Industrial Plants: Applications For Electric Power Distribution

TOTALLY INTEGRATED POWER
Industrial Plants
Applications
for Electric
Power Distribution
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Editorial
Industrial plants constitute a system composed of production facilities, transport and

storage possibilities, as well as office and infrastructure facilities. The electric power
supply of such a heterogeneous system is a central component used jointly by all
facilities and which can have an essential influence on their functionality. Therefore,
the most diverse operational and organizational requirements must be taken into
account for planning such a system.
Totally Integrated Power (TIP) by Siemens stands for consistent solutions in the
planning of the electric power supply for infrastructure, facilities and buildings
of industrial plants. Adjusted to the factory planning of Siemens, TIP provides the
approach for a reliable and efficient operation of the plants.
Based on the TIP expertise, this manual points out the general outline to be observed
for the design and layout of industrial projects during the first planning phases. The
quality and functionality of the products and systems by Siemens specify a broad
field of application, and can thus be dimensioned and configured in multiple respects.
Nevertheless, the overall project and its framework conditions must never be left out
of consideration.
This manual can give ideas and show what an industrial-specific procedure may look
like. Further project-specific support beyond the contents of this manual will be
provided by the TIP contact partners at Siemens.
Sebastian Büschel
Head of Consultant Support Totally Integrated Power
Contents
Contents
1 Introduction 6 Concept Finding for the Electric Power

1 4 Distribution of a Chemical Plant 94
2 Factory Planning
10
2
3 Power Supply and Energy Consumption
in Factory Operation 18
Management 113
3.2 Economic Burdens as a Result of Power Failures 21
3.3 Power Flow Diagrams 24
3
7 Annexes 122
4 Creation of a Planning Concept 34
4
Imprint 132
5 Concept Finding for the Electric Power Distri-

bution of a Beverage Filling Plant 62
5
2 Totally Integrated Power – Contents

Chapter 1
Introduction
(Virtualization, Business Agility)
1 Introduction
Contents
The series of application manuals on electric •

power distribution is based on the general planning network
instructions as described in the planning manuals (such •
as [1.1]). The application manuals substantiate the gen- storage
eral concepts and descriptions regarding the special •
1 - distribution)
ments for industrial networks is created and imple- •
mented in sample networks, taking into account the consumers
digitalization and integration of embedded generation. • High number of utilization hours for electrical
The different framework conditions and task definitions
and the optimization regarding common customer For simplification, no difference is made in the following
2 •
• environmental friendliness •
• future-proof design
• the manufactured products from time to time.
constitute the main tasks of an electrical planner. •
production of identical products; volume-related
The conception, implementation and operation of indus- ordering
3 • Process manufacturing = Production = Batch and flow
- production; differentiation between batch processes
bution Plants” [1.2] for appropriate planning. This appli- (discontinuous) and continuous processes.
cation manual takes up the facts in a more fundamental
-
thus also on the electric power distribution, the planner

4 bilities are outlined which offers for the plan-
-
in as much detail as possible, or to procure these specifi-
ning and construction of industrial plants. This docu-
ment points out a superordinate structure for the proce- adjusted solution. Among other things, these specifica-
dure to be followed when planning the electric power tions include:
- •
tion of the statements made in [1.2] that are much more view containing the essential loads with their electrical
- data
5 dure in the case of extensive planning projects, however, • Process and operational specifications – space- and
the statements in [1.2] should be taken as a basis. time-related
•
This application manual can be used, on the one hand,
for getting started in the electrical planning of industrial •
plants, and, on the other hand, serves as a kind of cat-
alog for projects of enterprises, general contractors, and
6 -
-
•
know-how.
conditions for planning will be an iterative process, in
These are some particularities of industrial networks
(see [1.2]): architect, production planner, electrical planner, and
• other parties involved should be as smooth as possible.
7 •
of operation
•
circuit current stress
4 Totally Integrated Power – Introduction

Contents
•
in electrical engineering planning for industrial plants,
•
plant engineering and mechanical engineering, automa- • Forecasting and self-regulation via algorithms and
- 1
• -
• Fig. 1/1).
•
These trends as well as the hardware- and software-

related cross-linking of industrial process and production
engineering with the information and communications 1). Digitali- 2
-
gent connection between power engineering and pro- • a cost-optimized flexibilization of all steps in the
management assumes an important part in order to • while preserving resources and the environment
3
storage, and power distribution on the one hand, and •
acceleration of the process flows on the other hand. • and the uncomplicated implementation of decisions
The interaction during the integration and implementa- •

tion of the individual trends becomes the guide for the
4
machine communication (M2M), human actions concen-
• the experience made in the past trate, above all, on the planning phase as well as on
• the current options and expectations the elimination of later failures in the flow of production
• or operation.
and the environment in the future, and determine their
solutions in the present.
5
value chain:
•
variables (use of sensors and measuring devices)
• Use of digital manufacturing and production
6
•
•
(digital twin)
7
1)
Totally Integrated Power – Introduction

Contents
Digitalization Industry 4.0
How is it possible to react autonomously?

“Self-optimizing”
1 What is going to happen?

“Be prepared”
Benefit
Why is it happening?
“Understand”
What is happening?
2 “See”
Forecasting
Computerization Connectivity Visibility Transparency capability Adaptability
1 2 3 4 5 6
3
1 Digital acquisition of parameters and process variables
2 Cross-linking of devices and processes
3 Virtualization and simulation (e.g. digital twin)
4 Analysis, dimensioning and automatic control
5 Forecasting for scheduling and resource planning as well as production control, among others
6 Automation, cloud-based web services and “M3” (Machine-Machine-Management)
4
Source: FIR e. V.,UdZPraxis, 2017
Fig. 1/1: Development path of Industry 4.0 for the digital transformation of companies [1.3]
construction and operation to modification or retrofit-

ting, and up to removal.
An important component for the planning of industrial
5
planning process. The modeling has to observe the cross to be considered as a building- and process-overlapping
- coordination and optimization concept [1.4]
planned in separate projects: -

• Plant engineering sions of the building information models :
• •
6 • Power engineering
•
•
•
• Architecture for the operation.
• Business processes
• Manufacturing or production processes
•
•
- •
7 nical planners create separate, digital partial models, •
which then remain saved in a central model for further •
construction process models, and integrated schedule
models

Contents
•
collection and data administration with a central data which means that the significance of a digital basis for
management diagrams, calculations, simulations, and vouchers – with
• Provision of a standardized tool with extended options
for marketing and public relations.
The standardized and structured information exchange 1

as well as the higher-level storage of the project data are
basic advantages (like in Fig. 1/2 - -
patibilities, coordination problems, intersections, redun- lated to the complete business environment and thus
also to the planning of industrial plants. The intensive
problems of time, additional costs, and dissatisfaction cooperation of the parties involved, the implementation
and documentation of results for other parties included
in the planning, as well as the creation of optimal solu-
tions that do also consider other installations, can partic-
2
defines the performance phases of the planning process -
applied.
before data drop 3 (project development), it would be 3

-
to be recorded and stored, but also processed and imple-
Tab. 1/1). mented in process updates and plant adjustments.
-
-
planning (
-
4
sion factors is of particular interest for the planning of
industrial plants. The demand for information multiplies
Moreover, inaccuracies or even missing information and

estimations can lead to expensive iteration loops. For
this reason, the planning expenditure for industrial
5
first three milestones from Tab. 1/1, for the sake of both
planning expenditure for information, documentation,
Project phase BIM

6
1
2 Demand determination Establishment of the project basis
3 Project development
4 Design / Approval Design planning and approval planning
Detailed design Execution planning, site supervision
Project close-out 7
Operation / Utilization
Tab. 1/1:

Contents
Project information model (PIM) Technical models

Coordination model + data Native formats
Common Data Environment (CDE)
1 IFC / CSV *
PIM
Results and Results and
documents IFC * Architecture documents
Native formats
Data basis for exchange Execution plans
Data validation / quality assurance

Visualizations Details
Supporting structure /
IFC *
Data constructional Simulations
2
Collision and rule check components
Native formats Tender
Quantities and masses
documents
Data drops / phase report IFC * Building technology Static
Tender documents Native formats calculations
Timeline / construction process /

construction progress Coordination
model
Electric power Siemens TIP
3 Information on management
and operation
distribution
Native formats SIMARIS tools
IFC / CSV *
Tender specification texts
* IFC Industry Foundation Classes
CSV Comma Separated Values BIMobject 3D models
Fig. 1/2: Schematic representation of a standardized data exchange in BIM [1.6]
4
of the first performance phases (see Tab. 1/1
-
-
procedure shall divide complex tasks into small seg-
5 accentuates the interaction and response to changes ments, or comprehensive models into partial models,
in planning projects. The significance of these points with which the experts are able to work faster and
with special technical competence. The linking of the
developments, improvements and coordination – from individual technical results and the structured data
planning step to planning step.
(see Fig. 1/2) enables automatic reviews and feedbacks.
-
6 tion and documentation in the project planning.
architect, and the planning colleagues. Planning targets

7 are developed and translated into planning approaches.
-
ments are adjusted.

Chapter 2
Factory Planning
(MindSphere, Production Process)
2 Factory Planning
Contents
- -
-
technical knowledge and commercial thinking, but the combination of both. As a general principle, the
Fig. 2/1) in the social,
natural and even human sciences [2.1].
1
Regarding the planning horizon of corporate deci-
sion-making, the following distinction can be made
[2.2]:
•
preceding phase, and makes use of particular methods – long-term corporate goal
and tools, and extending from the setting of objectives •
2 to the start of production.” A distinction is made
between:
– comparison of operation and goals with market
conditions
• Development planning (greenfield) •
• Replanning (brownfield), including for example – actions and means for achieving targets.
remodeling, conversion, expansions, optimizations
•
• structural diagram (Fig. 2/2) according to [2.3].
y
olog
chn Na
e
dt tu
ra
an l s
g
4
Architecture
Environment
rin
ci
Construction
en
ee
Geosciences
ce
gin
Information technology
s
En
Mathematics
Materials sciences
Physics
Electrical engineering
Chemistry
Food and beverage
Biology
5 Physiology Factory
science Management
Orthopedics Communications
es
H eal
ie nc
Biometry Business administration

th s
Economics
l sc
Nutrition
Law
ci e
c ia
Psychology
nc
So
Ergonomics
6
es
Art and ethics Education
Design
Huma
n sciences
7 Fig. 2/1: Multidisciplinarity of factory sciences according to the FOS categorization of the OECD [2.4]
Totally Integrated Power – Factory Planning

Contents
Time horizon Level Customer- and value-oriented planning system
Strategic:
Strategic Corporate Business objectives Finance Products Market and Society and
long-term
business planning guidelines and quality and prices and suppliers competitors environment
Tactical:
Factory structure
1
medium-term Sales and R & D and Production engineering Human
Concept level marketing Services and technology Buildings resources
Production Logistics
and surfaces
Information Building and

Operative: Planning level Production Material flow ICT *
flow energy technology
short-term
1 - 2 years
Project planning:
Project level e.g. security of supply and quality, IT security, test planning, warehouse utilization, transports,
shift operation, air conditioning, lighting, power generation and energy storage, operating conditions, ...
2
Legend: Areas of business planning which provide the framework for factory planning
Areas the factory planning has to coordinate with
Areas of factory planning

* ICT: Information and communications technology
Fig. 2/2: Structure of an integrated planning system similar to VDI 3637

3
2.1 Structure of Factory Planning concept phase, simple models and simulations can
support the planners, thus relieving them of routine
representatives in case of smaller replanning projects) and
point are structural concepts that have to be approved

4
• the production-technical structural concept with regard to economic, technical and geometric
(technological), information:
• the logistical structural concept
(related to process organization), LoD (= LOD) = LoI + LoG
• and the constructional structural concept 5
(as regards urban development)
Fig. 2/2
depicts a detailed planning structure on the basis of
This means: For execution planning, the information
digital twin will be in the future. concept must be implemented with further details as
Thanks to the standardization of planning processes, potential for the effective use of the tools of the “Digital
6
the advantages are, among others: ). The latter accelerate the planning
• -
• Facilitation of documentation and archiving ners, for example with standardized sample solutions.
of data.
arranging of production plants or of parts of the building
At the concept level, for example, decision papers shall
be prepared that contain data on the intended budget libraries or features. 7
well as the expected time frame for implementation and
Totally Integrated Power – Factory Planning 11

Contents
2.2 Phase Model of Factory Planning

extending further into the production and work pro-
cesses, digitalization pervades all phases and levels of
conversions, can be divided into phases, too. A corre-
- •
• Briefer project preparation and execution
1 Tab. 1/1 - •
ments of the enterprise are taken into account in the • Optimization, training and testing possibilities
Fig. 2/3). Detailed before commissioning.
explanations related to Fig. 2/3
scope here and can be looked up in the technical litera-
ture, for example and . brings the technical and economic aspects of digitali-
-
2 focus area in planning, which must be integrated in
corporate planning tasks are taken into account, the
-
in simulation models.
planning disciplines to be integrated include:
3 • Business planning
• and connected to that, the social and ecological linkages
• Personnel planning
• Financial planning
• -
ented planning of electric power distribution is exam-
Regarding the five planning levels in Fig. 2/3, a corre- ined, so that the social points of contact of the digital
4 sponding five-stage planning scheme can be developed:
• less, the ecological influence on the technical design of
-
• the electric power distribution and therefore on the

•
•
• Arrangement (process and workstation).
The consistent digital twin has three characteristics:
the product, the production, and the performance of
5 the creation and virtual operation of a digital twin product and production (Fig. 2/4), which shall be made
Fig. 2/4) when available in one joint data model .
developing a classical industrial enterprise into a
6 2.3 Digital Factory

-
-
a comprehensive network of digital models, methods

7 and tools – including simulation and 3D visualization –
12 Totally Integrated Power – Factory Planning

Contents
Planning characteristics Influencing factors
• Cost-efficiency Processes: Organization: Infrastructure:

• Acceptance • Process- and • Personnel • Buildings and surfaces
• Changeability control technology • Suppliers • Supply technology
• Cross-linking, interfaces • Mechanical engineering • Operational structure • Building technology 1
and plant engineering • Operational flows
Planning phases
Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 Phase 6 Phase 7

Setting of
objectives
Establish-
ment of the
Concept
planning
Detailed
planning
Preparation
for reali-
Monitoring
realization
Ramp-up
support 2
project basis zation
Project
Project management close-out
Planning levels Characteristics 3

• Stipulations of infrastructure connections
Production • Linking of locations
network layout • Influence of business relations
• Macro representation
4
Factory layout • Arrangement of buildings on the factory grounds
and functional areas in the factory buildings
• Rough representation of the functional areas

(e.g. production and logistic areas)
Rough layout
• Representation of main transport and 5
main material flow paths
• Fine representation with a high degree

of detailing
• Exact arrangement of operational equipment
Fine layout
• Representation of building technologies
and media supplies
6
• Micro representation
• Flow principles and concatenations
Workstation layout • Fine arrangement of individual operational
equipment in a workstation
7
Fig. 2/3: Phases of the factory planning process
Totally Integrated Power – Factory Planning 13

Contents
Digital Twin Digital Twin Digital Twin

Product Production Performance
Insights from performance with MindSphere

1
Verification Validation
Real
Virtual Virtual Real production Ideal
delivery machine in
machine production of machine
operation
Specification Commissioning Automation
2 Continuous improvement
Platform: Digital Enterprise Suite
Fig. 2/4: Virtualization with the Digital Enterprise Suite
3
offers a complete software portfolio around the
can generate optimum solutions for the manufacturing

operations management (MOM) from multiple compo- offers a secure, data-technological connection of
• Teamcenter – software for product data and product data transmission, applications and services on the
4 • NX – product design and engineering
platform – for example – can be used for service and
optimization purposes. The comparison of real data
• with the simulation results can point out problems like
test simulations for performance
• Tecnomatix – manufacturing simulation and process
optimization description can be found in .
•
comprehensive training opportunities for operating
5 personnel which own applications and services can be integrated.
•
process planning
•
•
states for optimizing process-engineering processes;
6 •
virtual training environment applications and services constitute the core compo-
automation and simulation of the automation logic. the four core components ( ):
14 Totally Integrated Power – Factory Planning

Contents
MindSphere Applications
MindSphere-APIs)
Analytics (using
Companies
Siemens Partner Industry Starter
Auto F&B O&G + more
1
Asset Optimized Optimized
Predictive
Condition Predictive Energy

Learning
Asset
Management Monitoring Perfomance Maintenance Predictive Resource Usage
Management Maintenance Management
Integration
Analytics
API
Dashboard Editor /
Data Modeling Trend Prediction Signal Validation Scheduler Library
Intelligence
2
Product
Model Deploy Anomaly Detection Alarm Management Mobile Native App + more
Core components MindAccess MindConnect MindApps MindServices
Devices / Edge
Edge Analytics
MindSphere
Connectivity Edge Apps 3

Devices
Agents
Fig. 2/5: Overview of the MindSphere architecture [2.8]
i. MindAccess • Visual Analyzer

4
provides an overview of the assets configured in
• MindAccess Developer
develop and test applications, and make them available as a tool for an in-depth data search with the option
to create specific views of aspects
• MindAccess User • TIBCO Jaspersoft™ Service 5

simplifies the creation of dashboards and reports.
ii. MindConnect
assets and users, as well as the storage of data
• Mindconnect Nano / MindConnect IoT2040
• Fleet Manager Hardware (devices) for connection of assets to
provides an overview of the assets configured in
transmission
6
based on different criteria and managing them
• MindConnect FB 1500
• Fleet Manager Plus
adds additional functionalities to the Fleet Manager,
such as rules with e-mail notification and asset
information, as a Plus option • CMS X-Tools PROFESSIONAL
7

Contents
iii. MindApps
• Product Intelligence
automates the context-dependent evaluation of
product performance data, thus increasing the
1
experiences
• Manage MyMachines
in small and large production facilities to increase their

2
iv. MindServices
• MindSphere Academy
stands for universal and diverse training opportunities
digitalization in companies, the development of

3 applications, technical possibilities and solutions with
• MindSphere Consulting
provides insights and know-how to support and
4 experience of our experts facilitates onboarding and

supports the development of business cases and apps
or customized solutions
• MindSphere Security Service

Plant
5
prevent future attacks.

Chapter 3
Power Supply and Energy Consumption
in Factory Operation
3.2 Economic Burdens as a Result

of Power Failures 21
3.3 Power Flow Diagrams 24
3 Power Supply and Energy Consumption
Contents in Factory Operation
Fig. 3/1 and

in , the stipulated objective of optimized Fig. 3/2
of gross
and facilities that is as economical as possible. Next to
1 the expenses for raw materials, personnel, supplies and
3. -
for the planned industrial plant also take into account of that of the
-
ical framework conditions and environmental aspects As a detail, it remains to be noted that the increase of
Fig. 3/1 [3.1] depicts the develop-
2 -
consumption will not stand out in the future, either. Yet,

of industrial
development (Fig. 3/2 per annum.
3
End-use energy consumption World
in 1015 Btu (British thermal unit)
700
600
4 500
400
300
5
200
100
2005
2015
2025
2035
2045
2050
2010
2020
2030
2040
Year
Liquid fuels Natural gas Coal Electricity Renewables
6 Total
Industry
Fig. 3/1:
Totally Integrated Power – Power Supply and Energy Consumption in Factory Operation
Contents
End-use energy consumption India End-use energy consumption China

in 10 15 Btu in 10 15 Btu
110 110
100
90
100
90
1
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
2
2005
2010
2015
2020
2025
2030
2035
2040
2045
2050
2005
2010
2015
2020
2025
2030
2035
2040
2045
2050
Year Year
Liquid fuels Natural gas Coal Electricity Renewables

Industry
End-use energy consumption OECD End-use energy consumption Non-OECD without China and India
in 10 15 Btu in 10 15 Btu
110
100
110
100
3
90 90
80 80
70 70
60 60
50 50
40 40
30 30
20
10
20
10
4
2005
2010
2015
2020
2025
2030
2035
2040
2045
2050
2005
2010
2015
2020
2025
2030
2035
2040
2045
2050
Year Year
Fig. 3/2: Development over time of end-use energy consumption for industrial use in various regions [3.1],
5
3.1 Energy Consumption and
Production Value
For a better assessment of the significance of end-use
carriers used for production (Fig. 3/4
costs must be considered in relation to other parts of
the production value, such as labor costs and raw
consumption values are linked with average prices for
-
6
material prices. Based on statistical information, numeri- tion; this is because the used technologies and the
-
and regions can be evaluated (Fig. 3/3
regional differences and the technical development in
between countries and regions. The development of the
cost shares. The differences resulting from the cost individual components of the production costs over
allocation in different manufacturing sectors are time, too, has a considerable influence on the resources, 7
procedures and technologies used.
Contents
8,000 100 %
Production cost shares

Production value for 2016 in billions US $
7,200 90 %
6,400 80 %
1
5,600 70 %
4,800 60 % Purchase of goods

and services
4,000 50 %
Gross operating
3,200 40 %
surplus
2,400 30 %
1,600 20 %
Personnel expenses
800 10 % Expenses for

2 0 0% energy products
Canada USA Belgium Great Netherlands Spain
Britain
India EU-28 Germany Italy Poland
Fig. 3/3:
countries / regions in 2016, averaged across the individual manufacturing sectors [3.2]
3
Examples for price and therefore also cost differences For Fig. 3/4
•
between domestic production and imports in the Tab. 3/1.
different countries [3.3] leads to fundamental price
4 •
differences
Natural gas
•
•
5
Tab. 3/1:
price ratio is 1.3 to 1)
data in [3.3, 3.4, 3.7]
•
6 for an average industrial plant

• production, securing reliable operation must also be
non-ferrous metals, chemicals, and mechanical section.
embedded generation of companies using coal and oil
Contents
Millions Electricity Gas Crude oil, oil products Coal products

€
25
20
15 1
10
0
…
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...
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et
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ee
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pe
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ac
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M
n-
al
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ag
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et
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ph
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Fig. 3/4: 3
3.2 Economic Burdens as a Result

of Power Failures
For the economic evaluation of a power failure, or rather
- 4
internal events (operational accident with destruction of

lines, or as a result of fire). Even small failures can lead to account in the clearing prices (the clearing price defines
- 5
-
is the cooling and hardening of melts, making it neces-
market, “non-technical” threats due to speculations in

VoLL =
Operating surplus 6
Electricity consumption of the company
Totally Integrated Power – Power Supply and Energy Consumption in Factory Operation 21
Contents
can be calculated that reflect the economic loss in Euro

processes as well as regional differences reflect, to
lack or failure of one kilowatt hour or megawatt hour of some extent, the economic significance of a reliable
and ,
1
VoLL in €/kWh
100
50
2 USA
Germany
China
Poland
Netherlands
Italy
Great Britain
Italy
10 Great Britain Italy USA Netherlands
Italy Spain Canada EU
5
EU EU India Belgium
Netherlands USA Germany Spain
Belgium Canada EU Poland
1 Spain Great Britain Poland USA
3 0.5
Poland
Canada
India
Belgium
China
Spain
China
China Netherlands Belgium

India
0.1
Manufacturing Forestry and Mining and Construction
agriculture quarrying
4 Fig. 3/5:
VoLL in €/kWh
100
5 50
Great Britain China India Canada

Netherlands Canada USA India
10 USA India Germany Netherlands
Italy USA Netherlands Germany
5
Germany Great Britain Great Britain Belgium
EU Germany Italy EU
Poland Italy EU Italy
6 1 Belgium EU Belgium USA
Spain Spain Spain Great Britain
0.5
India Netherlands Poland Spain
Canada Poland Canada Poland
Belgium
0.1
Metal and Food, beverage, Mineral, Machinery
metal fabrication tobacco no metal
7
Fig. 3/6:
and regions in 2016
22 Totally Integrated Power – Power Supply and Energy Consumption in Factory Operation
Contents
VoLL in €/kWh
100
50
India India United Kingdom Great Britain
10
Italy
Poland
USA
Italy
Netherlands
Belgium
Germany
USA
1
Germany Spain USA Canada
5
Netherlands EU Italy Netherlands
EU Belgium Germany Italy
Spain Germany Spain EU
1 Great Britain Great Britain EU Belgium
China Netherlands Canada Spain
0.5
USA
Belgium
Canada
China
Poland
India
India
Poland
2
Poland
0.1
Textiles, clothing, Chemicals, Wood, wood products, Vehicle construction
leather pharmaceuticals furniture
Fig. 3/7:
and regions in 2016
3
individual economic sectors and production industries

-
point for the economic significance of a secure electric
- 4
there will be a correlation of the values with the point of The legal framework for the importance of this task is
5
about 1. the industrial sector are added to the costs for the
costs for damages, re-commissioning, material scraps,

to are mentioned in
).
VoLL = Lost production + other costs

6
p.a.
Contents
Production sectors, overall about 0 € / - about 24 € / kWh
Electrical equipment (incl. computers) 3 - 24 € / kWh
Textile sector 1 - 12 € / kWh
1 Machinery
Transport equipment
2 - 17 € / kWh
3 - 7 € / kWh
Pulp, print and paper 0.5 - 19 € / kWh
Wood products 0.5 - 9 € / kWh
Food, beverage, tobacco 1 - 3 € / kWh 15 € / kWh (tobacco alone)
Rubber, plastics 1 - 5 € / kWh
2 Metal 0.5 - 4 € / kWh
Chemicals about 0 - 3 € / kWh 7 € / kWh (pharmaceuticals alone)
Fig. 3/8: Estimate of VoLL values of individual industrial sectors according to the CEPA study [3.12]
3 There, the value of Lost production is estimated as:
Lost PNF × SF × annual gross value added

=
production annual electricity consumption
cost-efficient. These prices reflect the current state of
4 PNF
with the preference for volatile power-generating tech-
the PNF is ; [3.13] recommends either an internal
PNF = for all industrial sectors (except PNF = for integration of embedded generating plants into the
agriculture) distribution networks (see next chapter).
5 SF
other industrial sectors [3.12].

