CONTENTS

INTRODUCTION:
Starting from the power generation for Lucky One mall till the finishing installation
for the luminaries a well synchronize system is observed that effectively delivered
the power to 21 Mega Watt connected load. This project can be recognize as a
vertically integrated system that involves generation, transmission and distribution
of power. Currently there are three main bench marks that insure maximum safety
and provide remedy from total power failures, they are listed as follow:

1. Power House.
2. Main Distribution Switch Gears (MDSG).
3. Substation
4. Electrical Control Room

Power house is installed with 4 caterpillar generators and 4 generators of Gen-Pak,

also there are 2 Diesel generators for backup purpose. From power house a total
of 8 high tention cables are used to feed four different zones of the mall. These
cables are responsible for connecting power house to MDSG. The main distribution
switch gears involves oil circuit breakers that avoid any possible arcing due to its
arc quenching medium. From here the HT cables are distributed to four
substations, in this fashion each one is supplied by two HT cables and here we use
ladder cable trays to lay down the heavy cables safely throughout the channel path.

The main purpose of substation is to step down 11KV voltage to 0.4KV line or 230V
phase voltage and here the lucky power has used 200 KVA dry type transformers
with delta to wye connection configuration. From the secondary side of these
transformers Schneider busways are feed, these power busways are of 630 ampere
rating. These busways are rigid and are not flexible but assure low maintenance
and immunity from fire due to its robust physical nature. For vertical distribution
of power risers are use which are similar to that of busways but their method to
connect with each other is different. They are used to energize electrical control
rooms that are used to provide power to various services, such as lightning scheme
is illuminated using lightning bus which is of 60 amperes. Moreover HVAC system,
emergency lights, escalators, travellators, motor control center, public addressing
service, back box, floor box, elevators are the services that are energized through
this power network.

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POWER GENERATION
As discussed earlier this project is capable of self-generation and for this purpose a
total of 10 generators are employed of which 2 diesel generators are reserved for
back-up purpose in case of any fault.

Specifically speaking 4 caterpillar generators are installed which are gas fueled in
nature the model name is Caterpillar 3520 and is of 1.95 MW generation capacity.
The remaining four generators of Gen Pak are also of gas each with of 1.33 MW
generation. The use of GAS fuel not only serves to reduce generation cost but also
gas is easily available in the current condition of the state. Here we use Automatic
Transfer Switch to move our load on the back-up generators In case of fault.

POWER DISTRIBUTION DRAWING

The best way to understand power distribution of any project is to read the
electrical distribution drawing. An electrical drawing, is a type of technical
drawing that shows information about power, lighting, and communication for
an engineering or architectural project. Any electrical working drawing consists of
"lines, symbols, dimensions, and notations to accurately convey an engineering's
design to the workers, who install the electrical system on the job. A complete set

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of working drawings for the average electrical system in large projects usually
consists of:

1. A plot plan showing the building's location and outside electrical wiring
2. Floor plans showing the location of electrical systems on every floor
3. Power-riser diagrams showing panel boards
4. Control wiring diagrams
5. Schedules and other information in combination with construction
drawings.

It is obvious that we focused on floor plans because in lucky one mall each floor
electrical diagram is of great importance. Starting from zonal division the lucky one
mall project is electrically distributed in 4 divisions except ground floor that is
divided into only 3 divisions. Each division is build on the basis of power provided
from sub-station so that any problem due to over loading can be eliminated. The
electrical drawing also shows the connections of HVAC system as well as back boxes
and floor boxes. The drawing also indicate the connection off UPS that are provided
to energize HVAC system and some specific luminaries in case of power failures.

The drawing not only indicate the power flow but also shows the specification of
cables used and Bus way power ratings, for example the power bus ways are of 630
ampere, bus risers for HVAC range from 200A to 600A depending upon nature of
load and the HT cables are 3C,30mm,Cu/xlpe/unarmored. All this information can
be read directly from electrical drawing. The symbols use to indicate an object are
pre-defined and can be easily found from online libraries. Lucky one has prepared
a uniform sketch which nearly remain same for all floors and help the engineers to
easily design lightning scheme and to conduct maintenance in future.

