Chapter - 3 .
Industrial Installation
Classification of industrial building
[Link]. Classification Products Power consumption
1 Small scale industry Small scale production, Up to 30 kilowatt
workshops repair,
equipment part product
2 Medium scale industry Production of machines, More than 30 kilowatt
motors, other machine to 5 megawatt
3 Large scale industry Automobile industries etc. More than 10
Production in a large scale megawatt
Comparison of Industrial and non industrial sector
[Link]. Point of comparison Industrial Non-industrial or
residential load
1 Electric Supply needed 11 KV feeder line For large scale load, 3
terminating at factory phase 4 wire supply
premises stepping down to taken and used for
400 volts, 3 phase 4 wire power and lightning
by transformer circuits. Power 3 phase
400 volt, lightning single
phase 230 volt
2 Tariff of Electric Supply HT tariff maximum demand Block rate tariff generally
Company and tariff adopted
3 Location In Industrial Area outside Populated( residential
residential area, MIDC area)
area
4 Safety Industrial safety is General safety is
observed followed
5 Type of load Industrial big load and Residential and small
lightning load too commercial, low
capacity load for lighting
and fan
6 Government acts to be All industrial acts to be Commercial acts to be
obeyed followed. Labour act followed
imposed
7 Overall cost Much more Medium/ Les cost
8 Land requirements Large Medium
9 Wiring system Surface conduit for Casing capping
machine and concealed concealed wiring
conduit for other.
10 Protective systems Protective systems, circuit General safety is
breakers, relays, [Link], ELCB.
emergency siren, fire
fighting, safety provisions
needed for big industry.
11 Government control Labour acts are imposed No such provision of act
on industry needed
General characteristics of industrial building
Generally two section a) Actual production b) Administrative offices
Production work building generally installed on ground. No multi storey structure
allowed due to machine activity/ vibrations.
The height of different production centres buildings are a much more as compared to
other type commercial or residential.
Proper ventilation - cross ventilation, air circulation is provided.
Entry of natural daylight, reflectors on the top side are to be provided.
Sufficient illumination is provided and spot lightening near the machine operations are
provided.
Fine fitting equipments are located at appropriate places
In emergency cases, warning bells, sirens are at particular places are installed and
operated by security staff.
Administrative staff buildings/ offices/ sectors are separate and located near main
entrance and away from production sectors. Buildings are multi stored.
Isolated buildings, canteens and lunch rooms are generally single stored are located
Security check counters are at the entry gate.
In automobile industries big covers shed and lifting, rolling crayons are accommodated
for movements and carrying goods from one to other sections. So this building is very
heighted and big length and much wide shaped.
A posh, furnished, small buildings near to entry gate is provided for visitors and client to
welcome.
In big industries, there is a attach training centre to train the technicians employed.
Lecture halls, practical rooms just like a college building is provided.
Garden is maintain around the buildings to create a pleasant atmosphere.
Industrial load
It is a power load and supply is 3 phase 400 volt AC and also single phase AC for small
motor like lathe machines, shaping machines, grinders,etc.
For big industrial organisations, a separate assembly station is provided to receive
power from electricity company by 11KV feeder line and step down to 400 volts 3 phase,
230 volts single phase AC for lighting and fan.
Total load may be much more in megawatt.
Non industrial load is generally filled by three phase 400 volt between RYB lines and
230 volts between phase and neutral. Bus bar and distribution boards are provided in
the wiring system for fans, lightning, air conditioners,etc.
Selection wiring system
i)Cleat wiring - for temporary work
ii) wooden Batten system - in small rooms, small houses
iii) wooden casing capping system - residential buildings.
iv)PVC casing capping system - residential buildings - offices, commercial places.
v)surface conduit wiring system - in industries in production centres to give supply through
conduit wiring to various machine.
vi)Underground wiring system - cables are used to run underground to give supply from one
place to other or to machines in industries.
vii)Concealed conduit wiring - industry office buildings.
so in the industries the wiring system used are:
a) surface conduit system
b) concealed conduit system
c) casing capping system
Wiring diagram and single line diagram for single phase and three phase motor
Design consideration of industrial installation
A) Power wiring
Due to superiority, the industrial drives is three phase induction motor.
Motor operates on 3 phase 400 volt AC supply
Surface conduit wiring is generally adopted for motors and supply connections.
Motors are fitted on foundation and base plate/ metal parts are earthed at two point
Switching and starting mechanism and protective system are located at a suitable height easy
for operator.
B) Light wiring
There are many sections in industry. For day and night operations sufficient/ appropriate
illumination level is to be provided for different activities.
Also administrative buildings and related offices need lightning system, heating, cooling system
and electric connections for sophisticated table operated devices.
