Power Installations – Continental Automotive Serbia | Elektrovat

Elektrovat carried out comprehensive works on the construction and reconstruction of electrical installations within several development phases of the production complex of Continental Automotive Serbia d.o.o. in Kać, Novi Sad.

The projects encompassed the entire infrastructure – from external power installations and supply systems, through backup systems and safety solutions, to internal installations and specialized transformer substations.

Special emphasis was placed on:

  • compliance with the laws and regulations of the Republic of Serbia,
  • application of European and international standards (IEC, SRPS, EN),
  • integration with the LEED Gold standard for energy efficiency and sustainability,
  • ensuring a high level of reliability and safety for the automotive industry.
Power Installations – Continental Automotive Serbia | Elektrovat

Scope of Works

EP1.1 – Production facility for auto parts (“Clean Room”) with internal transformer substation

EP1.2 – Technical building “South” with transformer substation

Works included the complete external and internal networks, with infrastructure enabling stable and flexible operation of the complex.

Construction of Electrical Installations

  • 20 kV cable network laid in HDPE pipes and concrete manholes, forming a closed cable ring interconnecting substations EP1.1 and EP1.2.
  • 0.4 kV cable network for supplying production and technical buildings, pumping stations, EV chargers, lighting, and sockets.
  • Installation of external lighting with LED luminaires on poles 8–12 m high, as well as façade floodlights.
  • External grounding of the complex using galvanized steel strips, interconnecting all buildings and metal poles into a single galvanic unit for safe lightning discharge and protection against surges.

Power Supply

  • Introduction of new 20 kV lines to the internal substations EP1-PRO-1 and EP1-HKLS-1.
  • The designed total power capacity of the complex is 7,000 kW, ensuring sufficient capacity for current and future needs.
  • Temporary supply provided via the existing Connection Substation (PRP) “Continental” until construction of the planned 110/20 kV substation “Kać”.

Specialized Transformer Substations

Transformer Substation TS »EP1-PRO-1« (20/0.4 kV)

Designed for the first project phase, equipped with two dry-type transformers rated 2×2500 kVA.

Technical characteristics:

    • MV switchgear 20 kV:
      • Type: Schneider Electric SM6, SF6 insulation, IP31, metal-clad.
      • Rated voltage: 20 kV (insulation 24 kV).
      • Short-circuit withstand: 16 kA/1s.
      • Rated current: 630 A, frequency 50 Hz.
      • Configuration: 2 line and 2 transformer feeders with fuses and disconnectors

  • Transformers:

      • Two dry-type transformers 2500 kVA, IP00.
      • Epoxy resin cast windings.
      • Equipped with 3 × Pt100 sensors for temperature monitoring.
      • Installed in dedicated transformer enclosures.
  • LV main distribution 0.4 kV:

      • Rated current: 4000 A.
      • Short-circuit withstand: 155 kA.
      • Free-standing, fixed execution, IP31/20.
      • Three-pole breakers on incoming and outgoing feeders.
  • Metering and compensation:

      • Control metering group for indirect LV metering.
      • Filter-based automatic reactive power compensation (installation after factory commissioning).

  • Cabling:

      • 20 kV: NA2XS(F)2Y 1×120/16 mm².
      • 0.4 kV: copper power cables N2XH-J.

  • Protection and installations:

      • Transformer thermal protection by relays.
      • TN-S system with automatic disconnection at first fault.
      • LED lighting IP65, visibly routed wiring.
      • Combined grounding system with MEBB busbar, Fe/Zn strips 25×4 mm.
      • Lightning protection via external installation.

Transformer Substation TS »EP1-HKLS-1« (20/0.4 kV)

Part of the second phase, providing reliable supply with a total capacity of 3×2500 kVA.

Technical characteristics:

  • MV switchgear 20 kV:

      • Type: Schneider Electric SM6, SF6 insulation, IP31, IEC 62271-200.
      • Metal-clad, front access design.
      • Rated voltage: 20 kV (insulation 24 kV).
      • Rated current: 630 A.
      • Short-circuit withstand: 16 kA/1s.
      • Configuration: 2 line feeders and 2 transformer feeders with fuses.

