TRADESWIND PLANTATION

MANAGEMENT SDN BHD

BASIC MILL ELECTRICAL

INSTALLATION COURSE
FOR
CADET ENGINEERS

BY

GAN SAIK NGAI

(TRAINING CONSULTANT)

12 MAY 2017

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 TABLE OF CONTENTS

1. ELECTRICAL POWER SYSTEM IN PALM OIL

MILL

2. SWITCHBOARD

3. ALTERNATOR UNIT

4. ELECTRIC MOTORS

5. POWER CABLES

6. COMMON ELECTRICAL FAULTS IN PALM OIL

MILLS

7. SHORTCOMING IN MAINTENANCE, OPERATION

AND CARE OF ELECTRICAL EQUIPMENT AND
MACHINE

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 1. TYPICAL ELECTRICAL DISTRIBUTION SYSTEM IN PALM OIL MILLS

1.1 LAYOUT OF POWER GENERATORS, MAIN SWITCHBOARD, MOTOR CONTROL

PANELS AND POWER CABLES

BAY

Power Supply System In Palm Oil Mill

Different Parts of Power System

(a) Power Generators

Comprising Turbo-Alternator sets and Diesel Generator sets

(b) Main Cables

Linking Power Generators and Main Switchboard. Commonly used are PVC/PVC Single Core
Copper Conductors laid in cable trench. Selection due to flexibility.

(c) Main Switchboard (MSB)

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 Comprising Main Generator Boards, Main Distribution Boards, Power Factor Correction
Board, and Synchronizing Panel

(d) Sub-Main Cables

Connecting Main Switchboards and Motor Control Centers / Sub-Boards. Commonly used are
4 Core Armored Cable laid in cable trench and on cable tray.

(e) Sub-Switchboards

Comprise Motor Control Centers and Sub-Boards. Starter Boards are located here.

(f) Electrical Machinery and Equipment

Comprising Electric Motors, Lighting, Power Sockets, Heater, Air-Conditioner, Electronic

Equipment.

1.2 MAIN SWITCHBOARD (MSB)

1.2.1 MAIN SWITCHBOARD

These are attachment of panels to control power intake from power generators and distribute
the same to load centers through the MDB under control conditions.

The Main Switchboard comprises :

(a) Main Generator Boards

(b) Main Distribution Boards

(c) Automatic Power Factor Correction Panel

(d) Synchronizing Panel

1.2.2 MAIN GENERATOR BOARD (MGB)

Each MGB comprises :

(a) 1 No. draw-out 3 Pole ACB c/w under voltage release and auxiliary contacts

(b) 1 No. Neutral Knife Switch

(c) 1 No. Digital type Over Current Relay

(d) 1 No. Digital type Earth Fault Relay

(e) 1 No. Electronic type Reverse Power Relay

(f) 1 No. Electronic type Under / Over voltage Relay

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 (g) 1 No. 144 mm Square Voltmeter c/w Voltmeter Selector Switch

(h) 3 Nos. 144 mm Square Ammeter

(i) 1 No. 144 mm Square Power Factor meter

(j) 1 No. 144mm Square Frequency meter

(k) 1 No. 144 mm Square Kilo-watt (kW) meter

(l) 1 No. Kilo-watt Hour (kWh) meter

(m) 1 No. Hour-run meter

(n) 7 Nos. Measurement Current Transformers

(o) 4 Nos. Protection Current Transformers

(p) 1 No. 1.5 kilo-ohm 3 Watts Voltage Trimmer

(q) 1 No. ‘Raise/Lower’ Governor Control Switch

(r) 10 Nos. SP MCBs

(s) Key Interlock Switch (if required)

(t) 4 Nos. Tinned Rectangular Copper Bus-bars

(u) Internal Cabling

1.2.3 MAIN DISTRIBUTION BOARDS (MDB)

The electrical power from MDB is distributed by:-

(a) Molded Case Circuit Breaker (MCCB)

(b) Fuse Switch (F/S)

(c) Socket Outlets

The advantages of MCCB over F/S (F/S is already obsolete)

(a) No change of fuse is necessary

(b) Re-set when trigger by overload

(c) Small and compact

(d) Large ratings can be manufactured

Standard Ratings of TP MCCB are :

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 (a) 30 A

(b) 60 A Overloads are fixed

(c) 100 A

(d) 225 A

(e) 400 A

(f) 600 A
Overloads can be adjusted
(g) 800 A

(h) 1000 A

(i) 1250 A

1.2.4 AUTOMATIC POWER FACTOR CORRECTION PANEL

(a) This panel comprises :

 Main Switch / TP MCCB (to protect total system)

 Load Break Switch / TP MCCB (to protect capacitor bank)

 AC Magnetic Contractor (to provide switching of capacitor bank)

 Power Factor Regulator (regulate power factor to set value)

 Measurement Current Transformer (to sense reactive power)

 Ammeter (measure amperes)

 Indicating Lights (to show no. of steps being switched on)

(b) Digital type Power Factor Regulator is normally available in steps of 6 and 12.

> 6-steps Regulator provide switching up to 6 capacitor banks.

> 12-step Regulator provide switching up to 12 capacitor banks.

(c) Measurement Current Transformer should be installed at location where the total power
demand flows through. This is to ensure total correction of all inductive reactive load to
the desired power factor.

(d) Type of Settings Required at Power Factor Regulator:

- Power Factor setting (0.85 – 0.92 lag)

- C/K setting (The time response setting to switch on capacitor bank at 70% of their
reactive power)
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 - Switching sequence of capacitor banks

(e) Example :

1. A PF correction system has 6 x 65 kVAr Capacitor Banks

2. The Measurement Current Transformer use is 2000/5A.
3. Thus Time Response Setting C / K
= kVARc / (1.732 x V x CT Ratio)
= 65,000 x 5 / (1.732 x 415 x 2000)
= 0.226
1.2.5 SYNCHRONISING PANEL

(a) This electrical components are:

 Synchronoscope (indicate lead / lag phase of incoming voltage)

 Double Voltmeter (indicate bus-bar voltage and incoming set voltage)

 Double Frequency (indicate bus-bar frequency and incoming set frequency)

 Selector Switch (to select the generator set to be paralleled)

 Synchronizing Light (indicate lead / lag phase of incoming voltage)

 MCB (to protect meter and relay)

(b) Synchronizing Panel is require to assist in paralleling of power generators

(c) Paralleling is done at the instance of :

 Equality in Voltage

 Equality in Frequency

 Equality in Phase Sequence

(d) Paralleling of power generator sets other than the above conditions can cause serious
damage to generators, switchgears and meters due to reverse power thus causing
motoring in one of the power generators.

