 28.0 38.0 36.0

4.0 500v 42.0 37.0 37.0 51.0 47.0

1.0 750v 20.0 17.5 17.5 24.0 24.0

1.5 750v 25.0 22.0 22.0 31.0 30.0

2.5 750v 34.0 30.0 30.0 42.0 41.0

4.0 750v 45.0 40.0 40.0 55.0 53.0

6.0 750v 57.0 51.0 51.0 70.0 67.0

10.0 750v 78.0 69.0 69.0 96.0 91.0

16.0 750v 104.0 92.0 92.0 127.0 119.0

Note that in (Table 4.11.1 and 4.12.1) 'P.V.C. Sheath means bare and exposed to touch or having an over-all covering of p.v.c. and 'Bare' means bare and neither exposed to touch nor in contact with combustible materials.

4.12 Volt drops for mineral insulated cables

Table 4.12.1

45

Cross-sectional area

Single-phase p.v.c. Sheath

Single-phase bare

Three-phase p.v.c. Sheath

Three-phase bare

(mm²) (mV/A/m) (mV/A/m) (mV/A/m) (mV/A/m)

1.0 42.0 47.0 36.0 40.0

1.5 28.0 31.0 24.0 27.0

2.5 17.0 19.0 14.0 16.0

4.0 10.0 12.0 9.1 10.0

6.0 7.0 7.8 6.0 6.8

10.0 4.2 4.7 3.6 4.1

16.0 2.6 3.0 2.3 2.6

4.13 Cable volt drop

All cables have resistance, and when current flows in them this result in a volt drop. Hence, the voltage at the load is lower than the supply voltage by the amount of this volt drop.

The volt drop may be calculated using the basic Ohm's law formula

U = I x R

where U is the cable volt drop (V)

I is the circuit current (A) and

R is the circuit resistance (Ohms)

46

Unfortunately, this simple formula is seldom of use in this case, because the cable resistance under load conditions is not easy to calculate.

Indicates that the voltage at any load must never fall so low as to impair the safe working of that load, or fall below the level indicated by the relevant British Standard where one applies.

Indicates that these requirements will he met if the voltage drop does not exceed 4% of the declared supply voltage. If the supply is single-phase at the usual level of 240 V, this means a maximum volt drop of 4% of 240 V which is 9.6 V, giving (in simple terms) a load voltage as low as 230.4 V. For a 415 V three-phase system, allowable volt drop will be 16.6 V with a line load voltage as low as 398.4 V.

It should be borne in mind that European Agreement RD 472 S2 allows the declared supply voltage of 230 V to vary by +10% or -6%. Assuming that the supply voltage of 240 V is 6% low, and allowing a 4% volt drop, this gives permissible load voltages of 216.6 V for a single-phase supply, or 374.5 V (line) for a 415 V three-phase supply.

Each cable rating has a corresponding volt drop figure in mill volts per ampere per meter of run (mV/A/m). Strictly this should be mV/ (A m), but here we shall follow the pattern adopted by BS 7671: 1992. To calculate the cable volt drop:

1. Take the value from the volt drop table (mV/A/m)2. Multiply by the actual current in the cable (NOT the current rating)3. Multiply by the length of run in meters4. Divide the result by one thousand (to convert mill volts to volts).

Example (b)

Calculate the volt drop and maximum length of run for the motor circuit of Exam. (a)

This time we have a mineral insulated p.v.c. sheathed cable, so volt drop figures will come from table 4.12.1.This shows 6 mV/A/m for the 6 mm² cable

47

http://www.tlc-direct.co.uk/Figures/Tab4.9.htm

selected, which must be used with the circuit current of 48.12 A and the length of run which is 10 m.

Voltage drop =

=1.92V

Maximum permissible volt drop is 4% of 415V =

= 16.6V

Maximum length of run for this circuit

with the same cable size and type will be =

= 250m

The 'length of run' calculations carried out in these examples are often useful to the electrician when installing equipment at greater distances from the mains position.

4.14 Cable Selection & length measurement

DescriptionLoad (in

KW) Amp Cable selectionLength(m)

TO BBT DB-1 148.1 267 4x1c-150 rm NYY 16TO BBT DB-2 148.1 267 4x1c-150 rm NYY 16TO BBT DB-3 124.1 224 4x1c-150 rm NYY 132TO BBT DB-4 196 353 4x1c-240 rm NYY 152TO BBT DB-5 196 353 4x1c-240 rm NYY 52TO BBT DB-6 280 504 4x1c-300 rm NYY 56TO BBT DB-7 280 504 4x1c-300 rm NYY 156TO BBT DB-8 280 504 4x1c-300 rm NYY 252TO BBT DB-9 308 554 4x1c-300 rm NYY 16TO BBT DB-10 308 554 4x1c-300 rm NYY 20TO BBT DB-11 308 554 4x1c-300 rm NYY 20TO BBT DB-12 315 567 4x1c-300 rm NYY 20

TO BBT DB-13 361 6502x4x1c-150rm NYY 56

TO BBT DB-14 113 203 4x1c-150 rm NYY 144TO BBT Blow 110 198 4x1c-150 rm NYY 40TO BBT W/C 95 171 4x1c-95 rm NYY 24