3.3 Power Flow Diagrams
ecological and economic challenges and objectives, the Another important step towards basic planning of the
electric power distribution is a rough estimation of
the power demand for the most important parts of a
6 methods is indispensable. For this reason, the following
-
depicts the cor-
relations between the basic components grid infeed/
“Final customers shall have the right to a contract with
their supplier that specifies: …
To some extent,
f) any compensation and the refund arrangements
7 which apply if contracted service quality levels are not
met, …“
Contents
shares of power flows will increase. Peak and maximum

specifications and adjustments of details – in order to
the plant.
all over the world, for example, distribution and trans-
an ever increasing access to high-performance genera-

tion, storage and consumer elements in order to be able 1
to ensure the stabilization of grid conditions in view of
fluctuating grid infeeds. Also, different contributions and
directions of power flows must be considered during flow diagrams.
when recharging storage elements, or when intention-
principle, the energetic input and output values are 2

processes of production. During data aggregation, the
a power flow from power generation to consumers. -
of motors, compressed air, or lighting.
3
Grid infeed
,
.. g
, . in
ck arg
ba ch
ed ,
fe up
e rt-
tiv ta
ra r s
Customer/utilization objectives:
ne to
ge ra
- Safety of personnel and property

4
re ene
- Cost-efficiency
G
- Time-to-Market
- Availability
start-up, feedbacks, ...
Normal power supply NPS,
- Environmental friendliness
- Future-proof design
- ...
Embedded generation,
Design parameters from the
storage user’s point of view:
- Energy efficiency, optimization of
expenses 5
- Process and product quality
- Process duration and operational
process
Sa nin ba
- Resource consumption, emissions

fe te ck
u ed
ty rru s,
fe
- Modularity, extensibility
po pt ...
- ...
w ibl
er e
su po
pp we
6
ly r
SP sup
S, p
Consumers,
ly
storage
UP
S,
Fig. 3/9: Cornerstones for basic planning
Contents
Onsite Process Nonprocess

Primary Energy Consumption: 21,108 PJ
Generation Energy Energy
422 2,697 371
1,953 Conventional 5,060 Process Heating 429 Facility HVAC
56 Boilers 1,587 388 285
2,482 379
138
1,130 33 124
4,039
Process Cooling 198 Facility Lighting
CHP, 231 and Refrigeration
1 Cogeneration 443
2,466
26
102
276
73 Other Applications
311 49
60
Other Facility
Support
23
40 Other 286
% of
Fuel Type total Electricity 118
Generation 14 42
12,192 Fuel Natural Gas 51 % 247 Electrochemical 66 Onsite
(excludes 5.91 PJ
Byproduct Fuels 36 %
15 Transportation
Offsite
renewable,
Generation
Coal 7% non-combustion Machine Drives
electricity generation) 226 351
Generation
and Distillate and
Transmission
1% 49
Losses
Residual Fuel Oils
HGL (excl. 1,633 674 Pumps 21 Other
5,290 Gasoline)
<1%
380 168 13 Nonprocess
Electricity Other Fuels 4% 21 122
322 Fans
21,108 8.033 Generation
Fuels
35 329
Generation 377 Compressed Air
2
and 57
Transmission 12,192 5,838 Electricity
Losses 196 Materials Handling 107
248 Heat/Steam 2,743 2,567 2,980 Export*
472
885 Generation 637 4,445 560 Materials Processing
68 Energy consumption data source:
Energy 889 110 Other Systems 2014 EIA MECS
PJ = Petajoule Steam Notes:
(10 15 Joule) Distribution Sector-wide aggregate data for year 2014
Losses Energy values and fuel type percentages
Fuel rounded to nearest whole number
Offsite generation shown on net basis
(purchases, sales, and transfers accounted
Electricity
for), including onsite non-combustion
renewable output
Heat/Steam * Refers to sales and transfers offsite of
electricity to utilities and other entities
Losses
3
Fig. 3/10:
shows a power flow diagram created on the

basis of statistical data for industrial production in the
4 industrial facilities is considered for all points of time
during operation, that it is integrated into the production
process chain, and that it should be “smart”, which
means, intelligent and controlled with specific objec-
take much longer until further reaching evaluations are tives.
made possible and increasing regenerative network
This approach must be taken into account in the plan-
into account in statistics. For the individual industrial -
5
chains and markets, while considering social, societal
-
3.4 Smart Grid for the Industry
6 annual average, as shown in the previous section. The

the time dependencies throughout the entire opera-
-
-
and photovoltaics, the application possibilities of storage Fig. 3/11 in a circular arrangement, similar to
-
ning phase and the setup of the associated installations
are offering to larger prosumers can no longer be
7
connection of generation and consumption of electric
Contents
Phase 3
Visualize 1
Phase 1 Phase 2
Collect Analyze
Assess Install
2
Implement
Learn
3
Fig. 3/11: Fundamental management process as a basis for Smart Energy Systems and Solutions
Fig. 3/12
supported:
•
4
Time is a critical factor in the planning. For this reason,
the number of iteration loops during concept finding
developed and simulations are calculated for all project kept to a minimum, as suggested in . However,
phases on the basis of modular simulation software it is important to take different development scenarios
®), and the results are compared for the industrial plant into account when creating the
• concept, as those scenarios help determine the indi- 5
vidual optimum and can thus have a significant influence
offer of hardware and software for monitoring, and for
simulations, specific scenarios can be run through.
•
regarding the usage of the industrial plant and the
Fig. 3/11 associated infrastructure, and time schedules are
defined. The concept for electric power distribution,
6
-
® ® ®
performing simulations makes it possible to run through

various versions and make a techno-economical compar-
Contents
Monetization
Efficiency and optimization
Transparency and awareness
Installation and control
Planning and resilience
PSS® SICAM DEOP Market platform Energy

Power Simulation Software for Microgrid & PV Plant Controller Distributed Energy OPtimization
market
1
Back office
Aggregator
Cloud apps
distributed energy systems Local hardware controller, Digital data, reporting and analyzing services Reliable forecasts, roadmap develop-
On site
to identify technical, economic failsafe and real time for microgrid optimization at investment, ment, trading optimization, ...
and ecological benefits operation, maintenance and planning
Network
Simulating operation Measuring Monitoring / reporting Archiving Virtual power plant
stability
Cost reduction
Economic and Generation Storage
control Optimizing supply Price forecasting Demand response
ecological development control Security of
supply
Dimensioning of Load Peak Load forecasting
Enhancing sustainability Load analyzing
power systems management shaving
2
CO2 Sustainability
Demonstrating feasibility Monitoring / Islanding / Optimizing own Market interaction
Maximizing efficiency
and reliability reporting blackstart requirements
Fig. 3/12: Integrated approach by Siemens for Smart Energy Systems and Solutions
® -based planning projects, a large number of
3 objectives and prioritizations. For example, a trade-off is selected configurations are considered throughout the
carried out between:
• conditions such as operational reserves, redundancies,
• start-up and run-down scenarios, conversion or modifi-
•
• defined and taken into account. Fig. 3/13 depicts the
• three phases:
4 •
•
•
•
For the simulations, a digital twin of the generating conditions)
•
® ® software for simu-
lating the implementation schedule for generating comparison of versions, technical assessment criteria,
5 ® -
• a better understanding of the correlations in the

-
• the assessment of important technical, economic and

• Project-specific time series, for example: load profiles, ecological parameters, which form the basis for the
6 environmental data for sun and wind, temperature
characteristics, labor and demand prices different scenarios
• Data on the medium- and long-term usage behavior for • as stipulation for tender priorities, taking into
the plants, as well as intended corporate development consideration possible monitoring and management
• Estimates on possibilities of variations and their
prioritization in order to generate assessment criteria • the identification and evaluation of alternatives in
order to make the smart industrial grid future-proof.
Contents
Project definition Simulation Evaluation and analysis

a) Project-specific time series, load profiles, a) Simulation of the system controller a) Optimization of the generation portfolio
tariff structures, climatic conditions, ... • Cost-based optimization step by step • Evaluation and comparison of the operational behavior
• Siemens MGMS (Microgrid Management System) for variations of the generation portfolio
for day-ahead planning • Deduction of financial core data, such as levelized cost of
• Siemens MGC (Microgrid Controller): consideration of electricity (LCOE) and return on investment (ROI)
algorithms, identical with operational algorithms
• Optimization of electrical/thermal parameters
• Percentage of renewable energies and ecological footprint
• Evaluations regarding cycles and service life of battery
storage systems
1
Return on investment
Levelized cost Net present

of electricity value Scenario 1
Scenario 2
Embedded Peak load
generation Scenario 3
b) Define scope of tasks: Environmental
technologies, participants, size, friendliness
number, costs, …
b) Reproduction of operational endurance of components b) Grid connection and supply system analyses
Generators • Conventional generators • Load flow considerations and short-circuit calculations
2
Networks
Energy • Energy storage systems, PV plants and wind turbines • Reliability and failure analyses
storage
• Dynamic network calculations
Turbines • Network protection analyses and concepts
• Power quality and network feedbacks
PV • Operational strategy analysis, e.g. for island situation
Wind • Analyses for energy consumption and energy supply
Consumers
30 %
25 %
20 %
c) Configure framework of tasks: 15 %

10 %
boundary conditions, time schedule, 5%
distributions, strategies, ... 0%

[0] [17] [22] [23] [35] [37] [38] [73] [75] [77] [78] [105][106][107][108]
c) Management of boundary conditions c) Roadmap
3
• Operational reserves • Implementation plan
• Grid stability conditions • Planning basis for participation in the energy market
• Redundancy requirements • Development plan
• Define permissible value ranges and natural • Show control points and checkpoints
model limits [37]
• Adjustments for time schedules and time series [38]
[73]
[75]
[77]
[78]
Completion Future
Fig. 3/13:
4
Smart Energy Systems and Solutions

in Fig. 3/14.
The technical implementation for monitoring, data
collection and evaluation, as well as the comparison 5
follows in the second phase of Fig. 3/11 and Fig. 3/12. •
hardware and software must be taken into account. • Turbines

•
® DE as well as in •
avoided.
•
• Photovoltaic plants
6
•
-
generating plants and consumers in order to ensure of achieving their economic and technical objectives,
Tab. 3/2). 7
Contents
File Microgrid Microgrid Assets Monitoring View Archive
6/22/2018 3:36:28 PM User: siemens Microgrid Communication Overview MGC Connection OK
PV01 Energy Management System HMI WP01
1 GPS Time server Microgrid Controller

Router CUSTOMER
SCADA
PV02 WP02
Ethernet Ethernet
switch 192.168.33.212 192.168.33.211 192.168.33.215 switch
PV03 WP03
Ethernet
2
switch
Ethernet
switch
BAT01 LOADS
BAT02 BAT03 EXTERNAL GRID DG01 DG02 DG03 Legend:

Com. protocol 1
PCC Com. protocol 2
Com. protocol 3
3
Fig. 3/14:
Functions
4 Blackout detection
Tariff monitoring & supervision
Operation modes
6 Peak shaving
Demand charge reduction
Reserve monitoring
Photovoltaic control / monitoring
Tab. 3/2: Readily available features of the Microgrid Controller
Contents
DEOP serves as a web portal as well as for remote moni-

available functions. Furthermore, these functions are
scalable in all their parts, and can therefore be used
via a web interface. Functions of the cloud application
are:
•
• Optimization of operational planning 1
After installing the flexible, secure and reliable Microgrid • Optimization of setpoint stipulations
•
compress, among others, data, values, notifications, • Monitoring and reporting
alarms, or automated switching and control operations •
(see Fig. 3/12 •
•
the indication at the plant and the human-machine
interface through the communication via web interface
• Archiving
• Price forecasting
2
up to the control room in the monitoring center. Exam- •
• The advantages that can be derived from this compared

• -
between consumption, generation, storage and .
• Managing blackout situations (e.g. restart plan after 3

shutdowns) provide information at a higher level via an intuitive user
• interface. Decisions at different hierarchical levels in the
• change depending on the situation illustrates the advan-

(e.g. power control, spinning reserves, virtual power
•
plants. 4
An important element of DEOP is the creation of virtual
processes. Of course, DEOP can create a link with sup-

plier and consumer markets as well as with distribution
).
5
Contents
Today’s typical dilemma of collecting data from various sources

Cumbersome
data collection Energy Complicated manual
Energy / 1
1
1
0
Managers collection of quality data
0
Asset
1
1 0 0 1 1 0
0 1 0 1
Monitoring 1 1 10 0
1 0 1
1
0 0 10 0
Asset Performance of assets
Managers difficult to benchmark
0 1 01 1 1
Faults or 1 0
1 0 0 0 0 1
0
Maloperation 1 1
10 01
1 1
0 O&M No access to full information
1
for critical decisions
Staff
2 Generation
1
0
0
0
1
1 0 1 0
100 01
Historical / 0 0 0 1 1 0 1 0
01 1 1 0 01 Different reporting standards
Forecast 1 0 1 All Users and input data from
Information lost or different DES sources
invisible in process
One central system eases the data administration and increases management capabilities
3 Energy
• Energy transparency & KPI
• Benchmarking against
Energy / 1
1
1
Managers business plan
0 0
Asset 1 00 1 1 0 • Decisions support
0 1 0
Monitoring
1
1 1 10 0
1 0 1
1
0 0 10 0 • Performance monitoring of
Asset assets – historical & forecast
Managers • Balance resources and assets
01 1 1 without compromising costs
Faults or 1 0
0 1
4
0 0
0 1 0
1 1 0
1
Maloperation 10 01 • Information for critical
1 1 1
0 DEOP O&M operational decisions
Staff • Improvement of maintenance
schedules and saving OPEX
0 1 0 1 0
Generation 0
0 100 01
1 1
Historical / 0 0 0 1 • Efficiency actions and
01 1 1
Forecast 0 All Users
benchmarking
1 • Announcing changes in perfor-
mance profiles by comparison
Distribution
Regional Energy
System
6 Operator
Markets Markets
Fig. 3/15: Comparison between conventional data collection and a centralized data cube such as DEOP
7
1)
Chapter 4
Creation of a Planning Concept
4 Creation of a Planning Concept
Contents
concept for planning the electric power distribution of the following three approximation steps are
an industrial plant. This applies to a new construction
1 (greenfield) as much as to a conversion or expansion
defined:
1. An estimate based on area specifications as
Fig. 2/3 comparison with similar projects: The actual

- cost will range from below or above
- the estimate.
ment, update and refinement of a power distribution 2. An engineering estimate based on a one-line
2 concept. Even for a first rough planning overview, funda- diagram [4.1] – hereafter called single-line
diagram: The actual cost will range from
to take location conditions into account while estab- below or above the estimate.
lishing the project basis, and to be able to incorporate an
development of a basic scheme for the electric power manufacturer offers and detailed drawings of
below or above the estimate.

3 -
-
tions – for example, regarding operational stipulations,
expansion possibilities, and embedded generation of planning should be built on simple data based on the
three pillars of electric power distribution in –
the concept and thus the cost situation. infeed, embedded generation, and consumers (storage
4 -
ated under former preconditions, assumes for a so-called
starting point for planning and configuration of the
costs of up to (see box) is possible. New develop- network (Fig. 4/1).
ments such as, among others,
•
(see )
5 •
6
power values, such as for example in [1.1], even more so
checks and coordination with the customer, a draft for

7
34 Totally Integrated Power – Creation of a Planning Concept

Contents
Concept finding:
- Analysis of the supply task

- Power demand determination
- Load characteristics
1
- Power supply options (e.g. primary energy, emissions)
- Supply quality (supply reliability and power quality)
- Creation of variations and realization test
- Concept selection with:
- Selection of the network configuration
- Selection of the network system
- Definition of the technical features
Calculation: 2
- Power and energy balance (consider future developments)
- Load flow (normal / failure / island operation / regenerative feedback)
- Short-circuit currents (prospective / influenced)
Dimensioning:
- Selection of operational equipment, transformers, cables, switching and protection devices, etc.
- Requirements regarding selectivity and back-up protection
- Consideration of energy management and operational capabilities 3
Verification:
Comparison of results between concept estimates and user requirements (cf. Fig. 3/9)
- Definition of evaluation stages of individual criteria (e.g. unacceptable, appropriate, acceptable, optimal)
- Weighting for individual criteria
- Evaluation of variations
With positive evaluation: With negative evaluation:
Refine concept and perform detailed Coordinate changed optimization approach

calculations and dimensioning and implement in the “concept finding” step
(design planning) (iteration loop for establishment of the project
basis and preliminary planning – see [1.1]) 5
Fig. 4/1:
A structural diagram (Fig. 4/2) is helpful for illustrating

and assessment of different variations is crucial for the
-
the process of concept finding. The fundamental deci-
sion-making levels for a rough concept are structured in
6
For those variations that seem suitable, calculations and 3. Embedded generation
dimensionings are performed in order to be able to, for 4. Medium-voltage switchgear and load centers at
process level
7
detailed in ).
Totally Integrated Power – Creation of a Planning Concept

Contents
Fig. 4/2 -
options for the individual levels does not become clear
that must be taken into account during concept finding
subitems. Further focal points for the design, which, for a reliable electric power distribution in industrial
however, depend on a more detailed knowledge of the plants. However, due to changes and/or extensions of
project, include:
1 • planning areas, the concept finding can be refined,
• can provide support

for a project-specific concept finding
loads and generators must be taken into account) (www.siemens.com/tip-cs).
•
distribution level
2 •
changes or start-up of large drives) 4.1 Infeed
•
in the process distribution level Two characteristics are decisive for the selection
• Network feedbacks and compensation in the entire
network
•
current and future power demand.
3 The above-mentioned points do not have a direct influ-
ence on the general procedure in creating the rough An infeed concept can be selected with the help of a
concept, but each piece of information on it can influ- simple decision diagram (Fig. 4/3):
4
1 Infeed
Infeed distribution and 20 kV

2
network configuration
5
3 Embedded generation
G G G
Switchgear and
4
load centers
10 kV
6
Consumer and
5 0.4 kV 0.4 kV
load distribution
P M P M P
7 Fig. 4/2: Structural diagram to illustrate the levels of a rough concept

Contents
• 1), •
voltage U = ) via one or multiple in-house
maximum connected load: transformers 3):
S max S max
U = U =
S max S max 1
U = U =
• Of course, it is important to coordinate the connec-
substation 2)
with two cable connections: (see, for example, for technical connec-
-
S max
ditions such as distances, short-circuit currents, use and
U =
S max
behavior of motors or motor starters and generators, 2
U = (see ).
3)
1) For looping into a public medium-voltage cable ring, an upper reference
of the embedded network (this is an advantage compared with the
2) The power limitation in case of direct connection to a main transformer

3
cannot be created at the transformer, but must be created via a neutral
dimensioning of the neutral earthing transformer and the earthing

the earth-fault compensation for neutral earthing. resistance.
4
10 kV
20 kV
Yes
Looping
UnS = 10 kV: Smax
into the normally open n. o. ring
UnS = 20 kV: Smax (n. o.) DSO ring
Infeed
distribution
No 5
10 kV
20 kV
No
Double radial line
UnS = 10 kV: Smax
directly from the busbar
UnS = 20 kV: Smax of the main transformer Infeed
distribution
6
No
110 kV grid
In-house
HV/MV transformer
supplied from the
110 kV busbar of Infeed
the high-voltage
transformer substation
distribution 7
Fig. 4/3: Decision diagram for the selection of the grid infeed of industrial plants

Contents
•
the simple approach is continued and adjusted based on overcurrent protection as main and back-up protection
Fig. 4/1 with changed parameters, if needed. due to lower short-circuit currents 4).
Fig. 4/4) of network configurations
can be differentiated:
1 4.2 Infeed Distribution and • Radial network
• Ringed network
Network Configuration • Meshed network.
From this, versions or combinations (Fig. 4/4) can be
derived, such as for example:
. stipulates standard voltages in •
medium voltage ( U ) and high voltage • Tree network
2 ( U ). notes that new public
distribution grids should no longer use a voltage level of
• Double radial line network.
Fig. 4/4
and does not provide details on infeed, generation and
) com-
consumption. The tree network represents a concatena-
pared with :
•
two infeed distributions, the double radial line network
(assuming the same short-circuit power; Ima and Isc
can be considered a simple combination of individual
at
3 )
ringed networks.
•
factor of 2 to 3 for , and up to approx. a factor of
4) I2t)
compared with ; assuming the
and a smaller peak short-circuit current (ip). The longer disconnection times
same power or short-circuit power to be transmitted) resulting therefrom have a positive influence on the possible grading levels
• of the definite time-overcurrent protection.
4
Basic types
Radial network Ringed network Meshed network
Variations of the basic types
6 Line / bus network Tree network Double radial line network
7 Fig. 4/4:

Contents
•
radial line network which differ in normal operation can •
be divided into “open” and “closed” modes of operation.
“open double radial line”, each individual ring is accord-

Due to an increasing interest in embedded generation in
1
Attention: The basic principle is that a “closed” operation consumption of wind, sun and biomass, the distribution
is not possible in case of infeed from two separate
offers
-
are supposed to replace such large power plants in
2
terms of grid stabilization for smaller generating plants
as well.
-
nized. For parallel operation of embedded generating plants
-
-
that the project-specific framework stipulates the 3
individual weighting of individual criteria and, if appli-
cable, defines specific criteria in order to prefer or
national and international standards as well as directives
and empirical values form the basis for these codes
as a radial, ringed or double radial line network, Tab. 4/1 (Tab. 4/2
shows important criteria for comparing these three
network configurations. The estimation of the criteria
can support decision making during project planning.
market, there is a constant process of adjustment in
laws, standards, specifications, directives, stipulations,
4
and conditions. For this reason, when these documents
are referred to, the latest version at the time must be
consulted.
4.3 Embedded Generation
There are various reasons for operating an embedded
generating plant in parallel with a distribution grid: 5
•
•
that can impair production processes
•
), for example
6
•
demand

Contents
Legend Radial network
DSO infeed
Property limit
2) 2)
1 for measuring and protection
4) Billing *) 4)
*) 3) 3)
for billing
1)
3
Design features for medium-voltage network Radial network
Cable fault,
source
4 supplied
Protection technology
disconnector/fuse combination)
Network monitoring in operation

as well as measuring / indicating devices
5 Voltage dip in case of short circuit
Danger to persons
6
Availability
case of fault
Installation of the switchgear

in the production hall (e.g. consideration of ambient conditions like
7
As described in Fig. 4/1
Tab. 4/1:

Contents
Ringed network Double radial line network
DSO infeed DSO infeed
Property limit Property limit

2) 2) 2) 2)
4) Billing *) 4) 4) Billing *) 4) 1
3) 3) 3) 3)
1) 1) 1) 1) 1) 1) 1) 1)
1) 1)
1) 1)
1)
2
5) 1)
1) 1) 5)
1) 1)
5)
1) 1) 5)
switching and protection device
supplied without interruption thanks to the ringed concept

(n. c.)
the double radial line network, connected transformers and associated
consumers are not supplied; consumers might have to restart again then
4
High expenditure (circuit-breaker plus protection device Medium expenditure (circuit-breaker plus protection device with current
with current and voltage transformers including direction transformers)
detection)
has to be taken into account in case of protection via circuit-breaker for

5
protection via circuit-breaker for fault detection, tripping, fault detection, tripping, internal time of the circuit-breaker, arcing time,
internal time of the circuit-breaker, arcing time, plus
6
design)
voltage dip (see above) is to be observed line to the other
switchgear to prevent hazards due to high short-circuit

measures
Totally Integrated Power – Creation of a Planning Concept 41

Contents
Standards
Regions Organization Standard
Europe
1 Australia / New Zealand
North America
Rules, directives, regulations
Regions Organization Directive, regulation
2 North America
Australia
Tab. 4/2:
of power-generating plants in parallel with the public electricity grids
3
4.3.1 Standards, Specifications
- the voltage level for grid connection and the maximum

-
4 and
-
which must then be narrowed down based on the
-
the stipulated power threshold values of the maximum
the national and international transpositions of the
(see ).
for example, a series of standards ( ) is drawn
5 The Regulation stipulates individual value ranges for
-
countries according to their specific conditions.

