Published On: Sat, Jul 27th, 2019

Electrical Installations in Steel constructions

Author: Radoje Jankovic.

All photos are picked by Jankovic

Fig. 1. One layout of the belt conveyor belt during installation on the mounting site. There are cable trails and a main distribution booth at the top of the drive station.

Practice of erection of electrical installations of LV an HV for:





Training experts,


Electrical engineers,


Supervisor engineers,


In this photo album I showed dozens of photos of practical implementation of electrical installation on steel structures. 
In this case, it is the drive station of belt conveyor with large capacity intended for a new surface mine field “C” in the mining basin “Kolubara” Lazarevac.

These are the kind of specific electrical installation, which many do not have opportunities, perhaps never to see or to work on their execution. Although for a professional electrician does not have any specifics; installation as well as all electrical installations. Just a little more or a lot more complicated than the standard electrical wiring in the classic buildings and buildings.

Fig. 2. Another view of the drive station of the ribbon conveyor with where the cables are placed on cable racks as well as the connected drive motor, right.

Many, and professors have not seen such an installation let alone worked on them, installed, connected equipment, interrogated, let up, maintain and even rarely any of them that has ever designed.

Such installations are performed highly professional workers, technicians and engineers with extensive work experience. Younger colleagues are experienced with these “wolves electrics” trained and taught the craft to such an installation.

Even in schools and at universities with these and similar installations do not study, and a special problem is that schools and colleges do not send students to practice in enterprises where this type or similar electrical installations are performed, at least to get familiar with the specifics of jobs is working on how to perform them.

Jankovic is a big part of their working life working on editing and execution of many types of electrical installation of the; the ordinary family houses, apartment buildings, industrial buildings, hospitals, schools, large production hall at power plasnts; hydro, diesel power plants, separations materials, concrete factories, cranes, excavators of all types of belt conveyors and transfer devices, drilling towers, oil fields, the separation of oil and gas , installations, cathodic protection, small photovoltaic solar power plants, heating plants, technological plants, administrative and factory buildings etc. and so on.

Because of his work in a very different electrical installations Jankovic has a large archive and project documentation with complete calculations, materials specifications, Bill of Quantities work …. and a large number of their own, original photo detail of electrical installation of the execution. 

Especially documented his masterful work embodiment thereof.
In this, the first part, I will show only the details with photographs. 

Each image shows clearly enough what is necessary to see and even to learn something new. With each picture gives a short description for a clearer perception and understanding of the photos and details on it. 

Otherwise, all the equipment is designed for outdoor installation and the most difficult climatic conditions. A climatic conditions in opencast mines are very harsh and extreme, flying to 45 or more degrees Celsius in the summer and winter frosts, snow and temperatures down to minus 20 degrees Celsius.

Here we present details of erection the electrical installation on steel structures, drive station a large belt conveyor for opencast mining of lignite coal. 
In the later parts will be shown in many other details with different electrical equipment and devices both during installation and after completion, as well as details of installation in service after several years.

Fig. 3. The appearance of laid low voltage cables with neoprene insulation and fine wire. 
These cables are designed for heavy exploitation conditions, just as in this case where there are large vibrations due to the transport of hundreds and hundreds of tons of coal or cubes of tailings.

Fig.4. As in the previous picture. Low-voltage neoprene fine-wire cables laid on steel cable racks are ready for connection.

Fig. 5. A regular push button on the right and mushroom red button known as “All Stop”, which stops everything in case of any danger or damage. When this key is pressed, the entire system consists of a rod miller at the beginning, multiple striped transponders, sometimes up to ten kilometers long, with drive stations, conveyor belts and, in the end, a digger depositing loose, or, if it is in the end a loading station for coal and it is switched off until the danger or malfunction is eliminated. Everything is time controlled.

Fig. 6. Cable connection in the distribution cabinet. 
It is clear from the picture that two cables are used because of high current or high electrical load. The illustration shows how to connect the connector correctly.

Fig. 7. Low voltage right, and high voltage cables left, neoprene – yellow, laid over vertical cable racks.

Fig. 8. Display the correct installation and connection of a local command button. The connection cable has a detailed number indicating where it goes and which drive it uses.

Fig. 9. Detail of the cable connection of one three-phase asynchronous low voltage motor. The bottom cable is LV power cable for motor, and the right cable for the elements of the winding temperature control of the motor. 

Fig. 10. One view of the cable tray beneath the lattice floor at the low and high voltage distribution switchgear of the drive station. It’s clear that cables are properly laid. 
Cable layouts are not allowed improperly. All cables on the cable route must be parallel to each other.

Fig. 11. Detail of the mounting of the external lamp at the drive station of the belt conveyor. Because of the high vibration, the luminaires must be so mounted that they do not “shake” during the operation of the station. Therefore, they are mounted on special elastic supports that prevent the vibration effects.