48

RoomTO BBT A/C-01 120 216 4x1c-150 rm NYY 24TO BBT A/C-02 240 432 4x1c-300 rm NYY 32TO BBT A/C-03 189 340 4x1c-240 rm NYY 96

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

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

DB-5 Ring-1 28 50.4 4x1c-16 rm NYY 48DB-5 Ring-2 28 50.4 4x1c-16 rm NYY 44

49

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

DB-6 Ring-1 28 50.4 4x1c-16 rm NYY 48DB-6 Ring-2 28 50.4 4x1c-16 rm NYY 44DB-6 Ring-3 28 50.4 4x1c-16 rm NYY 40DB-6 Ring-4 28 50.4 4x1c-16 rm NYY 36DB-6 Ring-5 28 50.4 4x1c-16 rm NYY 36DB-6 Ring-6 28 50.4 4x1c-16 rm NYY 44DB-6 Ring-7 28 50.4 4x1c-16 rm NYY 48DB-6 Ring-8 28 50.4 4x1c-16 rm NYY 52DB-6 Ring-9 28 50.4 4x1c-16 rm NYY 56DB-6 Ring-10 28 50.4 4x1c-16 rm NYY 60DB-6 Ring-11 28 50.4 4x1c-16 rm NYY 64

DB-7 Ring-12 28 50.4 4x1c-16 rm NYY 48DB-7 Ring-13 28 50.4 4x1c-16 rm NYY 44DB-7 Ring-14 28 50.4 4x1c-16 rm NYY 40DB-7 Ring-15 28 50.4 4x1c-16 rm NYY 36DB-7 Ring-16 28 50.4 4x1c-16 rm NYY 36DB-7 Ring-17 28 50.4 4x1c-16 rm NYY 40DB-7 Ring-18 28 50.4 4x1c-16 rm NYY 44DB-7 Ring-19 28 50.4 4x1c-16 rm NYY 48DB-7 Ring-20 28 50.4 4x1c-16 rm NYY 52DB-7 Ring-21 28 50.4 4x1c-16 rm NYY 56


DB-9 Ring-1 28 50.4 4x1c-16 rm NYY 56DB-9 Ring-2 28 50.4 4x1c-16 rm NYY 52DB-9 Ring-3 28 50.4 4x1c-16 rm NYY 48DB-9 Ring-4 28 50.4 4x1c-16 rm NYY 44DB-9 Ring-5 28 50.4 4x1c-16 rm NYY 40DB-9 Ring-6 28 50.4 4x1c-16 rm NYY 36

50

DB-9 Ring-7 28 50.4 4x1c-16 rm NYY 40DB-9 Ring-8 28 50.4 4x1c-16 rm NYY 44DB-9 Ring-9 28 50.4 4x1c-16 rm NYY 48DB-9 Ring-10 28 50.4 4x1c-16 rm NYY 52DB-9 Ring-11 28 50.4 4x1c-16 rm NYY 56

DB-10 Ring-12 28 50.4 4x1c-16 rm NYY 56DB-10 Ring-13 28 50.4 4x1c-16 rm NYY 52DB-10 Ring-14 28 50.4 4x1c-16 rm NYY 48DB-10 Ring-15 28 50.4 4x1c-16 rm NYY 44DB-10 Ring-16 28 50.4 4x1c-16 rm NYY 40DB-10 Ring-17 28 50.4 4x1c-16 rm NYY 36DB-10 Ring-18 28 50.4 4x1c-16 rm NYY 40DB-10 Ring-19 28 50.4 4x1c-16 rm NYY 44DB-10 Ring-20 28 50.4 4x1c-16 rm NYY 48DB-10 Ring-21 28 50.4 4x1c-16 rm NYY 52


DB-12 Auto-1 35 63 4x1c-25 rm NYY 56DB-12 Auto-2 35 63 4x1c-25 rm NYY 52DB-12 Auto -3 35 63 4x1c-25 rm NYY 48DB-12 Auto -4 35 63 4x1c-25 rm NYY 44DB-12 Auto -5 35 63 4x1c-25 rm NYY 40DB-12 Auto -6 35 63 4x1c-25 rm NYY 36DB-12 Auto -7 35 63 4x1c-25 rm NYY 40DB-12 Auto -8 35 63 4x1c-25 rm NYY 44DB-12 Auto -9 35 63 4x1c-25 rm NYY 48

DB-13 Auto -10 35 63 4x1c-25 rm NYY 48DB-13 Auto -11 35 63 4x1c-25 rm NYY 44DB-13 Auto -12 35 63 4x1c-25 rm NYY 40DB-13 Y/C 256 63 4x1c-240 rm NYY 200

DB-14 Comp -1 37.5 67.5 4x1c-25 rm NYY 20DB-14 Comp -2 37.5 67.5 4x1c-25 rm NYY 24DB-14 Comp -3 37.5 67.5 4x1c-25 rm NYY 28

51

4.15 Design of low tension switchgear

Fig: 4.3 (1&2)

52

4.16 Design of power factor improvement plant

Fig: 4.4

53

4.17 Machine layout with bus bar layout plan

Fig: 4.5

54

4.18 Bus bar layout plan with location of distribution board

Fig: 4.6

55

Chapter 5

Details technical specifications and estimating the low tension switchgear, power factor improvement plant and pre fabricated bus bar trunking system.