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1.2.6 LIST OF COMMON ELECTRICAL MATERIALS USED IN PALM OIL MILLS

No. Electrical Materials Model / Type Make

Air Circuit Breaker (Draw-out

1 3 Pole 600V DB Series FUJI
type c/w Multifunction OCR)
Molded Case Circuit Breaker
2 3 Pole 380V 50kA SA Series FUJI
(Main Switch)
Molded Case Circuit Breaker
3 3 Pole 380V 30kA SA Series FUJI
(Load Break Switch)
4 Miniature Circuit Breaker NC45A 220V 6kA MG
5 Voltmeter Selector Switch RC 310 –1M-7702 HB FUJI
6 Ammeter Selector Switch RC 310 –1A3 FUJI
7 Push-Button AR22FOR11 FUJI

8 Pilot Lamp DR22E3L FUJI

9 Magnetic Contactor AC3 380V SC Series FUJI

Combined Digital Over-
10 SPAJ 140C ABB
Current/Earth Fault Relay
11 Thermal Overload Relay TR – DW 3-Element Type FUJI

12 Earth Leakage Relay AC230V RASP 18NB 4CT KASUGA

13 Earth Leakage Circuit Breaker 2 & 4 Poles 300mA Sensitivity MG
14 Reverse Power Relay 256 PASW CROMPTON
3 phase 4 wire 375-420V KDV-
15 Over & Under Voltage Relay KASUGA
44D
16 Isolation Transformer 2A 380 / 80-240V HB TRAFO
3 phase 4 wire 220/380V F43-FV
17 Kilowatt-hour meter FUJI
Unbalanced Load Type
WTC 144AN 3 phase 4 wire 400V 3CT
18 Kilowatt meter Scale 90o Class 1.5 Unbalanced Load
CIRCUTOR

EC144 Scale 90o Class 1.5 1p 0-

19 Voltmeter CIRCUTOR
500V

20 Ammeter EC144 Scale 90o /5A Class 1.5 1.2p CIRCUTOR

HLC144 220/400V 47-53Hz Reed
21 Frequency meter CIRCUTOR
Type
22 Power factor meter FETC144 Scale 90o 400V 0.5-1-0.5 CIRCUTOR

23 Synchronoscope STC144 400V CIRCUTOR

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24 Hour run Counter 220V 48mmsq 5 ½ Digit GAE
25 Time Switch 240V NC, NO OMRON
26 Power Factor Regulator Electronic12-Step type NOKIAN
3-phase 380V Dry Type c/w
27 Capacitor Bank ABB
Housing
Metering (Class CM) & Protection
28 Current Transformer CIC / SEG
(Class 10P10)
Rain-Proof TBL 12FC 1.5A 250V
29 Ball Float Switch KASUGA
Level Relay c/w Stainless Ball
Float
Suspended Electric Hoist Push- Water Proof 5A 250V 4 Way Type
30 SHANHO
Button (for Capstan) SRE82 Push-button
31 Spring Balancer (for Capstan) 1.2 – 2kg Model 602 SHANHO

32 PVC GI Flexible Conduit Heavy Duty Type ANACOND

A
BS 1872 Electro Tinned Heavy
33 Cable Lugs UNIBELL
Duty Copper Lugs
JIS 3131 Heavy Duty 2mm Hot Rolled
34 Cable Duct /Trunking Steel Sheet Oven Baked Paint
ELPRO

JIS 3131 Heavy Duty 2mm Hot Rolled

35 Cable Tray Mild Steel Oven Baked Paint
ELPRO

JISC C 8305 Heavy Duty Class 4

36 GI Conduit ELPRO
Threaded Steel Conduit
1x18W Batten Fluorescent Light
37 TMS 012/118 PHILIPS
(Factory)
1x36W Fluorescent Light
38 TMS 012/136 PHILIPS
(Factory)
39 1x40W Fluorescent (Office) TK1.36IC (Lux) PHILIPS

40 2x40W Fluorescent (Office) TK2.36IC (Lux) PHILIPS

41 100W Spot Light Out-door type PHILIPS

SRP 810/125 HPL-N IP65 125W
42 Mercury Vapor Street Light PHILIPS
Mercury
SRP 810/100 SON IP65 100W
43 Sodium Vapor Street Light PHILIPS
Sodium
High Pressure Metal Halide MMF 383/250 HPI-T TANGO 3
44 PHILIPS
Floodlight IP54 250W
High Pressure Metal Halide MMF 383/400 HPI-T TANGO 3
45 PHILIPS
Floodlight IP54 400W
High Pressure Sodium Vapor SMF 383/250 SON-T TANGO 3
46 PHILIPS
Floodlight IP54 250W
High Pressure Sodium Vapor SMF 383/400 SON-T TANGO 3
47 PHILIPS
Floodlight IP54 400W
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48 Low / High Bay Light SDK580/150 (Hook) SON 150W PHILIPS
Dual Spot Lamp type, Nickel PHILIPS /
49 Emergency Light
Cadmium Battery, 3 Hour Standby GEC
NYA Single Core Pvc Sheathed SUPREME /
50 SPLN 42-1 1981 KABELIND
Copper Cable
O
SUPREME /
NYAF Single Core Pvc Insulated
51 SPLN 42-3 1981 KABELIND
Flexible Copper Cable
O
NYM Multi-Core Pvc Insulated SUPREME /
52 SPLN 42-2 1981 KABELIND
PV Sheated Copper Cable
O
NYY Single Core Pvc Insulated SUPREME/
53 SPLN.43-1 1981
Pvc Sheathed Copper Cable KABELIND
N2XY XLPE Insulated Pvc O
SUPREME/
54 SPLN 43-6
Sheathed Copper Cable KABELIND
NYFGbY Mult-Core Armoured SUPREME/
55 SPLN.43-2 1981
Copper Cable KABELIND
56 10A 220V Socket Outlet GPG426/16 SHUKO O
GP
57 15A 220V Switch Socket Outlet 2P+E P17 TEMPRA IP44 LEGRAND
58 20A 220V Switch Socket Outlet 2P+E P17 TEMPRA IP44 LEGRAND
59 30A Switch Socket Outlet 3P+N+E P17 TEMPRA IP44 LEGRAND
60 Lighting Switch Metal-Clad Industrial type MK

