Module 3

Electrical Installation for Commercial Building

 Electrical wiring installations of different types of buildings like hotels,
restaurants, colleges, schools, hostels, churches, hospitals, shopping
complexes offices etc.
 The electrical installations in the buildings are fan & light loads,
various electrical appliances, motors etc.
 Electricity supply authority supplies power to the consumers through
low voltage (415V/240V) three phase, four wire distributors.
 Large consumers are supplied at higher voltages, 6.6/11/33kV
through three wire high voltage feeders, such cases the consumer
has his own step- down substation to obtain the required voltage.
Small residential Installations:
For small installations, a single phase supply can be taken, a main
switch board or a fuse board is connected, and a final circuits are then
connected to the fuse board.
Medium large installations:
For medium large installations, a three phase supply would be
given. Both power and lighting to be balanced over the three phase, a
three phase four wire services are brought in, and a three phase meter is
installed for metering purposes.
Large installations:
In Large installations (factory), there may be 100kW of motor loads
or a multi stored building in which there are several thousands of light
points, and a number of other items like coolers, air conditioners,
refrigerators etc. A substation is required at the premises for
transferring power from high voltage to low voltage. Distribution boards
with bus-bar chamber may be employed as shown below.

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 For large multi stored building where there are several floors, the
main switch board controls the circuit to each floor. Sun DBs are placed
on different floors and all sub circuits are taken from them.Such a
system of wiring is known as ‘tree system of wiring’. In a tree system,
conductors are taken from the point of supply to the various load
points.The conductors constituting the main branch are known as rising
mains or risers.
Rising mains virtually forming a vertical bus-bar chamber. Such a
unit which is continued through out the height of a five storey building is
fitted into a GI chamber in the building is shown in figure.

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Design considerations of electrical installation in commercial buildings
1. Deciding the number of sub circuits: The total load in the
commercial building is calculated taking into consideration of general
lighting load, motor load and other power loads. The load on each light-
fan sub circuits shall be restricted to 800W or 10 outlets and load on

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each power sub-circuit is restricted to 3000W or 2 outlets. To
accommodate future growth, spare circuits are also provided.
2. Deciding the size and rating of switch board and distribution
boards: Sub circuits are fed from sub DBs, which in turn are fed from
main DBs. The sub DBs, main DBs are designed stage by stage
considering the load at different levels.The DBs, Isolators should be
accessible to maintenance personal and located such that faulty circuits
can be identified easily
3. Deciding the size of cables: The size of cables can be found by
calculating the actula current value at each stage. PVC /XLPE (armoured
or un armoured) cable can be used.
4. Deciding the size of conduits: Size of conduits determined from
the size of cables and the number of cables to be drawn through it.
The number of 1/1.80 Al or (1.5mm2 Cu) cable that can run through a
19mm (20mm) conduit are 6 or 5.
5. Bus-bar and Bus-bar Chamber: Bus-bar chamber consists of Bus
-bars which are strips of Cu or Al. The incoming lines are connected to
these distribution bus-bars through the main switch fuse and the load
circuits are supplied from the bus-bars through the switch fuse units. In
a bus-bar chamber there are fixed for bus-bars of which 3 are for the
three phase and the fourth for the neutral. Considering the current
carrying capacity the size of Al or Cu bus bars can be calculated.

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The size of Chamber depend on
1. The size and number of strips used
2. The number and rating of switches to be mounted on it.
It is usually made up of 16 SWG MS sheet.The bus bar strips are
mounted on bakelite or other supports having their width in their vertical
plane. Each SFU is connected to the Bus-bar Strips by means of strips or
wires of the same material as the bus-bar.
6. Mounting arrangements of switch boards and DBs: switch
boards and DBs can be mounted on the wall or on the floor. Any type of
mounting frame can be made with suitable angle iron
7. Earthing of the Electrical Installation: All the non-current carrying
metal parts shall be earthed properly. All metal conduits, trunking, cable
sheaths, switch gear, DBs, starters, motors, lighting circuits shall be
connected by means of two separate and distinct earth continuity
conductors to an efficient earth electrode.
8. Selection of earth electrode and earth conductors: For earthing
of installations in building, residential premises, small industries, only GI

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pipe (Cu) or rod earth electrodes are used. GI plate electrodes can be
used for industrial loads upto 30HP. For above 30HP and for power
house and substations, Cu plate earth electrodes are used.
Classification of Industrial Buildings
1. Based on fire hazard
2. Based on Power Consumption
3. Based on Pollution hazard
1. Classification based on fire hazard
(i)Group G1-Building used for low fire hazard industries
Operation/process conducted in those buildings,there
are no possibilities of self propagation of fire to occur.Only effect of
fire from external sources.
E:g; Cement factories,Glass factory,Rice mill,Soap and detergent
factory etc.
(ii) Group G2 Building of moderate fire hazard
In this type, operation/process are liable to give rise to fire that
will burn with moderate rapidity, produce considerable volume of
smoke or non toxic fumes and will not result in an explosion
E:g; Ship repairing docks, coir industry, chemical manufacturing,
flour mill etc
(iii) Group G3 Buildings with high fire hazard
In this type, operations/ process are liable to give rise to a fire
which will burn with extreme rapidity, generate poisonous fumes,
lead to explosions.
E:g; Alcohol distilleries, explosive manufacturing, fire work industries,
oil
mill, petrochemical.
2. Classification based on power consumption
(i) Light industries(Small)
(ii) Average industries (medium)

