PROJECT TITLE

Design of LV distribution kiosk and distribution board based on the load

estimate to accommodate circuits feeding a warehouse

by
Maduna Mbekezeli Sandile
[email protected]
22058185

Report submitted in compliance with the requirements for the subject DESIGN PROJECT 1
(DSPJ101) in the Department of Electrical Power Engineering
Faculty of Engineering and the Built Environment
Durban University of Technology, Durban, South Africa

Supervisor: Prof. I.E. Davidson

08 June 2022

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 ABSTRACT

In a long-term planning procedure of distribution networks, it is essential to design an appropriate

topology to satisfy economic and technical aspects. In this report, the low-voltage (LV) distribution
network for a storage warehouse is investigated by evaluating the loads that are in the warehouse.
This project aims to design an LV distribution kiosk and Distribution Board (DB) based on the
load estimate to accommodate circuits feeding the warehouse. Based on the applied load of 500A
from eThekwini Electricity (EE) that was made by the client due to assumptions, it was discovered
that the client made a mistake. This was verified by the load estimate that was performed during
the research and it was discovered that the load should be 100A. The voltage drop will be
calculated to check if the correct cables are used and if it corresponds with SANS 10142-1. The
luminous flux will also be calculated in this report to check if it corresponds with SANS 10114-1.

The design will be verified by performing a load flow analysis on the network using an engineering
software simulation tool called ReticMaster. This software will help in determining which cable
size to use and it will determine voltage drop, fault current, and circuit breaker sizing. DiaLux
software tool is also used in designing the warehouse and to determine and verify light level
intensity in the warehouse.

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 LIST OF ABBREVIATIONS

LV Low Voltage

DB Distribution Board

SANS South African National Standards

MV Medium Voltage

EE eThekwini Electricity

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 ACKNOWLEDGEMENT

I would want to offer my heartfelt gratitude to several people and organizations for their
unwavering support throughout my design project. First and foremost, I want to express my
heartfelt gratitude to Professor I.E. Davidson and Mr. Mthandeni Phakathi, my supervisor and co-
supervisor, for their enthusiasm, patience, insightful comments, helpful information, practical
advice, and never-ending ideas, which have greatly aided me throughout my research and writing
of this report. I was able to effectively accomplish this research because of their vast knowledge,
extensive experience, and professional expertise in Electrical Engineering. This endeavor would
not have been possible without their help and direction. In terms of project design, I could not have
asked for a better supervisor and co-supervisor.

I would also like to thank my cousin Jabulani, for assisting me with the knowledge needed to
complete this project. Finally, but certainly not least, I want to express my gratitude to my family
and friends for their support and encouragement in helping me complete this project.

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 Table of Contents
ABSTRACT .................................................................................................................................................. 2
LIST OF ABBREVIATIONS ....................................................................................................................... 3
ACKNOWLEDGEMENT ............................................................................................................................ 4
LIST OF FIGURES ...................................................................................................................................... 7
LIST OF TABLES ........................................................................................................................................ 8
CHAPTER 1: INTRODUCTION ................................................................................................................. 9
1.1 Background ................................................................................................................................. 9
1.2 Statement of Problem ................................................................................................................. 9
1.3 Specific Aim and Objectives........................................................................................................... 10
Aims.................................................................................................................................................... 10
Objectives........................................................................................................................................... 10
1.5 Organization of Report................................................................................................................... 10
CHAPTER 2: LITERATURE REVIEW .................................................................................................... 11
CHAPTER 3: DESIGN METHODOLOGY............................................................................................... 13
CHAPTER 4: RESULT, ANALYSIS, AND DISCUSSION ..................................................................... 21
Results .................................................................................................................................................... 21
4.1. Warehouse lighting design results ........................................................................................... 21
4.1.1. Luminous flux calculation ................................................................................................ 21
4.1.2. Analysis based on DiaLux ................................................................................................ 22
4.2. Warehouse total load calculation............................................................................................. 22
4.3. ReticMaster and voltage drop calculation .............................................................................. 23
4.3.1. Voltage drop calculation................................................................................................... 23
4.4. ReticMaster results .................................................................................................................... 25
4.4. 1. ReticMaster and voltage drop analysis ........................................................................... 26
4.5. Discussion................................................................................................................................... 26
CHAPTER 5: CONCLUSION AND RECOMMENDATION................................................................... 27
5.1 Conclusion ....................................................................................................................................... 27
5.2 Recommendation............................................................................................................................. 27
APPENDICES ............................................................................................................................................ 29
Appendix A – lighting lux level according to SANS 10114-1: 2005 .................................................. 29
Appendix B: Warehouse load estimate ............................................................................................... 30
B1: DB-A load estimate .................................................................................................................... 30

