Plant Engineering

Electrical Infrastructure Systems

 Infrastructure System in Industrial Plants
Efficiency of an industrial plant is not only influenced
by the major mechanical and electrical installations,
the appropriate infrastructure also plays an important
role.The contribution of a reliable plant infrastructure
consist of:

s/PTIMIZEDSUBSTATIONANDELECTRICROOMLAYOUTS
s#ABLEENGINEERING
s)NSTALLATIONENGINEERING
s%ARTHING
s,IGHTNINGPROTECTION
s0ROCESSANDSTREETLIGHTING
s&IREDETECTIONANDPROTECTION
Substation s#OMMUNICATIONSYSTEMS
Layouts
a tio
n s!IR CONDITIONINGANDVENTILATION
til
Ea

n
Ve
rth

4HECORRECTDIMENSIONINGSMARTPOSITIONINGAND
in
g

ADEQUATETECHNOLOGYCANHELPTOSAVEENORMOUSSUMS
Protection

OFMONEYNOTONLYINTHEINVESTMENTBUTALSOIN
Protection
Lighting

OPERATINGCOSTSWHEREANAPPARENTLYMARGINALSAVING
Fire

ADDSUPTOASIGNIlCANTENHANCEMENTOFPLANTECONOMY
Co

OVERTHELIFECYCLE
m
m
un yst
ic em
S

at s
io

ng
n

hti
Cable Lig
Engineering

2
Substation and
Electric Room Layout
Smart positioning saves money
The location of the electric rooms and substations is the
lRSTVITALDECISION0OWERLOSSESEQUALOPERATIONALCOSTSANDARE
DETERMINEDBYTHEAVERAGECABLELENGTHBETWEENELECTRICROOM
and consumer.The shorter the distance to the consumer,
THELOWERTHELOSSES4IMELYCONSULTINGOFANEXPERIENCEDINFRA
STRUCTUREENGINEERWILLSAVEINVESTMENTANDENERGYCOSTS
DUETOINNOVATIVEDESIGNOFTHEENERGYDISTRIBUTIONANDSMART
POSITIONINGOFSUBSTATIONSANDELECTRICROOMS

3
Earthing and
Lightning Protection

Limiting the disruption,

the fault and the damage
-AINTAININGHIGHOPERATIONALAVAILABILITYOF
electrical installations in any industry necessitates
APPLYINGACCEPTEDRULESCONCERNINGTHEDESIGN
ANDIMPLEMENTATIONOFEARTHINGSYSTEMS%ARTHFAULTS
are the most common faults in an electrical
NETWORK#ORRECTEARTHINGTHEREFOREIMPROVESTHE
TECHNICALPERFORMANCEANDREDUCESTHERISKOF
DISTURBANCESDAMAGESANDINJURIES

(EREARETHEMAINPURPOSESFOREARTHINGAN
ELECTRICALNETWORK

s0REVENTINGVOLTAGETOEARTH
s0ROTECTIONOFPERSONNELANDPROPERTY
s0ROTECTIONAGAINSTTRANSIENTOVERVOLTAGES
s0ROTECTIONAGAINSTSTATICDISCHARGES
s0ROTECTIONAGAINSTTHEEFFECTOFLIGHTNINGSTRIKES
s0ROTECTIONAGAINSTSTRAYCURRENTS
s#REATINGDElNEDNETWORKCONDITIONS
FORPROTECTIONANDMETERINGPURPOSES