Dry Type Transformers:

Dry type transformers require minimum maintenance to provide many years of
reliable trouble free service. A dry-type transformer has no moving parts and is a
completely static solid state device, under normal operating conditions, are usually
insure a long and trouble-free life. Unlike liquid fill transformers which are cooled
with oil or fire resistant liquid dielectric, dry type units utilize only environmentally
safe, CSA and UL recognized high temperature insulation systems. Dry type
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transformers provide a safe and reliable power source which does not require fire
proof vaults, catch basins or the venting of toxic gasses. These important safety
factors allow the installation of dry type transformers inside buildings close to the
load, which improves overall system regulation and reduces costly secondary line
losses.

Fire-resistant dry type or "cast resin" transformers are well suited for installation in
high-rise buildings, hospitals, underground tunnels, school, steel factories,
chemical plants and places where fire safety is a great concern. Hazard free to the
environment, dry type transformers have over the years proven to be highly
reliable. “Dry type” simply means it is cooled by normal air ventilation. The dry type
transformer does not require a liquid such as oil or silicone or any other liquid to
cool the electrical core and coils. Dry type transformers are voltage changing (Step-
up or Step-down) or isolation device that is air cooled rather than liquid cooled. The
transformer case is ventilated to allow air to flow and cool the coil (coils).

Dry type transformers differ from liquid-filled units in many ways, and separate
industry standards apply to their design, construction, and maintenance. Dry-Type
Transformers suitable for indoor and outdoor applications anywhere that safe and
dependable power are important. Cooling ducts in the windings allow heat to be
dissipated into the air. Dry-types can operate indoors under almost all ambient
conditions for commercial buildings and light manufacturing facilities. For outdoor
operations, a dry-type transformer's enclosure will usually have louvers for
ventilation. But, these transformers can be affected by hostile environments (dirt,
moisture, corrosive fumes, conductive dust, etc.) because the windings are
exposed to the air. Other approaches to building dry-type transformers for harsh
environments include cast coil units, cast resin units, and vacuum pressure
encapsulated (VPE) units, sometimes using a silicone varnish. Unless the dry-type
units are completely sealed, the core/coil and lead assemblies should be
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periodically cleaned, even in non-harsh environments, to prevent dust and other
contaminant buildup over time.

There are several different construction methods used in manufacturing dry type
transformers. Each of these different types is suited for particular environments or
applications. If you are looking for corona protection and increased mechanical
strength a VPI dry type transformer would be your best options. But, if you are in a
harsh environment a cast coil transformer may be your answer.

 Dry Type Transformers - Open Wound Transformer

These transformers are construction with a dip-and bake

method. It is accomplished by preheating the conductor oils and
then heated, dipping them in varnish at an elevated
temperature. The coils are then baked to cure the varnish.

 Dry Type Transformers - Vacuum Pressure Impregnated (VPI)

The VPI transformers are construction with high-temperature
insulation that exceeds the rating of cellulose or 'O' and 'K' class
fluids. They are comprised of high-temperature materials
coated with high-temperature, moisture-resistant polyester
sealant. The polyester sealant is typically applied with a vacuum
pressure impregnation process. They are used in diverse
commercial and industrial environments for decades. They are
generally rated up to 30 MVA.

 Dry Type Transformers - Vacuum Pressure Encapsulated

(VPE)
The VPE dry type transformers are similar to VPI transformers,
but employ a resin made of silicone instead of polyester. The
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 VPE includes several dip processes to encapsulate the coil
assembly and then the coating is cured in an oven. The resin
coating is thicker, sometimes by as much as a factor of four. VPE
transformers are highly resistant to humid and caustic
environments. These VPE are ideal for harsh environments such
as acids, alkalis and chlorides. They are also resistant to the the
effects of salt water and high humidity.