6

Contents
Legend:
Area of maximum active power limitation for type A
Area of maximum active power limitation for type B
Extension area type B, dependent on the area for type A
Area of maximum active power limitation for type C 1
Extension area type C, dependent on the area for type B
Area of maximum active power limitation for type D
Extension area type D, dependent on the area for type C
Continental Europe
Great Britain
2
EU 2016/631
Northern Europe
Ireland +
North. Ireland
Baltic States
Belgium 1)
3
DSO / TSO / Country only MV
Austria 2)
Switzerland 3)
up to 110 kV
Italy 4)
Germany 5)
4
Spain 6)
Denmark 7)
A1 (11 kW) A2 (50 kW)
England 8)
800 W 0.1 MW 1 MW 10 MW 100 MW

1)
5
2)
3) Empfehlung Netzanschluss für Energieerzeugungsanlagen (Recommendation for grid connection of power-generating plants);
4)
Norma técnica de supervisión de la conformidad de los módulos de generación de electricidad segun el Reglamento
Fig. 4/5:
Totally Integrated Power – Creation of a Planning Concept 43

Contents
4.3.2 Requirements for Grid Connection of

Power-Generating Plants -1 and -2 take the
( -2)
for grid connection of a power-generating plant regard- into account.
1 Exception: Power-generating modules with an

apparent power output of up to A can also be
connected to the medium-voltage grid according to the
• regulations (examples in ) must be observed.

2 •
• protection and automatic control must be applied hierar-
• -1 and -2 (decreasing
of network operation
• Minimizing critical events and determining
3
does not agree or b) foreseeable operating
•
higher resilience to operational events, and limitation engine, if applicable
of the effects of network events
• within the generating plant
•
4 in voltage
for distribution grid support or due to local

•
the grid
• Enabling coordinated operator action in overall
power-generating facilities in different situations
5 during trouble-free operation as well as in case of regulation, for example due to self-optimization
grid disturbances. stipulations, for economic reasons, or according to
local market conditions.
• Higher voltage level of the grid connection

of generating plants (according to EU Regulation -
) for ensuring a stable
6
-
ments for the high-voltage grid of
-1 and -2
stipulate a common framework for the medium- and
-
7

Contents
-1 and -2, which

Frequency in Hz
P
47.5 48.0 48.5 49.0 49.5 50.0
relatively to the momentary active power PM

a. Permissible minimum operating periods with 5%
Tab. 4/3 10 %
1
b. Permissible minimum active power at
15 %
voltage Un, the following applies for the agreed

20 %
Uc :
Uc Un .1 Uc
2
Requirement acc. to EN 50549-1 and -2
Uc Un .1 Uc Most stringent requirement acc. to EN 50549-1 and -2
Uc Un .1 Uc)
Fig. 4/6: Maximum permissible active power reduction at
underfrequency
3
problem) [4.3]
4
Frequency in Hz 47.0 47.5 48.0 48.5 49.0 49.5 50.0 50.5 51.0 51.5 52.0
EN 50549-1/-2 Minimum requirements 30 min Unlimited 30 min
More stringent
20 s 90 min Unlimited 90 min 15 min
requirements
Frequency in Hz 47.0 47.5 48.0 48.5 49.0 49.5 50.0 50.5 51.0 51.5 52.0
Continental Europe 30 min Unlimited 30 min
EU 2016/631
Northern Europe 30 min Unlimited 30 min 5
Great Britain 20 s 90 min Unlimited 90 min 15 min
Ireland /
90 min Unlimited 90 min
Northern Ireland
Baltic States 30 min Unlimited 30 min
Frequency in Hz 45.0 47.0 49.5 50.0 50.5 52.0 57.0
Unlimited operation possible Unlimited Unlimited operation possible

6
Power frequency 50 Hz
Frequency for a limited Frequency for a limited
operating time (0.5 s to 90 min) operating time (0.5 s to 90 min)
IEC/TS 62786
Frequency in Hz 57.0 59.5 60.0 60.5 61.8
Unlimited operation possible Unlimited Unlimited operation possible

Power frequency 60 Hz
Frequency for a limited Frequency for a limited
operating time (0.5 s to 90 min) operating time (0.5 s to 90 min)
7
Tab. 4/3: Frequency-dependent time stipulations for grid operation of power-generating plants according to EN 50549-1 and -2,
2016/631/EU and IEC/TS 62786

Contents
2. For grid-critical states:
provision
- Mode of setting point for Q
(setpoint for reactive power output)
1
- Q(U) (reactive power output as a function of
voltage)
- Q(P) (reactive power output as a function of
active power); not possible for power-generating
reactive power), and, in case of deviations from this, as a power-voltage
diagram (ratio of voltage U to nominal voltage Un as a function of the ratio plants according to -1
of reactive power Q to design active power P D). (P)
2
3 Required reactive power characteristics at nominal voltage Un
For generating plants type A and B at the medium-voltage grid (EN 50549-2)
P Default requirement
PD, standard Smax
Stringent requirement
PD, stringent
4 Design freedom area
Further requirement
in some countries
0.2 · PD, standard

0.2 · PD, stringent 0,1 · Smax Q / PD
-0.484 -0.33 0 0.33 0.484
Standard
Under-excited Stringent Over-excited
5
For generating plants type A and B at the low-voltage network (EN 50549-1)
P Requirement
Smax
Design freedom area
PD
Further requirement
6
in some countries
0.1 · Smax Q / PD
-0.484 0 0.484
Under-excited Over-excited
Fig. 4/7: Reactive power behavior of power-generating plants for grid support according to EN 50549-1 and -2

Contents
response
per second as a
maximum for a change
countries) -
-1 and -2: At least 2 Hz/s for non-

P / P ref
At least 1 Hz/s for

2
Required reactive power characteristics at active power PD

and deviations from the nominal voltage Un
3
For generating plants type A and B at the medium-voltage grid (EN 50549-2)
U / Un Range for I = Imax = constant with P < PD

Area is limited by the curve:
1.10
(1 / 0.95)2 - 1
1.05
Q / PD = ((U/Un +0.05) / 0.9)2 - 1 ·
(1 / 0.90)2 - 1 4
Q / PD
-0.33 0.33
0.95
0.90
5
Under-excited Over-excited
For generating plants type A and B at the low-voltage network (EN 50549-1)
U / Un Range for I = Imax = constant with P < PD

Area is limited by the curve:
1.10
Q / PD = (U/Un / 0.9)2 - 1
1.05 6
Q / PD
-0.484 0.412 0.484
0.95
0.90 Limit of minimum

requirement with
active factor = 0.9
0.85
Under-excited Over-excited 7

Contents
Active power increase at underfrequency (LFSM-U)
P/Pref
60 %
50 %
1 40 %
30 %
LFSM-U acc. to EN 50549-1 and -2 (red area):
20 %
Threshold frequency f2 f2
(Dotted red line: s = 5 %, f2 = 49.8 Hz,
10 % Frequency in Hz
corresponds to gradient g = -40 % per Hz for fN = 50 Hz)
50.2 50.6 51.0 51.4 51.8 52.2
2 48.2 48.6 49.0 49.4 49.8

-10 %
LFSM-O acc. to EN 50549-1 and -2 (blue area):
-20 %
Threshold frequency f2 f2
(Continuous blue line: s = 5 %, f2 = 50.2 Hz,
-30 % corresponds to gradient g = -40 % per Hz for fN = 50 Hz)
f / fn P / Pref)
-40 %
with
f / fn = Per-unit change in frequency
3 P / Pref
to the nominal frequency fn
= Per-unit change in power
-50 %
-60 %
to the reference power Pref
Active power reduction at overfrequency (LSFM-O)
Fig. 4/8:
4
power generating plants
disconnection of the power-generating plant and a converter connected power-

generating plants must be able to reduce their
avoided:
5 of rated current (or below) (see -1
and -2).
[4.4] provides an overview of all the differences among

ii) Reactive current infeed
European countries when it comes to the implementa-
topic of grid connection of embedded generating plants

6 For power-generating plants in the low-voltage
observed.
described in -2. The additional reactive

7 current is to be supplied at least up to the level of
U Uc
voltage Uc)

Contents
U / Un
OVRT for (0 ; 0.125) (0.1 ; 1.25)
power-generating plants: 1.2
(5 ; 1.2) (60 ; 1.15)
(0.1 ; 1.2)
(5 ; 1.15)
(60 ; 1.1)
1.0
Overvoltage-time limiting curve (0 ; 1.0)
for grid connection in case of fault 0.8
EN 50549-1 and EN 50549-2 0.6 1

0.4
0.2
0
0 0.5 4.5 5 5.5 59.5 60 60.5 Time in s
Default requirement
UVRT for synchronous

U / Un
2
1.2
power-generating plants:
(0 ; 1.0)
1.0 (180 ; 0.9)
(1.5 ; 0.85)
Undervoltage-time limiting curve 0.8
(0.15 ; 0.7)
(180 ; 0.85)
for grid connection in case of fault (0.7 ; 0.7)
0.6
EN 50549-1 and EN 50549-2 (0.25 ; 0.7)
0.4
EN 50549-1
3
(0 ; 0.3)
(0.15 ; 0.3)
EN 50549-2 0.2
(0 ; 0.05) (0.25 ; 0.05)
0
0 0.5 1 1.5 2 2.5 3 180 Time in s
Default requirement
U / Un
UVRT for non-synchronous
4
1.2
power-generating plants:
(0 ; 1.0)
1.0 (180 ; 0.9)
(1.5 ; 0.85) (2 ; 0.85) (3 ; 0.85)
Undervoltage-time limiting curve 0.8 (180 ; 0.85)
for grid connection in case of fault
0.6
EN 50549-1 and EN 50549-2
0.4
EN 50549-1 (0.2 ; 0.15)
EN 50549-2 0.2
(0 ; 0.15)
(0 ; 0.05)
5
(0.25 ; 0.05)
0 (0.2 ; 0.05)
0 0.5 1 1.5 2 2.5 3 180 Time in s
Default requirement
Fig. 4/9: Voltage-time characteristics according to EN 50549-1 and -2 *

behavior in case of fault
6
*
This also becomes evident when it comes to electromag-
on power
.
-1 and -2 point out how the latest -1 and -2 agree that local 7
series is oriented towards consumers. The standard
series
direct currents into the grid.

Contents
4.3.3 Interface Protection Tab. 4/4,
-1 and -2).
1 4.4 Medium-Voltage Switchgear

• Faults in the distribution grid and Low-Voltage Load Centers
• Unintentional islanding
• at Process Level
limit values.
The terms “load centers” and “switchgear” make it clear
2 the industrial plant must be taken into account during
step, it must be clarified – based on the existing tech-

nical data and the installation or arrangement of loads
and consumers – which voltage levels should be prefer-
generating units. Exceptions are converter connected

3
and so-called micro-generating plants according to
-1 (low-voltage connection and maximum low-voltage consumers – such as lighting, information
applications, as well as smaller drives – larger motorized

threshold value), in which an interface protection and a
measuring point can be integrated in the generating medium-voltage distribution of .
4 units of the power-generating plant.
Distribution grid
Producer’s network
Point of connection
(PoC)
5 Main switch
Interface protection relay
Producer’s
non-island operation Interface switch
6
Producer’s Generating unit switch
island operation
Power-generating unit
7 Fig. 4/10: Schematic example for the connection of a power-generating plant to a distribution grid based on IEC/TS 62786 or
EN 50549-1 and -2

Contents
Setting ranges
Protection function EU standard ANSI code Threshold Pickup
value range time range
Undervoltage protection Uc U Uc
Uc U Uc
Overvoltage protection Uc U Uc 1
Uc U Uc
Uc U Uc
2
Uc U Uc
Uc U Uc
Uc U Uc
Tab. 4/4: Protection settings for the interface protection according to EN 50549-1 and -2
3
The short-circuit currents of large motors must be
that are important for the structural concept of the load
electric power distribution in case of short circuit. The center are not taken into account.
higher the operating voltage, the lower the short-circuit
The load center determination is an iterative process for
current at , for example, is higher than at
. Further advantages of a higher voltage are:
which numerous detailed pieces of information should 4
• Reduction of cable cross-sections possible, such as for example shifting the consumers,
and thus the load center. To create a first concept draft
• -
• sumers, it is sufficient to consider the voltage drop in
extending the grading time ranges .
4.4.1 Low-Voltage Load Centers power on the low-voltage side. 5

i) Line lengths and voltage drop
load centers regarding short-circuit currents and voltage
-
is decisive for determining the cross-section. For the

number of load center substations depends on criteria
such as the load distribution and the associated area
6
in the building. The background of the load center deter- [1.2].
mination described in
estimations:
a low-voltage motor with a maximum power 7

I 2t
short-circuit current ip). For this reason, longer disconnection times are
of the definite time-overcurrent protection.

Contents
2 for ii) Short-circuit power and voltage stability
drop remains below . short-circuit power at the point of connection or
more expensive if a higher short-circuit power is
1 lperm = lstand Un / IB u
with: lperm = permissible line length due to the higher currents. The relative impedance
lstand = standardized value for the voltage ukr of the transformers is crucial for this.
permissible line length according
when designing the load centers:
the unit of lstand
Un = nominal voltage
2 IB = maximum operational current transformers S k“ (transformer) should be less
I k“
u = percentage for voltage drop
ukr = S rT / S k“
Example: Un IB = 422 A; multi-core maximum total rated power of the transformers
2 for an individual substation in the load center,
depending on ukr:
l
S rT (ukr = )
lstand
3 S rT (ukr = )
2, results in:
– A higher total short-circuit power of the
u = lperm / lstand IB / Un
)
(corresponds to I k“
For placing one or more load centers, the mitigates the voltage dips which are caused, for
distance must not be assumed as a line length
4 rather be taken into account, with rectangular with ukr and , the respective
range of the total transformer power for an
individual substation in the load center results as
follows:
S rT (ukr = )
S rT (ukr = )
5
Requested short-circuit withstand
strength I k“ of the switching and 55 kA 66 kA 85 kA 100 kA 130 kA
protection devices
S k“ = I k“
Corresponding short-circuit withstand

38 MVA 45 MVA 60 MVA 70 MVA 90 MVA
strength S k“ of the transformers
6 S max(transformer) = S k“ u kr
1 busbar / substation
Maximum total power
S max 2 busbars / substations
with u kr = 4 %
3 busbars / substations
1 busbar / substation
Maximum total power
7
S max 2 busbars / substations
with u kr = 6 %
3 busbars / substations
Tab. 4/5: Maximum total power of transformers depending on the requirements for the short-circuit behavior and the number

Contents
At a total power in the load center of more than

the maximum total power of the transformers
several substations (or separate connection
busbars). load centers (substations or connection busbars)
as well as on the impedance voltage ukr of the
As an overview for the different short-circuit Fig. 4/11 illustrates the
withstand strengths of the switching and protection correlations between the short-circuit withstand 1
devices and the associated short-circuit power of
the transformers, a table ( ) can be created. transformers at a connection busbar.
Apparent power Maximum permissible short-circuit current of the switchboards and devices
of transformer /
Short-circuit
2
55 kA 66 kA 85 kA 100 kA 130 kA
voltage
2,500 kVA /
6%
2,000 kVA /
6% 3
1,600 kVA /
6%
1,250 kVA /
6%
4
1,000 kVA /
6%
800 kVA /
6%
630 kVA / 5
6%
630 kVA /
4%
500 kVA /
4% 6
400 kVA /
4%
Parallel operation of 2, 3 or 4 transformers, commonly used
Parallel operation of 5 or 6 transformers, not very often in use
Parallel operation of more than 6 transformers, only under special conditions 7

Fig. 4/11: Overview of short-circuit requirements on low-voltage switchboards and devices depending on

Contents
iii) Maximum output of the individual transformers
u of the
in the load center
remains below . As described in item i), this can be
preferred as transformer protection on the medium-
voltage side (advantages being the limitation of
short-circuit current and short-circuit duration in
a power of 1, A or 1, A per transformer is
1 case of fault), a maximum transformer rating is
.
recommended as follows:
A at
with the total power of the motors. The two selected
1, A at
concepts are:
smaller cable cross-sections for the transformer 1. One load center substation:
2 feeders result in the event of short circuit thanks to
I2t values)
(advantages compared with circuit-breakers: Two versions can be selected here. On the one hand,
limitation of let-through current as well as faster all transformers – with 4 times 1, A or 3 times
1, A – are connected to a common busbar.
(on the medium-voltage side) and the transformer circuit withstand strength of I k“
circuit-breaker (on the low-voltage side), the fuse- 1, A) or I k“ A) are
3 to be used according to and Fig. 4/11
(Fig. 4/12 illustration a). For a low short-circuit
transformer circuit-breaker on the low-voltage side. withstand strength of I k“
are operated in parallel: For the 1, A
The procedure for concept finding with the help of table transformers, it is two that are operated at two
Fig. 4/12). busbars each, or one transformer each at three
busbars for the 1, A transformers (Fig. 4/12
4 can be created for one or multiple load centers depending illustration b).
2. Two load center substations:
•
• reasons and the transformers shall be installed close
to the wall, the solution involving the four 1, A
transformers is appropriate, as at least two separate
load centers must be established (Fig. 4/12 illustration c).
5 • The motors should be supplied via one or multiple
Uprim = Usec ). then be selected with I k“
installation.

Contents
a) Centralized installation with high short-circuit power on a common busbar
with with
4 × 1,000 kVA transformers 3 × 1,250 kVA transformers
50 m 50 m 50 m 50 m
1
50 m 50 m 50 m 50 m
50 m 50 m 50 m 50 m
2
50 m 50 m 50 m 50 m
b) Centralized installation with low short-circuit power on separate busbars
2 busbars with 3 busbars with

2 × 1,000 kVA transformers each 1 × 1,250 kVA transformers each
50 m 50 m 50 m 50 m 3
50 m 50 m 50 m 50 m
50 m 50 m 50 m 50 m
4
50 m 50 m 50 m 50 m
c) Installation at the sides of the room (or corners), with lower short-circuit power
Via 2 spatially separated load substations with

2 × 1,000 kVA transformers each
100 m 5
100 m 100 m
6
100 m
Fig. 4/12: Placement of load centers depending on the low-voltage cable length and the installation options

Contents
4.4.2 Medium-Voltage Switchgear

rated value, and can therefore be the cause for critical
it is reasonable to connect to a medium-voltage level. be checked whether the starting currents can cause a
As opposed to electric power distribution for low-voltage voltage drop of more than [1.2].
loads, the line length is negligible in medium-voltage
1 For a simple verification, the short-circuit power pro-
For the connection of motors to a medium-voltage
switchgear, for example, the line length (with the same
the low-voltage network – with all assumptions previ- Transformer short-circuit power:
“ = S rT
S kT ukr
2 Motor starting power:

S sM = S rM IsM / IrM)
be taken into account. The arising starting currents in “

u = S sM / S kT
3 Single-line diagram: Impedances for voltage drop estimation:
Supply grid 110 kV
Transformer Usec22 · ukr

SrT = 80 MVA ZTrafo =
SrT
Uprim2 / Usec2 = 110/20 kV
ZTrafo(80 MVA) = (20 KV)2 · 0.125 / 80 MVA =
4
ukr2 = 11 %
Medium-voltage distribution 20 kV
Transformer Transformer Usec12 · ukr

ZTrafo =
SrT = 5 MVA SrT = 5 MVA SrT
Uprim1 / Usec1 = 20/10 kV Uprim1 / Usec1 = 20/10 kV
ukr1 = 7 % ukr1 = 7 % ZTrafo(5 MVA) = (10 KV)2 · 0.07 / 5 MVA =
Motor distribution 10 kV
Usec12
5 Block motor
SrM = 4 MVA M M M M M
Group of motors (4 nos.)
SrM = 1 MVA
ZMotor =
SrM · IsM / IrM
IsM / IrM = 6 IsM / IrM = 6 ZMotor(1 MVA) = (10 KV)2 / (1 MVA · 6) =
Time-graded motor start
u= 3 · Ik · ZTrafo
ZMotor(4 MVA) = (10 KV)2 / (4 MVA · 6) =
Voltage drop at motor terminals: Voltage drop in the medium-voltage distribution 20 kV:
6 IrM =
SrM
3 · Usec1 Ik = Is 20 kV = IsM ·
Usec1
Uprim1
and therefore resulting in
SrM Usec1
Ik = IsM = (IsM / IrM) · uTr = 3 · IsM · · ZTrafo(80 MVA) =
3 · Usec1 Uprim1
resulting in SrM
SrM = (IsM / IrM) · · ZTrafo(80 MVA)
uM = (IsM / IrM) · · ZTrafo(5 MVA) Uprim1
Usec1
7 uM (4 MVA) = 6 · 4 MVA / 10 kV · uTr (4 MVA) = 6 · 4 MVA / 20 kV ·

uM (1 MVA) = 6 · 1 MVA / 10 kV · uTr (1 MVA) = 6 · 1 MVA / 20 kV ·
Fig. 4/13: Comparison of a staging motor start with the direct-on-line start of a large medium-voltage motor

Contents
(Uprim1 = ) remains below , so that the effects

“
S kT Transformer initial short-circuit power
S rT Transformer rated apparent power within acceptable limits.
ukr Transformer impedance voltage in percent
S sM
S rM
IsM / IrM
Motor rated apparent power
Ratio of starting current to rated current of This, in turn, leads to an extension of the starting time 1
motor (Fig. 4/14). For the starting duration t s, the following
The more precise determination of the voltage drop via

impedances is described in Fig. 4/13, it is ts = J Macc)
shown based on a simple example how a time-graded with
motor start (also called “staging” start) of multiple J Total moment of inertia which must be
compared with a direct-on-line start of a large motor

accelerated (in kgm2) 2
n Operating speed (in revolutions
(cable impedances are disregarded so that a maximum
per minute: rpm)
feedback is assumed). For both cases in Fig. 4/13, the
Macc
voltage drop in the medium-voltage distribution grid
1.2 3
Motor voltage / Rated voltage
1.0 U = Ur
U1 Ur
U1
Ur
0.8
4
0.6
0.0 0.2 0.4 0.6 0.8 1.0
Speed / Rated speed
2.5
2.0 5
Motor torque / Rated torque
1.5
M
(Mr)
Mr
1.0
M
(M1)
Mr 6
0.5
0.0
0 5 10 15 20 25
Time in s
Fig. 4/14: Example for the extension of the motor starting time by means of a voltage reduction 7

Contents
Torque M Power P over

Applications
over speed n speed n
Winding motor, M P
spinning machines,
facing lathe M ~ 1/n P ~ const.
1
n n
Conveyor belts, M P
cranes, elevators, P~n
rolling mills, M ~ const.
planing machines
2 n n
Eddy current brakes, M P

calenders, printing M~n P ~ n2
machines, smoothening,
embossing
3 Fans, centrifuges,
n n
M P
centrifugal pumps
M~n 2
P ~ n3
n n
Power at the shaft P = Torque M · Speed n / 9,550
4
Fig. 4/15: Starting behavior of different motor applications
- switching on and off as well as regulating individual

dent on the voltage. Overall, the acceleration moment motors.
which is important for motor ramp-up must be suffi-
cient to accelerate the drive to rated speed in the time Regarding feedback in the higher-level medium-voltage
5 - grid, the impedances of the network components as well
as the starting currents of the relevant drives are deci-
sive, as shown in Fig. 4/13. The voltage dip at the rele-
distribution network, such as for example in the design vant point in the network can be determined from this.
of feeders with contactor-fuse combinations.
voltage drop at motor start (as in the example of
Furthermore, the starting time depends on the starting Fig. 4/13) are shown in the next section.
6 class and the mode of operation (see [1.1]). The different
starting characteristics of the motor applications also Note:
) in selecting the motor starter
(see ). direct-on-line start, meaning that, as a general rule,
For a staging operation of several motors, suitable

). (
voltage motors, it is advisable for both the user and the
7 which the pressure or flow rate must be variable.