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 (iii) Heavy industries
SL Description Average power Examples
No. requirement
1 Light industry Up to 50 kVA Hosiery, garment making,
ornament making etc
2 Average above 50 up to Furniture pottery, glass,
Industry 2000kVA
Tobacco , electrical gadgets,
textiles, engine fitting, light
processing etc.
3 Heavy industry above 2000kVA Heavy electrical equipment ,
steel mills, foundries , ship
building, chemical plants,
fertilizer plants, metal
extraction, petrochemicals,
paper mills etc.

3. Classification based on pollution level

(i) Pollution degree 1
No pollution or only dry, non conductive pollution occurs.
The pollution has no influence
(ii) Pollution degree 2
Only non conductive pollution occurs except that occasionally a
temporary conductivity caused by condensation is to be expected.
(iii) Pollution degree 3
Conductive pollution occurs or dry non conductive pollution
occurs which becomes conductive due to condensation
(iv) Pollution degree 4

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 Continuous conductivity occurs due to conductive dust, rain
or other wet conditions.

Electrical Installations for small industries

Motor Circuit wiring
Every motor must be controlled by a main switch. A three phase motor
need a triple pole switch with fuse in each phase. A starter may be
required for starting and stopping the motor. The size of switch fuse unit
and that of the starter will depend on the rating of the motor. PVC/XLPE
cables of suitable size are used for wiring. For large capacity motors,
three phase UG cables are used.Wires and cables are enclosed in a rigid
heavy duty guage conduit of suitable size. Flexible conduits may be used
for connections from motor switch to starter and from starter to motor
terminals.

Each motor has to be controlled separately from the mains

through distribution boards.

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Design considerations of electrical installation in small industries
1. Motor current
When the motor is first connected to line, it will draw much
more current than its rated current till the motor comes upto
speed.This is Staring current of the motor.as the motor
reaches full speed delivering its rated horse power at rated
voltage the motor carries the full load current.
The current rating of cables for supply to motor may be
based upon the normal full load current of the motor, but the
rating of fuse should be based upon the starting current.
2. Deciding the size of cable
The cables shall have a current carrying capacity of not less
than 150 percent of the motor full load current rating.
For Eg:
(a) D C motors
Current required by a 400V 15hp DC motor at 80% efficiency
hp 746 15  746
=   33 . 2 A
V  400  0 . 8

The current carrying capacity of the cable should be 1.5 times the
full load current = 33.2 x 1.5 = 49.8A.
The size of the cable that can be used are: 7/1.63mm Cu
conductor cable of capacity 53A or 7/2.24 mm Al conductor cable of
capacity 59A.
(b) Single phase ac motors
The input current of a motor, 5hp single phase A C 240V at
hp  746 5  746
75% efficiency and 0.8pf =   25 . 5 A
V   pf 240  0 . 75  0 . 8

The current carrying capacity of the cable should be 1.5 times the
full load current = 25.5 x 1.5 = 38.23A.
The size of the cable that can be used are: 7/1.40mm Cu

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conductor cable of capacity 43A or 7/1.70 mm Al conductor cable of
capacity 43A.
( c) Three phase AC motors
The input current of a 3 phase motor, 10hp, 415V at 85%
hp  746 10 746
efficiency and 0.8pf =   15 A
3  V   pf 3  415  0 . 85  0 . 8

The current carrying capacity of the cable should be 1.5 times the
full load current = 15 x 1.5 = 22.5A.
The size of the cable that can be used are: 7/1.06mm Cu
conductor cable of capacity 28A or 1/2.28 mm Al conductor cable of
capacity 27A.
3. Determination of the size of conduit
The size of conduit depends on:
(a) The number of cables to be installed
(b) The cross sectional area of the cable
(c) The permissible conduit fill
4. Deciding the fuse rating
The criteria for selecting the correct size of fuse for motor
protection is that may carry the starting current safely.
For eg:
The full load current of a 3 phase motor, 10hp, 415V at 75%
hp  746 10 746
efficiency and 0.8pf =   17 A
3  V   pf 3  415  0 . 75  0 . 8

Starting current = 1.5 x full load current

= 1.5 x 17 = 26.6A
So, 30A switch fuse can be selected.
5. Deciding the starter, DB, main switch
Different types of motors have different methods of starting
as listed below.

