Design and Technical Validation of Industrial Transformer Substations with Integrated Electric Vehicle Charging Infrastructure


Creative Commons License

Toprak K. M., Terkeş M., Demirci A., Gökalp E.

5th International Thales Congress on Life, Engineering, Architecture and Mathematics, Cairo, Mısır, 16 - 18 Ekim 2025, cilt.1, sa.1, ss.1-14, (Tam Metin Bildiri)

  • Yayın Türü: Bildiri / Tam Metin Bildiri
  • Cilt numarası: 1
  • Basıldığı Şehir: Cairo
  • Basıldığı Ülke: Mısır
  • Sayfa Sayıları: ss.1-14
  • Açık Arşiv Koleksiyonu: AVESİS Açık Erişim Koleksiyonu
  • Yıldız Teknik Üniversitesi Adresli: Evet

Özet

The rapid integration of renewable generation, distributed resources, and electric vehicle (EV) charging infrastructure has imposed new challenges on the design and operation of modern industrial power systems. In this study, a comprehensive framework is developed for the medium-voltage/low-voltage (MV/LV) distribution transformer substation of a large-scale industrial facility, where conventional production-related electrical demands are combined with 33 units of 22 kW EV charging stations. The methodology encompasses detailed design calculations including cable sizing and voltage drop analysis, busbar dimensioning, transformer selection, compensation panel design with step calculation, and short-circuit analysis in accordance with IEC standards, covering both symmetrical and asymmetrical conditions as well as thermal and dynamic withstand currents. Additional considerations such as fault current contributions from DC components, specification of circuit breakers, and the selection of measurement and metering devices are incorporated to ensure robustness and compliance. The final design is validated through load flow and short-circuit simulations conducted in ETAP, confirming technical consistency and operational feasibility. Beyond addressing individual technical aspects, the proposed approach provides an integrated solution that bridges traditional industrial power system design with the emerging requirements of EV infrastructure. This contribution enhances system efficiency, reliability, and adaptability, and offers a practical reference for the future planning of industrial facilities in an evolving energy landscape.