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 B2: DB-B load estimate..................................................................................................................... 30
Appendix C ............................................................................................................................................ 31
Aberdare Conductor cable catalog .................................................................................................. 31
Appendix D ............................................................................................................................................ 32
Gantt chart ........................................................................................................................................ 32
Appendix E ............................................................................................................................................ 33
Bill of quantity ....................................................................................................................................... 33

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 LIST OF FIGURES
Figure 1-1: Electricity power flow. ............................................................................................................... 9
Figure 2-2: Fiberglass distribution kiosk .................................................................................................... 12
Figure 3-3: Warehouse 3D view. ................................................................................................................ 14
Figure 3-4: Warehouse floorplan view. ...................................................................................................... 14
Figure 3-5: Warehouse outside view. ......................................................................................................... 15
Figure 3-6: Distribution board layout. ........................................................................................................ 16
Figure 3-7: Lights connection and DB's positioning. ................................................................................. 17
Figure 3-8: Socket-outlets connections. ...................................................................................................... 18
Figure 3-9: LV network. ............................................................................................................................. 19
Figure 4-10: DiaLux simulation lux results. ............................................................................................... 22

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 LIST OF TABLES
Table 3-1: Warehouse dimensions .............................................................................................................. 13
Table 3-2: Phillips luminaire specifications................................................................................................ 15
Table 3-3: Cables used ................................................................................................................................ 19

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 CHAPTER 1: INTRODUCTION

1.1 Background
A power system is made up of a collection of interconnected components that create, transmit, and
distribute electricity to end-users [1]. These components are connected by a set of transformers
that step up and down the voltage to the appropriate level for system operation while reducing
network line losses. The LV distribution network is the final stage of the power network, and it is
directly connected to end-user customers, supplying a large number of dispersed small-scale loads
[2]. The LV networks are defined as a network with a maximum limit of voltage level 1 kV [1].
Power can be accurately transmitted up to 300 meters with the LV feeder [3]. The dispersion of
voltage drop between the medium voltage (MV) and LV network levels is not defined in South
Africa. Limits on voltage apportionment are determined by network and load parameters, as well
as the tap settings on distribution transformers [4]. The figure below shows the power flow of
electricity from distribution to the load or end-user customers.

Figure 1-1: Electricity power flow.

In South Africa, the standard LV service voltage is 230/400V; however, the previous standard was
220/380V, and many customers still use equipment with that rating. When run at the higher voltage
limit, some 220/380 V equipment may have issues (failure to work, lower efficiency, and/or life
lifetime). Even equipment rated for 230/400V LV voltage may not be compliant with the voltage
changes permitted by regulations [5]. The voltage loss within the customer's LV network (beyond
the service point) is limited to 5%, according to SANS 10142-1 [6].
1.2 Statement of Problem
There is a 315 kVA mini substation on-site that is on the way. There will be renovations on-site
and the mini substation will be removed. The mini substation was getting flooded with water and
it was no longer in use. The client made an application from EE of 500A load due to assumptions
after the mini substation was removed.

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1.3 Specific Aim and Objectives
Aims
• To design an LV distribution kiosk and DB to accommodate circuits feeding a warehouse.
• To design the warehouse and the lighting system using DiaLux software.

Objectives
• To simulate or model an LV network.
• To verify load flow analysis on the LV distribution network.
• To determine the load demand in the warehouse.
• To determine the light level intensity in the warehouse.

1.4 Scope and Limitations of the Study

The scope of this project is to design an LV network based on the load estimate and use correct
cable sizes and perform load flow analysis using ReticMaster software for loads in the network.
DiaLux software was used over ReLux software as it is easy and more efficient to use.

