Welcome To My Presentation

Presented by
Md. Omar Siddique
ID# 14305001

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 Industrial Substation Design, Load
Calculation and Protection System at
INNOVA Engineering Ltd

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 Contents

• Substation
• Classification of substation
• Design of 7.5MVA outdoor and indoor substation
• Components of substation
• Single line diagram of 7.5MVA substation
• Current calculation
• Breakers, bus-bars, Cables selection according to load
• Power Factor Improvement
• PFI arrangement and calculation for 7.5MVA Substation
• Wiring procedure of PFI plant
• C/K value calculation
• Instrument transformer ( CT, and PT)
• Earthing System
• Conclusion

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 Objectives

 Design and estimation of 7.5MVA substation

 Flore plane of outdoor and indoor substation (7.5MVA)
 Single line diagram (SLD) of 7.5MVA substation
 HT and LT current calculation
 Breaker, bus-bar and cable selection according to load
 PFI selection, calculation and arrangement procedure for 7.5MVA substation
 Earthing system of 7.5MVA substation

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 Substation

The substation is the medium of transfer the power from generating unit to the
consumer end.

 Classification of Substations by Design

• Outdoor Substation
• Indoor Substation

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Outdoor Substation Diagram(33kV/11kV)

Ground

X-F
CT VCB PT

Figure: 7.5MVA outdoor substation

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Outdoor Substation Design(33kV/11kV)
33kV Bus-Bar

11kV 11kV 7.5MVA 33kV Outdoor 33kV

Tower
Indoor C.T 33kV/11kV P.T VCB C.T
substation Transformer

Figure: 7.5MVA outdoor substation

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Indoor Substation Diagram(11kV/0.4kV)

Figure: 7.5MVA indoor substation

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 Indoor Substation Design(11kV/0.4kV)

X-F

X-F

Figure: 7.5MVA indoor substation

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 Components of Sub-Station

• Transformer
• Circuit Breaker (HT, LT)
• Fuse
• Bas-bar
• Cable(HT, LT)
• PFI Plant
• Instrument transformer (CT, PT)
• Earthing

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 Single Line Diagram (33kV/11kV/0.4kV)

Figure: Single line diagram of 7.5MVA substation

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 Current Calculation (33kV/11kV)

Total Current of HT Side (7.5MVA):

We know that,
S = √3*V*I
I = S/(√3*v)
I = 7.5*10^6 /(√3*33*10^3)
I = 131A

Total Current of LT Side (7.5MVA):

We know that,
S = √3*V*I
I = S/(√3*V)
I = 7.5*10^6/( √3*11*10^3)
I = 393A

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 Current Calculation (11kV/0.4kV) Cont.

Total Current of HT Side (4000kVA): Total Current of HT Side (3500kVA):

We know that, We know that,
S = √3*V*I S = √3*V*I
I = S/(√3*v) I = S/(√3*v)
I = 4000*10^3/(√3*11*10^3) I = 3500*10^3/(√3*11*10^3)
I = 209A I = 184A

Total Current of LT Side (4000kVA): Total Current of LT Side (3500MVA):

We know that, We know that,

S = √3*V*I S= √3*V*I
I = S/(√3*V) I = S/(√3*v)
I = 4000*10^3/(√3*400) I = 3500*10^3/(√3*400)
I = 5774A I = 5052A

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 Breaker
 Circuit Breaker:
• Automatically operated electrical switch
• Designed to protect an electrical circuit
• From damage caused by excess current
• From an overload or short circuit
• Basic function is to interrupt current flow after a fault is detected

Figure: vacuum circuit breaker Figure: Tripping circuit

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 Breakers Selection

 HT Breaker: We can use

• LBS(Load Break Switch)
• VCB( Vacuum Circuit Breaker)

 LT Breaker: We can use HT Breaker

• ACB(Air Circuit breaker) or

• MCCB(Molded Case Circuit Breaker)
• It is totally depend on line current rating
• It is must be used one size greater than
line current
LT Breaker

Figure: Breakers selection

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 Table of Available Breaker in the Market
MCB MCCB ACB
2A 40 A 630 A
4A 50 A 800 A
6A 63 A 1000 A
8A 80 A 1250 A
10 A 100 A 1600 A
12 A 125 A 2000 A
16 A 150 A 2500 A
20 A 200 A 3200 A
25 A 225 A 4000 A
32 A 250 A 5000 A
40 A 300 A 6300 A
50 A 320 A
63 A 400 A
500 A
630 A
800 A
1000 A
1250 A

VCB(Vacuum Circuit Breaker) Rating:

• 630A and 800A VCB are used for indoor substation.
• 1250A VCB is used for outdoor substation.

