The Battery Production Plant Project is a manufacturing facility in Russia with energy-intensive process lines. Devpan supplied the high-fault-rated main distribution, motor control centres and detuned power factor correction.
Electrical Profile of the Project
- LocationRussia
- Building typeManufacturing plant
- Installed power≈ 10,000 kVA
- Transformer configuration4 × 2,500 kVA
- Main busbar rated current2 × 4,000 A
- Short-time withstand current (Icw)80 kA / 1 s
- Devpan scopeLow voltage switchboards, engineering and site coordination
- Verification standardIEC 61439-1, IEC 61439-2
About the Project
Battery manufacturing is among the most demanding industrial processes from an electrical standpoint. Electrode mixing, coating and drying lines draw large thermal and motor loads. The dry rooms used for cell assembly require continuously running dehumidification plant to hold extremely low humidity. Charge and discharge equipment in the formation and ageing areas is dominated by power electronics that inject significant harmonic currents into the network. Even a brief interruption can compromise dry room conditions and halt production.
At this scale, distribution is built on a redundant architecture in which four transformers feed two separate main busbar groups. The 2 × 4,000 A busbars and 80 kA / 1 s withstand are selected for the high fault levels of parallel transformers. Form 4b separation lets individual process outgoers be isolated for maintenance while production continues. Two generators support critical loads such as dry room air handling and safety systems, while the compensation panels are fitted with detuning reactors.
Devpan Scope and Switchboard Architecture
Devpan’s scope covers low-voltage distribution from the transformer outgoers to the process lines, utilities and administrative areas.
- Main distribution boards (DevPanel): 2 × 4,000 A busbars, 80 kA / 1 s, Form 4b, IP54, coupler and generator transfer.
- Motor control centres (DevControl): starters and drives for coating, drying, mixing and utility motors.
- Power factor correction (DevComp): detuned reactive power compensation suited to power electronic loads.
- Sub-distribution boards (DevBox): distribution for formation, assembly and dry room areas.
- Lighting and power panels (DevPower): production halls, warehouses and office lighting.
Technical Configuration
| Installed power | ≈ 10,000 kVA |
|---|---|
| Transformer configuration | 4 × 2,500 kVA |
| Medium voltage level | 10 kV |
| Low voltage / frequency | 400 / 230 V, 50 Hz |
| Main busbar rated current | 2 × 4,000 A |
| Short-time withstand current (Icw) | 80 kA / 1 s |
| Form of internal separation | Form 4b |
| Degree of protection (IP) | IP54 |
| Generator back-up | 2 × 1,500 kVA |
| Verification standard | IEC 61439-1, IEC 61439-2 |
Devpan Products Used in This Project
Project-Specific Engineering Topics
Dry room continuity
Dehumidification plant is defined as a priority load on the generator-backed busbar and is among the first loads restored after an outage.
Harmonic management
Rectifier loads from formation equipment are limited through detuned compensation and appropriate transformer selection.
High fault levels
Large transformers operating in parallel produce high short-circuit currents, so busbars and breakers are rated for 80 kA / 1 s.
Dust and process environment
IP54 enclosures protect internal equipment from dust and particles in production areas.
Frequently Asked Questions
What is the installed power of the Battery Production Plant Project?
For a battery production plant of this scale, the installed power is approximately 10,000 kVA, with a typical transformer configuration of 4 × 2,500 kVA. Main busbars are typically rated 2 × 4,000 A with 80 kA / 1 s withstand, supplied at 10 kV and backed by 2 × 1,500 kVA generators.
Why do battery plants need detuned compensation?
Formation and test equipment relies on power electronics that inject harmonic currents. Plain capacitor banks risk resonance, so reactor-detuned solutions are preferred.
What does Form 4b bring to a production plant?
Each outgoer and its cable terminals are in separate compartments, so one line can be serviced while neighbouring process lines remain live.
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