  • Transformers:

      • Three dry-type transformers 2500 kVA, IP00.
      • Epoxy resin cast, with Pt100 sensors for thermal protection.
      • Designed for independent (non-parallel) operation.
      • Each transformer housed in a separate enclosure.

  • LV main distribution 0.4 kV:

      • Three boards: GRO-EP1-HKLS-1-1/3, -2/3, -3/3.
      • Rated current: 4000 A each.
      • Short-circuit withstand: 155 kA.
      • Free-standing, fixed, IP31 external / IP20 internal.
      • Three-pole breakers on transformer and outgoing feeders.
      • Transformer connections via shielded bus ducts (4000 A).

  • Metering and compensation:

      • Overall metering at CS Continental; additional indirect LV metering.
      • Three filter-based automatic compensation systems (to be installed after operational measurements).

  • Cabling:

      • 20 kV: single-core XLPE NA2XS(F)2Y 1×120/16 mm².
      • 4 kV: copper cables N2XH-J.

  • Protection and installations:

      • TN-S system, automatic disconnection at first fault.
      • Transformer protection via Pt100 sensors and thermal relay.
      • LED lighting IP65, visibly routed wiring, single-phase sockets.
      • Combined grounding, MEBB busbar, Fe/Zn strips 25×4 mm.
      • Ring-type grounding in transformer boxes.
      • Lightning protection via external installation.

Backup Power

Within phase EP1, a diesel generator G1 (Standby 1125 kVA / 900 kW, Prime 1022 kVA / 817.6 kW) was installed, in a soundproof enclosure, with integrated ATS panels for automatic transfer of supply.

The generator includes a 520 l fuel tank, providing autonomy of at least 2 hours (approx. 3.25 h at 75% load).

Critical consumers supplied by backup power:

  • sprinkler and hydrant pumps,
  • server rooms, IT equipment, and UPS systems,
  • fire alarm panels and fire doors,
  • CCTV and emergency/anti-panic lighting,
  • roof smoke extraction lanterns.

Internal Electrical Installations

  • Installation of LED lighting for general, safety, and emergency purposes.
  • Implementation of Philips Dynalite system for automated lighting control with presence and daylight sensors.
  • General-purpose sockets as well as specialized connections for IT and office infrastructure.
  • Roof lantern system for smoke and heat extraction.
  • UPS systems for critical loads and fire protection installations.

Safety Systems and Protection

  • Installation of fire detection and emergency lighting systems with independent batteries (minimum 1 h autonomy).
  • Electromagnetic locks on fire doors with automatic release in case of fire.
  • Automatic activation of sprinkler and hydrant systems, ventilation, and smoke extraction.
  • Fire-resistant, halogen-free cables type FE180/E90 – ensuring integrity under fire conditions and reducing harmful emissions.

Distribution Boards and Cabling

  • Installation of Schneider Electric distribution boards, type-tested according to IEC standards.
  • Thermographic testing after installation to verify heating and reliability.
  • Copper wiring with a minimum 30% spare capacity in panels and racks.
  • Cable routing in protective conduits, with mandatory fireproof sealing of penetrations between fire zones.

The projects carried out within the Continental Automotive Serbia complex represent a benchmark example of high-tech electrical solutions in the region.

Elektrovat provided:

  • Expansion of production capacities in line with automotive industry requirements,
  • Reliable and redundant electrical infrastructure,
  • Integration of existing and new systems into a functional whole,
  • Compliance with European standards and international certifications (LEED Gold, IEC, SRPS).

This project confirms Elektrovat as a reliable partner in delivering the most complex electrical projects in industrial complexes.

HOW CAN WE HELP ?

Do you need assistance with some project of yours, or you simply want to explore your options… don’t hesitate!

OFFICE LINE

+381 32 557 43 01

MAIL

info@elektrovat.net

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OFFICE LINE

+381 032 557 43 01

MAIL

info@elektrovat.net

WORKING HOURS

8:00am – 4:00pm