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 Bus-bars

 Bus-Bar :
• A metallic strip or bar
• Typically housed inside switchgear, panel boards and bus way enclosures
• It can carry (1sq mm = 2A current)

Figure: Bus-bars

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 Cables

 Electrical Cable:
• An assembly of one or more wires
• Running side by side or bundled
• Carry electric current

Figure: Cables

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 Cable Selection
 For HT Cable: HT cable selection
• Depends on short circuit current rating
• Cross sectional area of high voltage cable
• The value determined by following formula
S = ( I SC *√t ) / K

Figure: HT cables

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 Cable Selection Cont.
 For LT Cable:
• Depend on line current rating
• Takes one size greater than the line current rating
• LT Cable should be cupper made
• Cupper cable is more efficient than aluminum cable

Figure: LT cables

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 Available Cable Size in the Market

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 Power Factor Improvement

 Power Factor Improvement:

• The process of increasing the power factor
• To near unity without altering the original load
• Reducing the phase difference between voltage and current
• Reactive power is provided by the capacitor or capacitor bank
• Capacitors installed parallel with the load.

Figure: diagram of PFI

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 Power Factor Improvement Cont.
 Importance of PFI :
• To Reduce Demand Charges
• To Increase Load Carrying Capabilities
• To Improve Voltage
• To Reduce Power System Losses

Figure: PFI Plant

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 Arrangement and Calculation of PFI Plant

 PFI Arrangement and Calculation for Substation:

• PFI will be taken in 60% of apparent power
• Here ,
Cosθ=0.8
θ=Cosˉ1*0.8 =36.86
Sinθ=Sin(36.86)=0.60

• Now, 4000kVA = 4000*0.60 = 2400kVAR

• Use 12 stage PFI relay

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 Arrangement and Calculation of PFI Plant
Cont.
Table of Arranging 1200kVAR PFI Plant with Capacitor, MC and Fuse Size:

SL No. Capacitor Rating Stage of controller MC Size Fuse Size

1 25kVAR Directly connected

2 25kVAR 1 UA-30-50 A 63 A

3 50kVAR 2 UA-75-100 A 125A

4 50kVAR 3 UA-75-100 A 125A

5 50kVAR 4 UA-75-100 A 125A

6 100kVAR 5 UA-75-200 A 250 A

7 100kVAR 6 UA-75-200 A 250 A

8 100kVAR 7 UA-75-200 A 250 A

9 100kVAR 8 UA-75-200 A 250 A

10 100kVAR 9 UA-75-200 A 250 A

11 100kVAR 10 UA-75-200 A 250 A

12 200kVAR 11 UA-75-400 A 500 A

13 200kVAR 12 UA-75-400 A 500 A

Total = 1200kVAR

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 Wiring Procedure of PFI Plant

12 Stages PFI
Relay
Controller
CT
HRC Fuse

Magnetic
Contactor

Capacitor
Bank

Figure: wiring diagram of PFI Plant

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 C/K Value Calculation

The C/k value is calculated by

• The step size C divided by the ratio k of the current transformer
• Here,
C/K = (Q*5)/(√3*V*I)

• Example: If Q= 25kVAR, V= 400V; I = 800A ;

=> C/K = (25*1000*5)/(√3*400*800) = 0.226

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 Instrument Transformer
 Instrument Transformers:
• used in A.C system
• For measurement of electrical quantities like voltage and current
• used with protective relays for the protection of power system
• Basic function is to step down the A.C system voltage and current.

CT
CT PT
Figure: Current transformer and potential transformer
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 Earthing System

 Earthing: The basic purpose of the earthing system is provide

• Protection to human body from electric shock
• Stop the current flow in the circuit
• Done to make the line dead
• If due to failure of installation, some parts of the electrical equipment
which do not normally carry current are raised to a dangerous potential
w.r.t general mass of the earth

 Value of Earth Resistance :

Sl No. Resistance in ohm

01 Large power substation 0.5 Ω

02 Major substation <1Ω
03 Small substation ,< 2 Ω
04 Factory substation <1Ω

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 Earthing System Cont.

 4-Point Method of Earth Resistance :

• Should be 0.5Ω or less than 1Ω
• Used for soil resistivity measurements
• Confirmed the earth resistance between the electrode and true earth
• Value of voltage(V) between earth electrode and P have to be connected
• Calculated by using Ohm’s law R(g)=(V/I)
• Here ‘S’ should be greater than 20m.

Figure: Earthing system

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 Question and Answer

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 Conclusion

In final the issue comes out with an understanding that acquired practical knowledge
about power system engineering and its equipment as well as industrial engineering.
In the INNOVA Engineering Ltd, gathered a lot of knowledge about Industrial
instruments, substation and protective devices, automation and AutoCAD.
It was a big deal to learn about substation, because it is a very big arrangement of
different types of electrical instruments. I already visited different Industrial area,
where the INNOVA Engineering Ltd successfully done their installation of
substations. That is why discriminate the substation part widely such as design,
arrangement, lode calculation, components selection, protection system of
substation and also done practical part with relay, breakers, earthing and so on. The
practical experience was so much amazing. The authorities in INNOVA Engineering
Ltd were very concerned about all kinds of safety. The friendly environment in
INNOVA Engineering Ltd encourages co-operative with each other. Finally, learned a
lot and obtained practical knowledge from internship at INNOVA Engineering Ltd,
which will help me in my future life.

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 Thank You

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