Chapter 4: Design of Electrical System

4.1 Design methodology

Design
Optimizaion:
Codes and
Standards

Edsa Paladin
Design
AutoCAD
SolidWorks

Multiple
Constrain
ts

Desig
n
Inputs

Design
of
Electric
al
System

Desig
n
Outpu
t

Figure 4.1: Design Strategy

The design of electrical system needs to satisfy multiple constraints such as safety, manufacturability,
reliability and economic. In order to satisfy these constraints, there are provisions from different codes and
standards that were adopted in the design. For design optimization, there are three computer software that
can be used to optimize the design. AutoCAD was used in the design of electrical power distribution system
and emergency back-up power system. Solid-works was in the design of lightning protection system and
grounding system. EDSA Paladin Design Base was used for simulating the fault conditions at different
locations of the power system. The values of fault current were the basis in the design of electrical power
system protection.

Cable size computation/diameter size computation and ampacities & Short Circuit Analysis for the
KAIC rating of CBs
FULL LOAD CURRENT OF MOTORS
Section 4.30.2.4 Conductor supplying several motors and other loads shall have an ampacity at least
equal to the sum of the full-load current rating of all the motors plus 25 percent of the highest rated motor in
the group.
Full Load Current: (See table 4.30.14.4 page 424)
Motor 1: 20-Hp.54 Amperes
Motor 2: 20-Hp.54 Amperes
Motor 3: 20-Hp.54 Amperes
Motor 4: 5-Hp..15.2 Amperes
Motor 5: 5-Hp..15.2 Amperes
Motor 6: 5-Hp..15.2 Amperes
Motor 7: 5-Hp....9.6 Amperes
Motor 8: 5-Hp.9.6 Amperes
Motor 9: 5-Hp.9.6 Amperes
Motor 10: 5-Hp.9.6 Amperes
Motor 11: 5-Hp.9.6 Amperes
25% of the largest Motor
54 Amperes x 0.2513.5 Amperes
_________________________

Total Current...269.1 Amperes

Main Circuit Breaker: (See table 2.40.16 p. 140)

Use: 300 AT, Three-pole ITD Circuit Breaker
Feeder Size: (See table 3.10.1.16 p. 299)

Use: 3-150mm2 THHN

Equipment Grounding: (See table 2.50.6.13 p.196)
Use: 1-22mm2 THHN
Size of Conduit: (Table 9.1.1.4 p.1235)
For THHN-2, 150mm2 = 298.6mm2, 22mm2 = 52.8mm2 (Table 9.1.1.5 p.1240: Dimensions of Insulated
Conductors and Fixture Wires)
Total Area of Wires= Number of Wiresa Conduit Area of Wire
Total Areaof Wires=3 ( 298.6 mm 2 )+ 52.8 mm2=948.6 mm 2
948.6 mm2 <1323 mm2

Use: 65 mm IMC Conduit

1. For Motor-1, Motor-2, Motor-3 Air Blowers (Three 3-phase, 230 volts, 20-Hp motor)
Full Load Current: (See table 4.30.14.4 page 424)
20-Hp.54 Amperes
Branch Circuit Conductor:
The feeder conductors for motor loads are sized up according to provision in Article 4.30.2.2(a): Single
Motor wherein conductors that supply a single motor used in a continuous duty application shall have an
ampacity of not less than 125 percent of the motors full load current rating. The design formula for feeder
I
=1.25 I Motor
conductor sizing is Feeder
I f =1.25 I m=1.25 ( 54 A ) =67.5 A
Use: 3-14mm2 THHN (See table 3.10.1.16 p. 299)

Motor-Over Load Protection:

The fault protection for motor loads are sized up according to Article 4.30.4.2(a)(1). Where motor is
protected by a separate overload device, the motors are required to have a overload protection rated or set
to trip at not more than 125% of the full-load current. The design formula for over load protection conductor
I =m FP I Motor
sizing is FP
I f =1.25 I m=1.25 ( 54 A ) =67.5 A
Use: 67.5 Ampere(Maximum) [See Section 4.30.3.2(a)]

Branch Circuit Short-Circuit and Ground Fault Protection: (See table 4.30.14.6)
The fault protection for motor loads are sized up according Article 4.30.4.2(a)(1): Motor and Branch-Circuit
Overload Protection wherein the motor branch-circuit short-circuit and ground fault protective device shall
comply with Table 4.30.14.6, p626: Maximum Rating or Setting of Motor Branch-Circuit Short-Circuit and
I CB =mFP I FC
Ground-Fault Protective Devices. Formula for sizing fault protection is

Inverse Time Delay:

I CB =2.5 I FC =2.5 ( 54 )=135 A
Use: 150 AT, Three-pole ITD Circuit Breaker (See table 2.40.16 p. 140)