Contents
advantage of a flexible motor control with optimum use
Furthermore, a design advantage of converters without
under certain circumstances, the network feedbacks of 1

diode rectifiers are to be observed and filters to be
SINAMICS converter
input and output switching operations), the current
limitation can also intervene to limit the short-circuit
current. However, it must be observed to protect the
converter electronics (see -
2
connected motors (pulse-width modulated output
be observed, such as for example for the shaft fan, the

winding, and the bearing insulation.
SIMOTICS motor SIMOTICS motor SIMOTICS motor

3
-
Fig. 4/16: Motor staging for graded start and regulated operation
by means of control via a frequency converter efficient), it should be considered in the planning that
Other important assessment criteria for the selection of

a suitable motor starter are:
4
4.5 Influences on Motor Starting •
• Mechanical stresses and wear for movable drive
About two thirds of electrical industrial consumers are components (bearings, axes, shafts, gears, worms,
belts, wheels, chains, etc.)
combination consisting of a switching and protection •
device is used as a motor feeder in electric power distri- • Problems with abrupt starting and stopping, such as
for example water hammer in pipes 5
application and the electrical network, a starting method •
( ) is selected: voltage dip due to a high starting current
• Direct-on-line start •
• •
•
•
are listed.
6
-4-1 and -2 for low voltage, as well as the
standard series for medium voltage (e.g.
basic standard -1). According to the standard

series as well as
7
Other “classical” starting methods are auto-transformer starters and block
transformers as well as the use of reactors

Contents
Direct-on-line starter Star-delta starter Soft starter Frequency converter
Circuit-breaker Circuit-breaker Switch-disconnector Circuit-breaker

e.g. SIRIUS 3RV e.g. SENTRON 3VA e.g. SENTRON 3KL e.g. SENTRON 3VA
with fuses
1
e.g. 3 × 3NE
Contactor Contactors e. g.
e.g. SIRIUS 3RT 3 x SIRIUS 3RT Cable / line
Electronic overload relay Motor management Soft starter
e.g. SIRIUS 3RB system e.g. SIRIUS 3RW
e.g. SIMOCODE pro 3UF
Switch-disconnector
Cable / line Cable / line Cable / line
e.g. SENTRON 3KL
with fuses
e.g. 3 × 3NE
Contactor
e.g. SIRIUS 3RT
2 M
3~
Motor 3-pole
e.g. SIMOTICS GP M
3~
Motor 3-pole
e.g. SIMOTICS GP M
3~
Motor 3-pole
e.g. SIMOTICS GP
Frequency converter
e.g. SINAMICS G120
Cable / line
Motor 3-pole
M e.g. SIMOTICS VSD10 Line
3~
3 Fig. 4/17: Switching and protection systems of the different motor starting methods
Direct-on-line / Star-delta Soft starter Frequency

reversing start combination converter
Speed control No No Yes
4 Starting current In In 1 to 3 times In Approx. In (motor

adaptation)
Typical range of ratings Universal use
Reduction of current peaks No Yes Yes Yes

Starting moment / ramp-up Full motor moment in
problematic for some the entire speed range
applications impulses
5 Start / stop Abrupt Optimum adjustment
switching over during
abrupt stop
Space requirements High Medium High
Mechanical stress of the High Medium
switchgear
6 Device wear Mechanical wear in the

switchgear
Present Not present
Communication capability Optional Optional Optional Optional

Safety functions Additional hardware Optional
Investment costs Medium Medium High

Transistor losses,
Power loss
7 during braking
Tab. 4/6: Features of typical low-voltage starters

Chapter 5
Concept Finding for the
Electric Power Distribution
of a Beverage Filling Plant
5 Concept Finding for the Electric Power
Contents Distribution of a Beverage Filling Plant
To illustrate the basic considerations of , the

two following chapters describe examples for the con-
cept finding of an electric power distribution of indus-
trial production plants. This chapter focuses on the
1 low-voltage distribution for a beverage filling plant, and
on the medium-voltage distribution of a the blow molder. This process is called stretch blow
chemical plant. For the beverage filling plant, a photo- molding.
After that, all lines direct to the next process step for
2 5.1 Description of the Beverage filling process. Then, the bottles are closed with a top,
or the cans with a lid. The filled bottles go through a
Filling Plant
testing machine again which shall ensure that no foreign
The beverage filling plant for soft drinks described in objects are enclosed in the product.
At the end of the actual filling plant, the bottles or cans

mixing plant together with treated water and additives. are transported to the labeling machine to get their
labels. The packaging machines follow, which either
3 sample plant, separate lines are used for filling glass place the cans in cardboard boxes or the bottles in
boxes, or, as in the case of the PET bottles, just provide
for the plant is given in

and improve the ecological footprint of the plant, photo-
voltaic modules are installed on the roof of the plant,
4 (see
is not intended.
Production information Plant information
Production period 2
5 around the clock

2
Annual production period Extension area
Plant operating time Throughput of PET bottles
Use of water Throughput of glass bottles

1 liter of soft drink
Annual water consumption Throughput of cans
6 Annual soft drink production
Tab. 5/1:
Totally Integrated Power – Concept Finding for the Electric Power Distribution of a Beverage Filling Plant
Contents
SUGAR TREATMENT
Crystal sugar Liquid sugar 1
Water
Crystal
sugar silo Dissolved sugar Filter
Liquefied
sugar
2
Dissolving
Air
WATER TREATMENT MIXING PLANT 3

Sterilized
air
Gravel filter Additives
Water
Degassing
4
Additives
Recipe
tanks
Continuous
Batch mixing plant
Buffer tanks mixing plant
BLOW MOLDING LINE 1 WASHING LINE 2 LINE 3

5
FILLING FILLING FILLING
Water storage
tank
PACKAGING LINE 1 PACKAGING LINE 2 PACKAGING LINE 3 6
Fig. 5/1:
Contents
Sugar treatment
Water treatment
Concentrate & mixing
1 Chemicals Boiler Boilers Blow

Washer
molder
Maintenance / Refrigerators
Filling Filling Filling
technical equipment machine machine machine
Refrig Refrig
Extension Capper Crown
refrigerators Refrig Refrig
Test Test Test
Low-pressure machine machine machine
compressors
Extension Labeler Labeler
LP LP
140 m
compressors comp comp Shrink Packer: Shrink
2 High-pressure
packer
Palletizer
trays
Palletizer
packer
Palletizer
compressors
230 m
HP HP Line 1 Line 2 Line 3

Laboratory comp comp PET 0.5 l Glass 0.3 l Can 0.33 l
HP HP 50,000 50,000 50,000
comp comp bottles / h bottles / h cans / h
Office
rooms Depot
3
140 m 70 m
300 m
Fig. 5/2:
5
To illustrate a planned, future extension with three new For starting operations with three filling lines, a building
filling lines, the additional space is shown in dotted lines
on the floor area ( ). Furthermore, the floor area add three new filling lines, the building section has to
).
the grounds. The degree of automation and the condi-
6
for the total area (dotted limiting line).
Contents
5.2 Power Demand Estimation

for the Plant
extension with 3 filling lines at the beginning of produc-
1)
a rough estimation based on a simple area consideration

2). 1
a load list will be available in most cases.
5.2.2 Power Demand Determination with

5.2.1 Area-Dependent Power Demand Load List
Estimation
definitions of the spatial divisions and the production
2
plant, the power demand can be estimated based on the
items should be taken into account: consumers are shown in the individual rooms – without
lighting and socket outlets, for example – or summarized
1. For office buildings, dispatch areas, laboratories, as consumer groups.
chemical production processes (hereafter called 3
values are assumed according to [1.1].
2. For compressors, cooling devices and boilers, the
can be supplied via low-voltage connections.
from the beginning. This means that the extension
areas have to be left free.
4
2
2
2 is included, the resulting total power
6
1) According to the information given in [1.1], the following is assumed at
the beginning of production:
2 2
2 2
2 2
- Extensions for refrigerators,

2 2
7
2 2
2) For the final state, the following is assumed:

- m2 2
- m2 2
- Maintenance/services, depot approx. 2 2
- Production areas approx. 2 2
Contents
Sugar treatment
Water treatment
200 kVA
225 kVA Concentrate & mixing
LC 3
Chemicals Boiler Boiler
55 LC 4
kVA Blow
1 45 kVA molder Washer

Refrigerators
Spare parts / 45 520 kVA Filling Filling Filling
maintenance kVA machine machine machine
Refrig Refrig
Extension 30 Capper Crown
refrigerators kVA Refrig Refrig
Test Test Test
LC 2 Low pressure 440 machine machine machine
compressors kVA
Labeler Labeler
Extension 30
140 m
MV LP LP
compressors kVA comp comp Shrink Packer: Shrink
infeed
2 LP
comp
High pressure
LP
comp
900 Palletizer
packer
Palletizer
trays
Palletizer
packer
compressors kVA 1,510 kVA 1,330 kVA 1,290 kVA

HP HP Line 1 Line 2 Line 3
Laboratory comp comp PET 0.5 l Glass 0.3 l Can 0.33 l
200 kVA HP HP 50,000 50,000 50,000
comp comp bottles / h bottles / h cans/ h
LC 1
Office
3 rooms Delivery
305 kVA 40 kVA
140 m 70 m
Power demand of individual parts of the plant
4
Power Power
Room Application demand Line Application demand
in kVA in kVA
Air conditioning Packaging

Load center LC 1
PET stretch blow machine

Filling and closing
5 Dispatch
control
Load center LC 4
center LC 2
Packaging
Load
High-pressure compressors
Extension* Bottle rinsing
Filling and closing
6 Treatment plants
control
Boiler
Load center LC 3
Mixing plant
Mixer Packaging
Refrigerators
Filling and closing

7 Maintenance /
control
*
Fig. 5/3: Load overview and load centers for the production plant from Fig. 5/2
Contents
5.3 Connection to the Supply Grid

power match well with the values lk“
S k“
made power demand estimation with the evaluations in
Fig. 4/3 shows that a double radial line connection from simplified estimation. A more exact specification, where
the busbar of a main transformer substation is suitable. the ratio of resistance to reactance (R/X) is taken into
According to , ( ) or ( ) account, is described in - 1
sider reserves for motor feedbacks, a short-circuit
withstand strength of Isc
voltage values between phase conductors;
values in brackets belong to the second series). Due to (lb
(
of . 2
voltage levels still prevails signifi-
done with Un = . 5.4 Definition of the Load Centers

Attention: The individual load centers (
13. means of the load overview and the plan view of the
of the standard. 3
into account according to :
•
coil (resonance-earthed neutral). The selection of the load center substations and the consumers
neutral point earthing influences the design of the •
protection concept and the selection of the protection •
instrument transformers [1.2]. – regarding cost optimization when there are no 4
According to
withstand strength for the switchgear and switching powerful motors or impulse load due to large
devices in the medium-voltage distribution can be deter- consumers).
Zk and the short-circuit current Ik:

Zk U2 ) / S k“ (1)
would have to be established for the office section and 5
lk U )/( Zk) (2)
taken into account, suggests a division into four

is cancelled and the short-circuit current lk can be calcu-
Un and the initial
S k“: production area. The four areas marked in color in
lk = S k“ / ( U ) center substations:
6
S k“ is not known, • A
• A
, , • A
and – can be used according to
• A
practice: 7
lk“
Contents
For the filling area, a further subdivision according to (with a short-circuit withstand strength of the opera-
the 3 filling lines on the low-voltage side (with I k“ kA), the total power of the
1, A, 1, A and 1, A for the individual transformers in the individual load center substations
lines) would be appropriate from a performance and for ukr =
process perspective.
1 For installing fuse-switch-disconnectors as described 3x A transformers each are selected for the
in
1, A are to be selected (Uprim = or A As shown in
at Uprim = ). shows a single-line diagram for A transformers with
the medium-voltage distribution with the transformer
connections for the load center substations.
2 design of the production plants, the medium-voltage

-
-11.
distribution network is to be set up as a ringed network
(see Tab. 4/1 •
regarding the short-circuit power or dielectric strength, •
•
3
Infeed 1 from main Infeed 2 from main
transformer substation transformer substation
Switchgear
GIS 20 kV, 630 A SDC, 3-ph. SDC, 3-ph.
M M
20 kA / 1 s
VCB, 20 kV, VCB 20 kV,
MV infeed 630 A M
630 A M
PV
VCB 20 kV, 3 MVA
1) SDC, 3-ph. SDC, 3-ph. 630 A SDC, 3-ph. SDC, 3-ph. 1)
4
SDC, 3-ph. M
SDC, 3-ph.
M
M VCB 20 kV, M VCB 20 kV, M VCB 20 kV, M VCB 20 kV, M Z
630 A 630 A 630 A 630 A
M M M M
SDC, 3-ph.
Reserva Reserva M
VCB 20 kV,
250 A M
20 kV, 630 A, 20 kA / 1 s - Office, laboratory, dispatch LC 1 20 kV, 630 A, 20 kA / 1 s - Compressors LC 2
VCB 20 kV, VCB 20 kV, VCB 20 kV, VCB 20 kV,

M 630 A M 630 A M 630 A M 630 A
SDC-F, 3-ph. SDC-F, 3-ph. SDC-F, 3-ph. SDC-F, 3-ph. SDC-F, 3-ph.
SDC, 3-ph. SDC, 3-ph. SDC, 3-ph. SDC, 3-ph.
M M M M
5 Tr 1.1
Office
20/0.4 kV Dyn 5
800 kVA ONAN
Tr 1.2
Office
20/0.4 kV Dyn 5
800 kVA ONAN
Tr 2.1
Compressors
20/0.4 kV Dyn 5
800 kVA ONAN
Tr 2.2
Compressors
20/0.4 kV Dyn 5
800 kVA ONAN
Tr 2.3
Compressors
20/0.4 kV Dyn 5
800 kVA ONAN
20 kV, 630 A, 20 kA / 1 s - Machine hall, chemical LC 3
Legend: VCB 20 kV, VCB 20 kV,

LC Load center substation M 630 A M 630 A
SDC-F Switch-disconnector with fuses SDC-F, 3-ph. SDC-F, 3-ph. SDC-F, 3-ph.
SDC Switch-disconnector SDC, 3-ph. SDC, 3-ph.
VCB Vacuum circuit-breaker M M
PV Photovoltaic plant as network infeed, specified through an impedance Z

TR Transformer
GIS Gas-insulated medium-voltage switchgear
1) Transfer measurement
6
Tr 3.1 Tr 3.2 Tr 3.3
Treatment Treatment Treatment
20/0.4 kV Dyn 5 20/0.4 kV Dyn 5 20/0.4 kV Dyn 5
800 kVA ONAN 800 kVA ONAN 800 kVA ONAN
20 kV, 630 A, 20 kA / 1 s - Filling plants line 1, 2 and 3 LC 4
VCB 20 kV, VCB 20 kV,

630 A SDC, 3-ph. 630 A
M
SDC, 3-ph. M
SDC-F, 3-ph. SDC-F, 3-ph. SDC-F, 3-ph. M SDC-F, 3-ph. SDC-F, 3-ph. SDC-F, 3-ph. M SDC-F, 3-ph. SDC-F, 3-ph. SDC-F, 3-ph.
SDC, 3-ph. SDC, 3-ph.
M M
7 Tr 3.1.1
Line 1
20/0.4 kV Dyn 5
Tr 3.1.2
Line 1
20/0.4 kV Dyn 5
Tr 3.1.3
Line 1
20/0.4 kV Dyn 5
Tr 3.2.1
Line 2
20/0.4 kV Dyn 5
Tr 3.2.2
Line 2
20/0.4 kV Dyn 5
Tr 3.2.3
Line 2
20/0.4 kV Dyn 5
Tr 3.3.1
Line 3
20/0.4 kV Dyn 5
Tr 3.3.2
Line 3
20/0.4 kV Dyn 5
Tr 3.3.3
Line 3
20/0.4 kV Dyn 5
800 kVA ONAN 800 kVA ONAN 800 kVA ONAN 800 kVA ONAN 800 kVA ONAN 800 kVA ONAN 800 kVA ONAN 800 kVA ONAN 800 kVA ONAN
Fig. 5/4:
Contents
• Measures for groundwater protection center is ideal. The distances to the individual consumers
• Power increase up to
transformers with S r voltage drop in the network as low as possible. The
• is advantageous in this context; their current-limiting
• No loss of service life when utilizing the overload medium-voltage switchgear and the transformer in the 1
-
• No danger of impermissible switching overvoltages ment risks are reduced.
due to resonance excitation of the windings when
switching on or off using a vacuum circuit-breaker.
create an intermediate level above or below the area to
5.5 Placing of the Load Center of the production area (or at the building wall) as the
2
Substations by the Example of LC 4
good compromise to place the medium-voltage switch-
gear including the medium-voltage ring cabling outside
be observed: of the production area, and install the transformers
• (supplied via medium-voltage radial lines and protected
• ) as well as the low-voltage
• distribution boards for the production lines at the room 3
•
maintenance and replacement of components). however, concentrated at the edges of the room
( ).
From an electrotechnical perspective, the placement of
the electrical service rooms (for the transformers and
low-voltage distribution boards) at the core of the load
4
MV
LV1-1 LV1-2 LV1-3 Legend:

5
Blow
molder Washer
MV Medium-voltage switchgear
Filling Filling Filling
machine machine machine
Space for low-voltage switchboards and
Capper Crown LV1
transformers in the production room
Test Test Test
machine machine machine
LV2 Placement of the low-voltage switchboards
85 m LV2-1 LV2-2 LV2-3 and transformers upstream or downstream
Shrink Packer:
trays
Shrink
from the production room
6
packer packer
Palletizer Palletizer Palletizer

1,510 kVA 1,330 kVA 1,290 kVA
Line 1 Line 2 Line 3
PET 0.5 l Glass 0.3 l Can 0.33 l
50,000 50,000 50,000
bottles / h bottles / h cans / h
70 m
7
Fig. 5/5: Placement of the power distribution boards for LC 4
Contents
5.6 Medium-Voltage • The rated output power of the voltage transformer

Network Protection corresponds to the intended load of the protection
winding.
plant, and the infeed from the power supplier as well as No island operation is intended in this protection con-
the connection of the embedded generating plant to the
1 medium-voltage network takes place here, protection is addressed in , the switching
device assumes the function of the interface switch in
The objectives of protection are: ). The blue dotted lines mark the connec-
•
and the interface switch.
damages
2 • The two medium-voltage spare feeders shown in
are not significant for the protection concept of the
medium-voltage ring without extension, and are there-
fore not represented in -
.
between the protection devices. Besides the protection
concept for the power distribution, a measurement
- concept for monitoring and diagnostics must be created.
3 tion, red arrows in ) in the network. Faults on the The procedure is illustrated in the application manual on
back-up protection with definite time-overcurrent protec-

)
the definite time-overcurrent protection clears faults on 5.7 Connection of the

4 as a directional and interlocked protection, the definite
Photovoltaic Plant
An embedded generating plant with photovoltaic
over the protection of switchgear (purple arrows in
- concept (
can be realized within the switchgear in case of a fault. time, minimize the ecological footprint of the production
5 As shown in , the definite time-overcurrent

must be observed. The protection concept
fault clearance of the incoming cables. According to the
grid connection conditions for embedded generating or -2 for the medium-voltage interface
plants ( ), the devices can be installed for protection.
the interface protection of the photovoltaic plant
). According to
6 observed for the voltage transformers for interface the installation conditions, the roof area, and an appro-
protection (marked blue in ):
•
• Rated voltage factor (rated time according to able to replace a generator for continuing with
production.
7
phase conductor
– 1.2 for voltage transformers between phase
conductors
Contents
Infeed Infeed
7SJ82 7SJ82
1
n.c. I>> 0.6 s Overcurrent: I>> 0.6 s n.c.
Overcurrent:
I> v 0.1 s 46, 49, 51, 51N 46, 49, 51, 51N I> v 0.1 s
Interface protection (PV): Interface protection (PV):
27<<, 27<, 27D, 59>, 59>> 59N, 27<<, 27<, 27D, 59>, 59>> 59N,
7SJ82
81<<, 81 <, 81>, 81>>, 47 I>> 0.3 s 81<<, 81 <, 81>, 81>>, 47
Overcurrent:
51, 51N
n.c. n.c. n.a. n.c. n.c.

7SJ82 7SJ82
forward
backward
I>> 0.3 s
forward
backward
I>> 0.3 s
Directional Directional
overcurrent: overcurrent:
67, 67N, 51, 51N 7SD82 7SD82 67, 67N, 51, 51N
Differential Differential PV
2
protection: 87L protection: 87L
7SD82 7SD82
Differential Differential
7SJ82 protection: 87L protection: 87L 7SJ82
forward
backward
I>> 0.3 s
forward
backward
I>> 0.3 s
7SJ82 n.c.
Directional Directional Overcurrent: I>> 0.6 s
overcurrent: n.c. n.c. overcurrent: 49, 51, 51N, 67, 67N I> v 0.1 s
67, 67N, 51, 51N 67, 67N, 51, 51N
Substation Substation
LC 1 LC 2
n.c. n.c.
7SJ82 7SJ82
forward
backward
I>> 0.3 s
forward
backward
I>> 0.3 s
3
overcurrent: overcurrent:
67, 67N, 51, 51N 7SD82 7SD82 67, 67N, 51, 51N
protection: 87L protection: 87L
7SD82
Differential
protection: 87L 7SJ82
forward
backward
I>> 0.3 s
Directional
n.c. overcurrent:
67, 67N, 51, 51N
Substation
LC 3
n.c.
7SJ82
4
forward
backward
I>> 0.3 s
Directional
overcurrent:
7SD82 67, 67N, 51, 51N
Differential
protection: 87L
7SD82 7SD82
7SJ82 protection: 87L protection: 87L 7SJ82
forward
backward
I>> 0.3 s
forward
backward
I>> 0.3 s
5
overcurrent: n.c. n.c. overcurrent:
67, 67N, 51, 51N 67, 67N, 51, 51N
Substation
LC 4
n.c. n.c.
n.c.
n.a.
Normally closed
Normally open
ANSI device numbers (IEEE/ANSI C37.2):
27 Undervoltage protection
27D Undervoltage protection,
59
59N
Overvoltage protection
Overvoltage protection,
6
I> v Short-circuit tripping in the forward direction; this means in the direction of the line positive phase-sequence system zero-sequence system
47 Overvoltage protection, 67 Directional time-overcurrent protection
backward Short-circuit direction determination backward; this means in the direction of the busbar negative phase-sequence system 67N Directional earth-fault detection
forward Short-circuit direction determination forward; this means in the direction of the line 49 Thermal overload protection 81< Underfrequency protection
51 Inverse time-overcurrent protection 81> Overfrequency protection
Blocking 51N Earth-fault detection 87L Line differential protection
Interface protection
Note: Consider adding grading times for faults at the beginning of the ring!
7
Fig. 5/6: Protection concept for the medium-voltage ring
Contents
peak under
ideal conditions of use (peak value; i.e. power peak value -
meter of module area). For an electric total rated output

3), the roof of the production building would be
1
3). 5.7.1 PV Plant with String Inverters
A, are suitable for the intended
these inverters are connected in parallel to two sections

2 to a smaller inverter. Thanks to the parallel connection
( a). The connection to the medium-voltage
ringed network is done via a transformer to the switch-
of the string inverters, higher ratings can be achieved.
b). The
For connection to the distribution network,

offers both string inverters and central inverters to suit
3 the different application profiles. technical
consultants offer support for the selection of appropriate the additional section with ten inverters ( c).
suitable. Both -
- 5.7.2 PV Plant with Central Inverter
and, moreover, low harmonic dis-
4 tortion factors of less than .
power stack converter modules ( ). Thanks to
efficient:
• Easier adjustment to different
solar radiation conditions
5 • Easier expansion possibilities
•
in case of fault.
inverters prevail:
• Easier installation
6 •
7 3) The rating information corresponds to the electric apparent power at the
peak ”.
peak .
Contents
a)
Transformer
3 MVA, Dyn5 20 kV / 660 V
PV generator
1
Inverter busbar 1 Inverter busbar 2
String combiner with

DC disconnector RS485
Switchbox
Inverter: Inverter:
2
10 x KACO 10 x KACO
blueplanet 150 TL3 blueplanet 150 TL3
b)
Transformer Transformer
3
3 MVA, Dyn5 20 kV / 660 V 1.5 MVA, Dyn5
20 kV / 660 V
PV generator
Inverter busbar 1 Inverter busbar 2 Inverter busbar 3

DC disconnector RS485
Switchbox
Inverter:
10 x KACO
Inverter:
10 x KACO
Inverter:
10 x KACO
4
blueplanet 150 TL3 blueplanet 150 TL3 blueplanet 150 TL3
c)
Transformer
4.5 MVA, Dyn5 20 kV / 660 V
5
PV generator
Inverter busbar 1 Inverter busbar 2 Inverter busbar 3

DC disconnector
6
RS485
Switchbox
Inverter: Inverter: Inverter:
10 x KACO 10 x KACO 10 x KACO
blueplanet 150 TL3 blueplanet 150 TL3 blueplanet 150 TL3
Fig. 5/7: PV power-generating plant with string inverters
Contents
3-winding transformer
4.56 MVA, Dd0d0 20 kV / 630 V
1
Central inverter:
1 x SINACON
2 1 .............. 14 15 ............. 28
1 ............................... 14 15 .............................. 28
Combiner box with Combiner box with Combiner box with Combiner box with
DC disconnector DC disconnector DC disconnector DC disconnector
PV generator PV generator PV generator PV generator
4
Fig. 5/8: PV power-generating plant with central inverter
5.7.3 Protection-Technological Integration

of Embedded Generating Plants in
5 Island Operation
Based on the protection concept shown in , the illustrates the integration of power-generating
generating plants (see ) can also be this process, not the entire network of the plant operator
must be able to switch over to island operation. This is
- (option 1:
6 network). There are multiple other options which are
operation, the switching device for interface protection

in paper manufacturing, for example, organic residual can then be used as a switching device
of the generating unit.
Contents
Infeed Infeed
Point of connection Point of connection
Main
Interface protection: Interface protection: Main 1
switch 27<<, 27<, 27D, 59>, 59>> 59N, switch
27<<, 27<, 27D, 59>, 59>> 59N,
(Interface 81<<, 81<, 81>, 81>>, 47 (Interface
81<<, 81<, 81>, 81>>, 47
switch switch
Main substation
option 2) option 2)
for MV infeed
Power-
generating
plant
Switch of
Substation
Interface
switch
option 1
power-generating
plant
Substation
3
LC 1 LC 2
Inferface
switch
option 1
4
Substation
LC 3
5
Substation
LC 4
Option 1: Island operation only for the substation LC 2 with power-generating plant connection
Option 2: Island operation for the complete medium-voltage ring 7