1.5 Organization of Report

The remaining parts of this report are organized as follows:
Chapter 2: Literature Review
Chapter 3: Design Methodology
Chapter 4: Results and Discussion
Chapter 5: Conclusion and Recommendations

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 CHAPTER 2: LITERATURE REVIEW

According to SANS 1019, LV networks are defined as networks having voltage levels up to and
including 1kV [6]. The distribution network supplies power to the end-user consumer (domestic
and commercial loads) via LV distribution networks. Power can be accurately transmitted up to
300 meters with the LV feeder [3]. In urban areas, where loads are high and housing density is
high, underground cables are usually used to reticulate LV networks [4]. In terms of distribution
and utilization, there are residential, commercial, and industrial systems. Distribution systems can
be configured to connect various types of loads. 3 phase 4-wire, 3 phase 3-wire, and 1 phase 2-
wire distribution systems are all suitable for this.

The 3-phase 4-wire distribution system operates at 380-415V, 50Hz, the 3-phase 3-wire
distribution system operates at 380-400V, 50Hz, and the 1-phase 2-wire distribution system
operates at 120-240V, 50Hz [1]. Depending on the requirements, commercial and industrial low
voltage systems are connected in 3-phase 3-wire or 3-phase 4-wire systems, while residential
systems are connected in 3-phase 4-wire or 1-phase 2-wire systems. Residential power systems do
not have to maintain power factor (PF) while commercial systems and industrial systems are
required to do so [9].

The power from the LV side of the transformer is fed to the distribution kiosk and the power is
then distributed to the end-users. The kiosk is made up of metal or fiberglass and is usually placed
at the center of the loads that it is feeding. The figure below shows a typical fiberglass distribution
kiosk.

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 Figure 2-2: Fiberglass distribution kiosk

Although the voltage on the transmission side is well regulated and balanced, the voltage at the
end-user level may become unbalanced due to load variations in each phase and different
impedances [7]. The absolute loss of a phase, known as single-phasing, is an extreme case of
voltage unbalances in a three-phase circuit. The electricity industry typically strives to distribute
customer loads uniformly across the three phases of delivery networks [7]. Voltage imbalance can
cause unforeseen problems with electric distribution, such as the failure of power electronics
converters, heaters, office equipment, and variable speed drives to function normally [4].

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 CHAPTER 3: DESIGN METHODOLOGY

The aim is to design the LV distribution kiosk and DB to accommodate circuits feeding a
warehouse. To meet the requirements of this project it is divided into several stages.
Stage 1: Warehouse designing
The first stage of this design was to design or simulate the warehouse using DiaLux Evo software.
This software was chosen over ReLux software because it was more advanced, simple, and
efficient to use. DiaLux software is the software used to design, plan, calculate, and visualize
lighting for indoor and outdoor areas. The software has also been used to check if the lighting
levels in the warehouse meet SANS 10114-1 standard. The dimensions in table 3.1 were used in
designing the storage warehouse.
Table 3-1: Warehouse dimensions

Room Length (m) Breadth (m) Height (m)

1. Warehouse 40 35 5.5
(building)
2. Warehouse 31.2 35 5.5
(storage area)
3. Office 1 7 7 2.8
4. Office 2 7 7 2.8
5. Kitchen 7 7 2.8
6. Storeroom 7 10.8 2.8
7. Restroom 4.6 7.4 2.8

Storage warehouse 3-dimensional (3D), floorplan, and outside views designs from DiaLux
software are shown below.
Warehouse 3D view:

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 Figure 3-3: Warehouse 3D view.

Warehouse floorplan view:

Figure 3-4: Warehouse floorplan view.

Outside view:

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 Figure 3-5: Warehouse outside view.

For the lighting design, Phillip lights in table 3.2 were used.
Table 3-2: Phillips luminaire specifications

Luminaire type Quantity Specifications

1. High bay 38 73 W, 10000 lm, 137 lm/W
2. Recessed 23 44.5 W, 4197 lm, 94.3 lm/W
3. Recessed (waterproof) 2 40 W, 3498 lm, 87.4 lm/W

High bay luminaires were used in the warehouse storage area. Recessed luminaires (44.5W) were
used in offices, kitchen and storeroom, and the waterproof recessed luminaires (40W) were used
in restrooms. The lighting lux levels table for different rooms according to SANS 10114-1 is
shown in Appendix A. Luminous flux was calculated using equation 1 and the number of fittings
in a room were calculated using equation 2 below.
Luminous flux = lux × Area of the room (1)
Luminous flux
Number of fittings = lumen of the luminaire (2)

Stage 2: Warehouse loads

The load estimate was done to verify the loads in the warehouse. When designing the LV
distribution network of the warehouse, starting at the bottom is essential as this helps to know the
loads in the warehouse. The load estimate of the storage warehouse is shown in Appendix B. The

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total load needed in the warehouse is determined by adding the loads in the warehouse. To
calculate the load, equation 3 was used below.