4
4HEMOSTCOMMONEARTHINGPRACTICESININDUSTRIAL $AMAGECAUSEDBYLIGHTNINGSTROKESCANNOTBE
plants are: COMPLETELYPREVENTEDEITHERTECHNICALLYORONECONOMIC
GROUNDSBUTTHERISKCANBEREDUCEDTOANACCEPTABLE
s2IGIDEARTHINGOF(6
INSTALLATIONSEGSWITCHYARDS LEVEL,IGHTNINGPROTECTIONALWAYSINCLUDESANEARTHING
OVERHEADLINES system.
s2ESISTORORIMPEDANCENEUTRALEARTHINGTRANSFORMER !DISTINCTIONISMADEBETWEENEXTERNALANDINTERNAL
EARTHINGOF-6
INSTALLATIONS LIGHTNINGPROTECTION
s3OLIDEARTHINGOF,6
INSTALLATIONS4.
#
3NETWORK %XTERNALLIGHTNINGPROTECTIONCOMPRISESALLDEVICES
ACCORDINGTO)%#TERMINOLOGY located outside, at and in the protected installation,
FORTHEPURPOSEOFINTERCEPTINGANDDIVERTINGTHE
&ORELECTRONICSYSTEMSANDCIRCUITSASEPARATEELECTRONIC LIGHTNINGSTROKETOTHEGROUNDINGSYSTEMEGOVERHEAD
EARTHINGGRIDISOFTENANISSUE
)NVESTIGATIONSANDPRACTICALTESTSHAVESHOWNTHAT
SEPARATEGROUNDINGSYSTEMSFORELECTRONICSANDELECTRICAL
INSTALLATIONSCANLEADTOVOLTAGEDIFFERENCESINTHE
RESPECTIVEEQUIPMENTDUETOTHERESISTANCEOFTHESOIL
ANDORTHEGROUNDINGSYSTEM4HESEDIFFERENCESCANCAU
PROTECTIVEWIRESEARTHINGOFSTEELSTRUCTURESETC
)NTERNALLIGHTNINGPROTECTIONCOMPRISESTHEMEASURES
TAKENTOCOUNTERACTTHEEFFECTSOFTHELIGHTNINGSTROKE
CURRENTANDITSELECTRICALANDMAGNETIClELDSONMETAL
ASSEMBLIESANDELECTRICALAPPARATUSEGSURGEARRESTERS
SEUNCONTROLLEDSWITCHINGASWELLASELECTRONICSDEFECTS !TPRESENTTHEREAREFOURMETHODSOFDESIGNINGLIGHTNING
7HENPROTECTIVEANDSYSTEMGROUNDINGAREINTERCON
protection systems:
NECTEDINTERFERENCESUCHASLIGHTNINGCANBRINGTHE
ENTIREELECTRONICSSYSTEMTOAHIGHERVOLTAGEFORAshort s4HELIGHTNINGSPHEREMETHODFORHIGHLYINmAMMABLE
TIME.ODAMAGEISCAUSEDTOELECTRONICEQUIPMENT AREASSTORAGESEGOILGAS
SINCETHEREISNOVOLTAGEDIFFERENCEBETWEENTHE s4HEMETHODACCORDING$).6$%FORALLOTHER
PROTECTIVEGROUNDINGELECTRONICEQUIPMENTHOUSING BUILDINGS
ANDTHEELECTRONICSEARTHINGSYSTEM s4HE,INCK5NIVERSAL-ETHODLIGHTNINGRODSAND
!SEPARATEELECTRONICSGROUNDINGSYSTEMCANEVEN OVERHEADEARTHWIRESFOROVERHEADLINES
RESULTINADDITIONALRISKSANDISTHEREFORERARELYUSED s4HEMETHODACCORDING$).6$%
anymore. EXCLUSIVELYFOROUTDOORSWITCHYARDS

5
Industrial Lighting

Wasting the profit

$EPENDINGONTHELOCATIONLIGHTINGSYSTEMSMUSTFULlLA
BROADRANGEOFREQUIREMENTS
)NELECTRICROOMSOFlCESWORKSHOPSORLABORATORIESFOR
EXAMPLEHIGHERILLUMINATIONLEVELSARENEEDEDTHANIN
PRODUCTIONAREASSTORAGEZONESORROADWAYS
)NPRODUCTIONAREASITISNECESSARYTODIFFERENTIATEBETWEEN
LIGHTINGFORACCESSANDESCAPEROUTESORFORMAINTENANCE
PURPOSES"YESTABLISHINGOPTIMIZEDILLUMINATIONLEVELS
THEFOUNDATIONSFOROPTIMALENERGYSAVINGSCANBELAIDAT
ANEXTREMELYEARLYSTAGEOFTHEPROJECT
4HERESPONSIBILITYFORILLUMINATIONSTANDARDSISWITH
)3/AND#)%)NTERNATIONAL#OMMISSIONON,IGHTING 
4HEDEMANDINILLUMINATIONLEVELSHASINCREASEDDURING
RECENTYEARSANDSOMEKEYlGURESAREINDICATEDINTHE
TABLEBELOW

,IGHTINGSYSTEMSTODAYAREOFTENDESIGNEDFORTHEWORST
CASEIEFORTROUBLE SHOOTINGPURPOSES.OACCOUNTIS
TAKENOFTHEFACTTHATPURELYFORLIGHTINGAMEDIUM SIZED
CEMENTORMINERALPROCESSINGPLANTREQUIRESANINSTALLED
CAPACITYOFABOUTK7$URINGTHENIGHTLIGHTINGIS
SWITCHEDONBYANAUTOMATICSYSTEMUSINGFOREXAMPLE
photoelectric cells.
)NSTALLATIONSOFSUCHDIMENSIONCONSUMEACONSIDERABLE
AMOUNTOFENERGY3INCEENERGYISAPREDOMINANTCOST
FACTORITISWORTHCONSIDERINGLIGHTINGINSTALLATIONSIN
THEPERSPECTIVEOFANENERGY SAVINGCONCEPT(OWEVER
THECORRECTDESIGNANDLAYOUTOFLIGHTINGINSTALLATIONS
INANINDUSTRIALPLANTREQUIRESPROCESSKNOW HOWAND
EXPERIENCE