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 SL Types of motors Methods of starting
No.
1 Induction motors of very low DOL starter
rating
2 Induction motors of medium Star - delta starter
rating (upto 15 hp)
3 Induction motors of high rating Auto-transformer starting
4 Slip ring induction motors of Rotor Resistance starters
high rating
5 D C series motor Two point starter
6 DC shunt/compound motor Three point starter

The specification of the DB is decided from the number of

circuits to be fed from it. The voltage rating of DB is decided by
the voltage rating of the circuits which are fed from it and its
current rating is the highest starting current of the circuit fed from
it.
If the main switch has to control a group of motors, its
current rating should be equal to the starting current of the motor
of the highest rating plus the full load current of the remaining
motors.
6. Costing of electrical installations for small industries
Cost of material = Rate x quantity of material required
Cost of labour: Labour includes fixing of conduit, running of
wires, fixing of main switches, starters, providing earth
arrangements etc
No.of days required for one electrician and a helper to
complete one motor installation work is about 2 days.
Q1) In a workshop, one 15hp, 400V, three phase 50Hz motor is to be
installed. Prepare the estimate of the quantity of material required with a
layout of the wiring. The plan of the workshop is shown in fig.

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Sol:
The schematic or single line diagram for the motor installation is shown
below

(a) Size of wire: Assume the motor efficiency to be 85% and power
factor 0.8, the full load current of the motor,
hp  746 15 746
IL    23 . 1 A
3  V   pf 3  415  0 . 85  0 . 8

The current carrying capacity of the cable should be 1.5 times the
full load current = 1.5 x 23.1 = 34.6 A
The size of the cable that may be used is a single core PVC
insulated 7/1.70mm Al conductor cable.
(b) Size of conduit : From the main board to motor switch and from the
motor switch to motor starter, only 3 wires to be run. Hence 32mm
heavy gauge conduit is required. From the motor starter to motor
terminals 6 phase and one neutral wires are to be run and 38mm
heavy gauge conduit is used.

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(c) Rating of switch fuse: Starting current of the motor = 1.5 x 24 = 34.6A
So the main switch and motor switch to be used can be 40A
500Vgrade TPIC switches.
The complete wiring diagram for the installation is shown in fig.

(d) Length of the conduit required: the following assumptions are made:
the main switch, motor switch and the starter are installed at a height
of 1.5m above the floor level
Height of conduit run above floor level = 3m
(1) Length of 32 mm conduit
From main switch to motor switch =
Allowing 20 % wastage =
Total =

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 (2) Length of 38mm conduit:
(a) From motor starter to ground and 0.30m below it (1.5+0.3)
=1.8m
(b) From ground to motor foundation 0.5m above the ground level
(2.5+0.3+0.5) = 3.3m
Total = (a) +(b)
(3) Length of 32mm flexible conduit required = 0.6m
(4) Length of 38mm flexible conduit required = 1m
(e) Length of wire required:
(1) From meter to main switch (3 run) = 3 x 0.3 = 0.9m
(2) From main switch to motor switch = 3 x 27 + 2x 3 x 1.5 = 90m
(3) From motor switch to motor starter = 3 x 0.3 = 0.9m
(4) Form motor starter to motor terminals (7 runs) = 7x1 = 7m
Wastage 20%
Total =
(f) Length of earth wire required :
Two separate earth electrodes have to be provided. According to
IE rules, motor frames, starters, motor and main switches, all metal
parts are to be earthed by two separate and distinct earth
conductors to the earth electrode.
No.8 SWG GI wire can be used as earth wire .
Length of earth wire = 2 x 40 m = 80m
(g) Labour cost : As the distance between motor and main switch is 30m,
one electrician with a helper will take 3 days to complete the work
(h) Schedule of material

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Q2) A small workshop has to be equipped with the following machinery:
(1) One 5hp, 400V, 3phase motor
(2) One 3hp, 400V, 3phase motor
(3) One 1/2 hp, 230V, 1 phase motor
(4) One 1hp, 400V, 3phase motor
The positions of the machines are shown below. Draw the wiring
diagram, estimate the quantity of materials required.

Sol:
(a) Main supply: Assume the motor efficiency to be 85% and pf to be 0.8
for the machines.
hp  746 5  746
(1) Motor 1, I L1    7 .5 A
3  V   pf 3  415  0 . 85  0 . 8

hp  746 3  746
(2) Motor 2, I L2    4 .5 A
3  V   pf 3  415  0 . 85  0 . 8

hp  746 0 . 5  746
(3) Motor 3, I L3    2 . 25 A
V   pf 240  0 . 85  0 . 8

hp  746 1  746
(4) Motor 4, I L4    1 .5 A
3  V   pf 3  415  0 . 85  0 . 8

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 Total full load current for these motors = 15.75A

The cable shall have a current carrying capacity of 150 percent of

the motor full load current.