5.1 Cost of the Low voltage Switchgear

5.1.1 MAIN LT SWITCHGEAR PANEL-1:

16 SWG Sheet steel fabricated, floor mounting, tropicalized design, indoor type, low tension switchgear for 3 phase, 4 wire, 50 Hz, 380/415V AC system & shall be supplied complete TP + N+ PE bus bars sized & properly insulated arrange to withstand & short current of 50KA for 1 sec. Origin: France / UK / Germany / Japan

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

$

INCOMING :

12000A, 3P, 65KA, 415V, 50Hz, (ACB) 4

Nos. 2,684

0,737

With electronics Micro process based protection unit having adjustable over current and short circuit protection with shunt trip.OUTGOING :

22000A, 3P, 65KA, 415V, 50Hz, (ACB) 2

Nos. 2,684

5,368

With electronics micro process

56

based protection unit having adjustable over current and short circuit protection with shunt trip.

33200A, 3P, 85KA, 415V, 50Hz, (ACB) 1 No. 3,595 3,595 With electronics micro process based protection unit having adjustable over current and short circuit protection with shunt trip.

OUTGOING : (BBT- 01 & 03)

4 C.T ratio 2000/5A 6Nos

. 50 300

5Ammeter scaled (0-2000A) with selector 2

Nos. 35 70

Switch.

6Voltmeter scaled (0 - 500V) with selector 2

Nos. 35

70

Switch.

7 Phase indicating lamp 6Nos

. 5 3

2 RED/YELLOW/BLUE.

8 Control Fuse for protection circuit. 2 Sets 5 1

0 OUTGOING : (BBT- 02)


. 50 150 10 Ammeter scaled (0-3200A) with 1 No. 35 35

Selector switch.

11 Voltmeter scaled (0 - 500V) with 1 No. 35 3

5 Selector switch.


. 5 16 RED/YELLOW/BLUE.

13 Control Fuse for protection circuit. 1 Set 5 5

14 4000A TPN+E bus bar 1 Lot 6,200 6,20

57

0 Sized (100 x20) mm Cable, Cable Socket, Cable Tie & other accessories.

15Enclosure (L700x D800 x H 2000) mm. 6

Nos. 500

3,000

-------------- -----------

SubTotal in $ 9,624

5.1.2LT SWITCHGEAR PANEL-02 with COS

S/L TECHNICAL SPECIFICATIONS:Qty Unit U/P in $

T/P in $

INCOMING :

1 1000A, 3P, 85KA, 415V, 50Hz, MCCB 1 No. 832 83

2 Adjustable with thermal & magnetic standard protection trip unit.

2 630A, 3P, 36KA, 415V, 50Hz, MCCB 1 No. 313 313

Adjustable with thermal & magnetic standard protection trip unit.


. 50 150

4 Ammeter scaled (0-1000A) with 1Nos

. 35 35 selector switch

5 Voltmeter scaled (0 - 500V) with 1Nos

. 35 35 Selector switch.


. 5 1

6 RED/YELLOW/BLUE.


OUTGOING :

8 400A, 3P, 30KA, 415V, 50Hz, MCCB 1 No. 170 170

58

Adjustable with thermal & magnetic standard protection trip unit.

9 160A, 3P, 30KA, 415V, 50Hz, MCCB 4Nos

. 95 38


10 100A, 3P, 30KA, 415V, 50Hz, MCCB 7Nos

. 55 38


111250A TPN+E bus bar sized (100 x 6) mm 1 Lot 800

800

Cable Socket, Cable Tie & other accessories.

12Enclosure (L700 x D800 x H 2000) mm. 2

Nos. 500

1,000

-------------- -----------

SubTotal in

$ 4,12

1

5.1.3800KVAR AUTO/MANUAL PFI PLANT-1 1 SET Automatic power factor improvement plant of 800Kvar. Sheet steel fabricated, floor mounting, tropicalized design, indoor type, for 3 phase, 4 wire, 50 Hz 380/415V AC system and shall be supplied complete TP + N bus bars suitably sized & properly insulated arrange to withstand and short current of 50KA for 1 sec.

The panel shall comprise of

S/L. TECHNICAL SPECIFICATIONS:Qty Unit U/P in $

T/P in $

1 1600A, 3P, 65KA, 415V, 50Hz, (ACB) 1 No. 1,694 1,694With electronics Micro process based protection unit having adjustable Over current and short circuit protection with shunt trip.

225KVAR , 415V, 50 Hz, 3 phase, dry type, 1 No. 98 98Self healing compact PF capacitors

59

bank with discharge resistor. (Fixed)

325KVAR , 415V, 50 Hz, 3 phase, dry type, 2

Nos. 98 196

Self healing compact PF capacitors bank with discharge resistor.

4(25X2) = 50KVAR, 415V, 50 Hz, 3 phase , 4

Nos. 196 783

Dry type, self healing compact PF capacitors bank with discharge resistor.

5(25X3)=75KVAR, 415V, 50 Hz , 3 phase , 3

Nos. 294 881


6(25X4)=100KVAR, 415V, 50 Hz , 3 phase , 3

Nos. 392 1176


7TP Magnetic contactor Operation 40A, 2

Nos. 35 70

For 25Kvar capacitor.


