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工业园区电力系统计算器

为工厂或工业园区进行配电容量计算 — 总设备负荷、需用系数、电机占比与谐波源占比，并完成变压器与开关柜选型、无功补偿及 BOM。

开始计算工业制造解决方案

为什么使用此计算器

工业厂房中电机、加热与电子负载混合运行，自然功率因数低于 0.9，且谐波显著。本计算器将连接设备负荷转化为选型后的变压器与开关柜方案，并按 GB 50052 与 GB 50055 进行无功补偿与谐波滤波。

Worked Examples

Example 1 — 2 MW Factory Load (Demand Factor, Motor & Harmonic Share) · FOB $257,923

Industrial park power system · 10kV/0.4kV

1,600 kVA transformer

S13-M-1600/10 · demand 1,200 kW · PF 0.95

Connected load

2,000 kW

Demand (Kd 0.6)

1,200 kW

Motor share

60%

Reactive comp.

443 kvar

Est. total (FOB)

POA

📦 Bill of Materials

Equipment	Model	Spec	Qty
HV incoming panel	KYN28A-12-630-315	630 A / 31.5 kA · vacuum	1
Main transformer	S13-M-1600/10	1600 kVA · Oil-Immersed · Copper · S13	1
LV incoming panel	GGD-2500	2500 A busbar · In 2309 A	1
LV feeder panel (×2)	GGD-2500	distributes 8 circuits	2
Cable branch box (LV)	DFW-0.4	1-in / 4-out · 0.4 kV · 630 A	1
Main feeder cable (TX→LV)	YJV 0.6/1kV 300 mm² ×5	5× 300 mm² Cu · ΔU 1.20% @ 80 m · $154.0/m	5
Feeder cable — Plant feeder 1 (×8)	YJV 300 mm²	300 mm² Cu · 440 A · ΔU 1.1% · $154.0/m	8
Branch trunk cable (LV → branch box 1)	YJV 300 mm² ×4	4× 300 mm² Cu · 1760 A · ΔU 1.1% · $154.0/m	4
Main busbar (Cu)	Cu 125×10	125×10 · 2500 A rating · ref $147.8/m	included
Grounding electrode	Φ20mm × 2.5m rod	R₁ 39.6 Ω → 13 rod(s) ≤ 4 Ω	13
Detuned PFC capacitor bank	443 kvar	automatic · 7% detuned · 0.4 kV	1
Series detuning reactor (7%)	31.0 kvar	189 Hz tuning · below 5th harmonic	1

📐 Single-line diagram

⚙️ Electrical schematic (protection & metering)

⛳ Grounding grid layout

🔌 Cable schedule & routing

🗄 Switchgear arrangement

🛡 Protection configuration

📋 Protection settings

Circuit	Protection	Setting	Time	Standard
HV incoming 10 kV	50 instantaneous	739 A	inst	IEC 60255-151 / IEEE 242
HV incoming 10 kV	51 overcurrent	111 A	0.5 s	IEC 60255-151 / IEEE 242
HV incoming 10 kV	51N earth-fault	18 A	0.5 s	IEC 60364-4-41
Transformer 1600 kVA	49 thermal overload	79% of rated	alarm 90%	IEC 60076-7 / IEEE C57.91
LV incoming 0.4 kV	50 instantaneous	18475 A	inst	IEC 60947-2
LV incoming 0.4 kV	51 overcurrent	2771 A	0.3 s	IEC 60947-2 / IEC 60255
LV incoming 0.4 kV	51N earth-fault	462 A	0.3 s	IEC 60364-4-41
Plant feeder 1	50/51/51N (MCCB)	Ir 484 A - Im 3520 A - Ig 88 A	0.1 s (grading)	IEC 60947-2 / IEC 60255
Plant feeder 2	50/51/51N (MCCB)	Ir 484 A - Im 3520 A - Ig 88 A	0.1 s (grading)	IEC 60947-2 / IEC 60255
Plant feeder 3	50/51/51N (MCCB)	Ir 484 A - Im 3520 A - Ig 88 A	0.1 s (grading)	IEC 60947-2 / IEC 60255
Plant feeder 4	50/51/51N (MCCB)	Ir 484 A - Im 3520 A - Ig 88 A	0.1 s (grading)	IEC 60947-2 / IEC 60255
Plant feeder 5	50/51/51N (MCCB)	Ir 484 A - Im 3520 A - Ig 88 A	0.1 s (grading)	IEC 60947-2 / IEC 60255
Plant feeder 6	50/51/51N (MCCB)	Ir 484 A - Im 3520 A - Ig 88 A	0.1 s (grading)	IEC 60947-2 / IEC 60255
+2 more feeders	50/51/51N (MCCB)	per feeder load	0.1 s (grading)	IEC 60947-2

Settings are illustrative starting points — confirm with a protection coordination study per IEC 60255 / IEEE 242.

