An industrial electrical installation is far more than cables and switchboards. It is the backbone of any production facility, and a flaw in its design or execution can cause anything from production shutdowns to fires.
Designing a safe and efficient industrial electrical installation requires experience, rigorous calculation and a thorough understanding of current regulations. Below we review the key factors that separate a problem-prone installation from one that runs reliably for decades.
Proper circuit sizing
The starting point for any electrical installation is the power calculation. Undersizing conductors leads to overheating, excessive voltage drops and fire risk. Oversizing means unnecessary cost.
Good sizing takes into account:
- The rated power of each load and its actual diversity factor.
- Maximum permissible voltage drops (3% for lighting, 5% for motor circuits under Spain’s REBT regulations).
- Installation conditions: ambient temperature, cable grouping and the type of containment system.
- Provision for future expansion, especially in industrial buildings that may change use over time.
Every circuit must have its own individual protection against both overloads and short circuits, with selectivity that isolates a fault without affecting the rest of the installation.
Reactive power compensation
In industrial facilities with motors, compressors and discharge lighting, reactive power can represent a significant share of the electricity bill. Distribution companies impose surcharges when the power factor drops below 0.95.
The solution is to install capacitor banks — either fixed or automatic — that compensate for reactive power and keep the power factor within optimal values.
The savings are twofold: reactive power surcharges are eliminated from the bill, and the load on conductors and transformers is reduced, improving the overall efficiency of the installation.
Surge protection
Transient overvoltages caused by lightning, network switching or the starting of large loads can damage sensitive electronic equipment such as variable frequency drives, PLCs, control systems and IT hardware.
Spain’s REBT requires surge protection devices in certain situations, but in industrial environments it is advisable to install them as standard. A surge protector costs a fraction of what it takes to repair or replace a damaged variable frequency drive.
A tiered protection scheme is recommended: Type 1 protectors at the main switchboard (where there is a risk of direct lightning strike), Type 2 at sub-distribution boards and Type 3 at the most sensitive equipment.
REBT compliance
The Low Voltage Electrotechnical Regulation (REBT) and its Complementary Technical Instructions (ITC-BT) form the regulatory framework governing all low-voltage electrical installations in Spain. For industrial installations, the most relevant instructions are:
- ITC-BT-07: underground distribution networks.
- ITC-BT-19: general requirements for interior installations.
- ITC-BT-22: protection against overcurrents.
- ITC-BT-23: protection against overvoltages.
- ITC-BT-24: protection against direct and indirect contact.
Every industrial installation requires a certified technical project, a qualified project manager and an initial inspection by an Authorised Control Body (OCA) before it can be commissioned.
Quality switchboards and materials
A well-built electrical switchboard is a guarantee of safety and ease of maintenance. At Acoval we have our own workshop where we manufacture custom switchboards, giving us full control over the quality of every component: busbars, connections, labelling, ventilation and accessibility.
Using top-quality materials for conductors, cable trays, containment systems and switchgear is not a luxury — it is an investment in reliability. The most common electrical problems in industrial installations stem from poor connections, low-quality materials or installations carried out without a proper project.
An electrical installation is built to last
At Acoval we design, build and maintain industrial electrical installations in Valencia and the surrounding area. From initial calculations through to certification and periodic inspections, we support our clients throughout the entire lifecycle of the installation.
If you need a new installation, an expansion, or an upgrade to bring an existing system into REBT compliance, our technical team is at your service.