Nos. 78 311



Nos. 124 372



Nos. 177 531


11 Start pushbutton. 12Nos

. 2.71 33

12 Stop pushbutton. 12Nos

. 2.71 33

13 Auto manual selector switch with 1 No. 5 5

60

Adder block.


. 5 65RED/YELLOW/BLUE.


16HRC Fuse with fuse base of suitably sized, 39

Nos. 6 234


. 50 150

1812 Steps reactive power regulator which 1 No. 318 318Performs the switching of capacity bank in automatic power factor correction equip-ments depending on changes of reactive power complete with p. f. Luminescent indicators and digital power factor meter.

19 2000A TPN+E bus bar (100 x 10) mm 1 Lot 800 800


20Enclosure (L 700 x D 800 x H 2000) mm. 2

Nos. 500

1,000

-------------- -----------

SubTotal in $

8,753

5.1.4500KVAR AUTO/MANUAL PFI PLANT: 2 2 SET


S/L. TECHNICAL SPECIFICATIONS:Qty Unit U/P in $

T/P in $

1 1000A, 3P, 85KA, 415V, 50Hz, MCCB 1 No. 832 832Adjustable with thermal & magnetic standard protection trip unit.

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

61

type, Self healing compact PF capacitors bank with discharge resistor. (Fixed)

325KVAR , 415V, 50 Hz , 3 phase , dry type, 5

Nos. 98 490


4(25X2) = 50KVAR, 415V, 50 Hz , 3 phase , 7

Nos. 196 1,371



Nos. 35 176



Nos. 78 544



. 2.71 33


. 2.71 33

9 Auto manual selector switch with 1 No. 5 5Adder block.




12HRC Fuse with fuse base of suitably sized, 39

Nos. 6 234


. 50 150

1412 Steps reactive power regulator which 1 No. 318 318Performs the switching of capacity bank in automatic power factor correction equip-ments depending on changes of reactive power complete

62

with p. f. Luminescent indicators and digital power factor meter.

151250A TPN+E bus bar sized (100 x 6) mm 1 Lot 800 800Cable Socket, Cable Tie & other accessories.

16Enclosure (L 700 x D 800 x H 2000) mm. 2

Nos. 500 1,000

Country of Origin: Bangladesh-------------- -----------

SubTotal in $ 6,151

5.1.5250KVAR AUTO/MANUAL PFI PLANT-3 1 SET Automatic power factor improvement plant of 250Kvar. Sheet steel fabricated, floor mounting, tropicalized design, indoor type, for 3 phase, 4 wire, 50 Hz 380/415V AC system and shall be supplied complete TP + N bus bars suitably sized & properly insulated arrange to withstand and short current of 50KA for 1 sec.


S/L. TECHNICAL SPECIFICATIONS: Qty Unit U/P in $T/P in

$

1 400A, 3P, 30KA, 415V, 50Hz, MCCB 1 No. 170 170 Adjustable with thermal & magnetic standard protection trip unit.

225KVAR, 415V, 50 Hz, 3 phase, dry type, 1 No. 98 98Self healing compact PF capacitors bank with discharge resistor. (Fixed)

325KVAR, 415V, 50 Hz, 3 phase, dry type, 3

Nos. 98 294


4(25X2)= 50KVAR, 415V, 50 Hz, 3 phase, 3

Nos. 196 587

63



Nos. 35 106



Nos. 78 233



. 2.71 16


. 2.71 16

9 Auto manual selector switch with 1 No. 5 5Adder block.




12HRC Fuse with fuse base suitably sized 21

Nos. 6 126


. 35 105

1412 Steps reactive power regulator which 1 No. 275 275Performs the switching of capacity bank in automatic power factor correction equip-ments depending on changes of reactive power complete with p. f. Lumin-escent indicators and digital power factor meter.

15630A TPN+E bus bar sized (60 x 5) mm 1 Lot 600 600Cable Socket, Cable Tie & other accessories.

64

16Enclosure (L 800 x D 800 x H 2000) mm. 1 No 550 550Country of Origin: Bangladesh

-------------- -----------

SubTotal in $

3,218

5.1.6 DISTRIBUTION BOARD 01 & 02: 2 SET

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

S/L. TECHNICAL SPECIFICATIONS: Qty Unit U/P in $ T/P in $

INCOMING :

1 400A, 3P, 30KA, 415V, 50Hz, MCCB 1 No. 170 17



. 50 15

0

3 Ammeter scaled (0-500A) with 1 No. 35 3

5 Selector switch.


5 Selector switch.


. 5 1

6 RED/YELLOW/BLUE.


OUTGOING :

7 100A, 3P, 30KA, 415V, 50Hz, MCCB 9Nos

. 55 49

5 Adjustable with thermal & magnetic

65

standard protection trip unit.


600


9Enclosure (L 700 x D 500 x H 1600) mm. 1 No. 400

400


SubTotal in $

1,906

5.1.7 DISTRIBUTION BOARD -03 2 SET


$INCOMING :

1 400A, 3P, 30KA, 415V, 50Hz, MCCB 1 No. 170 17



. 50 15

0


5 Selector switch.


5 Selector switch.


. 5 1

6 RED/YELLOW/BLUE.

6 Control Fuse for protection circuit. 1 Set 5

5

OUTGOING :

7 63A, 3P, 30KA, 415V, 50Hz, MCCB 12Nos

. 55 660 Adjustable with thermal & magnetic

66

standard protection trip unit.

