New Assy Line Equip Load Deails

Demand
Connected load in kw
Station Equipment Description
load in kw (Continuous
)

Chassis line 1
Stn:1 to 26 Chain conveyor (COE) 2 drives : 5.5kwx2 11 8.25
Crane for frame loading
Stn-1 x,y,z drives 6
/unloading
Stn-2 Crane for Bogie x,y,z drives 4
Stn-4 Crane for Front Axle x,y,z drives 4
Stn-5 crane for axles rear 1 x,y,z drives 4
Stn-7 crane for axles rear 2 x,y,z drives 4
Stn-8 Turning device Rotation y,z drives 15 11.25
Stn-3 , 4 ( 2 no) ,
Slewing(Jib) crane: 5 no z drives 2
6,another extra
1 to 8 Electrical Tools 8 stations each approx .1kw 8
DC Nut Runner ( 4 No ) 4 x 2 kw each 8
Total Ch Line-1 66 19.5
Chassis line 2
Floor conv.for engine(Slat
drive unit 0.5 0.5
Conveyor)
engine loading hoist x,y,z drives 4
Engine Subassy
carrier motor 4 nox 1 kw(x), hoist
EMS.-monorail 4 carriers motor 4 no x 3.7kw,z drive = 18.8
18.8kw
Station :9 to 26 Electrical Hand Tools 18 tools each 1kw 18
Stn: 12&13 Transfer car 3 drives,each1kw 3 2.25
10 slewing(Jib) crane 4
Total Ch Line-2 48.3 2.75
Final assy.line
27 to 31 Double slat conveyor drive unit 7.5 5.63
HSD/ Axle Oil/ Steering Oil / AC
30 Different Filling Equipments Gas filling / Engine Oil Topup / 7 5.25
Radiator Filling etc
27 to 31 Electrical Tools 6 tools each 1 kw 6
DC Nut Runner ( 2 no) 2 x 2kw 4
Total 24.5 10.9
Cab Trim Line (Subassy)
Crane for Lifting & Dropping
1 x,z drives 2
Cabin
1 to 24 Slat conveyor drive unit 11 8.3
5 slweing (Jib) crane z drives 2
1 to 28 Electrical Tools 20 tools,each 1kw 20
carrier motor 1 kw,hoist motor
EMS EMS.-monorail conv.,7 carriers 32.9
3.7kw
Total 67.9 8.3
Cabin Transfer System ( From Paint Shop to Cab Trim Area)
Estimated load ( as per Durr
105 78.8
Report)

Grand Total 311.7 120.125

Demand
load in
kw
(Intermitt
ent)

4.5
3
3
3
3

1.5
6
6

14.1

13.5

4.50
3.00

1.5

1.5
15.0
24.7

115
 Equipment Lighting requirement
Sr. No. Description Require Qty. Connected Load (kw) Demand Load (kw)
1 Cab Station ( lux level - 500) (120 mts. X 3 mts.)
Total fixture - 62 62 5 3.72
62 fixture x 80 Watt = 4960 watt
2 Chasis Assembly ( lux level - 500)
Station - 1 to 12 ( 180 mts. x 3.5 mts.) 103 8 6.18
103 fixture X 80 watt = 8240 watt
Station - 13 to 31 ( 285 mts. x 3.5 mts.) 157 13 9.42
157 fixture X 80 watt = 12560 watt
3 Engine dressing conveyer ( lux level - 500)
Total Station - 5 X 2 Twin Light = 10 fixture 10 1 0.6
10 fixture x 80 watt = 800 watt
4 Axle Storage Area ( lux level - 500)
Front & rear axle sub assembly
Total station - 5 X 1 Twin Light = 5 fixture 5 0.4 0.3
5 X 80 Watt = 400watt
5 Bogie sub assembly ( lux level - 500)
Station - 1 X 2 Twin Light = 2 Fixture 2 0.2 0.12
2 X 80 Watt = 160 watt
6 DC Valve sub assembly / Relay valve sub assembly ( lux level - 500) 2 0.2 0.12
Total Station - 2 x 1 Twin Light = 2 Fixture
2 Fixture x 80 watt = 160
7 Inspection Area Station no. 9 ( 15 mts. x 5 mts.) ( lux level - 900) 22 1.8 1.32
Total Fixture - 22 x 80 watt = 1760 watt
8 Inspection Area Station no. 16 ( 15 mts. x 5 mts.) ( lux level - 900) 22 1.8 1.32
Total Fixture - 22 x 80 watt = 1760 watt
7 Inspection Area Station no. 29 ( 15 mts. x 5 mts.) ( lux level - 900) 22 1.8 1.32
Total Fixture - 22 x 80 watt = 1760 watt
9 Work Table ( lux level - 500)
Total Station - 20 x 1 fixture = 20fixture 20 1.6 1.2
Total Fixture - 20 x 80 watt = 1600 watt
10 Tool crib Area ( 15 mts. X 10 mts.) ( lux level - 500) 22 1.8 1.32
Total fixture 22 x 80 watt = 1760 watt
11 Store for machine & Spare ( 15 mts. X 10 mts. ( lux level - 500) 22 1.8 1.32
Total fixture 22 x 80 watt = 1760 watt
12 Maintenance Area ( 15 mts. X 10 mts. ( lux level - 500) 22 1.8 1.32
Total fixture 22 x 80 watt = 1760 watt
13 Electrical Control Room ( 15 mts. X9 mts. ) ( lux level - 300) 12 1.0 0.72
Total fixture - 12 x 80 watt = 960 watt
14 Toilet ( 10 mts. X 5 mts.) (lux level 50 - 100 - 150) 16 1.3 0.96
Total Nos. 8 x 2 fixture = 16 fixture
16 fixture x 40 watt = 640 watt
15 Model Show room - ( 30 mts. X 20 mts.) Lux Level - 500 77 6.2 4.62
Total Fixture = 77 x 80 watt = 6160
Total Equipment Lighting 598 47.84 35.88
 Electrical & Air loads of Testing & Rework and Ware House Area
El.connected Demand Load
Station Procss/ Equipment load (KW) with (kw) -
0.85 average PF Intermittent

