Electrical Engineering for Aluminum Extrusion Facility

Electrical Scope of Work:
Power Requirements and Engineering Studies for Aluminum Extrusion Facility number 2.

Scope of Electrical Engineering Services

The following electrical engineering services will be provided for the aluminum extrusion line installation:
1. Single-Line Diagram (SLD): Development of a comprehensive single-line diagram illustrating the complete electrical distribution system, including utility service entrance, transformers, main switchgear, distribution panels, motor control centers (MCCs), and all major loads.
2. Fault Study (Short-Circuit Analysis): Detailed short-circuit fault current calculations to determine available fault currents at all key points in the system, equipment ratings, and protective device coordination.
3. Arc Flash Study: Full arc flash hazard analysis per IEEE 1584-2018 and NFPA 70E standards. This includes incident energy calculations, arc flash boundary determination, personal protective equipment (PPE) requirements, and labeling recommendations for all electrical equipment.

Additional services may include protective device coordination study, load flow analysis, and harmonic analysis (if required due to the induction oven and VFD-driven motors).2. Project

Overview and Design Basis
• The facility building is designed to accommodate two aluminum extrusion lines.
• All power calculations and equipment sizing shall be based on two lines operating simultaneously (full building load).
• Utility service: 3-phase, 480V, 4-wire.
• Motors: All electric motors operate at 3-phase, 220V (step-down transformer required).
• Major loads include electric motors, a 1,000 kVA induction oven/heater, high-bay LED lighting, and high-power wall fans.
3. Equipment Power Requirements (Per Extrusion Line)Induction Heater/Oven
• Rating: 1,000 kVA
• Voltage: 480V (assumed, to be confirmed)
• Current: 1,203 Amps (3-phase)

Electric Motors (All 3-Phase, 220V)Detailed motor schedule:
QTY Amps per Motor Total Amps
2 6 12
21 1.6 33.6
2 4 8
3 4 12
1 3 3
1 3 3
1 6.8 6.8
1 100 100
1 4 4
3 3.5 10.5
3 3 9
1 3 3
4 1.6 6.4
1 54 54
1 1.5 1.5
2 6 12
1 6 6
1 22 22
2 13.1 26.2
1 4 4
1 3 3
1 2 2
1 20 20
4 1.6 6.4
1 9 9
3 3 9
1 5 5
2 3 6
1 13.5 13.5
5 45 225
2 33 66
2 33 66
1 50 50
1 180 180
1 45 45
Total - 1,042.9 Amps (at 220V)

Note: The summarized motor load in the initial data was listed as 480 Amps (likely the equivalent 480V side demand after transformation or with diversity factors applied). The detailed schedule above (1,042.9 A at 220V) will be used as the basis unless diversity or demand factors are formally applied.

Lighting
• High-bay LED fixtures: 168 pcs
• Total current: 170 Amps (at 480V)

Wall Fans
• High-power fans: 5 units
• Total current: 30 Amps (at 480V)
4. Transformer Requirements
• Step-down Transformer(s): 480V to 220V, minimum 400 kW (or appropriately sized based on motor load + 20–25% future capacity). Multiple transformers or a single larger unit may be required depending on load distribution.
• Utility/Service Transformer (if applicable): 1,000 kVA, 480V / 6,600V configuration noted for potential medium-voltage considerations or upstream supply.
5. Total Utility Power Requirements (480V, 3-Phase)Per Line (Summary Basis):
• Induction Heater: 1,203 A
• Motors (summarized): 480 A
• Lighting: 170 A
• Fans: 30 A
• Subtotal per line: 1,883 A

For Two Lines (full building): Approximately 3,766 A at 480V (equivalent to ~2,800 kVA before demand factors, power factor correction, and diversity).

Calculated kVA (at 480V, 3-phase) for 1,683 A example load: ~1,399 kVA. Final sizing will incorporate:
• Power factor (assume 0.85–0.95, with correction if needed)
• Demand factors per NEC or engineering standards
• 20–25% spare capacity for future expansion
6. Key Assumptions and Clarifications
• All values are based on provided data. Nameplate verification and field measurements are recommended during detailed design.
• Diversity and demand factors will be applied per industry standards (e.g., NEC Article 220) during final calculations.
• Harmonic mitigation may be required for the induction oven and large motor drives.
• Power factor correction capacitors or active filters should be considered.
• All equipment must comply with applicable codes: NEC, NFPA 70E, IEEE, and local authority having jurisdiction (AHJ).