61 Air-Conditioner & Starter Split-unit NATIONAL

62 Ceiling Fan 60-inch span c/w Speed Regulator NATIONAL

Column -mounted 24-inch 2 Blade
63 Industrial Fan NATIONAL
Type
64 Exhaust Fan Wall-mounted 12-inch Shutter Type NATIONAL
Non-radio Active Lightning
65 TP 125, TP 60, TP 25 THOMAS
Preventor
15mm Dia x 1.0m L x 1.51kg
66 Air Rods ERICO
Copper Rod
15mm Dia x 1.83m L x 3.37kg
67 Earth Rods ERITECH
Copper
25mm x 3mm x 0.67kg/meter
68 Roof Conductors ERICO
Copper Tape
19 x 2.14mm strands x 70sqmm x
69 Down Conductors 0.62kg/meter Bare Copper ERITECH
Conductor
70 Earth Chamber Heavy Duty / Top Cover Local

PLN
71 Transmission Poles 9m & 11m Steel Tubular Poles
Approved

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 PLN
72 Distribution Poles 7.5m Steel Tubular Pole
Approved
PLN
73 Pole for Compound Light 7.5m Steel Tubular Pole
Approved

74 HV Pin Insulator P 12.5 ET 150L 20kV VICKERS

75 HV String Insulator U 70BL 20kV Porcelain VICKERS

76 HV Fuse Cutout SV 100A 27kV 10kA VICKERS

77 HV Lightning Arrestors VP-10 24kV 10kA Porcelain VICKERS

78 LV Lightning Arrestors VariSTAR 24kV 10kA Type AZG COOPER

79 Power Transformer ONAN CENTRADO

3 Pole / 4 Pole AC22 400V FWA PETERREIN

80 Load Break Isolator
Series S
81 External Reset Push-buttons SP 229 FUJI

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1.3 MOTOR CONTROL CENTERS (MCC)

1. MCCs provide electrical power to electric motors and Lighting Distribution Boards

2. A MCC comprise:-

a) Main Switch (TP MCCB)

b) Metering (Voltmeter and Ammeter)

c) Motor Starter Boards

3. Each Motor Starter Board consists of:

a) Load Break Switch (TP MCCB)

b) Magnetic Contactor(s)

c) Thermal Overload Relay (TOR)

d) Start / Stop Push-buttons

e) Run / Trip Indicating Lights

f) Ammeter / Hour run meter (for large motor)

g) Assisted Start Device (Auto-transformer, Rotor Resistance, Soft Starter)

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1.4 ELECTRICAL DRAWINGS OF SWITCHBOARDS

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19 of 116
 2. ALTERNATOR UNIT
2.1 DIFFERENT REPRESENTATIVE VIEWS

FOR TURBO-ALTERNATOR UNIT

(2 BEARINGS)

FOR DIESEL GENEARTOR SET

(SINGLE BEARING)

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 BLOCK DIAGRAM OF AN ALTERNATOR

SCHEMATIC DIAGRAM OF AN ALTERNATOR

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2.2 PRINCIPLES OF OPERATIONS

2.2.1 GENERATION OF OUTPUT VOLTAGE

 Pilot exciter (PMG) injects a constant AC power into AVR

 AVR also receives feedback AC power from alternator output

 These 2 input signals are processed by the AVR. The resultant signal (DC
power) is then feed into the main exciter stator

 As the exciter rotor rotates around the exciter stator a 3-phase AC power is
produced in the exciter rotor which are rectified (DC power) and then feed into
main rotor

 Similarly 3-phase AC power is produced at main stator when main rotor rotates
over the main stator windings

2.2.2 PARALLEL OPERATIONS

Components Required for Synchronising:

 Synchronising Kits  Governor Switch

 Synchronoscope  Voltage Trimmer

 Double Voltmeter  Metering Voltmeter

 Double Frequency  Ammeter

 Double Lamps  PF meter

 Control knobs  KW meter

Conditions For Synchronising :

1. Same voltage (415 V)

2. Same frequency (50 Hz)

3. Same phase (R, S, T)

Procedures for Prallel Operation

1. Run up Set No.1 to take load at 415 V 50 Hz 0.9 PF

2. Start Set No.2 : Voltage = 415 V, Frequency = 50 Hz

3. At Synchronising panel select ”Set No.2”

4. Adjust V2 = V1 (trimmer) and F2 = F1 (Governor)

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5. When lamps are totally dark and synchronoscope almost 12 o’clock, Switch on
ACB for Set No.2

6. Adjust governor switch (kW) and voltage trimmer (Kvar) of Set No.2 to take
desired load

AUTOMATIC VOLTAGE REGULATOR

(LEROY SOMER R 448 LS AVR)

MAJOR POTENTIOMETER SETTINGS

P1 = VOLTAGE DROOP

P2 = VOLTAGE OUTPUT

P3 = STABILITY

P4 = LOW SPPED PROTECTION

P5 = EXCITATION CURRENT LIMIT

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MAJOR CONNECTIONS

ST3 : Insert Link on 50 Hz

ST4 : Remove Link to Connect to External Voltage Trimmer

Select Feedback to AVR : For 380 Volts : Connect = L3 (W) – L2 (V)

E+ / E- = Connect to Exciter Stator (Exciter Field)

X1 / X2 = Connect to Auxiliary Windings

24 of 116
25 of 116
 RELATION BETWEEN OUTPUT VOLTAGE, SPEED & FIELD CURRENT

Let Vs = Voltage induced in main stator/phase

f = Frequency (c/s)

 = Flux (webers)

T = No. of turns/phase

P = No. of poles

N = Speed (rpm)

B = Flux Density (Wb/m2)

I = Ammeters at Main Rotor

L = Length of Coil of Main Rotor

 = Absolute Permeability

A = Area of Coil

Vs = 4.44 f  T (1)

But f = PN (2)
120

and  = B.A (3)

and B = µIT (4)

L

  = µIT . A (5)
L

Substituting (2) and (5) into (1)

PN IT
Vs = 4.44 ( )(  A) T
120 L

Vs = KNI

It implies that Output Voltage is proportional to a) Speed and b) Current output from
Main Rotor

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2.3 TYPES OF PROTECTION RELAYS

2.3.1 PROTECTIONS FOR ALTERNATOR

A. Common Protection Relays

 Overcurrent

 Earth Fault

 Reverse Power

 Under and over voltage

 Electro-mechanical UVT unit

B. Other Protection Relays (Optional)

 Insulation Resistance

 Over-Excitation

 Over-Temperature

 Phase Sequence/Breaking

3-Phase Magnetive Overload Relay

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OVERCURRENT RELAY
Magnetic Type EARTH FAULT RELAY
MechanicalType

COMBINED OVERCURRENT AND EARTH FAULT RELAY

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REVERSE POWER RELAY
Mechanical Type

REVERSE POWER RELAY

Electronic Type

29 of 116
2.3.2 SYY 155 (Under/Over Voltage Relay)

2.3.2.1 Wiring Diagram

Any Combination
L1 L2 L3 N
L2 L3 L1
L3 L1 L2

6
5 7
4 8

3 9

2 10
1 11

SYY 155

2.3.2.2 Mode of Operation

Connected to three phases and neutral the SYY 155 meter sinusoidal voltages.
The phase sequence is arbitrary. The relay stays ON as long as all three phase-
neutral voltages are between an upper and lower limit. The two limit are
separately adjusted. If one or more of the phase-neutral voltages rises above the
upper limit or drops below the lower limit, the relay releases (OFF). The relay
operates again, when all three phase-neutral voltages are inside the set limits.
The hysteresis on operate is 2%.