The current carrying capacity of the main cable = 1.5 x 15.75 =

23.6 A

Four runs of Single core 7/1.06 mm Cu conductor having current

carrying capacity of 28A may be used from the meter board to the
main board.

The current rating of the main switch is the starting current of the
large motor plus the load current of the remaining motor.

I.e = (7.5 x 1.5 + 4.5 + 2.25 + 1.5) = 19.5 A.

So, 25A, 500V grade TPIC SFU shall be used as main switch.

Number of sub circuits = 4. So 4 way, 500V, 16A per way, 3 phase

IC DB with neutral link shall be used.

(b) Size of cable for each motor:

(1) Motor 1, IL1= 7.5A, Is1= 11.25A, 3/1.06mm Cu cable (15A)

(2) Motor 2, IL2= 4.5A, Is2= 6.75A, 3/0.737mm Cu cable (10A)

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 (3) Motor 3, IL3= 2.25A, Is3= 3.37A, 1/1.80mm AL cable (10A)

(4) Motor 4, IL4= 1.5A, Is1= 2.25A, 3/0.737mm Cu cable (10A)

( c) Size of conduit for each motor :

(c) Rating of switch fuse : The 3 nos. 3 phase motor of rating 5,3,1hp can
be controlled by 16A, 500V TPIC switches and the 1/2 hp single phase
motor can be controlled by a 16A, 250V DPIC SFU.

(d) Length of the conduit:

(e) Length of the wire:

(1) For motor1

(2) For motor 2

(3) For motor 3

(4) For motor 4

(f) Length of earth wire required: No.8 SWG GI wire = 2 x length of

conduits.

(g) Lighting Distribution

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 (1) Number of sub-circuits:

The no.of lamps to be used = 32 (Given)

Let the lamps be 100W mounted at equal intervals.

No.of lamps along length = 8

No.of lamps along width = 4

Four sub-circuits each of which consists of 8 light points.

Grading of Fuses
The feeder to a DB will be fed from SDB or MDB. It is necessary
that the major protective fuse shall not blow off before or along with
motor protective fuse in the DB. There shall be grading or discrimination
between these fuses. The fuses in two systems are termed as minor and
major fuses. For achieving grading, the minor fuse should be lower than

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half of the major fuse.

Eg: (1) 32A will grade with 63A and above

(2) 63A will grade with 100A and above

(3) 100A will grade with 160A and above

(4) 200A will grade with 320A and above

(5) 250A will grade with 400A and above

Substations
Types of substations:

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 1. Transformer substations

2. Frequency changing substations

3. Power factor correction substations

4. Converter substations

Indoor & outdoor substations

When the transformer and associated equipment are installed
inside the building , it is an indoor substation. In an outdoor substation
the transformers are pole mounted or floor mounted. Transformers of
low ratings say 25,40,63,100 & 200kVA are mounted on MS channels
which are rigidly fixed to a two pole structure. This type is economical
for rural electrification, agricultural load, domestic and commercial load
of small towns and medium industry load.

For transformers of capacities 250,300 & 400kVA, a platform is

constructed on a 4 pole structure for placing the transformer on it.

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Transformers above 400kVA are installed on a foundation or plinth with
a fence or wall surrounding it.

Out door substations

 On an H pole structure, the base channel 100mm x 50mm size, on
which substation is to be mounted, is erected at a height of 2.44m
from ground level.

 11kV LA (3 nos) are erected at the top of the H - pole structure for
the protection of the transformer against lightning. Earth terminals of
all 3 LA are joined together and connected to earth provided specially
for LA.

 11kV supply is given to the H pole structure by taking a T-

connection from the nearby 11kV line.

 11kV Gang operating (G.O)switch /Air break switch installed below

the 11kV conductor taps. The operating handle of the G O switch is
locaed on one of the poles at height of 1.25m from ground. By
operating this handle, the transformer can be isolated from the 11kV
supply.

 11kV horn gap fuses installed below the G.O switch and 11kV
transformer bushings to protect the transformer on the 11kV side.

 On the LT side of the transformer a three and a half core LT cable

is taken from the LT terminals of the LT main switch. This LT switch
is used to protect from feeder faults. LT main switch is connected to
LT distribution switches. LT cables are selected according to the
capacity of the transformer.

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24
25
Earthing arrangement of substations

Three pits are provided with earthed electrodes as shown.

 One earth electrode is exclusively used for for the connection of

lightning arrestors.

 The second earth electrode is used for the connection of neutral of

the transformer at the LT side

 The third earth electrode is connected to body of the transformer,

all non current carrying parts of the transformer, operating handle of
GO switch etc.

 All the three earth pits are inter connected.

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Bus-bar Arrangements
1. Single bus scheme.

2. Double bus scheme

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3. Ring bus system.