8 32A, 3P, 18KA, 415V, 50Hz, MCCB 6Nos

. 55 33



600


10Enclosure (L 800 x D 500 x H 1600) mm 1 No. 450

450


SubTotal in $

2,451

5.1.8 DISTRIBUTION BOARD 04 & 05: 2 SET


$

INCOMING :

1 630A, 3P, 36KA, 415V, 50Hz, MCCB 1 No. 313 31



. 50 15

0


5 Selector switch.


5 Selector switch.


. 5 1

6 RED/YELLOW/BLUE.


67

5

OUTGOING :

7 100A, 3P, 30KA, 415V, 50Hz, MCCB 8Nos

. 55 44

0 Adjustable thermal & magnetic standard protection trip unit.


650


9Enclosure (L 700 x D 500 x H 1600) mm. 1 No, 400

400


SubTotal in $

2,044

5.1.9DISTRIBUTION BOARD 06 to 10 5 SET

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

$INCOMING :

1 630A, 3P, 36KA, 415V, 50Hz, MCCB 1 No. 313 31



. 50 15

0


5 Selector switch.


5 Selector switch.


. 5 1

6 RED/YELLOW/BLUE


5

68

OUTGOING :

7 100A, 3P, 30KA, 415V, 50Hz, MCCB 12Nos

. 55 66



750



450


SubTotal in $

2,414

5.1.10 DISTRIBUTION BOARD 12 1 SET

S/L. TECHNICAL SPECIFICATIONS: Qty Unit U/P in $ T/P in

$

INCOMING :

1 630A, 3P, 36KA, 415V, 50Hz, MCCB 1 No. 313 31



. 50 15

0


5 Selector switch.


. 35 3

5 Selector switch.

69


. 5 16

RED/YELLOW/BLUE.


OUTGOING :

7 100A, 3P, 30KA, 415V, 50Hz, MCCB 10Nos

. 55 55


8750A TPN+E bus bar sized (75 x 5)mm 1 Lot 750

750



450


SubTotal in $

2,304



$

INCOMING :

1 630A, 3P, 36KA, 415V, 50Hz, MCCB 1 No. 313 31



. 50 15

0


. 35 3

5 Selector switch.

4 Voltmeter scaled (0 - 500V) with 1 Nos 35 3

70

. 5 Selector switch.


. 5 1

6 RED/YELLOW/BLUE.


5 OUTGOING :

7 400A, 3P, 30KA, 415V, 50Hz, MCCB 1 No. 170 17


8 100A, 3P, 30KA, 415V, 50Hz, MCCB 4Nos

. 55 220 Adjustable with thermal & magnetic standard protection trip unit.


750



50


SubTotal in $

2,144



$

INCOMING :

1 400A, 3P, 30KA, 415V, 50Hz, MCCB 1 No. 170 170Adjustable with thermal & magnetic standard protection trip unit.


. 50 150


. 35 35selector switch

71


. 35 3

5 selector switch


. 5 1

6 RED/YELLOW/BLUE.


5

OUTGOING :

7 160A, 3P, 30KA, 415V, 50Hz, MCCB 3Nos

. 95 28


8 32A, 3P, 18KA, 415V, 50Hz, MCCB 4Nos

. 55 22



600



450


SubTotal in $

1,966

5.1.13

Motor Control Panel(Star Delta & DOL) 1 SET

Star Delta Starter - 22KW : 05 Sets

1 63A, 3P, 30KA, 415V, 50Hz, MCCB 5Nos

. 55 27



. 25 37

5

72


. 35 17

5 selector switch


. 35 17

5 selector switch


. 5 5

4 RED/YELLOW/BLUE.

6 Magnetic Contactor 10Nos

. 80 80

0 22KW, Operation Current: 50A, Ith:80ACoil Voltage: 220VAC

7 Magnetic Contactor18.5KW, Operation Current: 40A, Ith:60A 5

Nos. 67

335

Coil Voltage: 220VAC

8 Thermal Overload Relay (18-26)

With Open Phase Protective device 5Nos. 31

155

9 Super Timer

Operating Voltage=100-240VAC 5Nos

. 35 175

10 Push Button (Start) 5Nos

. 4 1

9

11 Push Button (Stop) 5Nos

. 4 19

12 Signal Lamp(Start, Stop, Trip) 10Nos

. 5 5

0

Direct On Line Starter: 5.5KW : 05Sets

13 25A, 3P, MCB 5Nos

. 20 10

0

73

415V, 50Hz, MCB

14 Magnetic Contactor 5Nos

. 22 11

0 5.5KW, Opp. Current: 12A, Ith:20ACoil Voltage: 220VAC

15 Thermal Overload Relay (7-11) 5Nos

. 18 9

0 With Open Phase Protective device

16 Push Button (Start) 5Nos

. 4 2

0

17 Push Button (Stop) 5Nos

. 4 20

18 Signal Lamp(Start, Stop, Trip) 10Nos

. 5 50

19 Connector Terminal 10 Set 4 40

20400A TPN+E bus bar sized (50 x 5) mm 1 Lot 500 500 Cable Socket, Cable Tie & other accessories.