Fig. 5/9: Examples for protection concepts to enable island operation with embedded generating plants
MS-LTS 4.1.1 MS-LTS 4.1.2 MS-LTS 4.1.3
SDC with fuse SDC with fuse SDC with fuse
In (switch) = 200 A In (switch) = 200 A In (switch) = 200 A
In (fuse) = 63 A In (fuse) = 63 A In (fuse) = 63 A
3 x SIB: 3001413.63 3 x SIB: 3001413.63 3 x SIB: 3001413.63
MS-K/L 4.1.1 MS-K/L 4.1.2 MS-K/L 4.1.3

N2XS2Y N2XS2Y N2XS2Y
Contents
15 m 15 m 15 m
XLPE 3 x 35 XLPE 3 x 35 XLPE 3 x 35
Transformer 4.1.1 Transformer 4.1.2 Transformer 4.1.3

Sn = 800 kVA / AN Sn = 800 kVA / AN Sn = 800 kVA / AN
ukr = 6 % ukr = 6 % ukr = 6 %
20/0.4 kV Dyn5 20/0.4 kV Dyn5 20/0.4 kV Dyn5
4GX59643E 4GX59643E 4GX59643E
Non-automatic circuit-breaker
S 4.1.1 S 4.1.2 S 4.1.3
Busbar Busbar Busbar
3WA12322AA711AA2
25 m 25 m 25 m
LI-AM20005B-55 LI-AM20005B-55 LI-AM20005B-55
LTS 4.1 NPS-SPS

LS 4.1.1 LS 4.1.2 LS 4.1.3
In = 3,200 A
Circuit-breaker Circuit-breaker Circuit-breaker
In = 2,000 A In = 2,000 A In = 2,000 A
3WA11203NB611AA2/LSIN 3WA11203NB611AA2/LSIN 3WA11203NB611AA2/LSIN
MD NPS
1
TN-S Un = 400 V
LS AV
Circuit-breaker
In = 250 A
3VA23256HK320AA0/LI
K/L AV
Cable/Line
5m
Cu 1(3x50/50/25)
LTS AV
Switch-disconnector
In = 200 A
3KD36320PE100
SD NPS
TN-S Un = 400 V
LS AV 1 LS AV 2
Circuit-breaker Circuit-breaker
In = 63 A In = 63 A
3VA21635HK360AA0/LI 3VA21635HK360AA0/LI
2
K/L AV 1 K/L AV 2
Cable/Line Cable/Line
10 m 10 m
Cu 1(3x16/16/16) Cu 1(3x10/10/10)
SD NPS 1 SD NPS 2
TN-S Un = 400 V TN-S Un = 400 V
LS AV 1.1 LS AV 1.2 LS AV 1.3

Miniature circuit-breaker Miniature circuit-breaker Miniature circuit-breaker
In = 16 A In = 16 A In = 16 A
5SY61166/B 5SY61166/B 5SY61166/B
K/L AV 1.1 K/L AV 1.2 K/L AV 1.3 LS AV 2.1 LS AV 2.2 LS AV 2.3

Cable/Line Cable/Line Cable/Line Miniature circuit-breaker Miniature circuit-breaker Miniature circuit-breaker
25 m 25 m 25 m In = 16 A In = 16 A In = 16 A
Cu 1(1x2.5/2.5/2.5) Cu 1(1x2.5/2.5/2.5) Cu 1(1x2.5/2.5/2.5) 5SY41166/B 5SY41166/B 5SY41166/B
5SV33126 5SV33126 5SV33126
K/L AV 2.1 K/L AV 2.2 K/L AV 2.3
Cable/Line Cable/Line Cable/Line
L AV 1.1 Lighting L AV 1.2 Lighting L AV 1.3 Lighting 25 m 25 m 25 m
P Indoor P Indoor P Indoor Cu 1(1x2.5/2.5/2.5) Cu 1(1x2.5/2.5/2.5) Cu 1(1x2.5/2.5/2.5)
3
In = 4.56 A In = 4.56 A In = 4.56 A
Un = 230 V Un = 230 V Un = 230 V
1+N-pole 1+N-pole 1+N-pole
10x 10x 10x

L AV 2.1 Socket outlets L AV 2.2 Socket outlets L AV 2.3 Socket outlets
Indoor Indoor Indoor
In = 10.5 A In = 10.5 A In = 10.5 A
Un = 230 V Un = 230 V Un = 230 V
10x 10x 10x
M 4.1.1.14 a Palletizing
Motor
M 4.1.1.12 a Packaging conveyor
Motor
Control cabinet M 4.1.1.10 a Labeling
Motor
M 4.1.1.8 a Bottle conveyor
Motor
In = 122 A Control cabinet In = 160 A for packaging In = 49.1 A Control cabinet In = 314 A Control cabinet
Un = 400 V Un = 400 V Un = 400 V Un = 400 V
3-pole for palletizing 3-pole conveyor 3-pole for labeler 3-pole for bottle conveyor
L 4.1.1.14 b Pallet. - aggr./ctrl. L 4.1.1.12 b Pack.conv. - aggr./ctrl. L 4.1.1.10 b Labeler - aggr./ctrl. L 4.1.1.8 b Bottle conv. - aggr./ctrl.
Indoor Indoor Indoor Indoor
In = 12.2 A In = 16 A In = 4.9 A In = 31.4 A
4
Un = 400 V Un = 400 V Un = 400 V Un = 400 V
3+N-pole 3+N-pole 3+N-pole 3+N-pole
K/L 4.1.1.14 a K/L 4.1.1.14 b K/L 4.1.1.12 b K/L 4.1.1.10 a K/L 4.1.1.10 b K/L 4.1.1.8 b
Cable/Line Cable/Line Cable/Line Cable/Line Cable/Line Cable/Line
5m 1m K/L 4.1.1.12 a 1m 10 m 1m K/L 4.1.1.8 a 1m
Cu 1(3x50/-/25) Cu 1(3x6/6/6) Cable/Line Cu 1(3x6/6/6) Cu 1(3x10/-/10) Cu 1(3x6/6/6) Cable/Line Cu 1(3x6/6/6)
5m 5m
Cu 1(3x70/-/35) Cu 1(3x185/-/95)
MC-LTS 4.1.1.14 a MC-LTS 4.1.1.12 a MC-LTS 4.1.1.10 a MC-LTS 4.1.1.8 a

SDC with fuse SDC with fuse SDC with fuse SDC with fuse
In = 250 A LS 4.1.1.14 b In = 250 A LS 4.1.1.12 b In = 125 A LS 4.1.1.10 b In = 500 A LS 4.1.1.8 b
3 x 3NA3144 size 1 Circuit-breaker 3 x 3NE12272 size 1 Circuit-breaker 3 x 3NA3832 size 00 Circuit-breaker 3 x 3NE13342 size 2 Circuit-breaker
3KF33250MF11 size 1 In = 16 A 3KL55301AB01 size 2 In = 16 A 3KF23120MR11 size 00 In = 16 A 3KL61301AB02 size 3 In = 32 A
3RT10552AP36 3VA11965EE360AA0/LI 3RW40562BB44 3VA11965EE360AA0/LI 3RT20451AP00 3VA11965EE360AA0/LI 3RW40752BB44 3VA11325EE360AA0/LI
3UF71131BA010 M-UV 4.1.1.14 M-UV 4.1.1.12 3UF71121AA010 M-UV 4.1.1.10 M-UV 4.1.1.8
L 4.1.1.16 Filling information system TN-S Un = 400 V TN-S Un = 400 V TN-S Un = 400 V TN-S Un = 400 V
Indoor LT 4.1.1.14 LT 4.1.1.12 LT 4.1.1.4 LT 4.1.1.8
In = 50.1 A Switch-disconnector Switch-disconnector Switch-disconnector Switch-disconnector
Un = 400 V In = 200 A In = 200 A In = 200 A In = 630 A
3+N-pole 3KD36320PE100 3KD36320PE100 3KD36320PE100 3KD46320QE100
K/L 4.1.1.16
Cable/Line
5
2m
Cu 1(3x16/16/16) K/L 4.1.1.14 K/L 4.1.1.12 K/L 4.1.1.10 K/L 4.1.1.8
Cable/Line Cable/Line Cable/Line Cable/Line
10 m 5m 10 m 5m
Cu 2(3x95/95/50) Cu 1(3x120/120/70) Cu 2(3x95/95/50) Cu 2(3x185/185/90)
LS 4.1.1.14 LS 4.1.1.12 LS 4.1.1.10 LS 4.1.1.8

LS 4.1.1.16 Circuit-breaker Circuit-breaker Circuit-breaker Circuit-breaker
Circuit-breaker In = 400 A In = 400 A In = 400 A In = 630 A
In = 63 A 3VA24405HN320AA0/LSI 3VA24405HN320AA0/LSI 3VA24405HN320AA0/LSI 3VA23635HN320AA0/LSI
3VA20635HL360AA0/LI
70.00 m 65.00 m 60.00 m 57.00 m 55.00 m 50.00 m 45.00 m 42.00 m 40.00 m
LS 4.1.1.15 LS 4.1.1.13 LS 4.1.1.11 LS 4.1.1.9

Circuit-breaker Circuit-breaker Circuit-breaker Circuit-breaker
In = 400 A In = 630 A In = 100 A In = 100 A
3VA24406HN320AA0/LSI 3VA25635JP320AA0/LSI 3VA21105HN360AA0/LSI 3VA21105HN360AA0/LSI
K/L 4.1.1.15 K/L 4.1.1.13 K/L 4.1.1.11 K/L 4.1.1.9

10 m 5m 5m 10 m
Cu 2(3x95/95/50) Cu 2(3x240/240/120) Cu 1(3x16/16/16) Cu 1(3x50/50/25)
6 LT 4.1.1.15
Switch-disconnector
In = 200 A
3KD36320PE100
M-UV 4.1.1.15
LT 4.1.1.13
Switch-disconnector
In = 500 A
3KD44320QE100
M-UV 4.1.1.13
LT 4.1.1.11
Switch-disconnector
In = 200 A
3KD36320PE100
M-UV 4.1.1.11
LT 4.1.1.9
Switch-disconnector
In = 200 A
3KD36320PE100
M-UV 4.1.1.9
TN-S Un = 400 V TN-S Un = 400 V TN-S Un = 400 V TN-S Un = 400 V

MC-LTS 4.1.1.15 a MC-LTS 4.1.1.13 a MC-LTS 4.1.1.11 a MC-LTS 4.1.1.9 a
SDC with fuse SDC with fuse SDC with fuse SDC with fuse
In = 200 A LS 4.1.1.15 b In = 250 A LS 4.1.1.13 b In = 80 A LS 4.1.1.11 b In = 80 A LS 4.1.1.9 b
3 x 3NA3140 size 1 Circuit-breaker 3 x 3NE1272 size 1 Circuit-breaker 3 x 3NE18200 size 000 Miniature circuit-breaker 3 x 3NE18200 size 000 Miniature circuit-breaker
3KF33250MF11 size 1 In = 16 A 3KL55301AB01 size 2 In = 125 A 3KL52301AB01 size 00 In = 6 A 3KL52301AB01 size 00 In = 6 A
3RT20471AP00 3VA11965EE360AA0/LI 3RW40562BB44 3VA11125EE360AA0/LI 3RW40372BB14 5SY63066/B 3RW40372BB14 5SY63066/B
3UF71121AA010
K/L 4.1.1.15 a K/L 4.1.1.15 b K/L 4.1.1.13 a K/L 4.1.1.13 b K/L 4.1.1.11 a K/L 4.1.1.11 b K/L 4.1.1.9 a K/L 4.1.1.9 b
Cable/Line Cable/Line Cable/Line Cable/Line Cable/Line Cable/Line Cable/Line Cable/Line
5m 1m 5m 1m 5m 1m 5m 1m
Cu 1(3x16/-/16) Cu 1(3x6/6/6) Cu 1(3x70/-/35) Cu 1(3x50/50/25) Cu 1(3x10/-/10) Cu 1(3x2.5/2.5/2.5) Cu 1(3x10/-/10) Cu 1(3x2.5/2.5/2.5)
L 4.1.1.15 b Stretch p. - aggr./ctrl. L 4.1.1.13 b Shrink p. - heat./aggr./ctrl. L 4.1.1.11 b Cleaning - aggr./ctrl. L 4.1.1.9 b Screw cap - aggr./ctrl.
Indoor Indoor Indoor Indoor
In = 6.2 A In = 124 A In = 5 A In = 4.9 A
Un = 400 V Un = 400 V Un = 400 V Un = 400 V
7
3+N-pole 3+N-pole 3+N-pole 3+N-pole
M 4.1.1.15 a Stretch pack.

Motor
Control cabinet M 4.1.1.13 a Shrink p.
Motor
Control cabinet M 4.1.1.11 a Cleaning
Motor
Control cabinet M 4.1.1.9 a Screw cap
Motor
Control cabinet for
In = 62.5 A for stretch packaging In = 148 A
Un = 400 V
for shrink packaging In = 50 A
Un = 400 V
for cleaning machine In = 49.2 A
Un = 400 V
screw cap production
Un = 400 V
3-pole 3-pole 3-pole 3-pole
Fig. 5/10:
G
Generator 4.1 d
Pn = 1,800 kW
Sn = 2,250 kVA
Contents
Un = 400 V
K/L 4.1 d
Cable/Line
15 m
Cu 10(3x240/240/120)
LS 4.1 d
Circuit-breaker
In = 4,000 A
3WA12402NB711AA2/LSIN
MD SPS
1
TN-S Un = 400 V
LS SV
Circuit-breaker
In = 2,500 A
3WA12253NG611AA2/LSING
Additional outgoing feeder

for generator test operation
M 4.1.1.6 a CO2 evaporator M 4.1.1.4 a Compressed air M 4.1.1.2 Blower

M Motor Motor Motor
3 In = 49.2 A
Un = 400 V
Control cabinet In = 74.5 A Control cabinet for In = 363 A FC cabinet for
Un = 400 V Un = 400 V
3-pole for CO2 evaporator 3-pole compressed air production 3-pole stretch blower
L 4.1.1.6 b CO2 evap. - aggr./ctrl. L 4.1.1.4 b Compr. air - aggr./ctrl.
Indoor Indoor
In = 4.9 A In = 7.4 A K/L 4.1.1.2 b
K/L 4.1.1.6 a
4
Un = 400 V Un = 400 V Cable/Line
Cable/Line 2m
5m 3+N-pole 3+N-pole
Cu 2(3x150/-/150)
2 x Cu 1(3x10/-/10) K/L 4.1.1.6 b K/L 4.1.1.4 a K/L 4.1.1.4 b
Cable/Line Cable/Line Cable/Line FU 4.1.1.2
1m 5m 1m Frequency converter
Cu 1(3x6/6/6) Cu 1(3x16/-/16) Cu 1(3x6/6/6) G120P cabinet
MC-LS-YD 4.1.1.6 a 6SL37101PE346AA0
Circuit-breaker In = 460 A
In = 160 A Un = 400 V
3VA22167MS320AA0/I
3RT105542AP36
3RT105542AP36 MC-LS-DS 4.1.1.4 a
Circuit-breaker 3RT14566AP36
3RT10443AP00 LS 4.1.1.6 b LS 4.1.1.4 b
3UF71131BA010 In = 75 A LTS-S 4.1.1.2
Circuit-breaker 3RV23414KC10/I Circuit-breaker
In = 16 A In = 16 A SDC with fuse
3RT20451AP00 In = 560 A
3VA11965EE360AA0/LI 3UF71121AA010 3VA11965EE360AA0/LI
3 x 3NE14352 size 3
M-UV 4.1.1.6 M-UV 4.1.1.4 3KL61301AB02 size 3
TN-S Un = 400 V TN-S Un = 400 V
LT 4.1.1.6 LT 4.1.1.4
Switch-disconnector Switch-disconnector
In = 500 A In = 200 A
3KD44320QE100 3KD36320PE100
5
K/L 4.1.1.6 K/L 4.1.1.4 K/L 4.1.1.2 a
10 m 5m 5m
Cu 2(3x95/95/50) Cu 1(3x185/185/95) Cu 2(3x240/-/120)
LI-AM25005B-55
TN-S Un = 400 V
LS 4.1.1.6 LS 4.1.1.4 LS 4.1.1.2

SV 4.1.1
Circuit-breaker
B 4.1.1
Busbar
100 m
In = 400 A In = 250 A In = 630 A

3VA24405HN320AA0/LSI 3VA23255HN320AA0/LSI 3VA24635HN320AA0/LSI
35.00 m 30.00 m 25.00 m 22.00 m 20.00 m 15.00 m 10.00 m
LS 4.1.1.7 LS 4.1.1.5 LS 4.1.1.3 LS 4.1.1.1

In = 400 A In = 400 A In = 250 A In = 400 A
3VA23405HN320AA0/LSI 3VA24405HN320AA0/LSI 3VA23255HN320AA0/LSI 3VA24406HN320AA0/LSI
K/L 4.1.1.7 a K/L 4.1.1.5 K/L 4.1.1.3 K/L 4.1.1.1

5m 5m 10 m 5m
Cu 2(3x95/-/50) Cu 2(3x95/95/95) Cu 1(3x95/95/50) Cu 1(3x240/240/120)
LTS-S 4.1.1.7
LT 4.1.1.5
Switch-disconnector
In = 500 A
3KD44320QE100
M-UV 4.1.1.5
LT 4.1.1.3
Switch-disconnector
In = 200 A
3KD36320PE100
M-UV 4.1.1.3
LS 4.1.1.1
Switch-disconnector
In = 200 A
3KD36320PE100
M-UV 4.1.1.1
6
SDC with fuse
In = 315 A TN-S Un = 400 V TN-S Un = 400 V TN-S Un = 400 V
3 x 3NE12302 size 1 MC-LTS 4.1.1.5 a MC-LS-DS 4.1.1.3 a MC-LTS 4.1.1.1 a
3KL55301AB01 size 2 SDC with fuse Circuit-breaker SDC with fuse
In = 200 A LS 4.1.1.5 b In = 50 A LS 4.1.1.3 b In = 250 A LS 4.1.1.1 b
3RT14566AP36 3 x 3NA3140 size 1 3RV23414HC10/I 3 x 3NE12272 size 1
3KF33250MF11 size 1 In = 16 A 3RT20451AP00 In = 16 A 3KL55301AB01 size 2 In = 16 A
3RT20471AP00 3VA11965EE360AA0/LI 3UF71121AA010 3VA11965EE360AA0/LI 3RW40552BB44 3VA11965EE360AA0/LI
3UF71121AA010
FU 4.1.1.7
Frequency converter K/L 4.1.1.5 a K/L 4.1.1.5 b K/L 4.1.1.3 a K/L 4.1.1.3 b K/L 4.1.1.1 a K/L 4.1.1.1 b
G120P cabinet Cable/Line Cable/Line Cable/Line Cable/Line Cable/Line Cable/Line
6SL37101PE321AA0 5m 1m 5m 1m 5m 1m
In = 205 A Cu 1(3x16/-/16) Cu 1(3x6/6/6) Cu 1(3x10/-/10) Cu 1(3x6/6/6) Cu 1(3x35/-/16) Cu 1(3x6/6/6)
Un = 400 V
K/L 4.1.1.7 b L 4.1.1.5 b Mixer - aggr./ctrl. L 4.1.1.3 b Heat exchanger - aggr./ctrl. L 4.1.1.1 b Ventilation - aggr./ctrl.
Cable/Line Indoor Indoor Indoor
2m In = 6.2 A In = 4.9 A In = 11 A
Cu 2(3x50/-/50) Un = 400 V Un = 400 V Un = 400 V
7
M 4.1.1.7 a Filling
Motor
FC cabinet M 4.1.1.5 a Mixer
Motor
Control cabinet M 4.1.1.3 a Heat exchanger
Motor
Control cabinet M 4.1.1.1 a Ventilation
Motor
Control cabinet
In = 82.2 A for filling In = 62.6 A for mixer In = 49.2 A for heat exchange In = 110 A for ventilation
Un = 400 V Un = 400 V Un = 400 V Un = 400 V
3-pole 3-pole 3-pole 3-pole
Contents
5.8 Low-Voltage Distribution Boards For industrial applications, a linear power distribution
for the Load Centers
planned along the production line. An individual busbar
run is drawn as a sub-distribution for each filling line.
As an example, it is sufficient to look at filling line 1 in
(cooling and treatment), the electrical consumers of
1 - followed for the other low-voltage distribution circuits.
), through one transformer substation shows the single-line diagram as it is used for
with a low-voltage main distribution board each. The the billing, dimensioning, and project planning with the
dimensioning of the switching and protection devices for
the six individual low-voltage distribution boards of the examples for the individual results. The low-voltage
corresponds to
The starting point is the load overview in . the main distribution board with the three transformer
2 A similar procedure applies to all six low-voltage distri-
bution boards, starting from the distribution structure , the entire
- for
- the three filling lines.
vance of consumer specifics, etc.) through the calcula-
tions and dimensioning up to the exact determination contains the load data of the consumers of
3 for the motors. The individual applications are divided

voltage distribution boards. into motor loads and resistive loads, such as for example
On one hand, the different motor starter combinations

are addressed based on filling line 1. On the other hand, assumed for the resistive loads. For heating the pack-
aging film to create a shrink-wrapped packaging, an
and dispatch) how circuit-breakers with electronic additional resistive load of about A is taken into
4 characteristic tripping curve that come close to a fuse account.
distribution regarding cable and busbar cross-sections also illustrates that combinations are selected
start. During selection, energizing and de-energizing

of the motor, the starting and stopping behavior, as well
as the operational behavior and the motor protection
5 5.8.1 Motor starter Combinations for electric power distribution, the short-circuit protection
Filling Line 1
designed, apart from the motor protection.
The loads connected in the filling line 1 must be supplied
via a low-voltage distribution which allows for a power The overload and short-circuit protection of the motor
transmission of at least 1, feeders can be executed in both non-fused and fused
6 ) via three - •
– with circuit-breaker for short-circuit and
overload protection
– with circuit-breaker (for short-circuit protection) and
or a motor management device as well as contactors

for tripping (for overload protection)
•
7 (the fuses take on the short-circuit protection) and
management device as well as contactors for tripping

(for overload protection).
Contents
Incoming Incoming Incoming Incoming

feeder feeder feeder Outgoing feeder Bus coupler feeder Outgoing feeder
4.1a 4.1b 4.1c NPS NPS/SPS 4.1d SPS
SIEMENS SIEMENS SIEMENS SIEMENS SIEMENS SIEMENS SIEMENS

SIEMENS
SIVACON SIVACON SIVACON SIVACON SIVACON SIVACON SIVACON
3
400 400 400 1,000 800 1,000 600
Fig. 5/11:
5
To determine the load behavior at motor start, four
different combinations are used in filling line 1, which in the converter cannot be used in case of multi-motor
serves as an example: , the
• combinations of starters and protection devices stored
and contactor
•
and three contactors
device series for the four different motor start 6
•
• -
lines such as [1.1] and [1.2].
According to , a protection of the motors

-
7
overload protection, overtemperature protection, or
current limiting.
Contents
Ring- Ring-
main MV-SDC MV-SDC MV-SDC Bus MV-SDC MV-SDC MV-SDC Bus MV-SDC MV-SDC MV-SDC main
panel 4.1 a 4.1 b 4.1 c sectionalizer 4.2 a 4.2 b 4.2 c sectionalizer 4.3 a 4.3 b 4.3 c panel
310 430 430 430 430 430 430 430 430 430 430 430 310
3 Fig. 5/12:
Position
Nominal NPS - SPS / Quan-
Application Load type Motor start SIMARIS no. of tap-off
current Voltage tity
unit
Motor M 4.1.1.1 a 1
1
Motor M 4.1.1.2 1
4 Heat exchange
Motor Direct (non-fused) M 4.1.1.3 a 1
1
Motor Direct (non-fused) M 4.1.1.4 a 1
22 m
production 1
Motor Direct (fused) 1
Mixer
1
Motor 1
2 evaporator
1
Filling Motor 1
5 Motor 1
31.4 A 1
Motor 1
42 m
1
1
Automatic Motor M 4.1.1.11 a 1
cleaning unit 1
6 Motor M 4.1.1.12 a 1
1
Motor M 4.1.1.13 a 1
1
Motor Direct (fused) M 4.1.1.14 a 1
Palletizing
1
machine 1
Filling information
1
7
Tab. 5/2: Fig. 5/10
Contents
Max. mech. Device

Short-circuit protection Overload protection
power protection
Fused / Switching / Switching Fuses /

Release
non-fused protection device device circuit-breaker
Fused Fuses
3RU 3RT
1
3)
2) 3RB 3RT
Motor management device 3)

3RT
Direct-on-line
start 3RT
2
Non-fused 3RU 3RT
3)
3RB 3RT
Motor management device 3)

3RT
3RU
3 contactors
3RT
3
3 contactors
Non-fused
starter 3RB 3RT
Motor management device 3 contactors

