Stone Crushing Plant, Nanded

A stone crushing and processing plant at Nanded on a plot of 8,000 sq m with 3,000 sq m of construction - crushing units, screening, belt conveyors and material storage. A crusher plant is a collection of large motors started on and off all day: a 250 HP vertical-shaft impactor, a 240 HP cone crusher, jaw crushers of 150 and 125 HP, a 25 HP primary feeder, three screens and conveyors, spread across a long site. Four things decide the electrical design: the starting current of the big motors, the distance of the cables, the power factor the supply authority expects, and the site itself, which calls for indoor panels and armoured motor cables. The owner needed to know the transformer to apply for and the panels to order, and the cable drums to buy.

Load: we listed every motor with its rating - the five crushers, a feeder, three screens and 19 conveyor motors of 5 to 10 HP - 27 connections and 750.5 kW, which at the 0.9 power factor of the load sheet is 833.9 kVA, and 1,000.6 kVA with a 20% margin: a 1,000 kVA transformer. Cables: from the transformer, four runs of 3.5-core 300 sq mm aluminium armoured XLPE cable over 242 m carry 1,305 A to a six-way feeder pillar, with a drop of 1.17%; sub-distribution panels then feed the crushers on 120 and 185 sq mm cable, the screens on 25 sq mm and the conveyors on 4 sq mm copper armoured cable, so the longest motor feeders - up to 211 m to the impactor - drop about 2%. Panels: star-delta starter panels with an air circuit breaker incomer for the large motors, motor circuit breakers and contactors for the smaller ones, and an automatic power-factor panel of 400 kVAr. We issued the power schematic and the voltage-drop and cable schedule in September 2025.