A new machine may have a confirmed delivery date while the electrical arrangements are still being worked out. The foundation is ready, the floor space has been cleared, and the installation team knows where the equipment will sit.
But a large motor, furnace, or compressor can demand more power than the existing electrical system was designed to supply. The requirements become clearer once you compare the machine’s electrical specifications with the loads your plant already handles.
A transformer may have plenty of spare capacity during a quiet shift and run close to its rated limit when production reaches its peak.
Suppose your plant already operates several large motors and a furnace during the afternoon shift. Adding a heavy compressor that runs during those same hours will increase the combined load on the transformer.
Recent maximum-demand records, existing load schedules, and the new machine’s rated current can help your electrical team work out whether the present transformer has enough capacity.
If the existing unit is already heavily loaded, adding another transformer or increasing capacity may become part of the installation budget.
A large motor draws considerably more current while starting than it does once it reaches normal speed. Depending on the motor and starting arrangement, the difference can be several times the running current.
The resulting voltage drop may affect equipment elsewhere in the factory, especially when smaller motors, drives, and control circuits share the same supply.
For instance, starting a large crusher could cause a contactor on another machine to release if the voltage falls far enough.
The machine supplier can provide starting-current details and information about the proposed starter. An electrical engineer can use those figures to compare direct-on-line starting, soft starters, or variable frequency drives against the available supply.
The cable running from the distribution board to the new machine may need replacing, especially if the equipment draws more current or sits further away than the previous installation.
Long cable runs can cause additional voltage drop. Conductor size, installation conditions, and the distance from the supply all influence the cable selection.
Circuit breakers and switchgear deserve similar attention. Their current ratings, short-circuit breaking capacity, and protection settings must suit the revised electrical arrangement.
Large drives and rectifiers introduce another consideration because their harmonic currents can increase heating in transformers and cables.
Where additional transformer capacity is required, sharing the machinery specifications with a transformer manufacturer in Kolkata can help establish the voltage, rating, and operating duty needed for the application.
Electrical installation work continues after the machine has been positioned and connected. Earthing, bonding, cable insulation, phase sequence, and protection arrangements all need checking before energisation.
A machine with a three-phase motor, for instance, needs its phase sequence checked because an incorrect connection can cause the motor to rotate in the wrong direction.
The commissioning schedule should also leave time for testing protective devices and observing how the machine behaves during its initial operation.
Some problems only become apparent when the equipment starts drawing current. Having the installation team available during those first runs can make corrections easier to arrange.
A machine’s electrical requirements can affect work far beyond its connection terminals. The installation may call for a larger transformer, additional feeder capacity, different protective settings, or changes to the starting arrangement.
Much of this becomes easier to plan when the machine supplier provides the electrical data before installation work begins. It also gives the plant time to arrange any additional equipment and testing.
Our manufacturing work at Makpower includes power, distribution, furnace, and auxiliary transformers used in industrial facilities. If your new machinery requires additional transformer capacity, you can discuss the machine’s electrical requirements and existing supply details with us while planning the installation.
Specialized in Induction Furnace Transformers, Step-Voltage Regulators, and 25 MVA 132kV Substation Class Power Units.
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