3RT
Fuses
Fused
2) 3RT
4
Fuses 4)
Fuses
Fused 2) 3RT
devices)
5
Fuses
3RT
converter
3RT
devices)
Non-fused Fuses
6
3RT
1)
2)
3)
4)
Tab. 5/3: Device combinations stored in SIMARIS design for the start and protection of low-voltage motors 7
Contents
Motor protection
only temperature-
Protection of the motor for only current- current- and
dependent, e.g.
dependent, e.g. with temperature-
with thermistor
overload relay dependent
motor protection relay
1
overload in continuous operation
long starting and braking processes
too high switching rate
single-phase operation and current
2 application of the brakes on the rotor
connection with locked rotor in case of

stator-critical motor
connection with locked rotor in case of

rotor-critical motor
increased ambient air temperature –

3 hindered cooling –
– no protection
Tab. 5/4: Comparison of the motor protection methods
4 The portfolio for motor protection is completed

device as a direct motor protection is appropriate
•
• at high ambient air temperatures or in environments in are installed in the control cabinet in a space-saving
which cooling might be impaired (e.g. due to dust) design as a unit including circuit-breaker, contactor and
•
• components around motor starters and motor protection
5 speeds.
-
- rents can otherwise lead to problems in the low-voltage
network.
, the effectiveness
6 of different motor protection methods is compared.
Due to the I2t standard-compliant low-voltage motors are
stored for preselection. However, the corresponding
a simple protection against thermal overload as standard. tested starter combination can also be dimensioned for
means of temperature detection with additional

temperature sensors. more information on motor start.
Contents
5.8.2 Selectivity by Means of Appropriate

Selection of Circuit-Breaker Types
in Sub-Distribution Circuits and
This application manual can provide important informa-
Integration of a Static UPS System
tion on what to keep in mind during the design.
-
for the low-voltage distribution board of the load center - 1
over, the described example confirms that software tools
workplaces, but also the protection of a server rack can contribute to facilitating the task of planning, but
with single-phase supplied servers (current demand -
In
The lighting and socket outlets for the office rooms are As a first intervention, the load protection for the socket
distributed to three sub-distribution boards with sepa-
rate circuits for lighting and socket outlets ( ). up to a rated current Ir
2
cross-sections change as well.
- The comparison between and illus-

trates how the entire chain from the infeed up to the
- -
sponds to an infeed which supplies the consumers erations. The more distribution steps there are between
the infeed and the consumers, the more complex it can 3
- -
over, modifications in one circuit can also have conse-
connections are reproduced in , and that the
account.
from
4
characteristic that resembles the one of fuses and with
the help of which selective gradings can perhaps be
lighting facilities and all consumers connected to the

socket outlets in the office section in the event of a fault
5
arranged in the network. This, however, needs some
,
As a starting point for the readjustments,

(see ) are compared with the “automated”
- ). 6
and consumers are stipulated. The switching and protec-
an example how diverse the starting points for project

planning can be. More information on the correlation
switching and protection devices of the main distribution
Contents
MS-LTS 1.1 MS-LTS 1.2

SDC with fuse SDC with fuse
In (switch) = 200 A In (switch) = 200 A
In (fuse) = 63 A In (fuse) = 63 A
3 x SIB: 3001413.63 3 x SIB: 3001413.63
MS-K/L 1.1 MS-K/L 1.2

N2XS2Y N2XS2Y
1
15 m 15 m
VPE 3 x 35 VPE 3 x 35
Transformer 1.1 Transformer 1.2

Sn = 630 kVA / AN Sn = 630 kVA / AN
ukr = 6 % ukr = 6 %
20/0,4 kV Dyn5 20/0,4 kV Dyn5
4GX58643E 4GX58643E
S 1.1 S 1.2
Busbar Busbar
15 m 15 m
LI-AM10005B-55 LI-AM10005B-55
2 LS 1.1
Circuit-breaker
In = 1,000 A
3WA11102EB611AA2/LSIN
LS 1.2
Circuit-breaker
In = 1,000 A
3WA11102EB611AA2/LSIN
LS AV 1 LS AV 2 LS AV 3 LS Ventilation
In = 250 A In = 250 A In = 250 A In = 160 A
3VA23256HK320AA0/LI 3VA23256HK320AA0/LI 3VA23256HK320AA0/LI 3VA21165HN360AA0/LSI
K/L AV 1 K/L AV 2 K/L AV 3 K/L Ventilation

25 m 45 m 70 m 40 m
3
Cu 1(3x50/50/25) Cu 1(3x50/50/25) Cu 1(3x50/50/25) Cu 1(3x95/95/50)
SD NPS 1
Ventilation
TN-S Un = 400 V P Indoor
In = 148 A
Un = 400 V
to SD NPS 3 3+N-pole
Loads and distribution like NPS 1
LS AV 1.1 LS AV 1.2
Circuit-breaker Circuit-breaker to SD NPS 2
In = 63 A In = 63 A
3VA21635HK360AA0/LI 3VA21635HK360AA0/LI Loads and distribution like NPS 1
K/L AV 1.1 K/L AV 1.2

20 m 20 m
Cu 1(3x16/16/16) Cu 1(3x10/10/10)
4
SD NPS 1.1 SD NPS 1.2
TN-S Un = 400 V TN-S Un = 400 V
LS AV 1.1.1 LS AV 1.1.2 LS AV 1.1.3

Miniature circuit-breaker Miniature circuit-breaker Miniature circuit-breaker LS AV 1.2.1 LS AV 1.2.2 LS AV 1.2.3
In = 16 A In = 16 A In = 16 A Miniature circuit-breaker Miniature circuit-breaker Miniature circuit-breaker
5SY61166/B 5SY61166/B 5SY61166/B In = 16 A In = 16 A In = 16 A
5SY41166/B 5SY41166/B 5SY41166/B
5SV33126 5SV33126 5SV33126
K/L AV 1.1.1 K/L AV 1.1.2 K/L AV 1.1.3
25 m 25 m 25 m
Cu 1(1x2.5/2.5/2.5) Cu 1(1x2.5/2.5/2.5) Cu 1(1x2.5/2.5/2.5)
5 K/L AV 1.2.1
Cable/Line
K/L AV 1.2.2
Cable/Line
K/L AV 1.2.3
Cable/Line
25 m 25 m 25 m
L AV 1.1.1 Lighting L AV 1.1.2 Lighting L AV 1.1.3 Lighting
P Indoor
In = 4.56 A
P Indoor
In = 4.56 A
P Indoor
In = 4.56 A
Cu 1(1x2.5/2.5/2.5) Cu 1(1x2.5/2.5/2.5) Cu 1(1x2.5/2.5/2.5)
Un = 230 V Un = 230 V Un = 230 V

10x 10x 10x L AV 1.2.1 Socket outlets

Indoor
L AV 1.2.2 Socket outlets
Indoor
L AV 1.2.3 Socket outlets
Indoor
In = 10.5 A In = 10.5 A In = 10.5 A
Un = 230 V Un = 230 V Un = 230 V
8x 8x 8x
Fig. 5/13:
Contents
1
Generator 1.1
Pn = 264 kW
G Sn = 330 kVA
Un = 400 V
K/L 1.1 c K/L 1.1 d

5m 30 m
2
Cu 2(3x120/120/120) Cu 2(3x240/240/120)
LS 1.1 c LS 1.1 d
In = 400 A In = 630 A
3VA23405HM420AA0/LIGN 3VA24635HN420AA0/LSIN
MD NPS MD SPS
TN-S Un = 400 V TN-S Un = 400 V
LS 1 ext. bypass LS 1 int. bypass LS to rectifier & battery charger LS SV 1.1

Circuit-breaker Circuit-breaker Circuit-breaker Miniature circuit-breaker
In = 250 A In = 250 A In = 160 A In = 6 A
3VA23255HM420AA0/LIGN 3VA23255HM420AA0/LIGN 3VA21165HN360AA0/LSI 5SY61066/B
K/L SV 1.1.1
S ext. bypass S int. bypass S to rect.&batt. Cable/Line
Busbar Busbar Busbar „xx“
5m 5m 5m
3
Cu 1(1x1,5/1,5/1,5)
BD2-A-250 BD2-A-250 BD2-A-160
Emergency lighting
P Indoor
In = 4,56 A
Un = 230 V
1+N-pole
10 times in total
12x for every 12 consumers
for emergency lighting
with different cable
lengths “xx”
Internal Inverter Rectifier &
UPS
bypass
UPS inverter output
In = 144 A
battery charge
Rectifier / battery charge
Equivalent load
In = 159 A
4
Un = 400 V
Un = 400 V
Dummy inverter output 3-pole
Circuit-breaker
LS 2 int. bypass In = 250 A
Circuit-breaker 3VA23255HM420AA0/LIGN
In = 250 A
3VA23255HM420AA0/LIGN
UPS output UPS input
TN-S Un = 400 V TN-S Un = 400 V
LS USV 1.1
Circuit-breaker
5
In = 160 A
3VA22165HN420AA0/LSIN
S USV 1.1
Busbar
5m
LS 2 ext. bypass BD2-A-160
Circuit-breaker
In = 250 A
3VA23255HM420AA0/LIGN
SD UPS
6
TN-S Un = 400 V
LS USV 1.1.1 LS USV 1.1.2 LS USV 1.1.3 LS USV 1.1.4

Miniature circuit-breaker Miniature circuit-breaker Miniature circuit-breaker Circuit-breaker
In = 32 A In = 32 A In = 32 A In = 80 A
5SY71326/B 5SY71326/B 5SY71326/B 3VA10804ED360AA0/LI
K/L USV 1.1.1 K/L USV 1.1.2 K/L USV 1.1.3 K/L USV 1.1.4
15 m 15 m 15 m 40 m
Cu 1(1x6/6/6) Cu 1(1x6/6/6) Cu 1(1x6/6/6) Cu 1(3x35/35/16)
Rack 1&2 Rack 3&4 Rack 5&6 Fire alarm and protection
P Indoor P Indoor P Indoor P In = 75.8 A
7
In = 26.8 A In = 26.8 A In = 26.8 A Un = 400 V
Un = 230 V Un = 230 V Un = 230 V 3+N-pole
2x 2x 2x
Contents
MS-LTS 1.1 MS-LTS 1.2

SDC with fuse SDC with fuse
In (switch) = 200 A In (switch) = 200 A
In (fuse) = 63 A In (fuse) = 63 A
3 x SIB: 3001413.63 3 x SIB: 3001413.63
MS-K/L 1.1 MS-K/L 1.2

N2XS2Y N2XS2Y
15 m 15 m
1 XLPE 3 x 35 XLPE 3 x 35
Transformer 1.1 Transformer 1.2

Sn = 630 kVA / AN Sn = 630 kVA / AN
ukr = 6 % ukr = 6 %
20/0.4 kV Dyn5 20/0.4 kV Dyn5
4GX58643E 4GX58643E
S 1.1 S 1.2
Busbar Busbar
15 m 15 m
2
LI-AM10005B-55 LI-AM10005B-55
LS 1.1 LS 1.2
In = 1,000 A In = 1,000 A
3WA11102EB611AA2/LSIN 3WA11102EB611AA2/LSIN
LS AV 1
Circuit-breaker
3 In = 100 A
3VA20105HN360AA0/LSI
K/L AV 1
Cable/Line
25 m
Cu 1(3x35/35/16)
4
LS AV 1.1
Circuit-breaker
In = 63 A
3VA21635HK360AA0/LI
K/L AV 1.1
Cable/Line
20 m
Cu 1(3x16/16/16)
5
SD NPS 1.1
TN-S Un = 400 V
LS AV 1.1.1 LS AV 1.1.2 LS AV 1.1.3

In = 6 A In = 6 A In = 6 A
5SY61066/B 5SY61066/B 5SY61066/B
K/L AV 1.1.1 K/L AV 1.1.2 K/L AV 1.1.3

25 m 25 m 25 m
Cu 1(1x1.5/1.5/1.5) Cu 1(1x1.5/1.5/1.5) Cu 1(1x1.5/1.5/1.5)
6
L AV 1.1.1 Lighting L AV 1.1.2 Lighting L AV 1.1.3 Lighting
P Indoor
In = 4.56 A
P Indoor
In = 4.56 A
P Indoor
In = 4.56 A
Un = 230 V Un = 230 V Un = 230 V
10x 10x 10x
7
Fig. 5/14:
Contents
MD NPS
TN-S Un = 400 V
LS AV 2 LS AV 3 LS Ventilation
3
In = 100 A In = 100 A In = 160 A
3VA20105HN360AA0/LSI 3VA20105HN360AA0/LSI 3VA21165HN360AA0/LSI
K/L AV 2 K/L AV 3 K/L Ventilation

45 m 70 m 40 m
Cu 1(3x35/35/16) Cu 1(3x35/35/16) Cu 1(3x95/95/50)
SD NPS 1
Ventilation
TN-S Un = 400 V P Indoor
In = 148 A
Un = 400 V
4
LS AV 1.2 to SD NPS 3 3+N-pole
Circuit-breaker
In = 63 A Loads and distribution like NPS 1
3VA21635HK360AA0/LI
to SD NPS 2
K/L AV 1.2
Cable/Line Loads and distribution like NPS 1
20 m
Cu 1(3x10/10/10)
5
SD NPS 1.2
TN-S Un = 400 V
LS AV 1.2.1 LS AV 1.2.2 LS AV 1.2.3

In = 13 A In = 13 A In = 13 A
5SY61136/B 5SY61136/B 5SY61136/B
5SV33126 5SV33126 5SV33126
K/L AV 1.2.1
Cable/Line
K/L AV 1.2.2
Cable/Line
K/L AV 1.2.3
Cable/Line
6
25 m 25 m 25 m
Cu 1(1x1.5/1.5/1.5) Cu 1(1x1.5/1.5/1.5) Cu 1(1x1.5/1.5/1.5)
L AV 1.2.1 Socket outlets L AV 1.2.2 Socket outlets L AV 1.2.3 Socket outlets

Indoor Indoor Indoor
In = 10.5 A In = 10.5 A In = 10.5 A
Un = 230 V Un = 230 V Un = 230 V
8x 8x 8x 7
Contents
Fully selective sub-distribution circuit with 3VA2 circuit-breakers and ETU 340 (ELISA)
LS AV 1.1 Lower Switch

10 4
LV 1.1.1 Envelope of upstream devices
3VA21635HK360AA0/LSI LS AV 1.1
1 IR [A] 50 tR [s] 1.300
10 3
Ikmax = 16.859 kA
Ikmin = 2.205 kA
Envelope of downstream devices
Ii [A] 945
10 2
10 1
2
t in s
10 0
10
10 -1
3
10 -2
10 -3
10 0 10 1 10 2 10 3 10 4 10 5
I in A
Partially selective sub-distribution circuit with 3VA2 circuit-breakers and ETU 350 (LSI)
4 LS AV 1.1 Lower Switch
10 4
LV 1.1.1 Envelope of upstream devices
3VA20635HN360AA0/LSI LS AV 1.1
IR [A] 50 tR [s] 10 Ikmax = 13.962 kA
Ikmin = 1.862 kA
10 3
Isel-overload = 1.02 kA
Envelope of downstream devices
Isd [A] 400 tsd [s] 0,4

10 2
5
Ii [A] 756 10 1
t in s
10 0
10
6 10 -1
10 -2
10 -3
10 0 10 1 10 2 10 3 10 4 10 5
I in A
7
Fig. 5/15: Comparison of the selectivity outputs of SIMARIS design for circuit-breakers LS AV 1.1 and LS AV 1.2:
top, “optimized” according to Fig. 5/13 Fig. 5/14
Contents
5.8.3 Concept Examples for Low-Voltage are calculated without taking into account the upstream
Distribution Boards by the Example network influences and line impedances (the overview in
of Filling Lines 1 to 3 Fig. 4/11 is a graphical implementation of the values):
Due to the adjacent arrangement of three filling lines in S Tr

one production hall, the distribution concept in I“k =
√3 · ukr · 400 V 1
can lead to different focal points and concepts in plan-
ning. As some basic concepts for the low-voltage main
taken into account, which explains the differences in
addressed in the following as examples, the consumers the values in .
loads and the generator infeeds can be disregarded.

Design-specific characteristics of the concepts can be remain separate in all operating states. On the one hand,
2
found in and in the single-line diagrams in switching operations are avoided, but on the other hand,
a larger number of components (e.g. nine A
transformers in total) must be accepted for (n-1) avail-
A
individual lines advantageous regarding the short-circuit withstand

A strength of the devices. 3
couplers between the parts of the low-voltage
switchboard more convenient regarding the protection of persons
A for the third line) short-circuit currents in case of failure are higher than
A for
in concept 1., a higher short-circuit withstand strength 4
three lines) as well. The concepts 2.1 and 2.2 might not differ in
their general design, but different (n-1) failure actions
installation of the low-voltage switchboards advantageous to not close all couplers between the
A transformers with fans substations when a transformer fails, and thus switching
(a power increase to 1, A is possible with all remaining five transformers in parallel (concept 2.2).
fan operation) per substation, which are coupled 5
fails
A transformers per substation, The resulting short-circuit currents are therefore lower.
when a transformer fails The transformer configuration and the treatment in case
1, A transformer each with fans for the busbar which, compared with concepts 2.1 and 2.2,
6
voltage switchboards (closer to the individual filling
Rough calculations are performed for the considered lines) and also enables the right-hand and left-hand
basic concepts. The maximum short-circuit currents I“k substation to be coupled ( : “3.1” and “3.2”) even
A. 7
Contents
Distribution concept One substation Four substations

for the low-voltage couplers between the substations coupled through in the busbar
supply separated substations bypass busbar trunking system
ring supply three
Example / single-line 1. 2.1 2.2 3.1 3.2 4
1
Fig. 5/16
Transformers in normal
operation and main in 3 substations with open with open with fan in 3 substations, each
switchboards couplers in a couplers in a 3 substations, connected with fan in
substation substation connected through an 4 substations
through an
busbar
busbar
Transformers
2 at (n-1) failure
operation and main
non-affected
substations
coupled for
2 lines
coupled for
3 lines
(fan) coupled
for 2 lines
coupled for
2 lines
each with fan in
3 substations
switchboards
in affected for the third line (fan) for the for the third line
substation third line
Natural Natural Natural Natural
transformers in ventilation (AN) ventilation (AN) ventilation (AN) (AF) ventilation (AN) (AF)
(n-1) failure operation
3 Maximum theoretical
short-circuit stress: approx. approx. approx. approx. approx. approx.
Normal operation /
(n-1) failure
approx. approx. approx. approx. approx. approx.

4 calculation:
Normal operation /
(n-1) failure
Tab. 5/5:
5 power increase for the 1, A transformers up to for the concepts 3.1 and 3.2 regarding switching and
1, A 4) can be achieved in case of failure. Alterna-
The calculation of the short-circuit currents of the
used without installed fans, but with a power increase transformers is based on the rated values, regardless of
up to 1, fan installation. The short-circuit current to be expected
short-circuit currents increase compared with concept 3.1. is therefore independent of the power increase provided
6 -
4)
to do without the power increase of the transformers
consumption for fan operation, the power losses due to the transformer in the concepts 3.1 and 3.2, compared with concept 2.1.
support in determining the ventilation parameters, and can be installed
7 currents to the transformers, and thus three 1, A

transformers no longer suffice to provide the power
when larger transformers or a redundant transformer are not used because
for two filling lines.
Contents
15 m
800 kVA
25 m 1.
Three separate infeeds and distributions
via 3 switchboards 1
with 3 × 800 kVA GEAFOL transf. each
100 m
1,450 kVA
2
15 m
1,000 kVA
25 m 2.1 + 2.2
Separate infeeds with
3 × 2 × 1,000 kVA GEAFOL transf.,
via a common low-voltage
100 m
switchboard with open couplers 3
1,450 kVA
15 m 4
1,250 kVA /
1,000 kVA AF
3.1 + 3.2
25 m
Separate infeeds with
(3.1) 3 × 2 × 1,000 kVA GEAFOL transf.
with fans (AF),
(3.2) 3 × 2 × 1,250 kVA GEAFOL transf.,
25 m 25 m coupled through a bypass busbar
5
(normally open)
100 m
1,450 kVA
6
4.
1,090 kVA Busbar trunking system ring
1,090 kVA 1,090 kVA
1,090 kVA with four infeeds with one
40 m 40 m 1,250 GEAFOL transf. each,
with fan
15 m 10 m
1,250 kVA AF
15 m 50 m 15 m 10 m 15 m
1,250 kVA AF
7
Fig. 5/16:
Contents
failure. All loads of the three filling lines are simulated
1 themselves from two sides through busbar trunking
a compensation of the currents occurs, and the maximum
2 -
higher short-circuit currents in case of parallel connec-

tion of the transformers in normal operation must be
taken into account.
More exact evaluations must be undertaken project-

provide
support in this.
Chapter 6
Concept Finding for the
Electric Power Distribution
of a Chemical Plant
6 Concept Finding for the Electric Power
Contents Distribution of a Chemical Plant
Other than for the beverage filling plant in , •

the example considered in here for an air separation •
1 •
consumers is not described in detail in the sample plant.
as well as the additional links between the two lines.

6.1 Description of the Air Separation Unless stated otherwise, the data in the tables and the
2 Process graphics are referred to one line.
the ambient air. Three gas components can be extracted 6.2 Consumers and Requirements
from the earth atmosphere, with a mass percentage of
Besides the industrial processes, the electric power
nitrogen (N2) - 23. 2) -
-
1. argon (Ar) 1)
tional facilities, such as control rooms, staff rooms,
3 Air separation according to the low-pressure process is office rooms, meeting rooms, as well as installation
rooms for air conditioning, fire protection, and electronic
characterizes essential process steps: -

• ings (
• “Rectification” means countercurrent distillation of -

4 sent a site plan with exact positions or dimensions.
. For the process control room in , it is stipulated

that two medium-voltage switchgear assemblies sepa-
First, the air sucked in from the environment is cleaned, -
tionalizer circuit-breaker. Possible installation versions
down afterwards. The multi-step separation process uses
the boiling point differences of the individual gases two process lines:
5 (O2 2 •
bus sectionalizer in one room
• Fire protection separation: Two switchgear assemblies,
coupled through a connection, are separated from
section) and nitrogen (column top) takes place in the

high-pressure column according to the boiling point •
6 individual rooms, which are not next to one another.
the production plant, or transferred to tanks for storage

or transportation. For the sample plant, the following The load list in combines one of these two
output is estimated: buildings with the consumers of one of the two
production trains.
7
1)
2 2) -
Totally Integrated Power – Concept Finding for a Chemical Plant

Contents
Release of gaseous
nitrogen & oxygen
Refrigeration &
expansion of air
Storage & filling
of liquefied gases 1
8 Process control
Gaseous
nitrogen
Gaseous
oxygen
Gas release unit
Filtered &
Liquid nitrogen
storage tank 2
compressed air
Filtration & further Heat

compression of air Expander exchanger
2 Turbo
compressor
4
Liquid argon
storage tank
3
Liquefied
air
4
Air cleaning unit

Cryogenic decomposition
of air
Cryogenic rectification
of argon 4
Pre-cleaning & Exhaust
compression of air gas
Low-pressure Raw argon
column column
Liquid nitrogen
5
3
Raw material
liquid argon
6 Pure argon
Heat exchanger /
air filter
7
6
Liquid
oxygen
Storage & filling
of liquefied gases
1 Air compressor
(MAC)
6
Air
High-pressure
column Liquid oxygen
5 storage tank
Water cooling 7
Fig. 6/1: Schematic process representation of air separation
the assignment for Tab. 6/1)

Contents
Central power supply:

- DSO connection
1 - HV/MV transformers (110/30 kV)
- 30 kV MV main distribution
- MV transformers (30/10 kV)
Liquefied gas Liquefied gas

storage tank storage tank
2 N2 O2 Ar Ar O2 N2
Liquef. Liquef.
3 Pumps 4 G G 4 Pumps 3
4 4
Rectifi- Heater Heater Rectifi-
3 cation
tower
7
8 8
7 cation
tower
LV dis- Control Process center: Control LV dis-
tribution room - 10 kV MV distr. room tribution
450 m
- Transf. (10/0.4 kV)
Booster Pumps Pumps Booster

2 6 6 2
4 Fan
Cooling 5 5
Fan
Cooling
MAC ... ... MAC
1 1
10 10
5
9 9
Factory Factory
Factory building: building: building: Factory building:
- Transf.(30/0.4 kV) Tr.(30/0.4kV) Tr.(30/0.4kV) - Transf.(30/0.4 kV)
- LV distribution LV distrib. LV distrib. - LV distribution
370 m
Nominal voltages: Legend:
30 kV level G Generator MAC Air compressor Ar Argon
HV High voltage Tr. Transformer O2 Oxygen
10 kV level
7 0.4 kV level
LV Low voltage
MV Medium voltage
Transf.
DSO
Transformer
Distribution system operator
N2 Nitrogen
Fig. 6/2: Block diagram for the ASP ground sketch Fig. 6/1 and Tab. 6/1)

Contents
Total apparent
No. Quantity Description Load type Voltage Active power Current Starter
power
1 1 Motor 1) 3)
Turbo compressor
2 1 Motor 1) 3)
(booster)
3 1 Motor 1)
4 2 Pump Motor 1) 41.44 A Direct
1
5 11 Fan for cooling Motor 1) 3)
6 2 Motor 1) 3)
Resistive
7 4 Electric process heater -
load 2)
8 1 Process control Others 2) -
9 1 Others 2) -
2
10 1 Others 2) -
1)
2)
3)
Tab. 6/1: Consumer list for a single product line and two of the four factory buildings as starting point for the electric power
distribution concept of the ASP
3
• For future extensions / power increases, a reserve of at
designing the electric power distribution: least has to be provided for the transformers
• •
) and a reliable motor start,
• the voltage drop for the motor start is to be limited to
(at the motor terminals).
•
4
the building surfaces and taking into account the critical
loads in the buildings, two transformers ( )
without restrictions
• The process loads on the low-voltage side must be able ) are considered when designing the
to continue to operate also in case of maintenance medium-voltage distribution, as stipulation for the four
work or a power failure at the transformer .
• 5
For rating the apparent power demand of the entire
plant (S ), the apparent power data of the consumers
operation are multiplied with the associated
• As embedded generating plants, a generator with an
afterwards. This sum of the loads is supplemented with a

reserve of . For this, the rated apparent power of
-
6
both lines
• Two infeeds from the high-voltage grid (nominal is doubled (for two process lines):
) are assumed as linkage to
S = [( S S
• S
7

Contents
6.3 Network Layout and Basic ii) Neutral earthing at the medium-voltage level
Concept Parameters
According to the decision diagram in Fig. 4/3, a connec- operator in accordance with the grid infeed from the
tion to the high-voltage grid should be aimed at, prefer-
-
1 low- impedance neutral earthing has proven itself,
of an infeed from the high-voltage grid, the voltage
voltages during operation of an impedance-earthed
For economic reasons, a higher voltage is desirable “ is
neutral if the short-circuit-to-earth current I k1
when using several large motors. On the one hand, the
influence of the motor starting currents on the voltage
important to restrict the impact on the voltage of
2 a more cost-effective design of the switchgear outgoing
the low-voltage network in case of short circuit (e.g.
voltage band - U / UnN ). For the
feeders. The following nominal voltage levels are taken level, low-impedance neutral earthing is selected
into account in the design: with a limitation of the short-circuit-to-earth current
• grid infeed “
I k1
• distribution level
• consumer/process level for individual ratings For neutral earthing of the process level, the
medium-voltage motors have to be paid attention to.
3 • consumer/process level for individual ratings
short-circuit current must be limited to values lower
i) Network configuration
The following criteria matter when selecting the
network configuration: iii) Transformers for the 10 kV intermediate
• substation of the process loads
4 •
(even if one of the two grid infeeds fails) A
• normal operation) ensures the connection between

• Optimization of expenses regarding the protection the two lines. However, in case of failure with closed
infeed transformers
must be sufficient for the total load of the two lines.
The following features of the process level also
exert an influence on the selection of the network
5 configuration:
• iv) Transformers for the low-voltage process level
) -process level are supplied
•
• The transformers as well as the associated low-
• voltage switchboards are installed near the loads, but
for the work processes (control rooms, automation
6 and similar must of course be protected without
interruptions).
substations for the medium-voltage consumers.
v) Transformers of the 30 kV level

Tab. 4/1
makes clear that the double radial line network offers transformers of
conditions.

