Factory electrical design is more than just a technical task — it’s the foundation for safe, efficient, and sustainable operations. Join KTG Industrial as we explore the most up-to-date standards in factory electrical design to maximize performance and minimize risks from day one.
Electrical Design Standards for Factories
The design standards of an industrial facility play a critical role in determining whether your factory will operate smoothly over the next 5, 10, or even 20 years.
To avoid costly operational risks down the line, make sure you understand and apply the following essential standards:
- QCVN 12:2014 – National Technical Regulation on Electrical Installations of Dwelling and Public Buildings
- QCVN QTĐ-08:2010/BCT – National Technical Regulation on Low Voltage Electricity
- TCVN 8241-4-2: 2009 – This standard is crucial for electrical and electronic equipment operating in environments with a high risk of electrostatic discharge (ESD).
- TCVN 5699-1: 2010 – This standard defines the safety protection levels for equipment against electrical, mechanical, thermal, fire, and radiation hazards during normal use as instructed by the manufacturer. It also takes into account potential abnormal conditions and the impact of electromagnetic fields on equipment safety.
- TCVN 7922: 2008 – Ensure that the lighting system meets standards to enhance work efficiency.
- TCVN 3715: 82 – Design standards for electrical transmission lines and substations in industrial facilities
- TCXDVN 319: 2004 – Grounding system installation guide to ensure operational safety.
- 11 TCN 18: 2006 – Regulations on power grid systems and electrical equipment within manufacturing facilities.
- TCVN 9206:2012 – Installation of electric equipment in dwellings and public buildings – design standard.
Electrical safety engineering standards
The electrical system in factories must comply with electrical safety technical standards as stipulated in the National Technical Regulation QCVN QTD 8:2010/BCT, issued under Circular 04/2011/TT-BCT – the National Technical Regulation on Electrical Engineering by Bo Cong Thuong.
The requirements in this regulation aim to ensure labor and asset safety while minimizing potential hazards during electricity usage in factories.
The factory electrical system must strictly comply with QCVN.
Below are the key standards that help investors assess and implement the factory electrical system accurately from the start:
| Standard | Description |
| Protection against thermal effects | The electrical system must eliminate the risk of fire caused by excessive heat or sparks and ensure that electrical equipment does not cause burns to humans. |
| Protection against fault currents | Conductors and other components carrying fault currents must have sufficient capacity to withstand such currents without reaching excessively high temperatures. |
| Protection against overcurrent | Ensures the safety of people and property by preventing hazards caused by excessive temperature rise or mechanical forces generated by overcurrent. |
| Protection against overvoltage | Prevents harmful consequences due to insulation failure between live parts of circuits with different voltages or overvoltage caused by other factors. |
| Protection against electric shock | Ensure safety by preventing direct contact with live parts and indirect contact with exposed conductive parts in case of insulation failure, reducing the risk of electric leakage. |
Some Standards for Installing Electrical Cabinets in Factories
Factory electrical cabinets are not only the central hub for control devices but also serve to protect the electrical system from risks such as overload, short circuits, or electrical fires. Below are key standards that must be followed when installing electrical cabinets in factories:
| Category | Technical Requirements |
| Material |
|
| Power Supply |
|
| Electrical Cabinet Installation Standards |
|
| Electrical cabinet Dimensions |
|
Electrical cabinets serve as the control and protection center of the power system and must be installed according to technical standards to ensure safety.
Cable Tray Installation Standards
Cable trays provide structured support for electrical wiring in factories, ensuring organization and protection. To maintain safety, every detail—from support spacing and material thickness to load capacity—must strictly comply with standards, preventing overheating, collapse, or electrical hazards.
Below are the essential standards to ensure safety and stable operation in industrial settings:
| Category | Technical Requirements |
| Materials |
|
| Distance Between Supports |
|
| Cable Tray Thickness |
|
| Load Capacity |
|
| Cable Tray Bending Radius |
According to standards:
For systems with multiple parallel cables, flexible joints should be used to minimize mechanical stress on the cables. |
6 Steps to Designing a Standard-Compliant Factory Electrical System
Step 1: Accurately Determine the Calculated Load
The first step in designing a factory electrical system is precisely determining the required power consumption (calculated load). An incorrect assessment can lead to risks such as system overload, causing short circuits and fires, or excessive capacity, leading to energy waste.
For example, a production facility with high-power machinery requires careful calculations to select a sufficiently strong transformer, preventing voltage drops when multiple machines operate simultaneously.
When calculating the electrical load for a factory system, it is essential to consider the safety factor to ensure stable operation and avoid overloading or insufficient capacity. The safety factor typically ranges from 1.2 to 1.3, depending on the type of equipment used and potential future expansions. Proper capacity planning not only ensures system durability but also optimizes investment and operational costs.
Step 2: Layout of the High-Voltage Power Network for Factories
The high-voltage power network (≥ 35kV) serves as the main transmission line, delivering electricity from the national grid to the factory via substations. High voltage reduces energy loss over long distances and is ideal for factories with high power consumption. Due to its hazardous nature and strict technical requirements, the voltage level should be selected based on the production scale:
- Small to medium-sized factories typically use 22kV or 35kV.