Roll Brake Machine : 500Amp , 3 Ph 415VAC :With

0.8 PF , the reqired power = 1.732 x 415A x 500V 305 305
x 0.85 / 1000 = 305Kw
Side Slip Tester : 230V 1 Ph , 10 Amp : Power =
2.3 2.3
2.3 kw
Steering Turn Tables : 3 ph 415 VAC , 10 Amp & 1
BEP Testing Ph 230V 10 amp > Total Power requirement = 1.73
8.3 8.3
Machine x 415V x 10Amp x 0.85 + 230 x 10= 6 kw +2.3 =
8.3 kw
Head Light Aimer : 230V 1 Ph 10 Amp 2.3 2.3
Max Static Brake Tester : 3 Ph 415V 20 Amp 12 12
Tube light near Barake Testing Machine : 20
1.6 1.6
Fixtures x 80 watt each =1.6 kw
Total 331.5 331.5
Touchup Painting ( Heater ) Assuming 1' x 1' Size ,
the approximate load = 1.6 kw per heater x 4 6.4 6.4
heaters
Tube Light : Twin Tubelight > 16 fixturres : Load =
1.3 1.3
16x2 x 40 watt = 1.3 kw
Rework area
Welding Machine : 3 no x 18 kw each 54 27
Pneumatic Tools 5 no x 3 CFM = 15 cfm
Nut runner / Electric Tool : Assuming 10 Tools x 1
10 3
kw each = 10 kw
Total Rework 71.7 7.7
Motor : 7.5 kw x 2 no = 15 kw 15 12
Tube Light : Twin Tubelight > 6 fixturres : Load =
Shower Testing 0.48 0.48
6x2 x 40 watt = .48kw
Machine
Pneumatic line for removing water after shower
tester : 2 Point x 5 cfm = 10 cfm
Total Shower Test Machine 15.48 12.48
5 Pneumatic Tools x 3 cfm = 15 CFM
5 Electric Tools x 1kw = 5 kw 5 1.5
Office lighting : Area 45 x 20 = 900 sq. met : Tube
Warehouse 5.6 5.04
light : 70 no x 80 watt = 5.6 kw
Estimated Equipment Light : 50 Fixtures 4 3
Total Warehouse 14.6 8.04
Total Testing ,Rework & Warehouse 433.28 359.72 32
 Electrical & Compressed Air Load Details of Tankfarm Area
El.connected Demand
Station Procss/ Equipment Standby
load (KW) Load (kw)