30 of 116
 2.3.2.3 Operation Diagram

2.3.3 STT 115 (Over Temperature Relay)

 AC or DC supply voltage.

2.3.3.1 Wiring Diagram

Example 1 Example 2
Basic coupling Inversion
Black

Black

6 6
5 7 5 7
4 8 4 8

3 9 3 9

2 10 2 10
1 11 31 of 116 1 11

ST 115 ST 115
 Example 3
Slave coupler

6 6
5 7 5 7
4 8 4 8

3 9 3 9

2 10 2 10
1 11 1 11

ST 115 ST 115
Master Slave
2.3.3.2 Operation Diagram

2.3.3.3 Mode of Operation

In conjunction with a remote sensor, type ETR, this S-system can be used to
control temperature of heaters of refrigerators. In the latter case inverted relay
function should be employed as a precaution.

The variable hysteresis makes control by this S-system extra flexible. The
supply voltage must continuously be connected to the S-system.

The temperature in oC at which the relay shall operate or release is set on the top
potentiometer.

The hysteresis in oC. I.e. the difference of temperature required for a change in
position of the relay, is set on the bottom potentiometer. If the S-system is used
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 to control a refrigerator, pins 8 and 9 (example 2) are to be interconnected.
However, in the case of controlling a heater, these pins should not be connected
(example 1).

As shown in the wiring diagram (example 3), it is possible to slave couple up to

5 S-system, type ST 115 to the one connected with the ETR-sensor.

A step wise coupling of heating elements of refrigerators is thus possible. To

each of the S-system in use (with different scale ranges if wanted) a moving-coil
instrument, e.g. type ID 120 can be connected.

2.3.4 SM 170 (Phase Sequence & Phase Breaking Relay)

2.3.4.1 Wiring Diagrams

Example 1 Example 2

L1 L2 L3 L1 L2 L3 N

6 6
5 7 5 7
4 8 4 8

3 9 3 9

2 10 2 10
1 11 1 11

SM 170 SM 170

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2.3.4.2 Mode of Operation

The relay measures on its own 3-phased supply voltage and operates, when all
phases are present and the phase sequence is correct.

Example 1

The relay releases in case of corruption of one of the phases, provided that the
voltage regenerated by electric motors on the interrupted phase does not exceed
50% of the nominal voltage.

Example 2

By connecting neutral to pin 11, the sensitivity is slightly improved. At

regenerated voltages the amplitude depends on the size and the load of the
connected electric motor. In practice the value of the regenerated voltage can be
near the same as the value of the supply voltage.

2.3.4.3 Operation Diagram

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2.4 CALIBRATION OF PROTECTION RELAYS

2.4.1 PRIMARY INJECTION TEST METHOD

~
Protection
Current Injector Relay
Variac
Is = 0 – 5A
Iv Secondary Circuit
CT2 Ip
L
Nv CT1
Link
Bus Bars
Primary Circuit

N
No of turn of CT2 Ip = High Current
Iv  Nv  Ip  Np Np = 1

Iv  Nv
Ip = = Iv Nv Np = 1 (Eqn. 1)
Np

Ip = Iv  CT2 Ratio (step up) (Eqn. 2)

Ip
Is = (step down) (Eqn. 3)
CT1Ratio

Calculations

Let Iv =5A

CT2 = 2000 / 5A , CT1 = 2000 / 5A

2000
 Ip =5  (From Eqn 2)
5

= 2000 A

2000
and Is =  5A (From Eqn 3)
2000

=5A

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2.4.2 SECONDARY INJECTION TEST

36 of 116
2.4.3 OVER-CURRENT PROTECTION

Setting Values

i) To carry (without tripping) : 100% of Rated Amps

ii) To trip in one minute : 120% of Rated Amps

iii) To trip in one second : 150% of Rated Amps (immediate trip)

Example (Given These Electrical Specifications)

KW = 850 RPM = 1500

Volt = 415 P.F. = 0.8

Phase =3 Insulation Class = F

Rated Amps = 1478

Current Transformer = 1600 / 5A , 15VA, Class 10P10

Calculations

The setting values are :

Primary Amps Secondary Amps

i) To carry 1478 (100%) 4.62

ii) To trip in one minute 1770 (120%) 5.53

iii) To trip in one second 2217 (150%) 6.92

Pr imary Amps
Secondary Amps =
CT Ratio

1478
To Carry :  5  4.62 A
1600

1770
To trip in one minute :  5  5.53 A
1600

2217
To trip in one second :  5  6.92 A
1600

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2.4.4 EARTH FAULT RELAY

CT Ratio : 1600/5A
Setting : 10% (147.8A)
Trip Time : Within 1 second

Current Inject : (147.8 x 5) /1600 Amps

: 0.46 Amps

2.4.5 REVERSE POWER RELAY

MAKE / MODEL TYPES OF SETTINGS

i) TRANSAL 0 – 30%, 0 – 20 seconds

ii) BELUK WLR 11 elo 0.1 – 3A

iii) GEC WDG11 Type B 360 – 2520 Watts (Phase Values)

Other Brands

a) CROMPTON

b) MIKRO

i) Setting in %

DEPENDS ON INERTIA OF DRIVE

Nominal Settings : 7% 3 seconds

Turn % knob to 7

Adjust ‘second’ button to 3

ii) Setting in Amps

Rated Amps = 1478

CT Ratio = 1600/5A

Protection Setting = 7% of Rated Amps

7
=  1478 A
100

= 103.46 A
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 Pr imary Amps
Secondary Amps =
CT Ratio

103.46
= 5A
1600

= 0.32 A

 Rotate knob to 0.32A marking

iii) Setting in Watts

Rated Amps = 1478

CT Ratio = 1600/5A

Protection Settings = 7% of Rated Amps

7
=  1478 A
100

= 103.46 A

Pr imary Amps
Secondary Amps =
CT Ratio

103.46
= 5A
1600

= 0.32 A

Power = 3  V  I  P.F

= 3  415  0.32  1

= 230 Watts

Notes: Choose the nearest plug setting

Resitive Load = 1

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2.5 POWER FACTOR CORRECTION

2.5.1 WHAT IS POWER FACTOR ?

Definitions :

(a) The phase different between the Voltage and Current Vectors.