450

Country of Origin: Bangladesh-----------

Sub total cost of above goods in USD

3,987

5.2 Cost of power bus bar trunking system

74

Power Bas bar trunking system 1 Lot

SL #

Description Qty.Uni

t U/P in $T/P in $

2000A AL BUSWAY - 4w (IP54) GEN-1 TO GP-1

1 2000A 4P+PE Flanged end2

Pcs 360 720

2 2000A 4P+PE elbow4

Pcs 357 1,42

9

3 2000A 4P+PE straight length 12

m 260 3,02

7

4 2000A 4P+PE Connection Unit2

Sets

2347 4,69

4 GEN-2 TO GP-2


Pcs 360 72

0


Pcs 357 1,42

9


m 260 4,01

5


Sets

2347 4,69

4 GEN-3 TO GP-3


Pcs 360 72

0


Pcs 357 1,42

9


m 260 6,56

1


Sets

2347 4,69

4 GEN-4 TO GP-4


Pcs 360 72

0


Pcs 357 1,42

9


m 260 8,32

2


Sets

2347 4,69

4 GP-1 TO L.T-1


Pcs 360 72

0


Pcs 357 1,07

1

75


m 260 2,66

0


Sets

2347 4,69

4 GP-2 TO L.T-2


Pcs 360 72

0


Pcs 357 1,07

1


m 260 2,25

5


Sets

2347 4,69

4 GP-3 TO L.T-3


Pcs 360 72

0


Pcs 357 1,07

1


m 260 1,66

4


Sets

2347 4,69

4 BBT-01 MAIN BRANCH 2000A AL BUSWAY - 4w (IP54)


Pcs 360 36

0


Pcs 357 1,07

1


m 260 2,08

0

4 2000A/800A 4P+PE Reduction Unit1

Pcs 290 29

0


Pcs 290 29

0 BRANCH -A, 800A AL BUSWAY-4W (IP54)

6 800A 4P+PE elbow1

Pcs 187 18

7


m 145 6,52

5

8 End Cover1

Pcs 51 5

1 BRANCH -B, 1250A AL BUSWAY-4W (IP54)


m 211 4,22

0

76


Pcs 271 27

1 BRANCH-C, 800A AL BUSWAY-4W(IP54)


m 145 2,90

0

12 End Cover1

Pcs 51 5

1 Tap Off Box With MCCB

13 Plug in hole15

Pcs 13 19

5

14 630A Tap off Box with MCCB3

Pcs 1309 3,92

7


Pcs 664 3,98

4


Pcs 664 66

4


Pcs 307 92



Pcs 566 56

6


Pcs 462 2,31

0


m 409 24,94

9


Pcs 450 45

0 BRANCH A, 1600A AL BUSWAY-4W (IP54)


m 264 15,84

0


Pcs 250 25

0 BRANCH B, 1000A AL BUSWAY-4W (IP54)


m 191 7,64

0

8 End Cover1

Pcs 51 5


9 Plug in hole15

Pcs 13 19

5


Pcs 1309 7,85

4

77


Pcs 664 66

4


Pcs 307 61



Pcs 360 36

0


Pcs 357 1,78

6


m 260 24,70

5


Pcs 290 29

0 BRANCH -A, 1600A AL BUSWAY-4W (IP54)


m 264 3,43

2


Pcs 250 25

0 BRANCH -B, 1250A AL BUSWAY-4W (IP54)


m 211 7,17

4


Pcs 315 31

5

9 End Cover1

Pcs 51 5


10 Plug in hole15

Pcs 13 19

5


Pcs 1650 1,65

0


Pcs 1309 3,92

7


Pcs 664 66

4


Pcs 307 92

1 --------

-- Sub total cost of above goods in USD

210,424

5.3 Cost of lighting bus bar trunking system

78

Lighting BBT 1 Lot

SL # Description Qty. Unit U/P in $ T/P in $1 250A TPN+PE feed unit 2 Pcs 195 3902 250A TPN+PE centre feed unit 1 Pcs 215 215