HSD Storage Tank HSD Loading Pump ( 2 x 5 HP ) 7.46 3.4 3.4

& Transferring
System HSD Transfer Pump ( 2 x 5HP) 7.46 3.4 3.357

Axle Oil Storage & Oil Loading Pump ( 2 x 5 HP ) 7.46 3.4 3.357
Transferring
System Oil Transfer Pump ( 2 x 5HP) 7.46 3.4 3.357
DM Plant Connected Load 10 kw , Demand
10 7 7
DM Plant + Water Load 7 kw
Coolant Mixing & Coolant - Water Mixing System ( 2 x 5hp ) 7.46 3.4 3.357
Transferring Plant Coolant - Water Mixture Transfer Pump ( 2 x
7.46 3.4 3.357
5HP)
Gear Box Oil Oil Loading Pump ( 2 x 5 HP ) 7.46 3.4 3.357
Storage &
Transferring Oil Transfer Pump ( 2 x 5HP) 7.46 3.4 3.4
Mechanism Oil Oil Loading Pump ( 2 x 5 HP ) 7.46 3.4 3.357
Storage &
Transferring Oil Transfer Pump ( 2 x 5HP) 7.46 3.4 3.357
Total Load Tankfarm Area 84.6 38.07
Spare

3.4

3.4
 Transformer sizing Calculations for AMW (AS PER NEW CALCULATIONS)
Load (KW)
Continuous Intermittent Standby Spare
1 Assembly Line 120 115
2 Testing/Rework/W-H 360 32
3 Tankfarm 38 38 13
AHU/AC Package/Air
4 600
conditioners
5 Assembly line lighting 102.5
6 Ware House Lighting 55
7 Testing area 45
8 Office 25
9 Street Light 10
10 Tank Farm 10
11 D.M. Plant 75
12 Air dryer 10
13 Surrounding Lighting 5
14 Model Showroom 5
15 Equipment Lighting 35
16 Single Phase Sockets 36
17 Three Phase Sockets 720
Total 1495 903 38 13

Transformer Sizing In KVA

100% Continuous + 30% intermittent 1765.9 2207.375

Transformer Sizing Connected KVA xLoad Factor x Diversity Factor x 1.3 (for max. Demand)=1405.859 KVA

So go for Transformer sizing 1.6 or 2.0 MVA

Note:
Diversity Factor = 0.7
Load Factor = 0.7
 Power , Water , Air requirement for Utility Equipments Compressed
air
Sl No Description Electrical Load Water requirement
Connected Demand requirement Demand
CFM
Load in Kw Load in kw lit/day Load (CFM)
1 Equipments 312 120 306
2 Testing , Rework & Warehouse Area 433 360 32
3 AHU : Connected Load 4 no x 100 kw blower , demand load 80% 400 320
4 Tankfarm Area Equipments 85 38
5 DM Plant 10 7.5
6 250CFM Air Dryer 10 9
Shed Lighting Load : Assy + Testing , R/W + W/H(Total Area = 285
x 60 + 60x75 + 120 x 120 = 31635 sq. met : 1 no 442 watt MH
7 243.1 218.79
Fixture will cover 50 Sq. Met. Area : Total Required Fixtures = 550
Approximately
Street Lighting : Total Length of road = 300+300+180+180met =
8 960 Met : Every20 meter 1 fixture of 250 Watt > Load = 50 Fixtures 12.5 11.25
x 250 Watt = 12.5kw , Loading considered as 90%
Surrunding Lighting : Periphery : Assy 810 Met + W/H 480 = 1300
9 Met , One fixture of MV Lamp of 150 Watt > Total Load = 43 6.5 5.85
fixtures x 150 Watt = 6.5 kw
Tankfarm area surrounding lighting : 80 met x80 Met area : Total
10 1.7 1.53
Fixtures : 11 no x 150 watt = 1.7 kw
Office Lighting (Estimated value): Area 45 Met x 20 Met x 2
11 Floors : Twin Tube Light 70 No x 2 floors > Load 140 x 80 = 11.2 10.08
11200 Watt.
Model Showroor : 30 met x 20 met : 50 Pairs of tubelight + other
12 4.5 4.05
light (500watt) > Total Load = 50x80+500 watt = 4.5 kw
13 Equipment Lighting ( Refer separate detailed sheet) 47.84 35.88
Office Air Conditioner: Total Area = 45 met x 20 met x 2 floors =
1800 sq. met , 20% stair + Toilet > 1440 sq. met . AC requirement
14 163 122
is 1 ton per 11 sq. met > Total Tonnage = 131 Ton : kw = 131 x
1.25 = 163 kw , loading considered as 75%
15
16
17
18 Total 1740 1264 #REF! 338
Refer
Separate
w/sheet