KW Active Power
(b) P.F = Cos  = 
KVA Apparent Power

KW
=
3 V  I

Sometimes incorrectly called efficiency

2.5.2 CAUSES OF LOW POWER FACTOR (P.F.)

(a) Induction Motor (P.F. = 0.5 ~ 0.9)

(b) Electric Welding Set (P.F. = 0.2 ~ 0.4)

(c) Ballast (choke) units of Discharge Lighting (P.F. = 0.58)

(d) Single Phase Motor (P.F. = 0.4 ~ 0.8)

Note : The common characteristic of these equipment is they consist of Windings.

2.5.3 DISADVANTAGES OF LOW POWER FACTOR

(a) Reduce rated active power (Kw) of electric machinery due to large increase of
current thus temperature rise.

(b) Large voltage drop along power line (IR drop) and thus low receiving end voltage.

(c) Higher ratings of switch gear and cables required thus higher capital investment.

(d) Higher power losses (I2 R)

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2.5.4 POWER FACTOR IMPROVEMENT

(a) Static Capacitors ( Capacitor Banks )

(b) Synchronous Motor (By varying D.C. field to control Power Factor of motor)

(c) Phase Advancer (a special equipment to modify the magnetising current of motor)

P3 = 1.732 VL x IL x P.F

2.5.5 INDUCTIVE CIRCUIT

IL

XL
V Motor Winding

V


Vector
Diagram

IL
(Lagging)

 = Phase Difference between V and IL

Power Factor = cos  (0 to 1.0Lag, 1.0 to 0 Lead)

V
IL Lagging by  o

2



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2.5.6 CAPACITIVE CIRCUIT
IC

V XC Capacitor

IC (Leading)

Vector Diagram


V
  90o

Cos  = Cos 90o = 0 = Power Factor

Power = VI Cos 

= VI x 0

= 0 Watt

Note : Implies capacitor is Loss-Free

IC Leading V by 
o V

Phase Diagram
 2
/2


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2.5.7 POWER TRIANGLES

V


I Cos 
V

I Sin 
I

Multiply By ‘V’

VI Cos 
V

VI Sin 
VI

KW
V

KVA r Power Triangle
KVA

KW = Active Power >>(V I Cos )

KVA r = Reactive Power >>(V I Sin  ) = KW Tan 

KVA = Apparent Power >>(V I)

KW = KVA2  KVAr 2

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2.5.8 REACTIVE POWER (KVAR) BY CAPACITOR

I1 V
AC
Cos 
V
MOTOR

I1

I2 I1
V
V IC AC Cos 2
Cos 1
MOTOR
IC I2
IC
IC
Capacitor I1
Banks

KW

Cos 2

KVAr2
Cos 1
KVA2

KVAr1
KVA1
KVArC

KVAr1 = Total Reactive Power Before PF Correction

KVAr2 = Total Reactive Power After PF Correction

KVArC = Reactive Power Supplied By Capacitor Bank to Improve PF From Cos 1 to

Cos 2

2.5.9 WORKED EXAMPLE

The power plant of an Oil Mill supplies a combined load of 850 at 0.7 power factor
lagging. The normal ratings of these generating set are 3-phase 415 V 50 Hz.

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Calculate :

(a) The reactive power (KVAr) required to improve power factor to 0.9 lagging.

(b) What is the capacitance per phase of the capacitor banks is delta-connected in 6-
steps.

Solution

Active Power = 850 KW

Voltage = 415 V

PF1 = 0.7 lagging

PF2 = 0.9 lagging

Before Correction

PF1 = 0.7 , Cos-1 0.7 = 45.57o

Tan 1 = Tan 45.57o = 1.02

KVAr1 = KW Tan 1

= 850 x 1.02

= 867 KVAr

After Correction

PF2 = 0.9 , Cos-1 0.9 = 25.84o

Tan 2 = Tan 25.84o = 0.48

KVAr2 = KW Tan 2

= 850 x 0.48

= 408 KVAr

(a) KVArC supplied by capacitor banks

= KVAr1 – KVAr2

= 867 – 408

= 459 KVAr
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(b) If capacitor banks are connected in 6-step

459
 KVAr per step =
6

= 76.5 KVAr ( For 3 capacitors, Delta connections)

76.5
KVAr/step/capacitor =
3

= 25.5 KVAr (For 1 capacitor)

For delta connection voltage across each capacitor is 415 V.

25.5  1000
Current in each capacitor IC =  61.44 A
415
V 1
Ic  , where Xc 
Xc 2 fc
Ic  2 fcv

Ic 61.44
 c   471.25F
2 fv 2  50  415

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2.5.10 POWER FACTOR REGULATOR

LED
LIGHTS

BELUK
c/ Cos
0. k 0. 0.90  0.85
0. 3 2 0.
7 0.95
1 1
0.07 1 0.80
5
aut
cap ind - man
+

47 of 116
 2.5.11 C/K SETTING TABLES

For mains voltage Rating per Stage of Reactive VA Control System in KVAr
380 VAC
Current Transformer 5 6.67 8.33 10 12.5 15 16.7 20 25 30 33.3 40 50 60 100
30/5 0.83 1.07
50/5 0.50 0.65 0.83 1.00
75/5 0.33 0.43 0.55 0.67 0.83 1.00 1.11
100/5 0.25 0.32 0.42 0.50 0.63 0.75 0.84 1.00
150/5 0.17 0.22 0.28 0.33 0.42 0.50 0.56 0.67 0.83 1.00
200/5 0.13 0.16 0.21 0.25 0.31 0.38 0.42 0.50 0.63 0.75 0.83 1.00
300/5 0.08 0.11 0.14 0.17 0.21 0.29 0.28 0.33 0.42 0.50 0.56 0.67 0.83 1.00
400/5 0.02 0.08 0.10 0.13 0.16 0.19 0.21 0.25 0.31 0.38 0.42 0.50 0.63 0.75
600/5 0.06 0.07 0.08 0.10 0.13 0.14 0.17 0.21 0.25 0.28 0.33 0.42 0.50 0.83
800/5 0.05 0.06 0.08 0.09 0.10 0.13 0.16 0.19 0.21 0.25 0.31 0.38 0.63
1000/5 0.05 0.06 0.08 0.08 0.10 0.13 0.15 0.17 0.20 0.25 0.30 0.50
1500/5 0.05 0.06 0.07 0.08 0.10 0.11 0.13 0.17 0.20 0.33
2000/5 0.05 0.06 0.08 0.08 0.10 0.13 0.15 0.25
3000/5 0.05 0.06 0.07 0.08 0.10 0.17
4000/5 0.05 0.06 0.08 0.13