Equipment Grounding: (See table 2.50.6.13 p.196)

Use: 1-14mm2 THHN

Size of Conduit: (Table 9.1.1.4 p.1235)

For THHN-2, 14mm2 = 33.2mm2, 14mm2 = 33.2mm2 (Table 9.1.1.5 p.1240: Dimensions of Insulated
Conductors and Fixture Wires)
Total Areaof Wires= Number of Wiresa Conduit Area of Wire
Total Areaof Wires=3 ( 33.2 mm2 ) +33.2 mm2=132.8 mm 2
132.8 mm2 <151mm 2

Use: 20 mm IMC Conduit

2. For Motor-4, Motor-5, Motor-6 Pumps (Three 3-phase, 230 volts, 5-Hp motor)
Full Load Current: (See table 4.30.14.4 page 424)
20-Hp.15.2 Amperes
Branch Circuit Conductor:
I f =1.25 I m=1.25 ( 15.2 A )=19 A
Use: 3-3.5mm2 THHN (See table 3.10.1.16 p. 299)

Motor-Over Load Protection:

I f =1.25 I m=1.25 ( 15.2 A )=19 A
Use: 19 Ampere(Maximum) [See Section 4.30.3.2(a)]

Branch Circuit Short-Circuit and Ground Fault Protection: (See table 4.30.14.6)
I CB =2.5 I FC =2.5 ( 15.2 )=38 A
Use: 40 AT, Three-pole ITD Circuit Breaker (See table 2.40.16 p. 140)

Equipment Grounding: (See table 2.50.6.13 p.196)

Use: 1-5.5mm2 THHN
Size of Conduit: (Table 9.1.1.4 p.1235)

For THHN-2, 3.5mm2 = 8.6mm2, 5.5mm2 = 13.9mm2 (Table 9.1.1.5 p.1239: Dimensions of Insulated
Conductors and Fixture Wires)
Total Area of Wires= Number of Wiresa Conduit Area of Wire
Total Areaof Wires=3 ( 8.6 mm2 ) +13.9 mm2=39.7 mm2
2

39. mm < 89 mm

Use: 15 mm IMC Conduit

3. For Motor-7, Motor-8, Motor-9, Motor 10 and Motor 11 Pumps (Three 3-phase, 230 volts, 3-Hp
motor)
Full Load Current: (See table 4.30.14.4 page 424)
20-Hp.9.6 Amperes
Branch Circuit Conductor:
I f =1.25 I m=1.25 ( 9.6 A ) =12 A
Use: 3-3.5mm2 THHN (See table 3.10.1.16 p. 299)

Motor-Over Load Protection:

I f =1.25 I m=1.25 ( 9.6 A ) =12 A
Use: 12 Ampere(Maximum) [See Section 4.30.3.2(a)]

Branch Circuit Short-Circuit and Ground Fault Protection: (See table 4.30.14.6)
I CB =2.5 I FC =2.5 ( 9.6 )=24 A
Use: 30 AT, Three-pole ITD Circuit Breaker (See table 2.40.16 p. 140)

Equipment Grounding: (See table 2.50.6.13 p.196)

Use: 1-5.5mm2 THHN
Size of Conduit: (Table 9.1.1.4 p.1235)
For THHN-2, 3.5mm2 = 8.6mm2, 5.5mm2 = 13.9mm2 (Table 9.1.1.5 p.1239: Dimensions of Insulated
Conductors and Fixture Wires)
Total Areaof Wires= Number of Wiresa Conduit Area of Wire
Total Areaof Wires=3 ( 8.6 mm2 ) +13.9 mm2=39.7 mm2
2

39. mm < 89 mm

Use: 15 mm IMC Conduit

Motor Loads
Motor-1 Air Blower:

Three 3-phase, 230 volts, 20-Hp motor

Motor-2 Air Blower:

Three 3-phase, 230 volts, 20-Hp motor

Motor-3 Air Blower:

Three 3-phase, 230 volts, 20-Hp motor

Motor-4 Transfer Pump: Three 3-phase, 230 volts, 5-Hp motor

Motor-5 Feed Pump:

Three 3-phase, 230 volts, 5-Hp motor

Motor-6 Feed Pump:

Three 3-phase, 230 volts, 5-Hp motor

Motor-7 Decant Pump: Three 3-phase, 230 volts, 3-Hp motor

Motor-8 Decant Pump: Three 3-phase, 230 volts, 3-Hp motor
Motor-9 Sludge Reduction Pump: Three 3-phase, 230 volts, 3-Hp motor
Motor-10 Sludge Reduction Pump: Three 3-phase, 230 volts, 3-Hp motor
Motor-11 Sludge Reduction Pump: Three 3-phase, 230 volts, 3-Hp motor