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Indoor Substation -Floor mounted Type
 Indoor substations of 11kV/415V are quite frequently installed in
industrial areas and big cities where load requirements is heavy and
continuity of supply is very important.
 Industrial units, continuous processing plants, important commercial
complexes, railway stations, telephone exchange, cinema houses all
employ indoor substations.
General requirements:
 The substation building should be constructed providing the
necessary accommodation for the transformer, HT and LT switch
gear and cable trenches for incoming and outgoing cables.
 The building for housing the transformer should be spacious and
should be sufficiently high.
 Adequate clearance between the walls and equipment and between
different equipment should be provided to ensure safety of the
personal
 Adequate provision for ventilation must be ensured, so that there is
free circulation of air on all sides of the transformer and with in the
building.

Typical layout of Indoor substation

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 11kV OH line terminates on a pole structure outside the indoor
substation
 11kV GO(Gang operating) switch and LA (Lightning arrestors) are
installed in it for isolation and protection.
 The supply from the OH line is brought inside the substation through
an UG cable using an out door cable box.
 11kV CB (Oil/Air/Vacuum) is placed at the incomer enters the
substation
 Transformer shall have cable boxes at the HT and LT ends
 LT circuit breaker is connected at LT side using a four core cable.
 The size of the cable depends on the rating of transformer

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 Up to 300A SFU is used. Above that OCB is used at LT side
 The LT OCB. LT bus-bars, and the SFU feeding local circuits,
capacitor banks are all installed on a LT panel board.
 11kV metering by KSEB is provided at the 11kV side of the
transformer.
 PT & CT are installed at HT lines with the 11kV OCB. The output of
CT and PT are brought to metering devices.
 For LV metering, supply is run directly to the meters.
 Fire fighting equipment should also be provided at the room
 Portable CO2 dry chemical fire extinguishers shall be installed in the
substation at suitable place.
 Fire buckets shall be installed with a suitable stand for storage of
water and sand.
 First aid charts displaying methods of giving artificial respiration to a
recipient of electrical shock shall be provided at appropriate places
 Standard first aid boxes containing materials should be provided in
front of switch boards and other control equipment.
 Danger sign plates shall be provided on HV and MV equipment.
Earthing:
 LA should be earthed separately
 Two separate and distinct earth electrodes shall be provided for
neutral earthing.
 Body of the transformer,HV and MV panels etc, the earth conductor
is to be connected to a common earth bus run between another two
separate and distinct earth electrodes.
 For a single transformer substation total number of earth electrodes
shall be 5.(1 for LA, 2 for neutral, 2 for body parts).

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32
 Q1) An outdoor pole mounted 11kV/415V substation has to be
installed for supply to a residential area having a load of 63kVA.
Estimate the quantity of materials required.
Sol:
For erection of the transformer and allied accessories, PCC poles of
11m length can be used. On a double pole structure, LA, HG fuse units,
GO switch, and disc insulators are installed along with the distribution
transformer. 2 sets of stays and 3 sets of earthing arrangements are to
be made.
To find the size of cable to be run from the secondary side of the
transformer, the current rating should be found out.
63  10
3

Full load current = IL   88 A

3  415

We may choose 3-1/2 core 95sq.mm PVC insulated LT cable.

3-1/2 core 95sq.mm cable should be run from the transformer to the
distribution box and from the distribution box the different feeder cables
are to be selected by taking into consideration of the load of each circuit.

Single line diagram:

Estimate of the materials:

SL Description of material Quantity

No.

1 PCC poles 11 m long 2 nos.

2 11kV LA 3 nos.

3 11kV Disc insulators 3 nos.

4 11kV GO Air break (AB) switch 1 set

5 11kV horn gap fuse unit 1 set

6 11kV/415 V 63kVA distribution transformer 1 set

7 63kVA distribution box 1 set

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8 3-1/2 core 95sq.mm PVC insulated LT cable 8m

9 MS flat 50mm x 6mm 24 kg

10 MS angle 50mm x 50mm x 6mm 22 kg

11 MS channel 75mm x 40mm x 6mm 22 kg

12 MS channel 100mm x 75mm x 6mm 100kg

13 Stay sets 2 sets

14 Stay wire7/8SWG 30kg

15 Earthing sets 3 sets

16 GI wire no.8 SWG 3.5kg

17 Nuts and bolts of required sizes 10kg

18 Aluminium paint 2lts

19 Danger notice board 1 no

Q2) A substation has to be installed in a residential complex having a

load of 80kVA taking supply from a nearby 11kV line. Select the type of
substation, and make a list of materials required.

Sol:

The distribution transformer to be selected is 100kVA 11kV/415V

and can be mounted on H pole structure.
On a double pole structure, LA, HG fuse units, GO switch, and disc
insulators are installed along with the distribution transformer. 2 sets of
stays and 3 sets of earthing arrangements are to be made.
To find the size of cable to be run from the secondary side of the
transformer, the current rating should be found out.
10010 3
Full load current = IL   140 A
3  415

We may choose 3-1/2 core 185sq.mm PVC insulated LT cable.