2.5.12 SELECTING A CAPACITOR FOR INDUCTION MOTORS

Output Suitable Before Compensation After Compensation

KW Capacitor
KVAr Cos  Current A Cos  Current A

7.5 5 0.79 17 0.97 13.6

11 5 0.80 24 0.93 20.6
15 5 0.83 31 0.93 22.7
22 10 0.84 38 0.96 37
30 10 0.84 59 0.94 54
Synchronous 1000 r.p.m

37 15 0.84 73 0.95 65
45 20 0.85 88 0.97 76
55 20 0.85 107 0.95 95
75 30 0.85 145 0.96 127
90 40 0.85 172 0.97 151
110 40 0.85 210 0.95 187
132 60 0.85 252 0.97 220
7.5 5 0.78 17.5 0.96 14
11 5 0.78 25 0.91 20.9
Synchronous 750 r.p.m

15 5 0.79 33 0.89 29.2

22 10 0.82 46 0.95 39
30 15 0.83 61 0.97 52
37 20 0.83 75 0.97 64

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 45 20 0.84 90 0.96 78
55 20 0.84 110 0.94 96
75 30 0.85 145 0.96 127
7.5 5 0.74 18 0.93 14.2
11 5 0.73 26 0.86 22.1
15 10 0.73 36 0.93 28.1
22 20 0.73 52 0.98 39
30 20 0.73 69 0.93 54
37 20 0.77 80 0.93 66
45 30 0.78 96 0.97 78
55 30 0.78 116 0.95 96
75 40 0.80 154 0.96 128
11 5 0.89 21.5 0.99 19.2
15 5 0.89 29 0.97 26.6
18.5 5 0.89 35 0.96 33
Synchronous 3000 r.p.m

22 10 0.89 42 0.99 38
30 10 0.91 56 0.98 52
37 10 0.91 68 0.97 63
45 15 0.90 84 0.98 77
55 15 0.90 103 0.97 94
75 15 0.90 135 0.95 130
90 20 0.91 163 0.97 153
110 20 0.91 200 0.96 189
7.5 5 0.85 15.5 0.99 13.2
11 5 0.85 22.5 0.97 19.6
15 5 0.86 30 0.95 26.9
18.5 10 0.85 37 0.98 32
22 10 0.86 43 0.98 38
Synchronous 1500 r.p.m

30 15 0.87 58 0.99 50
37 15 0.88 70 0.98 62
45 20 0.86 86 0.98 76
55 20 0.86 105 0.96 93
75 20 0.88 140 0.95 128
90 30 0.88 167 0.97 150
110 40 0.88 202 0.97 183
132 40 0.88 245 0.96 222

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2.6 SPECIFICATIONS FOR SERVICING, MAINTENANCE, OVERHAUL AND REPAIRS
OF ALTERNATOR

2.6.1 SERVICING AND MAINTENANCE

Checks After Initial Start-Up of Alternator Unit

 After 20 hours of operation re-tighten all screws on the alternator

 Perform general inspection

 Check all electrical connections

Air Circulation

 Daily perform visual inspection that the air inlet and outlet grilles are not partially
blocked by any foreign materials.

Bearings (Leroy Somer Alternators)

 Lubricate bearings during operation.

 Regreasing use: Lithium Standard NLGI 3 (Factory Lubrication : Shell ALvania G3)

a) Bearing No. 6226 C3 6235 C3 NU 1028 / MC3

b) Qty of Grease 50 gm 70 gm 35 gm

c) Between Interval 3600 Hrs 1700 Hrs 2000 Hrs

 Check for compatibility berfore using another type of grease.

 Temperature rise in the bearings should not exceed 50 Deg C above ambient
temperature.

 Ambient temperature is taken at 40 Deg C.

Electrical Servicing

Types of Products for Cleaning Windings

 Normal Petrol (no additives)

 Toluene : Slightly toxic, inflamable

 Benzene : Toxic, inflamable

 Ciclohexare : Non-toxic, inflamable

 Cleaning Windings and Diode Bridge

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  Insulating components and impregnation system can be cleansed using approved
cleaning solvents.

 Apply solvent with brush; sponging frequently to avoid solvent accumulation in

housing.

 Dry the windings with dry cloth.

 Let traces of solvent evaporate before re-assembling the machine.

Mechanical Servicing

 WARNING : Cleaning the machine using water or high pressure washer is

prohibited. Warranty is cancelled

 Degreasing : Use a brush and detergent

 Dusting : Use an air gun

 Fitted With Air Filters : Clean filter elements regularly; once a week

 After cleaning check windings’ insulation resistance

2.6.2 OVERHAUL OF ALTERNATOR UNIT

2.6.2.1 3-Phase 380 V 50 Hz 1200 KW 1500 rpm STAMFORD Alternator

Total of Tender Price : Rp

: USD __________________________

Mobilisation Time : Days

Completion Time : Weeks

Warranty Period : Months

Warranty Terms : Reworks shall include labour, equipment, transport, cranage,

insurance coverage, documentation and taxes.

Details Contractor Witness

1. Personal Name : ______________________ ________________________
______________________ ________________________
2. I/C No. : ______________________ ________________________
3. Designation : ______________________ ________________________

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 4. Business Address : ______________________ ________________________
______________________ ________________________
______________________ ________________________
______________________ ________________________

5. Signature : ______________________ ________________________

6. Date : ______________________ ________________________

2.6.2.2 BILL OF QUANTITIES

Cost
Rp USD
1. Service at Site

1.1 Supply labour, tools, equipment, plant and

supervision to disconnect, dismantle and
move out alternator unit.

1.2 Supply labour, tools, equipment, plant and

supervision to re-install, re-connect, re-align
and commission alternator unit.

1.3 Supply cranage and insurance coverage to

load an unload alternator unit.