 Dry Type Transformers - Cast Coil

In the cast coil design, the coils are solidly cast in resin under a
vacuum in a mold. Winding processes controlled by advanced
electronics also ensure even distribution and high level of
precision. The cast coil transformers are reliable, have a high
short circuit withstands, and can be exposed to extreme
conditions with minimal maintenance. They are used inside
buildings and tunnels, on ships, offshore platforms and cranes,
food-processing plant, nuclear plants and mining industry.

Quality of Dry Type Transformers

Dry-type transformers can have their windings insulated various ways. A basic
method is to preheat the conductor coils and then, when heated, dip them in
varnish at a high temperature. The coils are then baked to cure the varnish. This
process is an open-wound method and helps ensure penetration of the varnish.
Cooling ducts in the windings provide an efficient and economical way to remove
the heat produced by the electrical losses of the transformer by allowing air to flow
through the duct openings. This dry-type insulation system operates satisfactorily

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in most ambient conditions are also sealed with an epoxy resin mixture. Another
version of the dry-type transformer is a cast coil insulation system. It is used when
addition coil strength and protection are advisable. These type of transformer are
used in located where environments are harsh, such as cement and chemical plants
and outdoor installations where moisture, salt spray, corrosive fumes, dust, and
metal particles can destroy other types of dry-type transformers. These cast coil
units are better able to withstand heavy power surges, such as frequent but brief
overloads experienced by transformers serving transit systems and various
industrial machinery.

Cast coil units are now being used where previously only liquid-filled units were
available for harsh environments. They can have the same high levels of BIL while
still providing ample protection of the coils and the leads going to the terminals.
Dry-type transformer according to ANSI/EEE C57.96-1989 that you can have a 20-
yr life expectancy for the insulation system in a transformer. For dry-type
transformers having a 220°C, insulating system and a winding hot-spot
temperature of 220°C, and with no unusual operating conditions present, the 20 yr
life expectancy is a reasonable time fame. However, due to degradation of the
insulation, a transformer might fail before 20 years. Most 150°C rise dry-type
transformers are build with 220°C insulation systems. Operating such a transformer
at rated kVA on a continuous basis with a 30°C average ambient should equate to
a "normal" useful life. The life of a transformer increases appreciably if the
operating temperature is lower than the maximum temperature rating of the
insulation. However, you should recognize that the life expectancy of transformers
operating at varying temperatures is not accurately known. Fluctuating load
conditions and changes in ambient temperature make it difficult, if not impossible,
to arrive at such definitive information.

Dry type Transformers - Classes of insulation

Dry-type transformers are available in three general classes of insulation. The main
features of insulation are to provide dielectric strength and to be able to withstand
certain thermal limits. Insulation classes are:

 220°C (Class R).

 180°C (Class H),
 155°C (Class F).
 130°C (Class B).
 105°C (Class A).

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Temperature rise ratings are based on full-load rise over ambient (usually 40°C
above ambient and are 150°C (available only with Class H insulation), 115°C
(available with Class H and Class F insulation) and 80°C (available with Class H, F,
and B insulation). A 30°C winding hot spot allowance is provided for each class. The
lower temperature rise transformers are more efficient, particularly at loadings of
50% and higher. Full load losses for 115 °C transformers are about 30% less than
those of 150°C transformers. And 80°C transformers have losses that are about 15%
less than 115°C transformers and 40% less than 150°C transformers. Full load losses
for 150°C transformers range from about 4% to 5% to 30 kVA and smaller to 2% for
500 kVA and larger. When operated continuously at 65% or more of full load, the
115°C transformer will pay for itself over the 150°C transformer in 2 years or less
(1 year). If operated at 90% of full load). The 80°C transformer requires operation
at 75% or more of full load for a 2-year payback, and at 100% load to payback in 1
year over the 150°C transformer. If operated continuously at 80% or more of full
load, the 80°C transformer will have a payback over the 115°C transformer in 2
years or less. You should note that at loadings below 50% of full load, there is
essentially no payback for either the 115°C or the 80°C transformer over the 150°C
transformer, Also at loadings below 40% the lower temperature rise transformers
become less efficient that the 150°C transformers. Thus, not only is there no
payback, but also the annual operating cost is higher.