S = √3 × 𝑉𝐿 × 𝐼𝐿 (3)
Where:
S = apparent power (load) in kVA or VA
VL = line to line voltage in volts
IL = line to line current in amps

Stage 3: Distribution board design

Two DBs (DB-A and DB-B) were used in the warehouse, where DB-A constitutes of 3-phase
loads and single-phase loads where the Red and White (or Yellow) phases are used. DB-B only
constitutes single-phase loads where the Blue phase is used. A typical DB design layout of the
warehouse was designed using Microsoft Visio, and the figure is shown below of the DB layout.

Figure 3-6: Distribution board layout.

The loads were distributed equally so that they can be balanced. Lights connection and position
DBs are shown in the figure below.

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 Figure 3-7: Lights connection and DB's positioning.

Lights and DB symbols:

100 W - exterior lights
44.5 W – interior lights (offices, kitchen & storeroom)
40 W – interior lights (restrooms)

73 W – interior lights (warehouse)

Distribution Boards

45 socket outlets for single-phase power and 2 socket-outlets for three-phase power were installed
in the warehouse. For single-phase power, 5 socket outlets are connected at 1 20A circuit breaker.
For three-phase power, each socket outlet is connected to a 20A circuit breaker for 3-phase. The
figure below shows how the socket outlets were connected.

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 Figure 3-8: Socket-outlets connections.

Socket outlets symbols:

Single-phase Socket outlet from DB-A

Single-phase Socket outlet from DB-B
Three-phase isolator (forklift charger)

Stage 4: LV network

The last stage of the design was to design the LV network using an engineering software simulation
tool called ReticMaster. It is used because it helps to determine which cable size to use and to
determine the voltage drop and fault current in the LV network. The MV of 11kV is fed to a 500
kVA 11kV/400V step-down transformer using a 95 XLPE cable for 320m. The LV of 400V is fed
to a distribution kiosk using a 240 PVC 4 core cable 15m from the transformer. A 35 PVC 4 core
cable is fed to a warehouse DB-A, 40m from the distribution kiosk. DB-B is connected from DB-
A with a 10mm2 PVC cable for 35m. The diagram below shows how the LV network is designed
using Microsoft Visio.

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 Figure 3-9: LV network.

Table 3-3: List of cables used.

Loads Cable sizes Distance (m)

Lights 1 & 3 2.5 mm2 PVC 85
Lights 2, 4 & 6 2.5 mm2 PVC 90
Forklift A socket outlet 6 mm2 PVC 20
Forklift B socket outlet 6 mm2 PVC 20
Socket outlet 3, 5, 7 & 9 6 mm2 PVC 60
Socket outlet 4, 6 and 8 4 mm2 PVC 60
Geyser 6 mm2 PVC 45
Fan filter 10 mm2 PVC 40
Roller shutter 10 mm2 PVC 50

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 The voltage drop will be calculated once the loads are connected to check if the percentage is
within the 5% range specified by SANS 10142-1. The equation below will be used to calculate the
voltage drop.

Voltage drop = mV/A/m × A× m (4)

Where:

mV/A/m = indicates millivolts lost for every amp that flows through every meter of the cable [8].

A = current that will be carried by the cable in amps.

m = the distance of the cable in meters.

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 CHAPTER 4: RESULT, ANALYSIS, AND DISCUSSION

Results
4.1. Warehouse lighting design results
4.1.1. Luminous flux calculation
For luminous flux and number fittings, Equations 1 and 2 are used.
For offices:
44.5 W lamp
Luminous flux = lux × Area (1)
= 500 ×7×7 = 24500 lumen
24500
Number of fittings = = 5.83 (2)
4197

= 6 lights
For warehouse:
73 W lamp
Luminous flux = lux × Area (1)
= 200×31.2×35 = 218400 lumen
218400
Number of fittings = = 21.84 (2)
10000

= 22 lights

The figure below shows the DiaLux Evo simulation results.