3250A TPN+PE straight length L=3m 26

Pcs149

3874

4160A TPN+PE straight length L=3m 24

Pcs120

2880

5 Fixing bracket 82 Pcs 4.48 3676 32A, Tap off box 46 Pcs 36 16567 25A 4P+PE feed unit 46 Pcs 19.38 891

8 25A 2PN+PE straight length L=3m101

2Pcs 26.27 26585

9 End cover 46 Pcs 2.98 137

10 Fixing bracket (For BBT)151

8Pcs 2 3036

11 Tap off connector (For light) 830 Pcs 2.5 2075

12 Fixing bracket (For Light )166

0Pcs 1.9 3154

13 DOUBLE TUBE LIGHT SHADE 830 Pcs 16 132802X36W Industrial Light with Ballast,

Starter Reflector & 2 Nos. Tube Light

------------

Sub total cost of above goods in USD

58,541

5.4 Total cost of the Low voltage Switchgear & pre fabricated bus bar

S/L. TECHNICAL SPECIFICATIONS: Qty UnitU/P in

$ T/P in $

01) MAIN LT SWITCHGEAR PANEL-1 1 Set 29,62

4 29,62

4

02)LT SWITCHGEAR PANEL-02 with COS 1 Set

4,121

4,121

03)800KVAR AUTO/MANUAL PFI PLANT 1 Set

8,753

8,753

79

04)500KVAR AUTO/MANUAL PFI PLANT 2 Sets

6,151

12,302

05)250KVAR AUTO/MANUAL PFI PLANT 1 Set

3,218

3,218

06) DISTRIBUTION BOARD 01 & 02 2 Sets 1,90

6 3,81

2

07) DISTRIBUTION BOARD -03 1 Set 2,45

1 2,45

1

08) DISTRIBUTION BOARD 04 & 05 2 Sets 2,04

4 4,08

8

09)DISTRIBUTION BOARD 06, 07, 08, 09, 10 & 11 6 Sets

2,414

14,484

10) DISTRIBUTION BOARD 12 1 Set 2,30

4 2,30

4

11) DISTRIBUTION BOARD 13 1 Set 2,14

4 2,14

4

12) DISTRIBUTION BOARD -14 1 Set 1,96

6 1,96

6

13)Motor Control Panel (Star Delta & DOL) 1 Set

3,987 3,987

14) Pre Fabricated Power Bus Bar 1 Lot2,10,42

42,10,42

4

15) Pre Fabricated Lighting Bus Bar 1 Lot 58,541 58,541

16)Transportation cost of 3x40’ container 3 Nos 2,400 7200

Total cost of above goods in USD

-----------

3,69,419

80

5.5 Local cost of the connecting cable, installation, testing & commissioning

S/L. TECHNICAL SPECIFICATIONS Qty UnitU/P in

$T/P in

$

01 1c - 300 rm NYY 572 m 299517,13,

140

02 1c - 240 rm NYY 500 m 236611,83,

000

03 1c - 150 rm NYY 428 m 14806,33,4

4004 1c - 95 rm NYY 24 m 945 22,680

05 1c - 25 rm NYY 617 m 2631,62,2

71

06 1c - 16 rm NYY 3904 m 1736,75,3

92

07 1c - 10 rm NYY 1080 m 1111,19,8

8008 1c - 6 rm NYY 1320 m 71 93,72009 1c - 4 rm NYY 320 m 50 16,000

10Cable Socket, cable tai, & other accessories 1 Lot

100,0000

500,000

11Installation, testing & commissioning 1 Job

750,000

750,000

------------

Grand total for local work in Taka.

63,69,523

81

Chapter: 6

Low tension switchgear, power factor improvement plant panel design and panel layout plan. The pre fabricated bus bar trunking system installation process & shop drawing,

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

6.2 Three basic technologies are used in functional distribution switchboards.Fixed functional units

82

These units cannot be isolated from the supply so that any intervention for maintenance, modifications and so on, requires the shutdown of the entire distribution switchboard. Plug-in or withdraw able devices can however be used to minimize shutdown times and improve the availability of the rest of the installation.

Fig 6.1 Assembly of a final distribution switchboard with fixed functional unitsDisconnect able functional units

Each functional unit is mounted on a removable mounting plate and provided with a means of isolation on the upstream side (bus bars) and disconnecting facilities on the downstream (outgoing circuit) side. The complete unit can therefore be removed for servicing, without requiring a general shutdown.

83

http://www.electrical-installation.org/wiki/File:FigE30.jpg

Fig 6.2 Distribution switchboard with disconnect able functional units

Drawer-type withdraw able functional units

The switchgear and associated accessories for a complete function are mounted on a drawer-type horizontally withdraw able chassis. The function is generally complex and often concerns motor control. Isolation is possible on both the upstream and downstream sides by the complete withdrawal of the drawer, allowing fast replacement of a faulty unit without de-energizing the rest of the distribution switchboard.

84

http://www.electrical-installation.org/wiki/File:FigE31.jpg

Fig 6.3 Distribution switchboard with withdraw able functional units in drawers

Different standards

Certain types of distribution switchboards (in particular, functional distribution switchboards) must comply with specific standards according to the application or environment involved. The reference international standard is IEC 60439-1 type-tested and partially type-tested assemblies

Standard IEC 60439-1

Three elements of standard IEC 60439-1 contribute significantly to dependability: - Clear definition of functional units - Forms of separation between adjacent functional units in accordance with user requirements- Clearly defined routine tests and type tests- Categories of assemblies Standard IEC 60439-1 distinguishes between two categories of assemblies:Type-tested LV switchgear and control gear assemblies (TTA), which do not diverge significantly from an established type or system for which conformity is ensured by the

85

http://www.electrical-installation.org/wiki/File:FigE32a.jpg

Type tests provided in the standard.- Partially type-tested LV switchgear and control gear assemblies

(PTTA), which may contain non-type-tested arrangements provided that the latter are derived from type-tested arrangements. When implemented in compliance with professional work standards and manufacturer instructions by qualified personnel, they offer the same level of safety and quality.

Functional units The same standard defines functional units:Part of an assembly comprising all the electrical and mechanical elements that contribute to the fulfillment of the same function.The distribution switchboard includes an incoming functional unit and one or more functional units for outgoing circuits, depending on the operating requirements of the installation. What is more, distribution switchboard technologies use functional units that may be fixed, disconnect able or withdraw able.