Fig. 12. Another so-called. “All-Stop” push button mounted on the station. 
Otherwise, at the drive station, there are several of these pushbutons in key locations for instant stopping all drives in case of any danger or damage or the overburden and overburden of the station with large quantities of recovered material.

Fig. 13. This picture shows the terminal box of the high voltage transformer 35 kV / 10 kV. 
See how the quality of the three-phase transformer is connected. 

Fig. 14. Another view of the three-phase power transformer connection at the drive station.

Fig. 15. Top view of the cable entry into the terminal box of the high-voltage and low-voltage three-phase transformer. All cables are marked with appropriate numbers for identification purposes

Fig. 16. Look at the power transformer at the top of the drive station. 
On the transformer platform, a luminaire for the illumination of the path and space around the transformer and in front of the distribution system is visible. Below you can see a second bulb for lighting a conveyor belt. 

Fig. 17. A look at a three-phase asynchronous three-phase motor with a derived connection using power cables. 
The motor is a power of 1,200 kW, a nominal voltage of 3 x 690 V, controlled by a frequency regulator. 

Fig. 18. More detailed view of the cables powered by a three-phase asynchronous motor of 1200 kW capacity, drive station of a stripe conveyor. What’s “like a picture”?

Fig. 19. The picture shows clearly. See also the following illustrations of a three-phase asynchronous motor for the conveyor belt drive. Beauty from the artwork of the installer – electrician.

Fig. 20. And this picture clearly shows the quality of electrical work on electric motors, as well as the previous ones.

Fig. 21. One of the transient command cabinets at the belt conveyor belt drive station. 

Figure 22. Another one-stop button, “All Stop” pushbutton. 

Fig. 23. A look at the introduction of the cables from the vertical rack into an auxiliary cabinet at the drive station. 

Fig. 24. A view of the oil heaters in the drive gearbox, the belt conveyor belt drive station. 
The individual power of the heaters is 2350 W, 230 VAC 

Fig. 25. View of the connection box of the electro-hydraulic brake for braking the drive motor during the stopping of the belt conveyor. 

Fig. 26. A look at the correct installation of the reflector for illuminating the drive station during night work, as these plants operate 24 hours during the day and 365 days during the year. 
27. A view of a cable divorce carried out by cable racks of the belt conveyor belt drive station. 
All cables from the drive station and the belt conveyor come to the HV and LV switchgear room visible above the cables. 

On the outside of the energy container, 6 pieces of air/conditioning units have been installed, which must maintain a constant temperature inside the plant and in summer and winter. 

There are also 3 dynamic braking resistors for transporter motor drives.

Fig. 28. A view of the three-phase AC motor connection for the conveyor drive and its electrohydraulic brake. 
Fig. 29. Cables laid by racks and ready to connect.

Fig. 30. One look at the cable racks with laid-out energy cables insulated with neoprene. 

Fig. 31. The installer works on fixing energy cables (power cables) laid over the vertical rack.

Fig. 32. High-voltage and low-voltage cables supplied to the transformer box .

Fig. 33. Mounted three-phase power transformer and high-voltage and low voltage cables for connecting the transformer in its terminal box. The right is the second transformer
Fig. 34. More one look at the transformer from the previous image. 

Fig. 35. Cables on a vertical rack for connection of three-phase power transformers. 

Fig. 36. Cables for the second power transformer at the drive station of the belt conveyor. 
Fig. 37. Radoje Jankovic at the drive station of the belt conveyor. 
I apologize to colleagues installers, I did not take the helmet even though I had been working on the assembly for many years and wearing it. I have violated the Occupational Safety Rule. 

Fig. 38. Cables for three-phase asynchronous motor drive for belt conveyor transport, motor power 1200 kW, 690 V AC. The motor is frequency regulated. 
Fig. 39. Jankovic near the connected three-phase asynchronous motor for the drive of the belt conveyor.
Electrical installations in steel construcion
Fig. 40. One view of three drive stations during the mounting on a mointing site of new belt conveyors.

About the Author

- Radoje - Rade Jankovic Electrician, Electrical Technician, Electrical Engineer, PhD, Ecologist, Environmentalist, Designer, Educator, Investigator... Today PROFESSIONAL TECHNICAL WRITER AND DOCUMENTATOR Massive practical experience in almost all fields of electrical engineering over 40 years. My International education group in Facebook: EEEW - ELECTRICAL & ELECTRONIC EDUCATION WORLD where published more than 8000 small or bigger articles, lessons, technical advice, projects, technical calculations, test questions with and without answers, illustrated test questions with and without answers; all my original works and few thousands of may original photos from practice, drawings, circuit diagrams, environmental lessons and examples from everyday practice etc., etc.

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Electrical Installations in Steel constructions