Such all works need single phase 230 volt AC supply.
Wiring systems in industries are
I) 3 phase, 4 wire AC supply 400 volts 3 phase 230 volt single phase.
Ii) three phase AC, 3 wire supply for machineries, motor.
Iii)ICTP,ICDP switching mechanism
Itiv)Starting, protecting mechanisms ( starters, controllers etc.)
V) for power distribution bus bar chamber and control room is needed.
For power Circuit Design we have to find
I) input current
Ii) selection of size of cables and conduit
Iii) determination of rating of fuse
Iv) selection of rating of main switch.
Size and rating current is decided from calculated load current of the circuit. Rating of fuse is
decided as per starting current = full load current x 1.5
Design of electrical installation schemes
Guidelines about power wiring ( and motor wiring) installation
Use metal conduit for wiring routes
Equipments used in power wiring should be of iron clad type
For underground connections armoured cable are used
Surface conduit is preferred instead of concealed conduit system. This facilitates in
addition, alteration, maintenance.
Black bolts shall be used for fixing metal clad parts with wall.
Don't use wooden gutties.
For easiness of maintenance there should we separate conduct for supply of each motor
unit. Don't run two supply wire in one conduct for two or more motor connection.
Flexible Conduit are needed for connection between terminal box of motor and their
starter. Its length is limited to 1.25 metre and not more than this.
It does not allow grouping of conductor from terminal of one motor to next motor
terminals.
Starting mechanism for different Motors -
I) motor resistance starter in addition to d o l starter suitable for three phase induction motor.
Ii) if not specified dual starter only may be used for low HP( up to 3 HP) if not specified.
Iii) use star delta starter for squirrel cage type motor.
Iv) used auto transformer starter for high HP motor.
V) use v i r wire for connection starter capable to carry twice the full load current.( starting
current is 1.5 to 2 is times the full load current)
As per IE rule for copper conductor a minimum cross sectional area is 1.25 mm square
for power wiring and Aluminium it is 1.5 mm square.
Frame of the motor should be obtained by two separate and distinct Earth wiring.
Conduit used in power wiring continuous electrical throughout the run and connected to
the frame of the motor.
Fuse rating is according starting current of motor. It should be twice the rating of cable.
Location of control panel shall be installed near to wall and motor Foundation.
Foundation height from floor to be 1 to 1.25 metres
Three saddle per metre run of conduct is provided
Voltage drop limit not more than 5% of declared supply voltage
Table to be referred for conduct size as per the wire to be run through it.
If numberof motor are on the same circuit the rating of main switch = starting current of
highest capacity motor + full load current of the remaining motor in the circuit.
All non current carrying metallic parts and bodies of the motor used in power wiring shall
be provided with two independent and distinct earthing is with two independent Earth
electrode.
These Are the points to be observed as per IS instructions for power wiring work
Power rating calculation
Machine A : 3 Phase 400V 5 H.P. cage induction motor full-load efficiency 0.85 and p.f. 0.8
Machine B : 3 Phase 400V 3 H.P. cage induction motor full-load efficiency 0.8 and p.f. 0.8
Machine C : 1 Phase 230V 3/4 H.P. cage induction motor full-load efficiency 0.75 and p.f. 0.7
Wiring diagram , showing arrangement and equipment which will be installed on the main
distribution board and at other places.
Specify the rating of
i)Cables
ii)Switches and
iii)H.R.C. fuses required for each machines.
1) Full Load current of Machines A –
Load current =
= 7.8A
Maximum starting current is 2 x 7.8 = 15.6 A . Hence, a 3 core 7/22 Cu conductor , P V C cable
will be used for motor.
Similarly for you can calculate for Machine B and Machine C .
Here is layout of plan of above questions –
Erection, inspection and testing of installation as per NEC - 2011
extract from the rules:
All the installations, on completion and before energizing must be inspected and also tested.
This should be carried out in accordance with the requirements of the is - section to verify as
far as practicable that the requirement of this clause have been meet.
Take care that no danger to person/ property/ equipments during testing.
Visual inspection
This is for verifying -
I) correctly selected and erected in accordance with the code of the section.
Ii) not visible damaged so as to impair safety.
Iii) inspect in complain with the applicable indian standard
Testing in sequence -
Continuity of ring final circuit conductor.
Continuity of protective conductors.
Testing earth electrode resistance.
Testing insulation resistance.
Insulation of nearer build assemblies.
Protection by electric separations
Insulation of non conducting floor and walls
Polarity testing
Earth fault loop impedance
Operation of fault operated devices.
Operation of residual current devices.
Practice MCQ
[Link]
9854-28e361f7da4d
[Link]
costing-test-questions-61