6
 Illuminance levels according to ISO 8995 (2002)
Activity zones LUX

Buildings:
%NTRANCESCORRIDORSRESTROOMSARCHIVESSTORAGE 
3TAIRWAYSANDESCALATORS 
Canteens 200
Conference rooms 500
Plant rooms, switch gear rooms 200
7ORKSHOP 
Precision measuring rooms, laboratories 500
Control room 500

Process:
Process area without manual intervention 50
0ROCESSAREAWITHOCCASIONALMANUALINTERVENTION 
Process area with continuous manual intervention 200
#ONTROLPLATFORMSLOCALCONTROLROOMS 
#RUSHINGGRINDING 
Preparation of materials, work on kilns and mixers 200
0ACKINGANDLOADINGAREA 
!UXROOMSEGPUMPSCONTROLSTATIONSWITCHBOARD 
3TAIRWAYSESCAPEROUTES 
Walkways and walkways along conveyors 20
Platforms and passenger subways (underpasses) 50
-ANSIZEDUNDERmOORTUNNELSCELLARSETC 

Outdoor:
Main roads 20
3ECONDARYROADS 
Storage areas 20
Petrol station 50
3WITCHYARDSOILWATERTANKS 
,OADINGANDUNLOADINGRAMPS 

High-efficiency lighting

Illumination power requirement on average 500 kW

Possible savings
s"YCHOICEOFEQUIPMENT K7
s/PTIMISINGTHELIGHTINGDISTRIBUTIONAND K7
location of armatures
s/PTIMIZINGTHEILLUMINATIONLEVELS K7

5TILIZATIONFACTOR 

!CTUALPOWERSAVING K7
#AREFULSELECTIONOFLIGHTINGEQUIPMENT 3AVINGSPAATHOURS K7H
ISANOTHERSTEPTOWARDSSAVINGENERGY 3AVINGSPAAT%UROK7H %URO
0RACTICALEXPERIENCEHASSHOWNTHATTHE
USEOFHIGH EFlCIENCYLIGHTINGEQUIPMENT
4HEUTILIZATIONFACTORCANVARYBETWEEN
CANSAVEACONSIDERABLEPERCENTAGEOF ANDACCORDINGTOTHEPLANT
THELIGHTINGENERGYCOSTS

7
Cable and
Installation Engineering

Reduced costs through

OPTIMIZEDDESIGN
#ABLEANDINSTALLATIONMATERIALCOSTSACCOUNT
for a substantial part of the total plant
ELECTRIlCATIONCOSTS)NTHEVASTAREACOVERED
BYANINDUSTRIALPLANTTHEENERGYDISTRIBUTION
FROMHIGH MEDIUM ANDLOWVOLTAGEFEEDERS
DOWNTOTHECORRESPONDINGCONSUMERS
INCLUDINGTHERELATEDPROCESSCONTROLEARTHING
ANDLIGHTNINGREQUIRESANEXTENSIVECABLE
NETWORK4HEOVERALLLENGTHOFPOWERANDCONTROL
CABLESCANEASILYREACHATOTALOFSEVERAL
HUNDREDKILOMETRES/PTIMIZEDINFRASTRUCTURE
ENGINEERINGSUPPORTEDBYMODERNNETWORK
Loss %
CALCULATIONTOOLSCANTHEREFORESAVEENERGY
and costs. 3,0

4OSELECTTHEAPPROPRIATECABLETYPEANDCROSS 2,5
SECTIONSEVERALFACTORSHAVETOBECONSIDERED
2,0
'RAPH
s!MBIENTTEMPERATURE
,OSSESINLOWVOLTAGEPOWER
s#ABLELAYINGMETHOD 1,5
CABLES#ABLESDIMENSIONED
s0ERMISSIBLEVOLTAGEDROP
FORVOLTAGEDROPWITH
s.OMINALCURRENT 1,0
50 75 100 125 150 RATIOOFSTART UPCURRENTTO
s#ABLELENGTH Average cable length per consumer (m) NOMINALOPERATINGCURRENT
s3HORT CIRCUITCURRENT
of 6.5
s4RIPPINGTIMESOFPROTECTIVEDEVICES
s,OADmOWCALCULATIONS
s(ARMONICDISTORTION Cable cost in 1000 Euro
s.ETWORKGROUNDING
350

