1.4.3.

Some basics of industrial electrical installations:

Industrial electrical installations are a critical component of any industrial facility or

factory, as they provide power to machines and equipment necessary for production
processes.
Here are some basics and important requirements that should be considered in industrial
electrical installations:
i. Electrical Safety:- Proper safety measures and regulations must be followed
ii. Power Supply:- Reliable power supply
iii. Electrical Panels:-Electrical panels distribute power throughout the facility
iv. Electrical Wiring:- must be properly sized, rated, and installed
v. Earthing (Grounding):-Proper grounding of the electrical system
vi. Circuit Protection:- proper protection devices fuses, circuit-breakers, and surge
protectors are used to
vii. Maintenance:-Regular maintenance including testing, inspecting, replacing worn and
updating the system …
Determining (Selecting)Automatic Circuit Breaker (ACB) and
Conductor (Cable) Size.
For any type of a load, rating of ACB and Cable are critical.
Depending on the type of cable, different types of cables or conductors have
different values of ampacity.
Ampacity:- is current carrying capacity of conductors. (Table B1-B30
EBCS).
In the process of determining ACB and cable size the following points need to
be known.
To select Automatic Circuit Breaker (ACB) rating and Conductor
(Cable) Size, the following parameters should be considered

1) Correction Factors
2) Material of conductor
3) Core type
4) Insulation type
5) Protection of cable
6) Installation method
Parameters that should be considered
(to select ACB and cable size….)
1.Correction Factors
i. Group Correction Factors ,cg, – If the number of wires which are
installed in the same conduit, truck or tube, its ampacity decreases
(because of heat). For this reason we should have to consider group
correction factor of a conductor (Table A1 – A3 of EBCS).
ii. Ambient Temperature Correction Factors ,ca,- The ampacity of
a conductor also depends on the temperature of the place. For this
reason we should have to consider Ambient Temperature Correction
Factor, ca, of a conductor. (Table A4– A6 of EBCS).
Continued……
1) Material of conductor
i. Copper
ii. Aluminium
2) Core type
i. Single core (TB1, TB5,…)
ii. Multi core (TB3, TB7,…)
3) Insulation type
i. PVC
ii. Thermosetting
iii. Rubber
iv. Mineral
Continued……
4) Protection of cable
i. Non armoured (TB1, TB3, ..)
ii. Armoured (TB5, TB7,….
5) Installation method
i. In conduit, in a wall (flush mounted)
ii. In conduit on a wall or trunking (Surface installation)
iii. Cliped direct
iv. On a perforated cable tray.
Clipped direct:
On a Perforated cable tray
 Procedure of selecting ACB and cable size

STEP 1: Determine the Design Current, Ib

For Single phase pure resistive design or circuit, the design current, Ib:

For Single phase with inductance design or circuit, the design current,
Ib:

For Three phase circuit, the design current, Ib:

Procedure of Selecting ACB & Cable Size

STEP 2: Select the rating of the protection,In

Rated Current of Protective Device Against Over Current,
In – is the nominal current or current setting of the device protecting the
circuit against over current, In
The total load on consumers service or branch
circuit shall be 80% of the circuit rating.
The rating of the protection (ACB,...), In,
should be greater than or equal 1.25 times
design current, Ib
In > or = 1.25 Ib
Procedure of Selecting ACB & Cable Size
STEP3: Select the relevant correction factors (CFs)
i) Group Correction Factor (cg) – When 2 or more than two
conductors are installed in the same PVC or conduit, we
should have to consider group correction factor(cg).
ii) Ambient Temperature Correction Factor,(ca) – It is a
correction factor due to temperature of surrounding area
Procedure of Selecting ACB & Cable Size
STEP 4: Determine tabulated current carrying
capacity, It, of conductor or cable
Tabulated Current carrying capacity will be
determined by the following expression dividing the
value of rating of protection, In by the relevant
Correction Factors cg & ca

Tabulated current indicates the minimum value of current that the cable
should be carry.
Procedure of Selecting ACB & Cable
Size