86

6.3 Panel Layout Plan

Fig 6.4 Panel layout plan

87

6.4 How do bus bar installations compare in terms of cost

Most favorably, historically, the material cost of bus bar has been a point of concern for electrical contractors. However, it is short sighted to compare the cost of bus bar against that of cable - and not the real cost of a cable installation to include multiple runs of cable, cable tray and fixing, let alone the protracted time and effort of the cable pulling operation. (A comparative study between a traditional system (cables) and one realized with bus bar trunking systems. The cost of bus bar systems has fallen in real terms over recent years. Add to this, the cost saving in installation time - up to 50% less than cable. The reality is that electrical contractors can offer a more competitive bid, at the same time as offering his client a "state of the art" power distribution installation which is infinitely more flexible in use. The installation time for bus bar is virtually the same as for installing cable tray - before the installation of the cables; this is obviously a very important consideration in these days of ever tightening completion deadlines. With its inherent properties of strong dielectric strength and wide temperature range(-70°C to +150°C), polyester film was the perfect choice for insulating our bus ducts. One important distinction between our products and competitors is that we apply 4 layers of polyester film in 125 micron layers. This causes the layers to overlap, resulting in an airtight seal that is sufficient to guard against any moisture that might make its way through the bus duct housing.

Not surprisingly, the insulation on our bus ducts is capable of withstanding at least 155KV of dielectric strength at any point of contact.

88

6.5 Process of bus bars operate

Bus bar trunking falls into two categories - distribution and feeder bus bar. Distribution bus bar distributes power through tap-offs points along the length of the bus bar at typically a 0.5 or 1.0 metre centres. Tap-off units are simply plugged in along the length of the bus bar to supply a load, (this could be a sub distribution board or in the case of a factory, to individual machines). Each individual tap-off can normally be added to or removed with the bus bar live, thus eliminating production down time.

Used vertically the same systems can be used for rising-mains applications, with tap-offs feeding individual floors. (Certified fire barriers are available at points where the bus bar passes through a floor slab). The fact that the protection devices (fuses, switch-fuses or circuit breakers) are located along the bus bar run, reduces the need for large quantities of distribution cables running to and from installed equipment.

High power feeder bus bar takes power directly from A to B. Usually from a power transformer or switchboard to switchboard. This basic configuration is often referred to as "a goal post configuration". However, if a power

89

source is required to be tapped off then it is possible to do this at a joint along the run - another example of the flexibility of bus bar. Both feeder and distribution bus bar systems in the medium and high power ranges are available in two forms: (a) the flat spaced configuration where the conductors are either air insulated or have PVC insulated conductors all within an earthed metal enclosure, (b) the sandwich configuration which is becoming the norm at these ratings. Sandwich construction means that the conductors are individually insulated and mounted to form a sandwich of conductors and insulation within the bus bar casing. The sandwich construction bus bar has very good mechanical strength, gives higher fault level withstand characteristics and has lower volt drop characteristics. This type of bus bar is very compact making it ideal for installing into the ever reducing available space which is allowed in the modern building services

When used for rising main applications, the sandwich configuration negates the need for fire-barriers because there is no air gap within the casing to give a chimney effect, which would allow the passage of smoke and fire.

6.6 Isometric drawing for installation

Fig 6.5 (a) Isometric drawing

90

Fig 6.5 (b) Isometric drawing

Fig 6.5 (c) Installation measurement drawing

Chapter 7

Appendix

In this project I describe the electrical power system in a spinning mill. This project work done we observed different type of electrical concept like that fuse, air circuit breaker (ACB), moulded case circuit breaker (MCCB), miniature circuit breaker (MCB) power factor improvement and pre fabricate bus bar which is modern technology of electrical distribution systems. Pre fabricate bus bar it is short sighted to compare the cost of bus bar against that of cable - and not the real cost of a cable installation to include multiple runs of cable, cable tray and fixing, let alone the protracted

91

time and effort of the cable pulling operation. A comparative study between a traditional system (cables) and one realized with bus bar trunking systems.

The cost of bus bar systems has fallen in real terms over recent years. Add to this, the cost saving in installation time - up to 50% less than cable. The reality is that electrical contractors can offer a more competitive bid, at the same time as offering his client a "state of the art" power distribution installation which is infinitely more flexible in use. The installation time for bus bar is virtually the same as for installing cable tray - before the installation of the cables; this is obviously a very important consideration in these days of ever tightening completion deadlines. Work this project I study various type of electrical Power Distribution Company like that Adex Corporation Ltd. (Sold distributor of world famous Schenider Electric of France), Automation Engineering & Controls Ltd. (Sold distributor of Fuji Electric Company Ltd., Japan), Energy Pac and also help from internet some data are collect from reference books and discussion with our teacher about this project.

During the work I have tried our best, especially in giving a more organized shape to follow the instructions that provided which gave us viewpoint of the whole task. The project was a challenging experience to us and I firmly believe that this assignment would be able to provide the details about the Electrical Installation of a spinning mills.

I have to work as how to do load calculation, electrical estimating of a spinning mills and how to installation of the electrical equipments I have gathered new experience from this project. I will utilize the experience in our future life.

References

i) Adex Corporation Ltd.

92

(Sold distributor of world famous Schenider Electric of France),

ii) Automation Engineering & Controls Ltd.

(Sold distributor Fuji Electric Company Ltd., Japan),

iii) Energy Pac Power generation Ltd.

iv) BRB Cable industries Ltd. &

v) Internet

93

Documents

JahangirThesis Final (27[1].04.10)