Wave Cast coil transformers from GE are characterized by high safety, reliability,
energy-savings, and convenient maintenance. Advanced design of the winding
assembly establishes superior performance to meet today’s exacting needs.
Indoors or outdoors, they are designed for use in the most demanding and diverse
environments and in all applications requiring reliable power.

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METAL CLAD SWITCH GEAR:
Metal-clad switchgear act as an intelligent fault detection switch, which disconnect
the supply under faulty conditions as well as for maintenance purpose. It may be
either a circuit breaker (usual) or a load-break interrupter switch (unusual). Circuit
breakers are always electrically operated. Extensive barriering, shutters over the
primary circuit elements when the interrupter is withdrawn, and insulation-
covered bus are all required. The minimum rated voltage is 4.76 kV. This rating is
commonly used on 2400 V ac circuits, but is seldom used at lower voltages. Ratings
are available up to 38 kV. Metal-clad is usually considered the top of the line of
medium-voltage metal-enclosed switchgear.

SECO WITHDRAWABLE METAL CLAD SWITCH GEAR:

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Seco Gear metal clad switchgear is designed and manufactured with advanced
technology and has been comprehensively and successfully type tested by KEMA.
Seco Gear switchgear is typically used in power plants, substations and suitable to
provide control and protection for transformers, capacitors and motors. The rated
voltage of Seco Gear is 12kV - 17.5kV and rated current ranges from 630A to 4000A
(4000A has force cooling). All Seco Gear with switching device are equipped with
Seco vacuum circuit breaker with corresponding specifications. Seco Gear
switchgear is designed for indoor applications, and is particularly suitable for
applications in industry, mining, oil and gas and infrastructure. Seco Gear is
designed, assembled and tested to meet or exceed applicable IEC and GB/DL
standards.

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BUSBAR TRUNKING (BUSWAYS)
Busways, also referred to as busbar trunking systems, stand out for their ease of
installation, flexibility and number of possible connection points Busbar trunking is
intended to distribute power (from 20 A to 5000 A) and lighting (in this application,
the busbar trunking may play a dual role of supplying electrical power and
physically holding the lights).

 Busbar trunking system components

A busbar trunking system comprises a set of conductors
protected by an enclosure. Used for the transmission and
distribution of electrical power, busbar trunking systems have all
the necessary features for fitting: connectors, straights, angles,
fixings, etc. The tap-off points placed at regular intervals make
power available at every point in the installation.

THE VARIOUS TYPES OF BUSBAR TRUNKING:

Busbar trunking systems are present at every level in electrical distribution: from
the link between the transformer and the low voltage switch switchboard (MLVS)
to the distribution of power sockets and lighting to offices, or power distribution to
workshops. There are essentially three categories of busways.

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 Radial distribution using busways

 Transformer to MLVS busbar trunking

Installation of the busway may be considered as permanent and
will most likely never be modified. There are no tap-off points.
Frequently used for short runs, it is almost always used for ratings
above 1,600 /2,000 A, i.e. when the use of parallel cables makes
installation impossible. Busways are also used between the MLVS
and downstream distribution switchboards. The characteristics of
main-distribution busways authorize operational currents from
1000 to 5,000 Amperes and short-circuit withstands up to 150 kA.

 Sub-distribution busbar trunking with low or high tap-off

densities
Downstream of main-distribution busbar trunking, two types of
applications must be

Supplied:

- Mid-sized premises (industrial workshops with injection

presses and metalwork machines or large supermarkets with
heavy loads). The short-circuit and current levels can be fairly
high (respectively 20 to 70 kA and 100 to 1,000 A)

- Small sites (workshops with machine-tools, textile factories

with small machines, supermarket with small loads). The short-
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 circuit and current levels are lower (respectively 10 to 40 kA
and 40 to 400 A) Sub-distribution using busbar trunking meets
user needs in terms of:

- Modifications and upgrades given the high number of tap-off

points

- Dependability and continuity of service because tap-off units

can be connected under energized conditions in complete safety.
The sub-distribution concept is also valid for vertical
distribution in the form of 100 to 5,000 A risers in tall buildings.