4OKEEPTHEVOLTAGEDROPWITHINREASONABLE
300
LIMITSLONGERCABLESREQUIRELARGERCROSS SECTIONS
THUSGENERATINGHIGHERCOSTS!REDUCTIONOFTHE
250
AVERAGECABLELENGTHOFLOWVOLTAGECONSUMERS
BYMCANSAVEAPPROXIMATELYOFTHE Graph 2:
200
total cable and installation costs. Modern cable #ABLECOSTSINRELATIONTO
ANDINSTALLATIONENGINEERINGSOFTWARESUPPORT AVERAGECABLELENGTH
150
THEOPTIMIZATIONOFTHEDESIGNANDIFCOMBINED #ABLESDIMENSIONEDFOR
WITHBARCODEREADERSENABLESTHEMONITORING 100
VOLTAGEDROPWITHRATIOOF
OFTHECABLEANDINSTALLATIONMATERIALDURINGCON 50 75 100 125 150 START UPCURRENTTONOMINAL
Average cable length per consumer (m)
struction on site. OPERATINGCURRENTOF


 Plant Communication
Systems

DRI Plant
Telephone System
Intercom Stations

Central for Public Announcement and Intercom

PABX

8 ports
availables for
analog
trunk lines
32 ports for
digital
extension

SMP/CSP Plant
Central for Public Announcement and Intercom

Who’s there?
0LANTCOMMUNICATIONBOTHINTERNALANDEXTERNALIS 7HILETELEPHONEFAXANDMOBILESANALOGUEORDIGITAL
EXTREMELYIMPORTANTININDUSTRIALPLANTS)TISUSEDFOR CONVENTIONALORBYSATELLITE SERVEMAINLYEXTERNAL
TROUBLESHOOTINGMAINTENANCEOREMERGENCYSITUATIONS COMMUNICATIONINTERCOMANDPAGINGSYSTEMSAREFOR
ANDIFINTER CONNECTEDWITHPROCESSCONTROLEVEN PLANTINTERNALPURPOSESONLY4HEACTUALARRANGEMENT
REMOTEANALYSISOFTHEPLANTISAVAILABLE4HEREFORETHE location and number of the apparatuses depends
DEMANDFORHIGHRELIABILITYANDCOMFORTOFTHEPLANT STRONGLYONTHEPLANTREQUIREMENTS4HESYSTEMITSELFIS
communication system has been drastically increased MODULAREXTENDABLEANDEQUIPPEDWITHAPROGRAMMABLE
DURINGRECENTYEARS main unit.
7ITHTHELATESTCOMMUNICATIONTECHNOLOGIESALOTOF -ODERNTELEPHONEANDINTERCOMSYSTEMSOFFEROPTIMIZED
FUNCTIONALITYHASMERGEDINTOSMARTTELEPHONEAND COSTBENElTRATIOSFOREXTERNALANDINTERNALPLANTCOM
COMMUNICATIONSYSTEMSCOMBININGTHEADVANTAGESOF MUNICATIONS"YUSINGMODERNlELDBUSTECHNOLOGY
THEPREVIOUSLYSEPARATEDSYSTEMS THEPERFORMANCEANDCOMFORTOFTHESESYSTEMSHAVETRE
MENDOUSLYINCREASEDATREDUCEDCABLINGANDINSTALLATION
4HEFOLLOWINGFUNCTIONALITIESAREINCOMMONUSETODAY COSTS.OTONLYFUNCTIONALITYISADESIGNCRITERIABUTALSO
s0HONEFAXMOBILES THEENVIRONMENTALCONDITIONS&IELDTELEPHONESOFTEN
s)NTERCOMPLANTCOMMUNICATIONNETWORK REQUIREHEAVYDUTYDESIGNTOCOPEWITHTHEMECHANICAL
s0AGING stress of a particular location.
.OISEANDPOLLUTIONSLEVELSGENERATEDBYTHEMACHINERY
ORTHEENVIRONMENTISANOTHERFACTORTOBECONSIDERED
DURINGENGINEERING

9
 Fire Protection

Don‘t play with fire

&IREPROTECTIONISAVERYSERIOUSBUSINESSANDPREVENTIVE
MEASURESARECOMPULSORYACCORDINGTOALLMAJORBUILDING
codes and insurance companies.This includes:

s3EPARATIONOFBUILDINGSINTOlREZONESAND
OTHERCIVILCONSTRUCTIONCOUNTERMEASURES
s)NSTALLATIONOFlRE BARRIERSPARTICULARLYWHERECABLES
CONDUITSORPIPESETCPENETRATETHEWALLS
s3ELECTIONOFAPPROPRIATElRERETARDANTMATERIALS
s)NSTALLATIONOFANINTEGRATEDlREALARMSYSTEM
s)NSTALLATIONOFlREEXTINGUISHINGSYSTEMS
s)NSTALLATIONOFlRElGHTINGEQUIPMENT