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 Figure 4-10: DiaLux simulation lux results.

4.1.2. Analysis based on DiaLux

Based on the number of fittings calculated for an office shows that 6 fittings should be installed
in the office. Also, for the warehouse, the number of fittings calculated should be 22 installed in
the warehouse (storage) area. When 6 lights were installed in DiaLux, they did not meet SANS
10114-1 lighting lux level of 500 lux. 8 lights were then installed to meet the requirements. For
the warehouse (storage), 22 fittings were installed first, and they could not meet the requirements
of 200 lux lighting level, instead, 38 fittings were used and met the requirements. DiaLux
software was helpful in terms of verifying that lighting levels were met in warehouse lighting
design. The lux level for the warehouse is 246 from DiaLux software results. This lux level was
ignored as there will be furniture and paint color which will decrease the lux level.
4.2. Warehouse total load calculation.
The total load current was obtained to be 100A from the load estimate in Appendix B.

S = √3 × 𝑉𝐿 × 𝐼𝐿 (3)

= √3×400×1
= 69.282kVA ≈ 70 kVA

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4.3. ReticMaster and voltage drop calculation
4.3.1. Voltage drop calculation
For voltage drop calculation, equation 4 was used.
mV/A/m for different cables are shown in Appendix C.
Formula
Voltage drop = mV/A/m×A×m
From kiosk to garage DB (25𝒎𝒎𝟐 PVC 4 core cable)
Voltage drop = mV/A/m×A×m (4)
= 1.515× 10−3 × 60 × 35 = 3.182%

From Kiosk to DB-A warehouse (35𝒎𝒎𝟐 PVC 4 core cable)

Voltage drop = mV/A/m×A×m (4)
= 1.097× 10−3 × 100 × 40 = 4.388%

From DB-A to DB-B (𝟏𝟎 PVC 4 core cable)

Voltage drop = mV/A/m×A×m (4)
= 3.793× 10−3 × 34 × 35 = 4.514%

From DB-A to Roller Shutter (10𝒎𝒎𝟐 PVC 4 core cable)

Voltage drop = mV/A/m×A×m (4)
= 4.384× 10−3 × 9.78 × 50 = 2.144%

From DB-A to Fan filter (10𝒎𝒎𝟐 PVC 4 core cable)

Voltage drop = mV/A/m×A×m (4)
= 4.384× 10−3 × 6.52 × 40 = 1.143%

From DB-A to Geyser (6𝒎𝒎𝟐 PVC 4 core cable)

Voltage drop = mV/A/m×A×m (4)
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 = 7.374× 10−3 × 6.52 × 45 = 2.164%

From DB-A to SSO 4_6_8 (4𝒎𝒎𝟐 PVC cable)

Voltage drop = mV/A/m×A×m (4)
= 11.034× 10−3 × 4.35 × 60 = 2.88%

From DB-A to SSO 3_5_7_9 (6𝒎𝒎𝟐 PVC cable)

Voltage drop = mV/A/m×A×m (4)
= 7.374× 10−3 × 4.35 × 60 = 1.925%

From DB-A to Forklift A (6𝒎𝒎𝟐 PVC 4 core cable)

Voltage drop = mV/A/m×A×m (4)
= 6.391× 10−3 × 14.43 × 20 = 1.844%

From DB-A to Forklift B (6𝒎𝒎𝟐 PVC 4 core cable)

Voltage drop = mV/A/m×A×m (4)
= 6.391× 10−3 × 14.43 × 20 = 1.844%

From DB-A to lights 2_4_6 (2.5𝒎𝒎𝟐 PVC 3 core cable)

Voltage drop = mV/A/m×A×m (4)
= 15× 10−3 × 3.05 × 90 = 4.118%

From DB-A to lights 1_3 (2.5𝒎𝒎𝟐 PVC 3 core cable)

Voltage drop = mV/A/m×A×m (4)
= 15× 10−3 × 3.55 × 85 = 4.526%

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4.4. ReticMaster results

Figure 4-2: ReticMaster single line simulation results.