📚 Calculation book

CALCULATION BOOK

1600 kVA - 10kV/0.4kV - single - illustrative

1. Load calculation

Standard: IEC 60076 - IEC 60364-5-52

Parameter	Formula	Value
Connected load	P = sum(kW)	2,000 kW
Demand factor	Kd	0.6
Demand power	Pd = P x Kd	1,200 kW
Power factor	cos(phi) before -> after	0.82 -> 0.95
Design apparent power	Sd = Pd / cos(phi)	1,263 kVA
Transformer loading	Sd / Srated	79%

2. Short-circuit calculation

Standard: IEC 60909

Parameter	Formula	Value
System impedance (pu)	Zs = S / Ssc	0.32% (on 1600 kVA base)
Transformer impedance	Zt = Z%	4%
Total impedance	Z = Zt + Zs	4.32%
LV prospective Isc	Isc = In / Z	53.5 kA
HV prospective Isc	Isc = Ssc / (sqrt(3) x V)	28.9 kA
Breaking check	Icu >= Isc	LV 65 kA (1.2x margin) PASS

3. Voltage drop

Standard: IEC 60364-5-52 Annex G

Parameter	Formula	Value
Main feeder	dU = sqrt(3) x I x L x R / V	300 mm2 - dU 1.20% @ 80 m
Limit	max 3%	within limit
Transformer volt. reg.	dU ~ loading x Z% x sin(phi)	1.0% at full load

4. Reactive power / harmonics

Standard: IEC 61921 (PFC) - IEEE 519 (harmonics)

Parameter	Formula	Value
Required compensation	Qc = Pd x (tan1 - tan2)	0 kvar
PFC bank	standard step	0 kvar
Detuned reactor	p = 6%	n/a

5. Grounding

Standard: IEC 60364-5-54 earthing arrangements and protective conductors LV earthing target 10 ohm (TN systems); 4 ohm used as a conservative design target - target 4 ohm

Parameter	Formula	Value
Single rod resistance	R1 = rho/(2 x pi x L) x ln(4L/d)	39.6 ohm
Rods required	n = R1 / (target x 0.8)	13 rod(s) <= 4 ohm
Rod spec	dia x length	20 mm x 2.5 m

This calculation book is illustrative it consolidates the computed values with the referenced standards. A licensed engineer must verify and seal final design documents for construction.

🔧 Secondary schematic (control & signal)

🔩 Terminal strip (typical)

🏭 Load profile

Parameter	Value
Connected load	2,000 kW
Demand factor	0.6 → demand 1,200 kW
Motor share	60% (720 kW)
Harmonic-source share	25% (300 kW)

🌀 Power quality

Parameter	Value
Reactive compensation	443 kvar detuned bank (7% reactor)
Harmonic current	Ih 137 A @ 30% THDi
APF required	No — below 30% threshold

📏 Standard basis (依据标准)

Topic	Standard
Standard basis	IEC · IEC 60364-5-52
Conductor ampacity	IEC 60364-5-52 Table B.52.2–B.52.5 (copper, 3 loaded conductors, 30°C ambient, PVC) — typical/rounded values, conservative (±3%)
Voltage-drop limit	IEC 60364-5-52 Annex G · max drop 3%
Winding temp rise	IEC 60076-2 — winding temp rise 65 K (Class A insulation, ONAN)
kVA ratings	IEC 60076-1 R10 preferred numbers
Breaker frames	IEC 60947-2 frame sizes (In)
Grounding target	IEC 60364-5-54 earthing arrangements and protective conductors — LV earthing target ≤ 10 Ω (TN systems); 4 Ω used as a conservative design target · target 4 Ω
Power supply design	GB 50052 — code for design of electric power supply systems
Low-voltage distribution	GB 50055 — code for design of electric equipment for industrial facilities
Harmonics	GB/T 14549 — quality of electric energy supply: harmonics in public supply network
Transformers	IEC 60076 — power transformers

🧮 How it was calculated

1. Connected equipment load = 2,000 kW

2. Demand = 2,000 × 0.6 = 1,200 kW

3. Motor share = 60% → 720 kW (drives natural PF 0.82)

4. Reactive compensation: Qc = 1,200 × (tanφ₁ − tanφ₂) = 443 kvar

5. Harmonic-source share = 25% → 300 kW → Ih = 137 A (30% THDi)

6. Loads: P=2,000 kW, PF 0.82, 8 circuits

7. Demand: 2,000 × 0.6 = 1,200 kW

8. Transformer: S = 1,200 ÷ 0.95 = 1263.2 kVA → 1,600 kVA standard

9. Loading: 1,263 ÷ 1,600 = 79% (good range)

10. Voltage regulation: 79% × 4% × sinφ ≈ 1.0% at full load

11. HV: In 92.4 A, Isc 28.9 kA → KYN28A-12-630-315

12. LV: In 2309 A, Isc 53.5 kA (Xfmr Z 4% + system 0.3%) → GGD-2500, 2 feeder panel(s)

13. Cable branch boxes: 1 × DFW-0.4 (1-in/4-out) for feeder grouping

14. Grounding: R₁ 39.6 Ω → 13 rod(s)

15. Main feeder: 5× 300 mm² · ΔU 1.20% — OK

Summary
Estimated total (FOB Qingdao, EXW) — priced equipment				$257,923

📋 Design notes

Pricing basis: FOB Qingdao (EXW) equipment price. Freight, duty and installation are not included — add for landed economics.