&IRESOFELECTRICALORIGINARECAUSEDBYARCINGFAULTS
EXCESSIVETEMPERATURERISEDUETOOPERATIONALOVERLOADS
ORSHORT CIRCUIT(ENCETHEMAINFOCUSISONCABLE AND
electric rooms, cable tunnels and transformers.

)FAlREISDETECTEDEARLYANDACTIONSTOlGHTITARETAKEN
QUICKLYANDEFlCIENTLYTHEDAMAGEANDTHEINTERFERENCE
TOTHEPLANTISREDUCED!NAUTOMATIClREALARMSYSTEM
PROVIDESTHISFUNCTIONALITY
4HElREISINDICATEDBYSMOKETEMPERATUREORmAME
DETECTORSWHICHSETOFFTHEALARMANDTRIGGEREXTINGUISHING
SYSTEMSIFINPLACE4HEPREVIOUSLYUSEDRADIO ACTIVE
ISOTOPESENSORSHAVEBEENREPLACEDBYELECTRONICSENSORS
FORSAFETYREASONS!DDITIONALLYELECTRICALISOLATIONAND
THESHUTDOWNOFVENTILATIONSYSTEMSOFTHEAFFECTEDAREA
must be initiated by the system.


Ventilation & Cooling

Keep cool
Heat losses reduce the performance and insufficient
COOLINGCANRESULTINOVERLOADOREVENDAMAGEOFELEC
trical equipment. Where most of the components are
OPERATEDONNATURALAIRmOWONLYOTHERSSUCHASPOWER
ELECTRONICSREQUIREPERMANENTFORCEDCOOLING
to protect critical components.Temporary forced
COOLINGISALSOUSEDTOCOVERPEAKDEMANDSOF
EQUIPMENTEGFORCEDCOOLINGFORTRANSFORMERS/.!& 
6ENTILATIONANDCOOLINGSYSTEMSENSURECONSTANTOR
EVENINCREASEDPERFORMANCEOFELECTRICALEQUIPMENT
ANDIFCOMBINEDWITHAHEATEXCHANGERANDORCOOLANT
PROVIDESSPACESAVINGANDHIGHLYEFlCIENTSOLUTIONS
TOMEETEVENTHEHIGHESTOPERATIONALDEMANDS

6ENTILATIONANDCOOLINGSYSTEMSINCLUDE
s6ENTILATIONOFSWITCHGEAR ANDCONTROLROOMS
s!IRCONDITIONINGOFSWITCHGEAR ANDCONTROLROOMS
s&ORCEDCOOLINGOFSWITCHGEARANDOTHERCOMPONENTS
s6ENTILATIONANDCOOLINGSYSTEMSFORMOTORS
s6ENTILATIONANDCOOLINGSYSTEMSFORPOWERELECTRONICS

4HESEMI CONDUCTORELEMENTSOFHIGHCURRENTFREQUENCY
CONVERTERSGENERATEENORMOUSHEATWHICHHASTOBE
DISSIPATEDFROMTHEROOM4HISCANBEDONEBYWATER
COOLINGUNITSWHICHTRANSPORTTHEHEATLOSSESVIA
WATER TO WATERANDAIR TO WATERHEATEXCHANGERSTOTHE
EXTERIOR


Commitment to Industrial Plants
!""ISCOMMITTEDTOINDUSTRIALPLANTS3INCE !""ISLEADINGGLOBALSUPPLIEROFPLANTELECTRIlCATION
!""HASADEDICATED#ENTREOF%XCELLENCE SYSTEMS)TSENGINEERINGDEPARTMENTSWITHTHEIR
BASEDIN3WITZERLANDTHATDEVELOPSSTANDARDS INDUSTRYSPECIlCVALIDATIONPROCEDURESENSUREAHIGH
FORTHEMINERALSMININGALUMINIUMINDUSTRIES QUALITYININFRASTRUCTURETECHNOLOGIES
)NTHELASTYEARS!""HASSUCCESSFULLY
DELIVEREDELECTRIlCATIONSOLUTIONSTOOVER
INSTALLATIONSWORLDWIDE

Contact us, use our experience.

"(3:!"%2%6!0OMCANYS

ABB Switzerland Ltd

#( "ADEN$ËTTWIL
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