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 3-1/2 core 185 sq.mm cable should be run from the transformer to
the distribution box and from the distribution box the different feeder
cables are to be selected by taking into consideration of the load of each
circuit.

Single line diagram:

Estimate of the materials:

SL Description of material Quantity

No.

1 PCC poles 11 m long 2 nos.

2 11kV LA 3 nos.

3 11kV Disc insulators 3 nos.

4 11kV GO Air break (AB) switch 1 set

5 11kV horn gap fuse unit 1 set

6 11kV/415 V 100kVA distribution transformer 1 set

7 100 kVA distribution box 1 set

8 3-1/2 core 185sq.mm PVC insulated LT cable 8m

9 MS flat 50mm x 6mm 24 kg

10 MS angle 50mm x 50mm x 6mm 22 kg

11 MS channel 75mm x 40mm x 6mm 22 kg

12 MS channel 100mm x 75mm x 6mm 100kg

13 Stay sets 2 sets

14 Stay wire7/8SWG 30kg

15 Earthing sets 3 sets

16 GI wire no.8 SWG 3.5kg

17 Nuts and bolts of required sizes 10kg

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18 Aluminium paint 2lts

19 Danger notice board 1 no

Q3) A 11kV/415 V, 300 kVA substation is to be installed in a densely

populated area. What type of substation will you select.? make a list of
the quantity of materials required. LT panel consists of an incoming line
with OCB, and five outgoing lines with SFU of 1 nos. 200A, 2 Nos. 100A
and 2 Nos. 63A capacity.

Sol:

As it is densely populated area, indoor substation is preferred. An

11kV/415V, 300kVA indoor type transformer with HT and LT cables can
be used. The supply is taken from the 11kV OH line nearby. By taking
jumpers from the OH line and through an outdoor 11kV cable box
suitable for 11kV cable, supply is given to the transformer through the
HT OCB.
To find the size of cable to be run from the secondary side of the
transformer, the current rating should be found out.
30010 3
Full load current = IL   417 A
3  415

Taking a factor of safety, 2 runs of 3-1/2 core 400sq.mm PVC /XLPE

insulated LT cable can be used.

The LT panel is having:

One incoming line of 500kVA OCB

Five outgoing lines of

(1) 1 no. 200A SFU

(2) 2 nos. 100A SFU

(3) 2 nos. 63A SFU along with LT bus bars and cable boxes.

LT cables:

36
 (1) 3-1/2 core 185 sq.mm PVC insulated LT cable to rum from
200A SFU

(2) 3-1/2 core 95 sq.mm PVC insulated LT cable to rum from 100A
SFU

(3) 3-1/2 core 50 sq.mm PVC insulated LT cable to rum from 63A
SFU

Single line diagram:

Estimate of the materials:

SL Description of material Quantity

No.

1 Out door 11kV cable box suitable for 25mmsq. 1 set

11kV cable with cable joining material

2 11kV jumpers with insulation sleeves 3 nos.

3 11kV paper insulated 3 core 25 sq.mm cable 40m

4 11kV 400A OCB with metering and protection 1 set

devices

5 GI pipe for carrying 11kV cable along the pole 5m

6 Clamps for fixing GI pipe and cable end boxes 8 nos

7 11kV/415V 300kVA three phase 50Hz indoor type 1 set

transformer with HT & LT cable boxes

8 3-1/2 core 400sq.mm PVC insulated LT cable 25 m

9 LT panel having: one incoming line of 500kVA 1 set

OCB, five outgoing lines and 1 no. Of 200A, 2 nos.
Of 100A, and 2 nos. Of 63A SFU along with LT bus
bars and suitable cable end boxes

10 3-1/2 core 185sq.mm PVC insulated LT cable 50m

37
11 3-1/2 core 95sq.mm PVC insulated LT cable 50m

12 3-1/2 core 50sq.mm PVC insulated LT cable 50m

13 Angle iron 50mm x 50mm 100 kg

14 Angle iron 25mm x 25mm 30kg

15 Earthing sets 5 sets

16 Earth strips 50mm x 6mm 100 kg

17 Nuts and bolts of required sizes 10kg

18 Aluminium paint 2lts

19 Danger notice board 1 no

20 Fire extinguisher 1 no.

21 First aid box 1 no.

22 Shock treatment chart 1 no.

23 Rubber mats Lumpsum

Q4) Estimate the materials required for the installation of a

300kVA foundation mounted outdoor substation.
Sol:
The supply is taken from 11kV, 3 phase 50Hz OH transmission line
which terminates on a pole structure.the protective devices such as GO
switch, HG fuses, LA are all erected on the pole structure.the supply is
taken by 11kV 3 core 25 mm2 paper insulated cable. The 300kVA
outdoor substation is mounted on a plinth or foundation.a 500A LT OCB
is mounted inside a cubicle is also erected inside the substation near the
transformer.the substation is to be fenced around and proper earthing
also to be done.
30010 3
Line current at the secondary of the transformer, IL   417 A
3  415

Taking a factor of safety, 2 runs of 3-1/2 core 400sq.mm PVC /XLPE

38
insulated LT cable can be used.