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4.4.1. ReticMaster and voltage drop analysis
Voltage drop was calculated for different cables and was less than 5% specified by SANS 10142-
1. The calculations were then verified by ReticMaster software. From the figure above it is shown
that the voltage drop at 500kVA 11kV/400V transformer is 100.57%. The LV distribution kiosk
was connected from the transformer using 240mm2 PVC 4 core cable, which was recommended
to be used by EE. DB-A was fed from the kiosk using a 35mm2 PVC cable for 40m. The voltage
drop at DB-A is 100% the connected load’s voltage drop varies between 0.21% to 2.11%. The
green color represents MV (11kV) load, the blue color is for 3-phase loads (400V) and the brown
color is for 1-phase loads (230V).

Different cable sizes were used first for different loads, but the voltage drop was exceeding the 5%
standard, then moving to the next cable size was an option and the voltage drop standards were
met.

4.5. Discussion
The lighting levels in the warehouse were met and some of the rooms have exceeded the level
because there is no furniture installed and different color may be used, as color affect lights or
lights lux level. The calculated voltage drops in the LV network meet the SANS 10142-1 standard
and it was verified by ReticMaster. The total load in the warehouse is calculated to be
approximately 70 kVA.

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 CHAPTER 5: CONCLUSION AND RECOMMENDATION

5.1 Conclusion
The storage warehouse was designed using DiaLux to verify the lighting intensity in the
warehouse. The lighting lux level obtained in DiaLux are corresponding with the SANS 10114-1
standard. The load estimate for the warehouse was performed and the load that the client should
apply for from EE should be 100A. The allowance of 30% for spare capacity was included in the
load estimate for future purposes. With the aim of designing an LV distribution kiosk and
distribution board to accommodate circuits feeding a warehouse. ReticMaster software was used
to verify the load flow analysis in the LV network and to design the LV network. The calculated
and simulated voltage drop falls within the maximum 5% range standardized by SANS 10142-1.
The total load drawn in the warehouse is 70kVA with the 30% spare capacity included.

5.2 Recommendation
The current carrying capacity of the cable must not exceed the circuit breaker current so that when
the current in the cable exceeds the circuit breaker's current, the circuit breaker will break the
circuit. The circuit breaker must protect the cable, it must not work as a fuse. The distribution kiosk
should be placed at the center of the load that it is feeding.

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 REFERENCES

[1] V. K. Mehta, and R. Mehta, “Principles of Power System: Including Generation, Transmission,
Distribution, Switchgear and Protection: for BE/B. Tech., AMIE and Other Engineering
Examinations,” New Delhi: S. Chand Publishing, 2005, pp. 356-373.
[2] M. A. Al-Jaafreh, and G. Mokryani, “Planning and operation of LV distribution networks: A
comprehensive review,” IET Energy Systems Integration, vol. 3, pp. 133-146, Sep. 2019.
[3] A. V. Taylor, “Electricity distribution network design,” IEE Review, vol. 4, pp 154, Apr. 1990.
[4] C. G. Carter-Brown, and C. T. Gaunt, “Model for the apportionment of the total voltage drop
in combined medium and low voltage distribution feeders,” Journal of South African Institute of
Electrical Engineers, vol. 1, Mar. 2006.
[5] C. G. Carter-Brown, and C. T. Gaunt, “Voltage management by the apportionment of total
voltage drop in the planning and operation of combined medium and low voltage distribution
systems,” Transactions of the South African Institute of Electrical Engineers, vol. 1, Mar. 2006.
[6] W. L. Fritz, “Challenges of tying small scale renewable energy systems to the grid in South
Africa,” In Proc. 2013 IEEE Power Engineering Society Transmission and Distribution Conf., pp.
1-5.
[7] O. P. Taiwo, R. Tiako, and I. E. Davidson, “Investigation of voltage unbalance in low voltage
electric power distribution network under steady state mode,” In2017 IEEE 3rd International
Conference on Electro-Technology for National Development (NIGERCON), pp. 932-939.
[8] Aberdare cable chart [online]. Available: https://www.aberdare.co.za/product-categories/lv-
armoured-cable/.
[9] G. Vertigan, “AC Circuits and Power Systems in Practice”. New York: John Wiley & Sons, 2017, pp.
28.

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 APPENDICES

Appendix A – lighting lux level according to SANS 10114-1: 2005

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Appendix B: Warehouse load estimate
B1: DB-A load estimate

B2: DB-B load estimate

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Appendix C
Aberdare Conductor cable catalog

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Appendix D
Gantt chart

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Appendix E
Bill of quantity

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