STEP 5: Choose a cable size to suit It

To select conductor or cable size, we sholud have to consider that
Design circuit (dc, single phase, three phase)
Type of cables (Single core, multi core, with or without sheath,
armoured or non-armoured,...)
Installation method (in an insulated wall, on enclosed in coduit
on a wall or ceiling, on cable tray,.......)
Iz > or = It
Procedure of Selecting ACB & Cable
Size
STEP 6: Check the voltage drop.
The size of conductors shall be, such that the voltage drop
between the supply terminal and. fixed current-using equipment
shall not exceed 4% of the nominal voltage of the supply line,
when the conductors are carrying the full, load current. [EBCS
p96].
If the voltage drop is greater than 4%, select the next size of
conductor and check the voltage drop
Procedure of Selecting Cable Size (Summary)

1) Determine the Design Current, Ib

2) Select the rating of the protection,In
3) Select the relevant correction factors (CFs)
4) Determine tabulated current carrying capacity, It,
of conductor or cable.
5) Choose a cable size to suit Iz
6) Check the voltage drop.
Automatic Circuit Breaker (ACB) Rating Size (In A)
and Conductor/Cable/ size in sq.mm

Single phase

6, 10, 16, 20, 25, 32 and 40 Ampere

Three phase

10, 16, 20, 25, 32, 40, 50, 63, 80, 100, 125, 150, 200, 250, 300, 350,
400 and 450 ampere

Conductor /cable/ rating (sq. mm)

1, 1.5, 2.5, 4, 6, 10

4 X 2.5, 4 X 4, 4 X 6, 4 X 10, 4 X 16, 3 X 25 / 16, 3 X 35 / 16, 3

X 50 / 25, 3 X 70 / 35, 3 X 95 / 50, 3 X 120 / 70, 3 X 185 / 95, 3
X 240/120, 3 X 240/120 and 3 X 300/150.
EXAMPLE 3
Select cable size and Protective Device of
stove (Injera Mittad) ,
P = 3.0 KW, V = 220 V. ca =1, cg =
0.8 ,
Type of conductor: Multi, non armoured.
Distance between MDB and load is 20 m.
Installation type in closed in wall (flush)
Selection of cable size and protective devices of IM
Determine Line Current (or Design Current, Ib)
For Single phase Motor: IL(Ib) = P1/ (V*pf)
Eff = P2/P1 → P1 = P2/Eff
For 3 phase IM: IL(Ib) = P1/(1.73*VL *pf)
Eff = P2/P1 → P1 = P2/Eff
NB: Single Phase Motors has low power factor (from 0.4 – 0.6)
Three Phase IM has better power factors
(From 0.8 – 0.96)
 EXAMPLE 4 –
A single phase supply source supllies power for portable
drlling machine with the following data:
Cable type of multi core pvc insulated, non armored enclosed in
conduit mounted directly on the wall(Surface).
Take (cg = 0.9, ca = 1.0)
Data of the Motor:
Supply Voltage V= 220 V, f= 50 Hz,
Out put Power of the motor P=3.0 KW, Efficiency 75%,
its power factor is 0.6 and Length = 80 M
Determine;
a) The nominal value of over current protective devices.
b) The appropriate size of the conductor and Check the
voltage drop.
 EXAMPLE 5
A three phase supply source supllies power for a lathe
machine with the following data:
Cable type of multi core pvc insulated, non armored enclosed in
conduit mounted directly on the wall (Surface).
Take (cg = 0.85, ca = 0.94)
Data of the Motor:
Supply Voltage VL= 380 V, f= 50 Hz,
Out put Power of the motor P=12.0 KW, Efficiency 92%,
its power factor is 0.8 and Length = 100 M
Determine;
a) The nominal value of over current protective devices.
b) The appropriate size of the conductor and Check the
voltage drop.
EXAMPLE 6 (HW)
Select cable size and Protective Device of
water heater with the following data,
P = 2.5 KW, V = 230 V.
ca =0.91, cg = 0.8
Distance from MDB to heater = 40 M
Type of cable Single Core, non sheathed,
non armoured. Installation type is on a
trunking.
 (Example 7 HW)
A branch of an Electrical Design `supplies power for a single
phase water pump motor with a cable type of multi core PVC
insulated, on trucking non-armoured.The motor is operating
at 220 V of 50 Hz and rated power of 2.8 KW, Efficiency
75%.The motor power factor is 0.6 and length of cable is 65m.
Take cg=0.85 and ca=0.95. Determine;
a) The nominal value of over current protective devices.
b) The appropriate size of the cable and Check the voltage
drop.
Activity 3
 Methods to Use Efficient Building
Electrical Design
1. Using Energy efficient lighting.
LED lamps.
Type of Bulb Watts Lumens Luminosity
Tungsten 60W 700 to 850 lm 8 to 10 lm/w
Halogen 42W 700 to 850 lm 12 to 15 lm/w
CFL 12W 700 to 850 lm 30 to 60 lm/w
LED 10W 700 to 850 lm 40 to 90 lm/w