Line diagram:

Estimation of materials:

SL Description of material Quantity

No.

1 PCC poles 11 m long 2 nos.

2 11kV LA 3 nos.

3 11kV Disc insulators 3 nos.

4 11kV GO Air break (AB) switch 1 set

5 11kV horn gap fuse unit 1 set

6 11kV outdoor cable box suitable for 25 mm2 11kV 1 set

cable with joining materials.

7 MS channel 100mm x 50mm x 6mm, 2m long for 2 nos.

fixing the above accessories

8 GI pipe for carrying the 11kV cable 8m

9 Clamps for fixing GI pipe 8 nos.

10 Plinth for transformer 1 no.

11 11kV 3 core 25mm2 paper insulated cable 15m

12 11kV/415 V 300kVA distribution transformer 1 set

13 500A OCB with ammeter, voltmeter, CTs, overload 1 set

trip coils etc

14 Plinth for LT OCB 1 no.

15 3-1/2 core 400 sq.mm PVC insulated LT cable 40 m

16 Stay sets 2 sets

39
17 Stay wire7/8SWG 30kg

18 Earthing sets 3 sets

19 GI wire no.8 SWG 3.5kg

20 Nuts and bolts of required sizes 10kg

21 Aluminium paint 2lts

22 Danger notice board 1 no

Q5) In a village residential load of 10kW, agriculture load of 25hp,

and water works of 15hp has to be electrified. Select the type of
substation to be erected. Make a list of materials for installing the
substation.
Sol:
Total load in kW = (25+15) x 0.746 +10 = 40kW
Assuming a pf of 0.8, load in kVA = 40/0.8 = 50kVA
A 63kVA, 11kV/415V, 3 phase 50Hz transformer is to be mounted
on a double pole structure.
To find the size of cable to be run from the secondary side of the
transformer, the current rating should be found out.
63  10
3

Full load current = IL   88 A

3  415

We may choose 3-1/2 core 95sq.mm PVC insulated LT cable.

3-1/2 core 95sq.mm cable should be run from the transformer to the
distribution box and from the distribution box the different feeder cables
are to be selected by taking into consideration of the load of each circuit.

The distribution box consists of one 100A incoming main switch and
4 nos. Of outgoing switches.

1 no. 63A for 25hp agricultural load, 2 no.s of 30A for 10kW
residential load and 15hp water works, 1 no. 30A spare for future

40
expansion.

Cable to be run are:

3-1/2 core 50mm2 cable from 63A switch

4 core 16mm2 cable for 30A switches

Single line diagram:

Estimate of the materials:

SL Description of material Quantity

No.

1 PCC poles 11 m long 2 nos.

2 11kV LA 3 nos.

3 11kV Disc insulators 3 nos.

4 11kV GO Air break (AB) switch 1 set

5 11kV horn gap fuse unit 1 set

6 11kV/415 V 63kVA distribution transformer 1 set

7 63kVA distribution box consists of 1 no. 100A 1 set

incomer and 4 outgoing switches

8 3-1/2 core 95sq.mm PVC insulated LT cable 8m

9 3-1/2 core 50sq.mm PVC insulated LT cable 10m

10 4 core 16sq.mm PVC insulated LT cable 25m

11 MS flat 50mm x 6mm 24 kg

12 MS angle 50mm x 50mm x 6mm 22 kg

13 MS channel 75mm x 40mm x 6mm 22 kg

14 MS channel 100mm x 75mm x 6mm 100kg

15 Stay sets 2 sets

16 Stay wire7/8SWG 30kg

41
17 Earthing sets 3 sets

18 GI wire no.8 SWG 3.5kg

19 Nuts and bolts of required sizes 10kg

20 Aluminium paint 2lts

21 Danger notice board 1 no

Q6) An 11kV OH line is to be run through a distance of 3km from an

existing 11kV OH line. An indoor substation 11kV/415V is to be erected
at the terminal point of this OH line. The transformer feed the following
loads:

1. A production shop having a load of 400kW of 3 phase & single

phase motors

2. A Foundry shop having a load of 150kW

3. An administration block having light & fan load of 100kW.

Estimate the quantity of materials required for the installation of OH line

& indoor substation.

Sol:

The total length of the OH line = 3km

Take the length of span between two poles as 60m.