- Large industrial zones may require 110kV – 220kV
Depending on the terrain and operational needs, businesses can choose between prestressed concrete poles, steel towers, or wooden poles for power transmission. For wide-area coverage, concrete poles or steel towers are preferred for durability. In urban areas or locations where overhead lines pose safety risks, underground cables should be used.
For example, a large industrial zone typically utilizes concrete poles or steel towers for high durability and load-bearing capacity. In contrast, smaller factories may only require a low-voltage line from the local grid.
High-voltage poles are commonly used in industrial zones to ensure stable and safe power transmission.
Step 3: Layout of the Low-Voltage Power Network for Factories
Once the voltage is stepped down to a safe level through the substation, the low-voltage power network (≤ 380V) distributes electricity to different production areas. This system supplies power to production units, lighting systems, and office spaces, typically operating at 220V – 380V. Since this voltage directly affects both equipment and personnel, several key principles must be followed when designing the low-voltage network:
- Select appropriate wiring: Wires that are too small can overheat, posing safety risks, while oversized wires lead to unnecessary costs.
- Strategic placement of control panels: Electrical panels should be positioned for easy operation and kept away from fire-prone areas. For example, in a mechanical workshop, panels are typically installed in dry areas, away from metalworking zones, to prevent sparks from causing accidents.
- Ensure a proper grounding system: Grounding reduces the risk of electric shocks, which is especially important in factories with heavy machinery made of conductive metals.
The low-voltage power network in factories must strictly adhere to safety principles.
When designing, the location of the control panels must be carefully calculated to ensure convenience for operation and maintenance while also ensuring proper distribution of electricity.
Step 4: Designing the Lighting System
Lighting is more than just installing fixtures—it’s about optimizing efficiency and energy savings. According to TCVN 7922:2008, factory lighting systems must provide adequate illumination to ensure a safe and productive work environment.
Today, LED lights are gradually replacing traditional lighting due to their energy efficiency, long lifespan (up to 50,000 hours), low heat emission, and stable brightness.
A well-planned lighting system must be carefully calculated to meet operational needs while maximizing energy efficiency. To achieve optimal results, businesses should:
- Determine lighting requirements for each area: For example, electronic assembly zones require bright white light to enhance the visibility of small details, whereas storage areas need only moderate lighting.
- Select appropriate lighting types: LED lights are preferred over traditional fluorescent bulbs due to their superior energy savings.
The factory lighting system must be designed in accordance with the TCVN 7922:2008 standard.
Step 5: Power Factor Correction Design
The power factor correction system not only helps stabilize voltage but also reduces energy loss, optimizing the distribution and use of electricity within the factory.
This is especially important for businesses that use many electric motors, welding machines, and air compressors, as reactive power compensation is a crucial solution to prevent overload, reduce electricity bills, and meet grid operation standards.
The power factor correction design process includes:
- Calculating the reactive power compensation needs: Reactive power is the portion of power that does not perform useful work but still exists in the electrical system due to the characteristics of inductive loads such as electric motors, transformers, and fluorescent lights with ballasts. If not properly compensated, it can cause voltage drops and reduce energy efficiency. It’s important to determine the compensation level required to select the appropriate equipment.
- Choosing the right capacitor bank: Capacitors can be placed either centrally at the substation or distributed across areas with high-power equipment. After calculating the compensation power, businesses need to select the most effective compensation method. Common methods include centralized compensation, group compensation, and direct compensation at the load.
For example, a mechanical workshop with many powerful motors may require capacitors placed directly at the machines to increase efficiency. - Proper placement: Capacitors should be installed in well-ventilated areas, away from high temperatures, high humidity, or excessive vibrations, to ensure longevity and performance.
Proper placement of power factor correction capacitors helps optimize the power factor and reduce electricity costs.
If the power factor correction system is designed effectively, businesses can not only significantly reduce energy consumption but also enhance the durability of equipment, ensuring the electrical system operates at its optimal performance.
Step 6: Testing and Commissioning the Electrical System After Installation
At this stage, it is essential to conduct tests to ensure the electrical system operates stably, with no hidden risks of fire, explosion, or short circuits, while also meeting all technical standards and legal regulations before being put into operation.
The testing process includes:
- Measuring insulation resistance.
- Verifying the operation of protective devices.
- Testing the grounding system.
KTG Industrial – Industrial Real Estate Solutions with a Safe and Standardized Electrical System
A high-quality factory is more than just a place to house machinery—it serves as the foundation for efficient operations, risk reduction, and cost optimization. At KTG Industrial, we understand that every minute of downtime impacts your profitability.
That’s why our electrical system is designed to meet international standards, ensuring a stable and safe power supply. Our automatic fire prevention and suppression system minimizes risks, while our rooftop solar power system not only reduces costs but also supports sustainable development. Additionally, our scientifically arranged electrical cabinets and cable trays optimize space, allowing businesses to focus on production without disruptions.
Choosing KTG Industrial means investing in more than just a factory—it’s a commitment to a safe, modern, and cost-effective manufacturing environment.
Conclusion
A well-designed factory electrical system not only optimizes operations but also ensures long-term safety for businesses. We hope this article provides valuable insights as you build and expand your production space.
