The projects covered the complete infrastructure – from external electrical installations and power supply, through backup systems and safety solutions, to internal installations and specialized substations.
Special emphasis was placed on:
compliance with applicable 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.
Phase EP3 – Reconstruction and Expansion of the Complex
External Power Installations
20 kV cable network laid in HDPE pipes and concrete manholes, forming a closed cable ring that connects substations EP3 and Connection Substation (PRP).
0.4 kV cable network for supplying production and technical facilities, pumping stations, EV chargers, lighting, and sockets.
Installation of external lighting using LED luminaires on poles 8–12 m high, as well as façade floodlights.
External grounding of the complex with RF strips, connecting all buildings and metal poles into a single galvanic unit for safe dissipation of atmospheric discharges and lightning protection.
Power Supply
Introduction of new 20 kV lines to the internal substation EP3-PRO-3.
The designed total power of the complex is 7,000 kW, ensuring sufficient capacity for current and future needs.
Temporary supply was provided via the existing CS “Continental”, until the construction of the planned 110/20 kV “Kać” substation.
Internal Electrical Installations
Installation of LED lighting for general, safety, and emergency lighting.
Implementation of the Philips Dynalite system for automated lighting control, combined with presence and daylight sensors.
General-purpose outlets as well as specialized sockets for IT equipment and office infrastructure.
Roof lantern system for smoke extraction and heat removal.
UPS systems for supplying critical consumers and fire protection installations.
Safety Systems and Protection
Installation of fire alarm systems and emergency lighting with independent batteries (minimum autonomy 1h).
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 fire endurance and reduced emission of harmful gases.
Distribution Boards and Cable Routing
Installation of Schneider Electric distribution boards, type-tested according to IEC standards.
Thermographic imaging after installation to check heating and reliability.
Copper wiring, with a minimum of 30% spare space in panels and racks.
Cable routing in protective conduits, with mandatory fireproof sealing of penetrations between fire compartments.
Planned Facilities
Production hall for electronic car parts,
Administrative and technical premises,
Technical block with infrastructure systems,
New 20/0.4 kV substation.
Power Infrastructure
onnection to the 20 kV grid of ED Novi Sad via CS “Continental”.
Maximum approved capacity: 7,000 kW (5,530 kW from Phase I + 1,470 kW from Phase II).
TS EP3-PRO-3 – substation with two transformers of 2,500 kVA each (expandable to 4×2500 kVA).
Internal 20 kV cable ring connecting CS and substations.
Diesel generator G3, rated 715 kVA (520 kW), with automatic ATS switching and integrated communication with the BMS system. The generator provides at least 2 hours of autonomy and backup supply for critical consumers:
- IT racks and server equipment,
- fire alarm control panel and fire protection systems,
- CCTV and security lighting,
- transformer protection.
Installations in Buildings
LED lighting with levels of 250–500 lx, depending on the functional purpose of the space.
External LED lighting on poles 8–12 m high for parking, docks, and roads.
Safety systems: fire alarm panel, evacuation PA system, roof lanterns, fire dampers, and electromagnetic door locks.
Halogen-free and fire-resistant cables, type FE180/E90.
Schneider Electric distribution panels with 30% reserve capacity and 30 mA differential protection.
Lightning protection executed as a Faraday cage with a 5×5 m grid and lightning rods.
Special Systems
Pluvia rainwater drainage system, with heated drains to prevent icing.
Ventilation and smoke extraction – combination of mechanical and natural exhaust, with controlled activation.
Electronic access control system at all entrances and gates.
Energy efficiency: Philips Dynalite lighting control, daylight sensors, automatic intensity regulation.
Specialized Substations
Substation TS “EP3-PRO-3” (20/0.4 kV)
The EP3-PRO-3 substation was designed as part of phase EP3.1/3.2 for the needs of the extended production facility. The designed capacity is 2×2500 kVA, with the possibility of later expansion to 4×2500 kVA.
Technical characteristics:
MV switchgear 20 kV:
- Type: SM6 Schneider Electric, SF6 insulation, IP31.
- Modular, metal-clad, type-tested, expansion-ready.
- Contains 2 line cells (disconnectors + earthing switches) and 2 transformer cells (630 A circuit breakers, manual and motorized drive).
- Parameters: rated voltage 20 kV, rated current 630 A, short-circuit withstand 16 kA/1s.
Transformers:
- Two 2500 kVA dry-type transformers, epoxy resin cast, IP00.
- Built-in Pt100 sensors for thermal protection of windings.
- Designed for independent operation (not in parallel).
LV main distribution 0.4 kV:
- Two sections: GRO-EP3-PRO-3-1/2 and GRO-EP3-PRO-3-2/2.
- Rated current: 4000 A.
- Short-circuit peak withstand: 220 kA.
- Protection: three-pole breakers, connected via shielded busbar trunking 4000 A.
Metering and compensation:
- Control metering group for indirect metering on the LV side.
- Filtered automatic reactive power compensation, installed after trial operation and measurements.
Cable connections:
- 20 kV – NA2XS(F)2Y 1×120/16 mm².
- 0.4 kV – N2XH copper conductor cables.
Protection and installations:
- Thermal protection of transformers via Pt100 sensors.
- TN-S grounding system, common grounding electrode and main equipotential bonding bar.
- LED lighting IP65, lightning protection, and equipotential bonding.
The projects carried out within the Continental Automotive Serbia complex represent a benchmark example of high-tech power solutions in the region.
Increased production capacity in line with the requirements of the automotive industry,
Reliable and redundant power 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 power engineering projects in industrial complexes.
