Warehouse Electrical Planning Guide: What Every Bengaluru Operator Needs to Know

Why Electrical Planning Matters

A warehouse electrical system must support lighting, material handling equipment, EV chargers, office areas, HVAC, CCTV, fire safety, and possibly cold storage — all simultaneously. For a 20,000 sq ft warehouse in Dobbaspet or Peenya, connected loads of 80–200 kVA are typical depending on operations.

Step 1: Load Calculation

Estimate connected load covering high-bay lighting (50–80W per fixture), material handling equipment (forklift chargers, conveyor motors), office and breakroom (10–15 kVA), HVAC, CCTV and security (2–5 kVA), fire safety (1–3 kVA), and future expansion buffer of 20–30%. Total connected load determines your sanctioned load from BESCOM and the sizing of your LT panel.

Step 2: BESCOM Load Sanction

For new warehouse connections: file load sanction application with the relevant BESCOM ESCOM, submit single-line diagram, load schedule, and site plan, pay estimated cost of connection, and BESCOM installs metering and service connection. LT connections up to 100 kVA take 4–8 weeks. HT connections above 100 kVA take 8–16 weeks and require substation space.

Step 3: LT Panel Design

Your main LT panel should include an incoming MCCB sized to sanctioned load, sub-circuit MCBs for each load group, ELCB/RCCB for earth fault protection, bus bar sized for peak current, metering instruments, and an APFC panel if load exceeds 20 kVA (to avoid low power factor penalties from BESCOM). Panels should be manufactured to IS 8623 and tested before installation.

Step 4: High-Bay Lighting Design

Lighting is typically the largest electrical load in a warehouse. Standard warehouses require 100–150 lux at floor level. Picking and packing zones need 200–300 lux. LED high-bay fixtures (100–200W) are standard. Arrange in rows parallel to racking. Include emergency battery backup on 10–20% of fixtures. Motion sensors reduce energy consumption by 30–40%.

Step 5: DG Backup Planning

Bengaluru's industrial zones experience power outages. Plan DG backup by sizing for critical loads only (lighting, servers, CCTV, fire), using an ATS for seamless changeover, treating the DG room with acoustic treatment and exhaust, sizing the fuel tank for minimum 8-hour runtime, and ensuring KSPCB compliance for DG emissions.

Step 6: Cable Selection and Routing

Use XLPE/armoured cables for main runs and PVC conduit for sub-circuit wiring. Size cable trays with 40% fill maximum. Prepare a cable schedule document for future maintenance. Label all cables at both ends.

Common Mistakes to Avoid

Undersized main panel (no room to add circuits later); no power factor correction (monthly BESCOM penalties); single-point earthing (creates potential difference and equipment damage); no cable schedule (future maintenance becomes guesswork); and lighting layout not coordinated with racking plan (shadows in pick zones).