 I-Line II Bus Duct & Busway

 Lighting distribution busbar trunking

Lighting circuits can be distributed using two types of busbar
trunking according to whether the lighting fixtures are suspended
from the busbar trunking or not.
Busbar trunking designed for the suspension of lighting fixtures
these busways supply and support light fixtures (industrial
reflectors, discharge lamps, etc.). They are used in industrial
buildings, supermarkets, department stores and warehouses. The
busbar trunkings are very rigid and are designed for one or two 25
A or 40 A circuits. They have tap-off outlets every 0.5 to 1m.
Busbar trunking not designed for the suspension of lighting
fixtures Similar to prefabricated cable systems, these busways are
used to supply all types of lighting fixtures secured to the building
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 structure. They are used in commercial buildings (offices, shops,
restaurants, hotels, etc.), especially in false ceilings. The busbar
trunking is flexible and designed for one 20 A circuit. It has tap-
off outlets every 1.2 m to 3 m.
Busbar trunking systems are suited to the requirements of a large
number of buildings.

 Industrial buildings: garages, workshops, farm buildings,

logistic centers, etc.
 Commercial areas: stores, shopping malls, supermarkets, hotels,
etc.
 Tertiary buildings: offices, schools, hospitals, sports rooms,
cruise liners, etc.

STANDARDS
Busbar trunking systems must meet all rules stated in IEC 61439-6.This defines the
manufacturing arrangements to be complied with in the design of busbar trunking
systems (e.g.: temperature rise characteristics, short-circuit withstand, mechanical
strength, etc.) as well as test methods to check them.

The new standard IEC61439-6 describes in particular the design verifications and
routine verifications required to ensure compliance. By assembling the system
components on the site according to the assembly instructions, the contractor
benefits from conformity with the standard.

THE ADVANTAGES OF BUSBAR TRUNKING SYSTEMS

 Flexibility
 Easy to change configuration (on-site modification to change
production line configuration or extend production areas).
 Reusing components (components are kept intact): when an
installation is subject to major modifications, the busbar
trunking is easy to dismantle and reuse.
 Power availability throughout the installation (possibility of
having a tap-off point every meter).
 Wide choice of tap-off units.

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  Simplicity
 Design can be carried out independently from the distribution
and layout of current consumers.
 Performances are independent of implementation: the use of
cables requires a lot of derating coefficients.
 Clear distribution layout
 Reduction of fitting time: the trunking system allows fitting
times to be reduced by up to 50% compared with a traditional
cable installation.
 Manufacturer’s guarantee.
 Controlled execution times: the trunking system concept
guarantees that there are no unexpected surprises when
fitting. The fitting time is clearly known in advance and a quick
solution can be provided to any problems on site with this
adaptable and scalable equipment.
 Easy to implement: modular components that are easy to
handle, simple and quick to connect.

 Dependability
 Reliability guaranteed by being factory-built
 Fool-proof units
 Sequential assembly of straight components and tap-off units
making it impossible to make any mistakes

 Continuity of service
 The large number of tap-off points makes it easy to supply
power to any new current consumer. Connecting and
disconnecting is quick and can be carried out in complete
safety even when energized. These two operations (adding or
modifying) take place without having to stop operations.
 Quick and easy fault location since current consumers are near
to the line
 Maintenance is nonexistent or greatly reduced

 Major contribution to sustainable development

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  Busbar trunking systems allow circuits to be combined.
Compared with a traditional cable distribution system,
consumption of raw materials for insulators is divided by 4 due
to the busbar trunking distributed network concept.
 Reusable device and all of its components are fully recyclable.
 Does not contain PVC and does not generate toxic gases or
waste.
 Reduction of risks due to exposure to electromagnetic fields.

Example of a set of 14 x 25A loads distributed along 34 meters (for busway,

Canals KS 250A)

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