Transformer loading: 79% at design demand — good range.

Short-circuit check: HV 28.9 kA vs 31.5 kA (1.1× margin) · LV 53.5 kA vs 65 kA (1.2× margin).

Voltage regulation: ≈ 1.0% at full load (typical limit 5%).

Copper price linkage: Copper-wound transformer price tracks LME copper (current $14,219/t · 2026-09-12 · LME Copper (Sina hf_CAD)).

Parallel conductors: Single-cable ampacity exceeded — parallel conductors specified: main feeder 5× 300 mm², branch trunk 1 4× 300 mm² (per IEC 60364-5-52 / GB 50054).

Cable & grounding pricing: Cable conductors and grounding are priced from the confirmed cables-trays-grounding price reference (per-metre copper YJV; aluminium remains POA). The main copper busbar is POA — its length is project-specific.

Busway (high-current feeders): For LV feeders above ~2500 A, a busway (母线槽) trunking system is recommended instead of parallel cables.

Demand factor: 0.6 demand factor avoids oversizing — not all plant equipment runs simultaneously at full load.

Motor & harmonic load: 60% motor load (natural PF 0.82); 25% harmonic-source load (detuned PFC is sufficient.)

Zone / plant metering: For multi-tenant parks, per-zone / per-plant revenue-grade metering (分区分厂计量) at the LV feeder enables sub-billing and energy accountability — quoted per project.

Harmonic sources: Typical harmonic sources: VFD drives (THDi ~30%), rectifiers / electroplating (~25–35%), UPS (~10–20%), welding machines and LED lighting. The 25% share is applied as an aggregate — a detailed equipment list refines APF sizing.

Transformer loading: Transformer sized at the target PF 0.95; final capacity must be confirmed against the actual equipment schedule.

计算过程说明

选型计算原理

计算功率 P = 连接负荷 × 需用系数 Kd（并非所有设备同时运行）。电机占比决定自然功率因数；无功补偿 Qc = P × (tanφ₁ − tanφ₂) 将其校正至目标 PF。谐波源占比给出谐波电流 Ih = I₁ × THDi，由调谐电容器组滤波。

适用标准

选型参考 GB 50052（供配电设计）、GB 50055（工业低压配电设计）、GB/T 14549（谐波）及 IEC 60076（变压器）。

常见问题

工业园区该取多大的需用系数？

园区多家工厂不会同时开满设备，需用系数典型 0.55-0.7。2000 kW 装机、0.6 需用系数、0.9 功率因数得约 1330 kVA，宜配 1600 kVA 或两台 800 kVA。计算器用需用系数与电机占比为中低压厂区选型。

工厂密集的园区需要多少谐波治理？

当 60% 负荷为变频电机、25% 为非线性（整流、UPS）时，THDi 可达 15-25%。IEEE 519 要求公共连接点 THD 限 5-8%，故需 7% 去谐电容器组或 APF。计算器按谐波占比配置补偿与去谐。

工业园区的标准中低压架构是怎样的？

典型架构：10 kV（或 35 kV）市电 → 环网或放射式中压开关柜 → 每厂/每区块一台变压器 → 0.4 kV 开关柜 → 电机控制中心。沿环网布置环网柜的 10 kV 环网可提供 N-1 供电。计算器为园区聚合负荷选变压器、开关柜与补偿。

如何为每家工厂分配变压器容量？

每家工厂配一台按需用容量加 20-25% 裕量的独立变压器，小租户可合用一台大变压器。独立变压器隔离故障、便于计量，但共享方案成本更低。计算器聚合园区需量并给出单台与分拆方案。

工业园区应维持多大功率因数？

供电公司通常要求 0.9-0.95 功率因数，低于约 0.9 收取罚金。电机为主的园区初始功率因数 0.75-0.85，加电容器组可提到 0.95。计算器算出从实测 pf 到目标所需的 kvar 补偿并选低压电容柜。

园区中压网络通常提供什么冗余？

带常开联络的环网中压网络提供 N-1 冗余：任一段电缆或环网柜故障可被隔离并从另一方向恢复供电。放射式馈线更便宜但故障即失电。计算器的架构说明覆盖环网与放射式的可靠性和成本权衡。

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