2. Transportation

Provide transportation to and from including

documentations, insurance coverage, custom tax
etc in order to deliver alternator unit from power
house to repaire workshop and vice-versa.

3. Service at Workshop

3.1 Mount and then run-up alternator unit.

Record vibration readings at various spots.

3.2 Mark, label and diassemble alternator unit.

3.3 Withdraw main rotor unit carefully.

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3.4 Conduct insulation and voltage drop tests.
Record readings.

3.5 Complete cleaning of main stator, main

rotor, exciters and permanent magnet
generator by steam/electric solvent.

3.6 Check journal areas, shaft run-out, core

deflection and other parts. Record
dimensions and observations.

3.7 Touch up and bake windings in electric

oven.

3.8 Re-varnish all windings by dipping into

Class-H varnish.

3.9 Bake and cure varnish in electric oven.

3.10 Clean, re-tropicallise and test AVR unit.

3.11 Dynamic balancing of :

a) Main rotor only

b) Exciter rotor only

c) PMG rotor only

d) Cooling fan only

e) Main rotor with exciter rotor, PMG rotor

and cooling fan installed.

SUB TOTAL c/f Rp USD

3.12 Re-assemble and reconnect alternator unit

3.13 Measure air gaps and insulation resistance.

Record readings.

3.14 Mount and then run-up alternator unit to rate

speed. Measure and record all electrical
readings and vibration level at no-load.

3.15 Repaint complete alternator unit.

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 3.16 Close up all openings with blanks.

3.17 Compile and submit full measurement and

test reports

4. Replacement Cost
MS 
4.1 Supply and replace DE and NDE bearings.

4.2 Supply and replace forward and reverse

diodes (6 pcs)

4.3 Supply and install electric heater c/w

teminat box

4.4 Supply and install zener diode at main rotor

TOTAL OF TENDER PRICE RP USD

(3.1 to 3.17)

2.6.2.3 SCHEDULE OF PARTICULARS

(To be completed by Tenderers)

Item No. Materials Make Type/Class

1. Copper Conductor
2. Varnish
3. Insulation Materials
a) Sleeve
b) Slots
c) Binder
4. Diodes
a) Forward
b) Reverse
5. Bearings
a) Drive End
b) Non Drive End
6. Electric Heater
7. Zoner Diode
8. Paint

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2.6.3 REWINDING OF ALTERNATOR UNIT

2.6.3.1 Phase 380V 50Hz 1500rpm 1200kW ATAMFORD Alternator Unit

Total of Tender Price : Rp _________________

: USD _______________

Mobilisation Time : Days

Completion Time : Weeks days

Warranty Period : Months year

Warranty Terms : Reworks shall include labour, equipment, transport, cranage,

insurance coverage, documentation and taxes.

Details Rewinding Company Witness

1. Personal Name : ______________________ ________________________
______________________ ________________________
2. I/C No. : ______________________ ________________________
3. Signature :
______________________ ________________________
4. Name & Address : ______________________ ________________________
of Company
______________________ ________________________
______________________ ________________________

5. Designation : ______________________ ________________________

6. Date : ______________________ ________________________

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2.6.3.2 SCOPE OF WORKS

Item Supply Labor, Tools & Equipment, Materials, Supervison to Amount

No. Perform the Tasks Described Below:- Rp USD
1. WINDINGS
a) Rewind main stator with Class F Wires
b) Rewind main rotor with Class H Wires
c) Rewind exciter stator with Class F Wires
d) Rewind exciter rotor with Class H Wires
e) Rewind permanent magnet generator with Class F Wires
f) Re-stack stator laminations
2. DIODES
a) Replace 3 pieces forward diodes (Part No. xxxx)
b) Replace 3 pieces reverse diodes (Part No. xxxx)
c) Provide 1 piece zener diode (Part No. xxxx)
3. BEARINGS
a) Replace 1 piece drive end bearing (Part No. xxxx)
b) Replace 1 piece non-drive end bearing (Part No. xxxx)
4. AIR FILTER
Replace 2 pieces air filter cartridges
5. ELECTRIC HEATERS
Embed 3 pieces electric heating elements and metal-clad
terminal box
6. METERS
a) Provide 1 piece KYORITSU 0 – 100V DC Voltmeter
b) Provide 1 piece KYORITSU 0 – 5A DC Ammeter
c) Provide 1 piece 0 – 100oC Jacketed Thermometer
7. DYNAMIC BALANCING
Provide skilled labor, equipment, weights, and supervision
to perform dynamic balancing for rotors, stators, fan and
others
8. AUTOMATIC VOLTAGE REGULATOR (AVR)
Replace 1 unit AVR (Part No. xxxx)
9. PAINTING
Clean and repaint alternator unit

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 10. CRANAGE AND TRANSPORTATION
Provide cranage, transportation and labour to :
a) Move alternator unit from Palm Oil Mill’s Engine Room
to Electrical Workshop
b) Return alternator unit from Electrical Workshop to Palm
Oil Mill’s Engine Room
11. INSURANCE
Purchase all-risk insurance coverage for alternator unit from
date of removal to date of return
TOTAL OF TENDER PRICE Rp USD

2.6.3.3 SCHEDULE OF PARTICULARS

(To be completed by Tenderers)

Item Materials Make Type/Class

No.
1. Copper Conductor
2. Varnish
3. Insulation Materials
d) Sleeve
e) Slots
f) Binder
4. Diodes
c) Forward
d) Reverse
5. Bearings
c) Drive End
d) Non Drive End
6. Electric Heater
7. Zoner Diode
8. Paint

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2.7 ALTERNATOR’S FAILURE : CASE STUDY

2.7.1 Typical Excitation Values (Regulator Output)

a. No-Load Conditions

3PH 50HZ 1500 RPM 3PH 50HZ 1800RPM

BRF FRAME DC DC DC DC
VOLTS AMPS VOLTS AMPS
315/2 12.00 0.53 11.0 0.6
315/3 16.00 0.71 16.0 0.71
315/4 18.00 0.8 17.0 0.76
400/2 14.00 0.63 13.0 0.6
400/3 18.00 0.8 17.0 0.75
450/2 20.00 0.9 18.5 0.82
450/3 22.00 0.98 21.0 0.95
500/1 13.50 0.625 11.5 0.53
500/2 15.00 0.65 11.5 0.6
500/3 15.00 0.65 11.5 0.56
500/4 15.70 0.7 16.0 0.65
500/5 21.00 0.9 19.0 0.8

b. Full Load Conditions

3PH 50HZ 1500 RPM 3PH 50HZ 1800RPM

BRF FRAME DC DC DC DC
VOLTS AMPS VOLTS AMPS
315/2 63.0 2.4 59.0 2.3
315/3 65.0 2.5 61.0 2.4
315/4 68.0 2.6 64.0 2.45
400/2 63.0 2.4 59.0 2.3
400/3 65.0 2.5 61.0 2.4
450/2 68.0 2.6 64.0 2.45
450/3 70.0 2.7 66.0 2.7
500/1 44.0 1.6 38.0 1.4
500/2 57.0 2.3 55.0 2.2
500/3 60.0 2.5 53.0 2.2