Contents
vi) Transformers for the infeed level supplied through a medium-voltage switchgear
with sectionalizer. For the low-voltage process
consumers, separate substations with medium-
(S infeed transformers voltage switchgear, transformer, and low-voltage
switchboard are installed, so that the line lengths
selected.
( 1
vii) Operating modes switchgear sections at the
To create a distribution concept, the following of the low-voltage process consumers ensures
operating modes are considered:
• Normal operation: belonging to the process line of the medium-
– Both grid infeeds are in operation voltage switchgear in the process control room.
– The two process lines are supplied and operated
2
in-house transformers of the voltage level 6.4 Design of the Medium-Voltage
Switchgear
feed into the
each process line Based on the single-line diagram in , the suitable
• medium-voltage switchgear assemblies are selected.
3
into the be clarified:
process line • Rated voltage Ur Un
• • Rated current of the busbar and the feeders
Ir Ib
each other (no parallel operation) • Rated short-circuit breaking current
– The consumers of the
level are not supplied
and voltage Isc
• Rated short-circuit making current Ima
I k“
I k“
4
level 2) 3)).
• Failure operation for the low-voltage process

consumers in case of a failure on a connection A precondition for determining the above- mentioned
between the central process distribution and ratings of the medium-voltage switchgear is the calcula-
the process-line-specific sub-distribution I k“ for
board the different short-circuit events. For this, the imped- 5
– The direct connection to the process infeed is ances of transformers, generators and motors are calcu-
interrupted lated and concatenated as described in
distribution of the second process line.
viii) Single-line diagram for the power distribution

concept
Based on the data, positionings and assignments
6
made before, a first draft of a power distribution
structure can be created; however, the more
detailed dimensioning and specification of
3)
the single-line diagram in , the medium-
for determining the rated peak withstand currents of a medium-voltage
voltage consumers of the two process lines are
(peak factors of the rated short-circuit making current are to be selected 7
2) current at the respective mounting location of the switchgear are

Contents
, the formulas for the individual components

and for the concatenations in case of series and parallel feedback (braking operation) as motor starter can be
connection of the components are stated. The use of the neglected in the calculations according to
- For the following calculations, the worst case is consid-
tions for short-circuit events at the level and at the ered. For selecting the switchgear of the level and
level. the level, the maximum short-circuit currents at
1 both voltage levels must be determined.
Process line 1 Process line 2

110 kV / 50-60 Hz 110 kV / 50-60 Hz
2
80 MVA 80 MVA
uk = 12.5 % uk = 12.5 %
110/30 kV 110/30 kV
Dyn5 *) Dyn5 *)
1 kA 1 kA
5s 5s
n. c. n. c.
3 n. o.
n. c. n. c.
16 MVA / 10 kV 16 MVA / 10 kV
1.6 MVA 2 MVA 63 MVA 63 MVA 1.6 MVA 2 MVA
uk = 6 % uk = 6 % uk = 11 % uk = 11 % uk = 6 % uk = 6 %
30/0.4 kV 30/0.4 kV 30/10 kV G G 30/10 kV 30/0.4 kV 30/0.4 kV
Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5
0.2 kA 0.2 kA
10 9 5s 5s 10 9
4 n. c.
n. c.
n. c.
n. o.
n. c.
n. c.
n. c.
n. c. n. o. n. o. n. c.
5
SoSt VFD VFD SoSt VFD VFD
M M M M M M M M M M
0.3 MW 0.3 MW 4.84 MW 5.8 MW 11.2 MW 0.3 MW 0.3 MW 4.84 MW 5.8 MW 11.2 MW
4 4 3 2 1 4 4 3 2 1
Legend:
G Generator
M Motor
1.6 MVA 1.6 MVA SoSt Soft starter
1 MVA 1 MVA
uk = 6 % uk = 6 % uk = 6 % uk = 6 % VFD Variable frequency drive
6 Σ Total load of
10/0.4 kV 10/0.4 kV 10/0.4 kV 10/0.4 kV
Dyn5 Dyn5 Dyn5 Dyn5 multiple consumers
*) In the case of
Dyn transformers,
a neutral-point generator
has to be planned for
earthing the 30 kV level
Σ Σ VFD VFD Σ Σ VFD VFD

200 kW 1,148 kW 200 kW 1,148 kW
8 7
M M 8 7
M M
350 kW 440 kW 350 kW 440 kW
7 6 5 6 5
Fig. 6/3: Single-line diagram for the ASP power supply concept Fig. 6/1 and Tab. 6/1)

Contents
Motor Generator Transformer
Impedance Z UrM2 U 2 “ u kr U2rT

d
ZM = Z = ZT =
s M P rM S S rT
Initial short-circuit Un
current I k“ I k“ =
ZK 1
Associated values
Un Nominal voltage
sM Motor starting factor sM = I sM / IrM (see )
2
P rM Rated active power of the motor
UrM Rated voltage of the motor
χd“
S Rated apparent power of the generator
U Rated voltage of the generator
u kr
S rT Rated apparent power of the transformer
UrT Rated voltage of the transformer
Calculation steps
Parallel connection Series connection Transformer ratio
3
1
=
Ztot Ratio
1 tr = Uprim / Usec
= + 1 + ... + 1
Z1 Z2 Zn Z1 + Z2 + ... + Zn = Ztot
Z2 = Z1 · t 2r
1) Z :Z =Z 4
with K = (Un / U χ“d 1 - cos 2 Un U = rated generator voltage,
= rated power factor of the generator at rated operation; here, K
2) Z T is stated for two-winding transformers: Z TK = Z T T
with K T χT χ T = relative reactance of the transformer; here, K T
Tab. 6/2: Formulas for initial short-circuit currents and impedances of transformers, generators, and motors feeding back,
as well as their interconnection in distribution concepts
5
6.4.1 Short-Circuit Current Calculation for For the short-circuit calculation, it is easier to calculate
a Short Circuit at the 30 kV Level
To illustrate the calculations with the component imped-
Based on the design of , a short circuit is assumed ances, shows the input variables for the calcula-
in one of the -
). The vidual partial steps. To determine the motor starting
sM
6
lines is assumed, and that the sectionalizer in the
starter, as it has to be assumed that the motor has
switched over to direct operation after the start and that
circuit, but also the two generators and the motor con- the soft starter is therefore bridged when a short circuit
sumers at the level. occurs, so that there will be a direct feedback through
the line.
7

Contents
I k“ tot current according to

lines are supplied through one infeed transformer for the calculation with the impedances:
(in case of a short circuit in normal operation, the contri-
c ⋅ Un
butions of the motors and the generator from the second I k“ tot( ) = =
I k“ tot( ) is Ztot( )
1
110 kV / 50-60 Hz
2
80 MVA
uk = 12.5 %
110/30 kV
Dyn5
I k“ T2
3 n. c.
I k“ tot n. c. n. c.
I “k T1(30 kV)
16 MVA / 10 kV 16 MVA / 10 kV
4 63 MVA 63 MVA Ik“T1(30 kV)

10/30 kV uk = 11 %
30/10 kV
G G uk = 11 %
30/10 kV 10/30 kV
I k“ T1(10 kV)
Dyn5 Dyn5
Ik“T1(10 kV)
I k“ G I k“ G
n. c. n. c. n. c.
n. c. n. o. n. c. n. c.
5
n. c.
n. c. n. o. n. o.
I “k M4 I k“ M4 I k“ M3 I k“ M4 I k“ M4 I “k M3
6 SoSt VFD VFD SoSt VFD VFD
M M M M M M M M M M
0.3 MW 0.3 MW 4.84 MW 0.3 MW 0.3 MW 4.84 MW
4 4 3 4 4 3
Fig. 6/4: Simple single-line diagram for illustration of the short-circuit situation at the 30 kV level

Contents
Parameters Motor Motor Motor Generator Transformer Transformer

M4 M4 M3 G T1 T2
1.1 1.1 1.1 1.1 1.1 1.1
Rated voltage Ur
1
Motor starting factor sM
Active power P r
Rated apparent power S r
“
d
transformer u kr
Transformer ratio tr 3 3 2
Short-circuit current calculation through concatenation of impedances Equivalent diagram
Z M3 2
Z M4 2
Z 2
Step 5
3
110 kV
c · Un
I k“ = T2
Z' M3 = Z M3 √3 · Ztot c · Un
~ I k“ Ztot
30 kV
Z' M4 = Z M4 √3
Step 4
Z' = Z 1
Ztot = 2 1
Zges
+
1 Z ‘T2
+ Z‘T1
1 2 1
Z' T1 2 + +
Z ‘M3 Z M4
‘ Z ‘G
Z' T2 2
Step 3 ‘
Z T2
2 ‘ ‘
ukr · U rTx Z T1 Z T1
Z ‘Tx =
Ztot: SrTx
Ztot =
1
= Step 2
‘
Z M4 ‘
Z M4 ‘
Z M3 Z G‘ ‘
Z M4 ‘
Z M4 ‘
Z M3
T1
Z G‘ 4
2 1 Z ‘x = Zx · t 2r T1
10 kV
+ ZM4 ZM4 ZM3 ZG ZM4 ZM4 ZM3 ZG
1 1.406 Ω
+ 1.571 Ω Step 1 G G
1 + 2 + 1 2
U n ·cos φ · η
25.91 Ω 418.0 Ω 6.694 Ω Zx = s · Pr
M4 M4 M3 M4 M4 M3
= 0.9930 Ω
Ztot
level:
I k“ 5
Tab. 6/3: Short-circuit current and impedance calculations as well as equivalent diagram for illustration of a short circuit
at the 30 kV level of the ASP
6.4.2 Short-Circuit Current Calculation

for a Short Circuit at the 10 kV Level Z' T1 and Z' T2 must be converted
with the ratio factor tr = / to ZT1 and ZT2.
6
Based on the design of (normal operation, After that, the concatenation at the level can be
sectionalizer at level open), a short circuit is calculated. On the following page, shows the
assumed in one of the , and
switchgear assemblies for the low-voltage process the associated calculations.
).
For the total impedance, the shares from the infeed current according to 7
via the transformers T1 and T2 and that from the feed-
back of the three motors M3 and M4 as well as of the c ⋅ Un
I k“ tot( ) = =
Ztot( )

Contents
110 kV / 50-60 Hz
80 MVA
uk = 12.5 %
1
110/30 kV
Dyn5
I k“ T2
n. c.
n. o.
n. c.
2 63 MVA
16 MVA / 10 kV
I k“ T1(30 kV) uk = 11 %
30/10 kV G
30/10 kV Dyn5
I k“ T1(10 kV) I “k G
n. c. n. c.
n. c. n. o.
3 I k“ tot
n. c. n. o.
I “k M4 I “k M4 I “k M3
SoSt VFD VFD
M M M M M
4
0.3 MW 0.3 MW 4.84 MW
4 4 3
Fig. 6/5: Simple single-line diagram for illustration of the short-circuit situation at the 10 kV level
5 Short-circuit current calculation through concatenation of impedances Equivalent diagram
110 kV
ZT1 = Z‘ T1 / t 2r
ZT2 = Z‘ T2 / t 2r T2
ZT2‘ 30 kV
c · Un
~ Ik“ Ztot
ZT1‘ √3
T1
6 Z M3 2 10 kV
From 2 ZT2 G
Z M4
Z 2
ZT1 M4 M4 M3
ZG Ztot
Total impedance: ZM4 ZM4 ZM3
Ztot
= 1 / [1 / Z M3 Z M4 Z ZT1 ZT2
Step 1 Step 2 Step 3
1 c · Un
ZTx = ZTx‘ / tr2 Ztot = Ik“ =
7
1 2 1 1
+ + + √3 · Ztot
ZM3 ZM4 ZG ZT1 + ZT2
I k“
current
Tab. 6/4: Short-circuit current and impedance calculations as well as equivalent diagram for illustration of the short-circuit current
calculation for a short-circuit at the 10 kV level of the ASP

Contents
6.4.3 Selection of the Medium-Voltage For the medium-voltage switchgear of the level,
Switchgear Types
The basis for switchgear selection are the rated voltage
and the rated current of the feeding transformers, as ):
well as the short-circuit currents resulting from the • Direct-on-line starter (motor M4)
previous sections. From the overviews of possible – 1
and , as well as from –
the parameters relevant for selection, a switchgear with –
the matching design values is then selected.
•
–
switchgear at the level: •
Ur
– 2
Ir ( S rT2 / ( U r) =
According to the selection table
distribution
I k“ tot(
current of
Isc .2 kA
Ima - 3
tion near the chemical processes, air insulation and the
selected from . For the distribution level of
iii) At the
suitable for use in aggressive ambient conditions thanks 4

operational extensions.
Rated voltage:
Operating voltage: 6.5 Dimensioning the Medium-
Voltage Motor Feeders 5
Rated short-time , the
the power factor are important data for dimensioning

switchgear at the level: the motor feeders in the medium-voltage switchgear.
Apart from this motor data, the following information is
Ur
Ir ( S rT1 / ( U r) =
• Data of the feeding transformer, such as for example 6
short-circuit impedance
I k“ tot( •
•
Isc .2 kA
• Permissible voltage drop at the busbars during motor
Ima as a maximum).

Contents
Consumer / Protection Switching Rated Rated Rated Rated Siemens Typical

feeder function function voltage short-circuit current of current of switchgear applications
breaking busbar feeders type
current
1
Medium-voltage
/ switchgear
-
bution, as well as
consumer
medium-voltage
(switching
2 circuit-breaker
circuit-
motor feeders:
breaker)
soft starter or
converter in
separate housing
General
medium-
3 voltage
consumers
2)
2)
2)
2)
the transf. 2)
via the
4 disconnector without
2)
2)
Transformers
with contactor 2)
2)
2)
2)
- Medium-voltage
2) motors
5
vacuum
contactor 2) 2)
1)
1)
2)
Tab. 6/5: Selection table of medium-voltage switchgear for general consumers
6 -
ages can arise. To limit these overvoltages to harmless
no. 1, 2, 3 and 4 in ) is suitable to limit the values, surge arresters or surge limiters are installed.
currents, vacuum circuit-breakers are selected for line

protection of the motor feeders 1, 2 and 3. A numerical the motor and no series-connected reactor is used for
7
for monitoring and tripping ( ). The motor is
1 and 3.
converter).

Contents
Consumer / Protection Switching Rated volt- Rated Rated Typical Siemens Typical
feeder function function age short-circuit current of motor switchgear applications
breaking busbar rating of type
current the feeders
3)
- Pumps
circuit-breaker
Motor direct- 3AE/3AH/3AK)

contactor
3)
1
- Fans
on-line start - Transformers
or via block
transformer
vacuum
contactor
3TM starting current:
In 2)
vacuum
- Pumps
2
circuit-breaker contactor - Fans
Soft starter
3AE/3AH/3AK) (in separate starting current:
housing) In 2)
HARMONY
3
- Pumps
- Fans
Frequency circuit-breaker
converter HARMONY
3AE/3AH/3AK)
starting current:
In 2)
1)
1)
2)
3)
Tab. 6/6: Selection table of medium-voltage switchgear for more special consumer connections
5
Depending on the neutral earthing, minimum rated voltage transformers, this combination ensures both line
voltages can be determined based on -4 to
dimension the surge arresters ( ). As an imped-
ance-earthed neutral is given, a rated voltage of is
selected for the surge arresters.
For the smaller motors in feeders 4, surge arresters must

means of the vacuum contactor. 6
contactors are the best choice as switching and protec- circuit protection protect the switching devices (here for
example, the vacuum contactors) that do not feature a
rated motor currents and the starting conditions. For
the motor feeders with direct-on-line starting, vacuum
contactor/fuse combinations are installed to ensure a are used in combination with vacuum contactors for
rated voltages Ur Ur 12 . 7
) and the matching current and suitable for switching currents in the range of their

Contents
Feeder 1 Feeder 2 Feeder 3 Feeder 4

Active power P rM
Starting factor s M 1 1 3
Starting current I sM 124.3 A
Calculation of “
1 voltage drop
u = S sM / S kT Un I sM) / (S rT / u kr)
u
Protection device: Protection device: Protection device:
Line protection
Protection device:
Motor protection
Tripping: vacuum
2 contactor
Overvoltage protection recommended recommended
NXAIR (40
NXAIR
kA/12(40
kV/50
NXAIR
kA/12
Hz)
(40
kV/50
NXAIR
kA/12
Hz)
(40
kV/50
kA/12
Hz)kV/50 Hz)
NXAIR (40
NXAIR
kA/12(40
kV/50
NXAIR
kA/12
Hz)
(40
kV/50
NXAIR
kA/12
Hz)
(40
kV/50
kA/12 NXAIR (40
Hz)kV/50 Hz) NXAIR
kA/12(40
kV/50
NXAIR
kA/12
Hz)
(40
kV/50
NXAIR
kA/12
Hz)
(40
kV/50
kA/12
Hz)kV/50 Hz)
NXAIR (40
NXAIR
kA/12(40
kV/50
NXAIR
kA/12
Hz)
(40
kV/50
NXAIR
kA/12
Hz)
(40
kV/50
kA/12
Hz)kV/50 Hz)
HV HRC fuses
HV HRC fuses
HV HRC fuses
HV HRC fuses
3 x 63 A 3 x 63 A 3 x 63 A 3 x 63 A
Vacuum CB
Vacuum CB
Vacuum CB
Vacuum CB Vacuum CB
Vacuum CB
Vacuum CB
Vacuum CB Vacuum CB
Vacuum CB
Vacuum CB
Vacuum CB
1,250 A 1,250 A 1,250 A 1,250 A 1,250 A 1,250 A 1,250 A 1,250 A 1,250 A 1,250 A 1,250 A 1,250 A 7SK8 7SK8Vacuum
7SK8contactor
Vacuum
7SK8contactor
Vacuum contactor
Vacuum contactor
400 A 400 A 400 A 400 A
3 Single-line diagram
for the designEarthing Earthing
3
Current transformer
Current
Earthing
3
transformer
Current transformer
Earthing
3 3
Current transformer Current
Earthing Earthing
3
transformer
Current
Earthing
3
transformer
Current transformer
Earthing
3 3
Earthing Earthing
3
transformer
Current
Earthing
3
transformer
Current transformer
Earthing
3 3
Earthing Earthing
3
transformer
Current
Earthing
3
transformer
Current transformer
Earthing
3 3
Current transformer
switch switch switch switch switch switch switch switch switch switch switch switch switch switch switch switch
Surge arrester
Surge arrester
Surge arrester
Surge arrester Surge arrester
Surge arrester Surge arrester
Surge arrester Surge arrester Surge arrester
Surge arrester Surge arrester Surge arrester
Surge arrester
Surge arrester
Surge arrester
(optional)(optional)(optional)(optional) (12 kV) (12 kV) (12 kV) (12 kV) (optional)(optional)(optional)(optional) (12 kV) (12 kV) (12 kV) (12 kV)
(12 kV) (12 kV) (12 kV) (12 kV) (12 kV) (12 kV) (12 kV) (12 kV)
Frequency
Frequency
converter
Frequency
converter
Frequency
converterconverter Frequency
Frequency
converter
converter
Frequency
Frequency converterconverter Soft starter Soft starter
Soft starter Soft starter
M M M1Motor
Motor M M1Motor
M M1Motor M1 M M M2Motor
Motor M M2Motor
Motor M M3Motor
Motor M M4Motor
M M4Motor M4
4 Common motor data

Transformer data
Rated voltage Ur
S rT u kT
Tab. 6/7: Data and selection of the switching and protection devices for the motor feeders at the 10 kV level
-
5 vacuum for the short-circuit protection of the motor circuit are
contactor 3TM). The end of the mechanical endurance is selected according to:
operating • Rated voltage Ur and rated motor current IrM
• Motor starting current IsM
• Motor starting time t sM
•
breaking current of 3TM up to Isc • Ambient air temperature 4).
6 -
tection of the vacuum contactor in case of short circuit For selection of the numerical overload protection
be checked ( shows curves and points for the

):
-
tion of vacuum contactor and fuse can be used up to a
7
4) The increased temperature results in a worse heat dissipation to the
has to be considered; manufacturer information is to be observed.

