The Kastamonu Entegre Tatarstan Plant is a large continuous-production industrial facility in Russia’s Tatarstan region. Devpan supplied the motor control centres, main distribution, power factor correction and auxiliary distribution boards.
Electrical Profile of the Project
- LocationTatarstan, Russia
- 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
In large plants with continuous production lines, most of the load consists of motors driving fans, conveyors, presses, pumps and compressors. An unplanned stop can turn into hours of lost output while a line is brought back up to speed. The dusty production environment makes enclosure protection a deciding factor, while Tatarstan’s harsh winters and warm summers mean plant rooms must cope with a wide temperature range. For a factory of this scale the installed power is typically around 10,000 kVA, and short-circuit levels are correspondingly high.
In the typical solution, four 2,500 kVA transformers fed from the 10 kV network supply a 2 × 4,000 A main board split by a bus coupler, with the busbar system designed for an 80 kA / 1 s short-time withstand. Production lines are fed from motor control centres housing drive and starter feeders that communicate with the process control system. Form 4b segregation and IP54 enclosures allow a withdrawable unit to be replaced in a dusty environment without stopping the line. A 2 × 1,500 kVA generator provides backup for controlled shutdown and safety loads.
Devpan Scope and Switchboard Architecture
Devpan’s scope extends from motor control of the production lines to the plant main distribution and auxiliary buildings.
- Motor control centres (DevControl): Drive and starter drawers for line fans, conveyors, pumps and compressors.
- Main distribution boards (DevPanel): 2 × 4,000 A, 80 kA / 1 s, Form 4b, two sections with bus coupler.
- Power factor correction (DevComp): Detuned automatic compensation for motor and drive loads.
- Sub-distribution boards (DevBox): Distribution for workshops, warehouses and administrative buildings.
- Lighting and power panels (DevPower): Production hall, warehouse and external 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
High fault level
With four 2,500 kVA transformers contributing in parallel, the main busbar and breakers are selected for an 80 kA / 1 s withstand.
Withdrawable motor control
Form 4b withdrawable MCC units let a faulty feeder be swapped within minutes without stopping neighbouring motors.
Protection against dust
IP54 enclosures and filtered ventilation keep production dust out of the switchboards and limit heat build-up.
Controlled shutdown
During a grid outage the generator supplies the loads needed to bring the line to a safe stop without damaging equipment.
Frequently Asked Questions
What is the installed power for a plant like Kastamonu Entegre Tatarstan?
For a factory of this scale the installed power is approximately 10,000 kVA, with a typical transformer configuration of 4 × 2,500 kVA. The main busbar is typically 2 × 4,000 A with an 80 kA / 1 s rating, supplied at 10 kV medium voltage.
Why are Form 4b and IP54 used in factory switchboards?
Form 4b separates each functional unit and its terminals, allowing maintenance while the line runs; IP54 protects against dust and splashing water in a production environment.
How is power factor corrected with drive-fed motors?
Because drives generate harmonics, compensation uses detuned steps, which prevents resonance and keeps the power factor on target.
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