Advantages of LED Bulbs:

LED bulbs have 10 times longer life in comparison to fluorescent and incandescent
lights.
LED bulbs does not contain filament so there is less chance of damage.
Common incandescent bulb become hot and generate lot of heat in the room while LED
bulb prevents the heat build-up and helps in reducing the air conditioning cost in room.
As power consumption of LED lamp is very less, use in solar panels is increasing.
Initial cost of LED bulb is more in comparison to fluorescent bulb with they have long life
and they can be easily move from one place to another without breakage and save
electricity also.
LED bulbs are not sensitive to temperature or humidity.
LED bulb does not contain mercury also hence do not provide harm to environment also.
2. Implement smart controls and automation
 (Example 8 CW)
(Street Lighting Installation)
A certain street lighting installation which contains 30 lamps and each of them
has 100W of power is supplied from 380V, 50Hz three four wire system. The
distance between SDB (SS) and the last pole is 900 meters. The cable is
installed in the ground.
Cable type of multi core pvc insulated, non armored.
(Take Group correction factor cg = 0.85 and ambient temperature correction
factor, ca = 1.0)
Determine;
a) The nominal value of over current protective devices.
b) The appropriate size of the conductor and Check the voltage
drop.
OF-FTI-ALL -18 Iss 25
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Sample of SDB
1.5 Efficient Building Electrical Design

Energy efficiency defined as the ratio between

output performance compared with the input
of energy.
It consists of the following:
using less energy for the same performance;
using the same energy for better
performance, or
 improving the conversion of energy into
electricity.
 Difference between Industrial or
Commercial Wiring and
Residential Wiring
There are several key differences between industrial or commercial
wiring and residential wiring. Here are some of the most significant
differences:
Power Requirements: Industrial or commercial buildings generally
require a higher level of power than residential buildings. This means
that industrial or commercial wiring systems are designed to handle
higher voltage and current levels than residential wiring systems.
Wiring Size: Due to the increased power requirements, the size of
the wiring in industrial or commercial buildings is generally larger than
that used in residential buildings.
Complexity: Industrial or commercial wiring systems tend to be more
complex than residential wiring systems. This is because they must be
able to handle a larger number of circuits, more complex distribution
systems, and multiple power sources.
Safety Considerations: Safety considerations are much more critical
in industrial or commercial wiring systems due to the higher levels of
power involved. Industrial or commercial wiring systems often include
specialized safety devices such as ground fault circuit interrupters
(GFCIs) and arc fault circuit interrupters (AFCIs) to prevent electrical
shock and fire hazards.
 Summary of Electrical Installation.
1) In cooperation with the local electric utility, decide upon the point of service entrance, service
voltage and metering location (KWHM) and others. Locate the Main Distribution Board (MDB) to
the appropriate place with Switch board or KWHM and with SDB
2) Design all lighting, SOL, HVAC, tele, TV, bell, etc installation. Select appropriate ACB ,
conductor and conduit size.
3) Depending on the type of facility, it may be necessary to separate the lighting layout from the
receptacle and signal device layout for the sake of clarity of the plans.
4) Design MDB and SDB schedule.
5) Design Grounding diagram, Riser diagram and Lightning diagram
6) Depending on the site, prepare the site plan of Electrical Design
7) Make an electrical load estimate based on Illumination, areas involved, building data, and any other
related data.
8) Determine feeder sizes (Demand load) which will be requested to the EEPCO and all protective
equipment ratings, (ACB).
9) Write electrical report.
10) Prepare Bill Of Quantity (BOQ).
Final Stage
All Hard Copies should printed out and will be submitted
to the concerned authority for approval,
1) Blue Print of Electrical Design
2) Hard copy of Electrical Report
3) Hard Copy of Cost Estimation or BOQ.
OF-FTI-ALL -18 Iss 31
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