Contents
FG Function group
Crtl Control
CB Circuit-breaker
RTD Indications from RTD box

SIPROTEC 7SJ82/85
27 Undervoltage protection
1
FG voltage/current
32 Power protection, active power
CB1 CB2 50/51 50N/51N 67
67N 67Ns FL 38 Temperature supervision
FG circuit-breaker CB2 46 Unbalanced-load protection
79 Ctrl 48 Starting time supervision
49R/49S Thermal overload protection, rotor/stator

2
50/51 Time-overcurrent protection, phases
SIPROTEC 7SK82/85 50N/51N Time-overcurrent protection, earth

FG motor
CB1 59/59N Overvoltage protection: “3-phase”, or “zero-
27 32 38 46 48 49S 49R sequence component U0”, or “positive phase-
50/51 59 59N 66 67Ns sequence system U1”, or “universal Ux”
FG analog units 66 Restart inhibit for motors
RTD 67 Directional time-overcurrent protection, earth 3

FG circuit-breaker CB1 67Ns Sensitive earth-fault detection for resonant-
earthed and isolated systems
M RTD Ctrl
79 Automatic reclosing
Fig. 6/6:
4
short-circuit breaking current IsHHmin
must be above the motor starting current (IsHHmin can be found in the data sheets of the
characteristic IsM and the motor starting time t sM IB IsHHmin )
2. The tripping characteristic of the overcurrent

protection must be above the characteristic for IsM 5
and t sM
vacuum contactor) circuit currents) must be installed in the switchgear.
3. The take-over current IB (intersection of the current-
tripping characteristic of the overcurrent protection, the corresponding switchgear.

point B in ) must be greater than the minimum 6
Maximum system voltage Us
Minimum rated voltage Ur in kV for

Solidly earthed neutral system 3
7
System with isolated neutral or for delta winding 24
Impedance earthed neutral system 3 12 21 33
System with earth-fault compensation 24
Tab. 6/8: Design of the rated voltage Ur for surge arresters according to IEC 60099-4

Contents
Fuses with a current-time characteristic that is espe- combination provide curves or tables which take the
their low heat loss. To select suitable fuses, the manu- current of the motor feeder to be protected into
facturers of switchgear with a vacuum contactor/fuse account.
1 Number of starts per hour K factor

-
2
process, however, the influence of the motor starting
4
-
, the K
,
2 32 a permissible pre-arcing characteristic of a fuse-link is
Tab. 6/9: K the current characteristic with the K factor).
103
Time
3 in s
102
31,5
250
100
125
200
160
25 A
40 A
50 A
63 A
80 A
A
A
A
A
A
B
101
tsM = 5 s A*
4
100
10-1
5 8
6
5
4
3
2
10-2
101 2 3 4 56 8 102 2 3 4 56 8 103 2 3 4 56 8 104

Current
6 IrM = 20.7 A IsM(A*) = IsM / K =
= 124.3 A / 0.48 = 259 A in A
IsM = 124.3 A IsHHmin = 200 A Isc(3TM3) = 5 kA
Legend:
Motor current characteristic
Motor current characteristic (A*) modified with K
HV HRC fuse characteristic 80 A (SIBA fuses [6.2]: Article No. 30 102 53.80)
Tripping characteristic of numerical protection relay SIPROTEC 7SJ82

7 B
Rated short-circuit breaking current of vacuum contactor 3TM3: Isc = 5 kA
Characteristic intersection (HV HRC fuse - time-overcurrent protection): B
Fig. 6/7: Characteristics diagrams for selecting a suitable combination of protection devices for motor M4

Contents
,K 6.6 Motor Start with

Block Transformer
For the K factors or the motors M4, the following Under certain circumstances, the use of a soft starter or
applies:
•
• block transformer as a more cost-effective motor starter 1
• Maximum 2 starts in immediate succession. version. This can be done, for example, if no automatic
and overcurrent protection when dimensioning a suit- the rated motor voltage, the starting current that must
able combination for the motor feeder M4, in ,
Due to the block transformer ratio, the current on the
protection, and vacuum contactor are entered, and
important points for the selection are marked. The
2
associated device parameters and calculations for the
selection matching with motor M4 are likewise stated in transformer is sufficient to limit the voltage drop during
. the start to the desired extent.
Process line 1
3
110 kV / 50-60 Hz
SrT(grid) = 80 MVA u = SaM / S“kT(red) Ur IaM) / (SrT(red) / ukr(red))

ukr(grid) = 12.5 %
1 kA
5s
Dyn5
4
n. c.
SsM Ur IsM U 2r / Ztot

n. c.
IsM Ur / [ Ztot
Ztot Ztot(10 kV) t 2r
5
16 MVA 8 MVA
1.6 MVA 2 MVA Ztot(10 kV) = ZT(10 kV) + ZsM
=
ukr = 6 % ukr = 6 % ukr = 11 % ukr = 8 % ukr = 8 %
Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 ZT(10 kV) = U 2r ukr / SrT

0.2 kA 0.2 kA 0.2 kA
10 9 5s 5s 5s +
M M ZsM = Ur / ( IsM)
n. c.
n. c. 1 2
6
SoSt VFD VFD
M M M M M
4 4 3 2 1
i) ii)
7
Fig. 6/8: Single-line diagram for connecting the two sample motors, and equivalent diagram for determination of impedances and
voltage drop in Tab. 6/10
Totally Integrated Power – Concept Finding for a Chemical Plant 111

Contents
Active power P rM
Starting factor s M
Rated current IrM
Motor impedance Z sM
1 Data of block transformer S rT u kr S rT u kr
Transformer impedance Z T
Ztot
Ztot
S sM
Data of grid transformer S rT(grid) u kr(grid)
2 Short-circuit power of grid transformer S “
Calculation of voltage drop “ =(
u = S sM / S kT Ur I sM) / (S rT / u kr)
u
Calculation of motor starting voltage with
I sM Ur Ztot UsM I sM ZsM
block transformer UsM
Motor starting voltage UsM
3 UsM U r] 2
Tab. 6/10: Results of the sample calculations for the use of a block transformer
is too large for the voltage drop at the level,

compared to the stipulation of a maximum of .
-
4 and the starting duration are sufficient to ensure normal
former with the data from
voltage drop of 4.
with a permissible
the original concept with the connection of these two
For the sample calculations of the block transformer, again.

the two large motors are considered, which shall be
of the 6.7 Generator Protection

5
UsM2), the terminal voltage at the motor must not drop as a rule for all circuit-breakers. The generator
below of the rated voltage.
-
sample motors 1 and 2 at the level via a block ments to which the circuit-breakers are subjected when
6 transformer. The impacts on further network setup
(e.g. in -
switching generators (
•
):
former / ) are not considered. The results are the missing current zeros resulting therefrom
stated in . •
• Higher test voltage levels.

must exceed at least of the nominal operating
-
7 due to
112 Totally Integrated Power – Concept Finding for a Chemical Plant

Contents
Fault location a): System-source 6.8 Network Protection Concept

short circuit with constant AC component and Energy Management
Measuring devices, digital protection devices, current
and voltage transformers, as well as evaluation and
control units must be adjusted to each other. For this,
both the grid connection conditions ( ) and 1
better overview, the network protection concept and the
I k“ T -
-
a) vided as a central connection point for controlling the
G
b)
I k“ G The facilities are mirrored for the two process lines and,
2
for controlling these important components can be
ensured.
i) Network protection concept

To develop the protection concept, the procedure is
as follows: 3
Fault location b): Generator-source
short circuit with no zero transitions
as from the project-specific and operational
Fig. 6/9: Short-circuit stress of a generator breaker for
modes of operation of the plant, generator
operating modes)
-
4
the individual protection targets (e.g. transformer,
generator, motor, line) and the most appropriate
degree of protection (e.g. definite time-overcurrent
• Rated voltage protection, differential protection, distance
• Rated current protection)
•
• Behavior in case of generator-source short circuit.
3. Dimensioning and selection of suitable protection
current transformers.
5
For this, a calculation of the short-circuit currents is
carried out taking into account the two fault locations
influence on the protection concept, the protection
functions to be selected (e.g. sensitive earth-fault
-
detection, direction detection), the selection and
tween the generator manufacturer and the circuit-
design of the protection current transformers (for
breaker manufacturer. Essential circuit-breaker charac-
teristics to be tested are:
detecting small earth-fault currents in isolated and
6
•
compensated networks, voltage transformers for
•
direction detection).
circuit-breakers for generator switching applications is For the medium-voltage side network protection in
sufficient for rated currents up to 14 kA, apparent power the electric power distribution concept, numerical
, and rated
short-circuit breaking current Isc 7
. The protection functions of the individual
devices are listed in according to the num-
bering in .
Totally Integrated Power – Concept Finding for a Chemical Plant 113

Contents
110 kV / 50-60 Hz
80 MVA
1
uk = 12.5 %
110/30 kV
Dyn5
SICAM A8000 Microgrid Controller

7SJ85
Fiber-optic cable
50,51,50N,51N
25,27,59,59N
81O,81U,81R
1
(communication protocol: IEC 61850) 67,47 1)
2 3 4 7SJ82
50, 51
5
50N, 51N
7UT85 7SJ82 16 MVA / 10 kV

50, 51, 87T 50, 51
7SJ82 7SJ82
G
2
50N, 51N 50N, 51N
50, 51 50, 51
50N, 51N 50N, 51N 63 MVA
uk = 11 %
30/10 kV
Dyn5
6 7 8 5
7UM85
7SJ82
51V, 59N, 81
50,51
24, 32R, 27TH 7VE85 7SJ82
50N,51N 25, 87T, 64F 25 50, 51
40, 46, 49 50HS 50N, 51N
7SK82 7SK82 7SJ82 7SJ82 7SJ82

50,51,50N,51N 50,51,50N,51N 50, 51 50, 51 50, 51
27, 32, 38
46, 48, 49, 59
27, 32, 38
46, 48, 49, 59
50N, 51N 50N, 51N 50N, 51N
11 12 11 12
10 10 10
Back-up protection Back-up protection
3
7SD82 7SJ82 7SD82 7SJ82
9 9 87L
87N T
50, 51
50N, 51N
87L
87N T
50, 51
50N, 51N
SoSt VFD VFD

M M M M M 11
7SD82
87L
87N T
11 7SD82
87L
87N T
0.3 MW 0.3 MW 4.84 MW 5.8 MW 11.2 MW
Protection application Protection function Protection device

1 Infeed from DSO Time-overcurrent and feeder protection SIPROTEC 7SJ85
4 2 Transformer feeders 30/0.4 kV

Transformer feeders 30/10 kV:
Transformer differential protection SIPROTEC 7SJ82
3 Primary protection Transformer differential protection SIPROTEC 7UT85 2)

4 Back-up protection Time-overcurrent and feeder protection SIPROTEC 7SJ82
5 Interface 3) Time-overcurrent and feeder protection SIPROTEC 7SJ82
6 Interface switch Time-overcurrent and feeder protection SIPROTEC 7SJ82
7 Generator Generator protection SIPROTEC 7UM85
8 Paralleling device SIPROTEC 7VE85
9 Motor feeders (motor and line) Paralleling device SIPROTEC 7SK85
5 10 Motor feeders (line)

Connecting lines10 kV:
Time-overcurrent and feeder protection SIPROTEC 7SJ85
11 Primary protection Differential protection SIPROTEC 7SD82

12 Back-up protection Time-overcurrent and feeder protection SIPROTEC 7SJ82
1) Functions for the interface protection are marked in blue
2) For transformer feeders with line lengths of more than 500 m, a differential protection relay SIPROTEC 7SD82 is recommended
3) The protection device ⑥ protects the interface and serves for tripping the interface protection (measurement and decision are made in protection device ①)
Fig. 6/10: Main components, protection functions, and links in the network protection concept for the ASP
6
The basics for dimensioning and selection of the protec-
tion current transformers are the standard -2 the current transformer must reach saturation in due
-
missible errors (
7 and can be found in the respective manuals (e.g. for offers
consultants will be pleased to provide support in

designing the current transformer.
114 Totally Integrated Power – Concept Finding for a Chemical Plant

Contents
ANSI Function Abbrev.
24 Overexcitation protection U/f
Undervoltage protection
32R Reverse-power protection 1

Underexcitation protection 1/xd
2
Thermal overload protection

Time-overcurrent protection, phases
Time-overcurrent protection, earth
2
Rotor earth-fault protection

Directional time-overcurrent protection, phase
3
Earth-fault differential protection
Transformer differential protection
Tab. 6/11:
4
ii) Measurement concept and • Power values per phase: active and reactive
energy management system component
• Active factors per phase and as sum
• Power factors per phase and as sum
three levels: • Harmonic content of voltage (THDU) and current
•
• Distribution • Flicker, etc. (depending on device). 5
• Due to the in-house medium-voltage network after
the customer –, the measuring point operator mea- course also be done at the medium-voltage level of
the user.
feedback of the embedded generating plants into For the measurement concept shown in , the
6
different levels.
measuring point operator to the plant operator, and to
receive more detailed information, the customer can
for such control measurements. The measuring

devices can deliver the following values: 7
•
•
component

Contents
Connected
Ip Is / Isr
burden = 20 VA
10
-5 %
Is SIPROTEC Connected
protection burden = 40 VA
1 device 5
5 10 Ip / Ipr
Protection current transformer
100 / 1 A = rated primary / secondary current
20 VA Cl. 5P10
2 Rated values:
Accuracy limit factor Ip Primary current to be measured
Core type, e.g. Ipr Rated primary current
P = protection current transformer Is Secondary current to be measured
Accuracy class Isr Rated secondary current
Rated burden
Fig. 6/11:
3. Distribution levels and transformers: ).
of currents -
4 variables such as alternating current, alternating voltage,
5 stage, failures and damages can be avoided. Therefore,

the measuring devices should be able to provide the addition to the monitoring function:
•
offers a corresponding
service, for which a discussion of experts with the • Recording of mean, minimum and maximum values
customer is the essential feature for assessment. of different network parameters in flexible intervals
6 •
of electrical measuring variables, such as for example -

terization and measured-value output is carried out via
to the standard
measurement. Besides the monitoring function, the
7 -
tion: Measured values can be recorded in programmable

Contents
Other device characteristics are:

and background illumination for flush mounting or •
•
values of voltages (phase-to-phase and/or phase-to-
earth), currents, active/reactive/apparent power and • Real-time clock, so that measured values and states 1
can be recorded with time stamp
and voltages, total harmonic distortion (THD) per phase •
•
well as external signals and states. log entries
2
110 kV / 50-60 Hz Infeed control with
Microgrid Controller:
1 Point of connection (PoC)
80 MVA
2 Main switch
uk = 12.5 %
3 Interface switch
3
110/30 kV
Dyn5
4 Generator circuit-breaker
SICAM A8000 Microgrid Controller
Q100 1 5 Generator control
Fiber-optic cable
(communication protocol: IEC 61850) 2
P850 P850 P850
16 MVA / 10 kV 4
63 MVA G 5
uk = 11 %
30/10 kV
Dyn5
P850 P850
4
P850 P850 P850 P850 P850

3
P850 P850 5
SoSt VFD VFD

M
0.3 MW
M
0.3 MW
M
4.84 MW
M
5.8 MW
M
11.2 MW
6
1.6 MVA 1 MVA

P50 uk = 6 % P50 uk = 6 %
10/0.4 kV 10/0.4 kV
Dyn5 Dyn5
Fig. 6/12: Measurement concept for energy management of the ASP and infeed control with the Microgrid Controller

Contents
3 months.
), as a power manage-
2 side at the
generators at the level, both during normal
impacts on the normal production processes in the plant
3 both automatic operation and user-led operation.

Fig. 6/13: Automation box as a system application of the
Microgrid Controller
ensure that no regenerative feedback of the generators

occurs in the feeding grid, and that the generator infeed 6.9 Front Views and Room Planning
- of the Medium-Voltage Switchgear
4 be complied with. As described in , these
conditions follow national stipulations, standards, laws
Following the dimensioning of the switching and
protection devices for medium-voltage switchgear
or guidelines (see ). The basis for this are interna- assemblies at the level and the level, the
tional regulations and standards ( ), which dimensions, weights and installation conditions can be
reflect the recognized state of the art. determined. An important help for this is the engi-
level
measuring points and switching devices marked with is shown including all the panels in
5 blue boxes in are selected in the network
process distribution at the level is shown in
in accordance with . The connection of the
- mirrored. The smaller medium-voltage switchgear
is sufficient ( ).
6

Contents
Circuit- Circuit- Circuit- Circuit- Circuit- Circuit- Circuit- Circuit-

breaker breaker breaker Metering breaker Combination breaker Metering breaker breaker breaker
panel panel panel panel panel panel panel panel panel panel panel
1
2,700
152 600 600 600 600 600 1,200 600 600 600 600 600 152
7,504 Dimensions in mm
Depth: 1,625 mm
Minimum distances:
3
Control aisle ≥ 800mm This information does not correspond to any construction
Wall distance on the right for operation ≥ 100 mm execution data and drawings.
Wall distance on the right for replacement ≥ 500 mm Further planning instructions for switchgear installation
Wall distance on the left for operation ≥ 100 mm can be found in Catalog HA 35.11 [6.7].
Wall distance on the left for replacement ≥ 500 mm
Wall distance to the rear
for wall-standing arrangement ≥ 100 mm
for free-standing arrangement ≥ 800 mm
Ceiling height ≥ 2,850 mm
Fig. 6/14: Front view and data for installation of the 30 kV switchgear 8DA
4
Left-hand switchgear half 10 kV
coupling
Right-hand
Contactor Circuit- Circuit- Circuit- Circuit- Metering Circuit- Bus sectionalizer with bus riser panel Circuit- Circuit- Generator Bus sectionalizer with bus riser panel
panel breaker breaker breaker breaker panel breaker breaker breaker circuit-breaker switchgear
panel panel panel panel panel panel panel panel
half
“mirrored”
5
2,525
1,540
435 435 800 800 800 800 1,000 1,000

9,470
1,000 800 800 800 1,000 1,000 6
20,940
Minimum distances: Ceiling height:

Control aisle for operation ≥ 1,250 mm Ceiling height with pressure relief duct: Dimensions in mm
Control aisle for panel replacement ≥ 1,750 mm ≤ 17.5 kV / ≤ 40 kA 1 s or 0.1 s ≥ 2,500 mm
Wall distance on the right ≥ 150 mm
Wall distance on the left ≥ 150 mm Ceiling height without pressure relief duct:
≤ 12 kV / ≤ 25 kA 1 s or 0.1 s ≥ 2,800 mm
Wall distance for contactor panel: ≤ 12 kV / 31.5 kA 1 s or 0.1 s ≥ 3,000 mm
Wall distance on the right ≥ 150 mm ≤ 12 kV / 40 kA 1 s or 0.1 s ≥ 3,500 mm
Wall distance on the left ≥ 150 mm ≤ 17.5 kV / ≤ 31.5 kA 1 s or 0.1 s ≥ 3,500 mm
≤ 17.5 kV / 40 kA 1 s or 0.1 s ≥ 3,500 mm
Wall distance with pressure relief duct on
the opposite side of the switchgear: This information does not correspond to any construction
Wall distance on the right ≥ 500 mm execution data and drawings.
7
Wall distance on the left ≥ 500 mm Further planning instructions for switchgear installation
can be found in Catalog HA 25.71 [6.8].
Wall distance at the rear:
for cable connection at the front ≥ 150 mm
for cable connection at the rear ≥ 500 mm
Fig. 6/15: Front view of one half of the switchgear assembly including bus sectionalizer, as well as data for installation of the
10 kV switchgear NXAIR

Contents
Circuit- Circuit- Circuit- Circuit-

breaker breaker breaker breaker
panel panel panel panel
600 600 600 600
4 Wall distances:
Fig. 6/16: Front view and data for installation of a medium-voltage switchgear NXPLUS C

Chapter 7
Annexes
7 Annexes
Contents
7.1 List of Standards Cited
Standards,
guidelines, Year Title
regulations
3
(Australia / New Zealand)
Regola tecnica di riferimento per la connessione di utenti attivi e passivi alle reti AT
ed MT delle imprese distributrici di energia elettrica
(Reference technical rules for the connection of active and passive consumers to the
4
cables and lines in consideration of fault protection, protection in case of short circuit,
and voltage drop)
-
ment in parallel with public distribution networks
122 Totally Integrated Power – Annexes

Contents
Standards,
regulations
Electromechanical contactors and motor-starters
transformers
5
current switchgear and controlgear
contactor-based controllers and motor-starters
7
circuit-breakers
Recommended practice for electric power distribution for industrial plants
Totally Integrated Power – Annexes 123

Contents
Standards,
regulations
Norma técnica de supervisión de la conformidad de los módulos de generación de
3
Technical rule for distributed resources connected to power grid
Technical regulation
3.2.1 (Denmark)
Technical regulation
4 Technical rules for the connection and operation of customer installations to the
Building information modeling – Fundamentals
of human resources in simulation models
124 Totally Integrated Power – Annexes

Contents
7.2 List of Abbreviations
FRT Fault-ride-through
A 1
Regulators G
Architects and Engineers

Btu British thermal unit
3
C
I
4
Engineers
5
K 6
L
E
EU European Union
Totally Integrated Power – Annexes

Contents
R
R&D Research and development
1
RPM Revolutions per minute
RTD Resistance temperature detector
M
M2M Machine-to-machine S
M3 Machine-machine-management
2
MOM Manufacturing operations management
3 N
T
THD Total harmonic distortion
O
4 O&M Operation and maintenance

THDU Total harmonic distortion voltage U
and Development
OPEX Operational expenditure
P
5 U
PDM Product data management
PP Performance phase

Contents
7.3 Bibliography
Author Year Title
Planning of Electric Power Distribution: Technical Principles

1.1
1.2 Kiank, Fruth

1
acatech – Deutsche Akademie
1.3
der Technikwissenschaften
1.4
2
Fabrikplanung und Fabrikbetrieb
2.1
Dissertationsschrift: Objektorientierte Fabrikplanung
2.2 M. Bergholz
2.3 E. Uhlmann
2.4
3
operations)
implementation of adaptable production plants)
4
3.1
Administration
Eurostat https://ec.europa.eu/eurostat/de/data/database
https://www.eia.gov/outlooks/aeo/
3.2
5
3.3 Heat Roadmap Europe
3.4
(Download am 6
BP p.l.c.
D. Röhrlich [www.deutschlandfunk.de/ruesten-gegen-den-blackout-unsi
7
[ ]

Contents
Author Year Title
Datenzusammenstellung von (Data compilation of) [https://

3.11
1 databank.worldbank.org/source/world-development-indicators]
3.12
3.13
2 3.14 [
]
4.1
4.2
America
4.3
3
4.4
selection criteria
5
application in data centers
(Manual for high-voltage fuses)

6

Contents
7.4 Units System
SI basic units
Size Unit Symbol / abbreviation
Meter m
1
Kilogram kg
Time s
Electric current Ampere A
Temperature Kelvin K
cd
2
SI units
Size Unit Symbol / abbreviation Derived
Hertz Hz 1 Hz = 1 s-1
Force Newton N 2
3
Pressure, tension Pascal Pa 1 Pa = 1 N/m2
2 /s 2
2 /s 3
Electric charge
Electric voltage 2 3
4
Electric resistance Ohm
-1
Tesla T 2
H 5
lm 1)
lx 1 lx = 1 lm/m2
1) sr = steradian (measuring unit for the solid angle sr, so that an area A is enclosed on a sphere with a radius r: sr = A/r 2 )

Notes
Contents
Totally Integrated Power – Notes

Notes
Contents
Totally Integrated Power – Notes 131

Contents
We would like to thank the following persons for their

technical support in the preparation of this manual:
Braga, Rodrigo
Englert, Ingo
Erschen, Benjamin
1 Gemsjäger, Ben
Glas, Johannes
Kapinosova, Kateryna
Maschek, Jürgen
Ramirez Jordan, Saul
Shamim, Taiyab
Weber, Ralf
2 Wegehaupt, Klemens
4
Imprint
Totally Integrated Power – Consultant Support
Applications for Electric Power Distribution
Industrial Plants
5 Published by
Siemens AG
Smart Infrastructure
Distribution Systems
Editor
Siemens AG
6 Dr. Siegbert Hopf
E-mail: siegbert.hopf@siemens.com
Publishing House
Saatchi & Saatchi GmbH
Arnulfstraße 60
80335 Munich, Germany
7 Image Rights
All images and all graphics: © Siemens AG
132 Totally Integrated Power – Imprint

Siemens AG Subject to change without prior notice. The informa-
Smart Infrastructure tion in this manual only includes general descriptions
Distribution Systems and/or performance characteristics, which do not
always apply in the form described in a specific
Mozartstr. 31c application, or which may change as products are
91052 Erlangen developed. The required performance characteristics
Germany are only binding if they are expressly agreed at the
E-Mail: consultant-support.tip@siemens.com point of conclusion of the contract.
GEAFOL, MindSphere, NXAIR, PSS, SENTRON,

SICAM, SIMARIS, SIMATIC, SION, SIVACON, TIA and
All rights reserved. TIP Totally Integrated Power are registered trade-
All data and circuit examples without engagement. marks of Siemens AG. Any unauthorized use is
prohibited. All other designations in this document
may represent trademarks whose use by third
parties for their own purposes may violate the
proprietary rights of the owner.
© 2021 Siemens AG, Berlin and Munich, Germany

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TOTALLY INTEGRATED POWER

Industrial plants constitute a system composed of production facilities, transport and

1 Introduction 6 Concept Finding for the Electric Power

5 Concept Finding for the Electric Power Distri-

2 Totally Integrated Power – Contents

The series of application manuals on electric •

thus also on the electric power distribution, the planner

4 Totally Integrated Power – Introduction

These trends as well as the hardware- and software-

The interaction during the integration and implementa- •

Totally Integrated Power – Introduction

Digitalization Industry 4.0

How is it possible to react autonomously?

1 What is going to happen?

construction and operation to modification or retrofit-

planned in separate projects: -

Totally Integrated Power – Introduction

The standardized and structured information exchange 1

before data drop 3 (project development), it would be 3

Moreover, inaccuracies or even missing information and

planning expenditure for information, documentation,

Project phase BIM

2 Demand determination Establishment of the project basis

4 Design / Approval Design planning and approval planning

Detailed design Execution planning, site supervision

Totally Integrated Power – Introduction

Project information model (PIM) Technical models

Common Data Environment (CDE)

Data validation / quality assurance

Timeline / construction process /

Fig. 1/2: Schematic representation of a standardized data exchange in BIM [1.6]

architect, and the planning colleagues. Planning targets

Totally Integrated Power – Introduction

Biometry Business administration

Art and ethics Education

Totally Integrated Power – Factory Planning

Time horizon Level Customer- and value-oriented planning system

Information Building and

Areas the factory planning has to coordinate with

Areas of factory planning

Fig. 2/2: Structure of an integrated planning system similar to VDI 3637

representatives in case of smaller replanning projects) and

point are structural concepts that have to be approved

Totally Integrated Power – Factory Planning 11

2.2 Phase Model of Factory Planning

corporate planning tasks are taken into account, the

• the electric power distribution and therefore on the

6 2.3 Digital Factory

a comprehensive network of digital models, methods

12 Totally Integrated Power – Factory Planning

Planning characteristics Influencing factors

• Cost-efficiency Processes: Organization: Infrastructure:

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 Phase 6 Phase 7

Planning levels Characteristics 3

• Rough representation of the functional areas

• Fine representation with a high degree

Totally Integrated Power – Factory Planning 13

Digital Twin Digital Twin Digital Twin

Insights from performance with MindSphere