No.of poles required = 3000/60 + 1 = 51

Dead end poles and every 10th structure is to be double pole and
the rest are single pole structures. The no.of poles required = 57

Insulators
11kV pin insulators on all intermediate pole structures = 45 x 3
=135

11kV strain disc insulators = 3 + (6 x 4) + 3 = 30

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Cross arms
GI cross arms 1.5m x 12.5 cm x12.5 cm = 45

GI cross arms 2.15m x 12.5 cm x12.5 cm = 2 x 2 +2 x 4 =12

Angle iron pieces 38mm x 38mm x 6mm for supporting earth wire
on double pole structure = 12

Angle iron pieces 38mm x 38mm x 6mm for supporting earth wire
on intermediate structure = 45

Cross bracing sets for double pole structure = 6

Conductor
Length of ACSR conductor 6/1x2.59mm = 3 x 3000 + 2% for sag
and wastage =9180m

No.8 SWG GI wire = 500kg

Stay sets = 4 sets

Stay wire 7/8 SWG = 25kg

Earthing sets at four points in every 1.6km = 8 sets

11kV danger notice plates = 50 nos.

Substation
The supply is taken from 11kV, 3 phase 50Hz OH transmission line
which terminates on a double pole structure. The protective devices
such as GO switch, HG fuses, LA are all erected on the pole structure.the
supply is taken by 11kV 3 core 25 mm2 paper insulated cable.
The capacity of the transformer can be calculated based on the
connected load
400  150  100
Total connected load =  0 . 6  500 kVA
0 .8
( Assume pf 0.8 &
load factor 0.6)
An 11kV/415V 500kVA transformer is to be installed in the indoor
substation. An LT OCB 1000A 415V can be connected to protect the LT

43
panel.
The LT panel consists of:
1. A 600A, 415V LT OCB to feed the production shop load.
2. A 300A SFU to feed the foundry shop load
3. A 200A SFU to feed the light & fan load in the administration
block.
4. One 200A & 300A SFU as spare
Size of cables
50010 3
Line current at the secondary of the transformer, IL   696 A
3  415

Taking a factor of safety, 3 runs of 3-1/2 core 240sq.mm PVC /XLPE

insulated armoured LT cable can be used.
40010 3
Line current in the feeder to the production shop, IL   556 A
3  415

Taking a factor of safety, 2 runs of 3-1/2 core 300sq.mm PVC /XLPE

insulated LT cable can be used from LT panel to the production shop.
15010 3
Line current in the feeder to the foundry shop, IL   208 A
3  415

single run of 3-1/2 core 240sq.mm PVC /XLPE insulated LT cable

can be used from LT panel to the foundry shop.
Line current in the feeder to the administration block,
10010 3
IL   139 A
3  415

single run of 3-1/2 core 150sq.mm PVC /XLPE insulated LT cable

can be

used from LT panel to the administration block.

Single line diagram:

Estimate of Materials

44
SL Description of material Quantity
No.

1 RCC poles 11m long 57 nos.

2 ACSR conductor 6/1/2.59 9180m

3 11kV pin insulator along with pins 135 nos.

4 11kV strain disc insulators 30 nos.

5 GI cross arms 1.52 m x 12.5cm x 12.5 cm for 45 nos.

single poles

6 GI cross arms 2.15 m x 12.5cm x 12.5 cm 10 nos.

7 Angle iron pieces 38 x 38 x 6 mm 45 nos.

8 Cross bracing sets 6 sets

9 No.8 SWG for earthing 500kg

10 11kV jumpers with insulation sleeves 3 nos.

11 11kV LA 3 nos.

12 11kV GO switch 1 set

13 11kV HG fuse 1 set

14 11kV paper insulated 3 core 25 sq.mm cable 40m

15 11kV 400A OCB with metering and protection 1 set

devices

16 GI pipe for carrying 11kV cable along the pole 5m

17 Clamps for fixing GI pipe and cable end boxes 8 nos

18 11kV/415V 500kVA three phase 50Hz indoor type 1 set

transformer with HT & LT cable boxes

19 3-1/2 core 240sq.mm PVC insulated LT cable 30 m

20 LT panel having: one incoming line of 1000kVA 1 set

OCB, four outgoing lines and 1 no. Of 600A, 2

45
 nos.of 300A, and 2 nos.of 200A SFU along with LT
bus bars and suitable cable end boxes

21 3-1/2 core 300 sq.mm PVC insulated LT cable 50m

22 3-1/2 core 150 sq.mm PVC insulated LT cable 50m

23 Angle iron 50mm x 50mm 100 kg

24 Angle iron 25mm x 25mm 30kg

25 Earthing sets 5 sets

26 Earth strips 50mm x 6mm 100 kg

27 Nuts and bolts of required sizes 10kg

28 Aluminium paint 2lts

29 Danger notice board 1 no

30 Fire extinguisher 1 no.

31 First aid box 1 no.

32 Shock treatment chart 1 no.

33 Rubber mats Lumpsum

46
47