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 500/4 66.0 2.8 57.0 2.4
500/5 82.0 3.4 77.0 3.2

2.7.2 Ventilation Requirements

BRF VOLUME OF AIR AT 1500 RPM VOLUME OF AIR AT 1800 RPM

FRAME FT2 MIN M2 MIN FT2 MIN M2 MIN
315/2 2350 67 3000 86
315/3 2450 69 3500 100
315/4 2800 78 3900 110
400/2 2700 77 3600 102
400/3 3300 94 4600 130
450/2 3200 91 3900 110
450/3 4900 140 6200 175
500/1 4200 119 5400 153
500/2 4600 130 5700 163
500/3 5400 153 6800 193
500/4 6200 176 7600 215
500/5 7200 204 8400 238
2.7.3 Generator Reactances (Typical Values)

BRF FRAME SUB-TRANSIENT TRANSIENT SYNCHRONOUS

SIZE (x”d) (x”d) (xd)

315/2 18.0 26.0 360

315/3 15.0 22.0 330
315/4 13.5 19.0 325
400/2 16.0 22.0 240
400/3 13.5 20.0 220
450/2 16.0 24.0 267
450/3 15.0 23.0 225
500/1 16.0 265 240
500/2 16.0 24.0 246
500/3 15.3 23.0 230
500/4 15.7 24.0 232
500/5 14.4 21.0 224

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2.7.4 Winding Resistances (Typical Values)

EXCITERS STATOR STATOR MAIN

BRF
STATOR ROTOR WINDING 1 WINDING 2 ROTOR
FRAME
OHMS OHMS PH OHMS PH OHMS PH OHMS

315/2 22.3 0.14 0.0176 0.0176 1.36

315/3 22.3 0.14 0.0106 0.0106 2.7
315/4 22.3 0.14 0.0055 0.0055 3.16
400/2 22.3 0.14 0.0066 0.0066 1.8
400/3 22.3 0.14 0.0037 0.0037 2.2
450/2 22.3 0.14 0.0032 0.0032 2.0
450/3 22.3 0.14 0.0029 0.0023 2.0
500/1 21.3 0.04 0.00465 - 0.83
500/2 21.3 0.04 0.0029 - 1.00
500/3 21.3 0.04 0.0022 - 1.10
500/4 21.3 0.04 0.0015 - 1.30
500/5 21.3 0.04 0.0011 - 1.50

2.7.5 Reminder (Operating Principles of Alternator Unit)

AVR
MAIN OUTPUT

STATOR STATOR STATOR

DIODES
ROTOR
FIELD

SHAFT

PMG MAIN MAIN

EXCITER EXCITER GENERATOR

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2.7.6 Reminder ( Relationship Between Output Voltage and Excitation Amps / Voltage)

Vs = Voltage induced in main stator/phase

f = Frequency (c/s)

 = Flux (webers)

T = No. of turns/phase

P = No. of poles

N = Speed (rpm)

B = Flux Density (Wb/m2)

I = Amperes at Main Rotor

L = Length of Coil of Main Rotor

 = Absolute Permeability

A = Area of Coil

Vs = 4.44 f  T (1)

PN
But f = (2)
120

and  = B.A (3)

 IT
and B = (4)
L

 IT
 = A (5)
L

Substituting (2) and (5) into (1)

 PN    IT 
Vs = 4.44    A T
 120   L 

Vs = KNI

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2.8 POWER CORRECTION COEFFICIENTS FOR ALTERNATORS

i) Standard ratings for generator are given for the following site condition :

a. Ambient Temperature : Up 40oC

b. Altitude : Up to 1000 m

c. Power Factor : 0.8 p.f

d. Operating Duty : i) Standby and ii) Continuous

For special conditions of operation, the standard ratings given should be multiplied by one or
more of the following coefficient (k).

Where more than one special condition is involved, the total multiplication factor is the
product of the individual coefficient.

ii) Ambient Temperature (Above 400C)

1.1

Rating 1.0
Factor

0.9

0.8
20 30 40 50 60 oC
Ambient
Temperature

Coefficient at 400 C = 1.0

Example : Generator Rated Power at 40oC = 630 kVA
If ambient temperature at site = 50oC
k at 50oC = 0.94
Derated Power Rating at 50oC = 630 x 0.94 = 592 kVA

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iii) Altitude (above 1000 m)

1.0

Rating
Factor 0.9

0.8

0.7
1000 2000 3000 4000

Coefficient at 1000m = 1.0

Example : Generator Power Rating (at 0-1000 m) = 630 kVA
If altitude at site = 2500 m
k at 2500 m = 0.94
Power Rating at 2500 m = 630 x 0.9 = 567 kVA

iv) Power Factor

A) Power Factor (lagging) 0.6 0.7 0.8 – 1.0

B) Derating Factor k 0.85 0.92 1

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 3. ELECTRIC MOTORS AND STARTERS

3.1 PRINCIPLES OF OPERATIONS

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3.1.1 INTERACTION OF CONDUCTOR FLUX AND FIELD FLUX

Notes :

a) Apply current into conductor. Magnetic flux is produced. Use cork screw rule to
define direction of flux.

b) The inter-action of the field flux and the conductor flux produced a force

c) Use Left Hand Rule to determine direction of turn

Left Hand Rule

ThuMb : Motion

First Finger : Magnetic Field

SeCond Finger : Direction of current inside conductor

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 3.1.2 INTER-ACTION BETWEEN STATOR FLUX AND ROTOR FLUX

a) Apply power supply to stator ; alternating flux is produced by stator

b) This alternating flux from the stator cut the rotor bars as such current is generated at
the rotor bars

c) The current generated at the rotor bars in turn produced another set of flux.

d) Because of the inter-actions between the stator flux and rotor flux, a force is
produced

e) The rotor turns according to Left Hand Rule

3.2 CHARACTERISTICS OF MOTOR

3.2.1 CLASSES OF DUTY

1) Continuous Running Duty (Duty Type S1)

Operation at constant load of sufficient duration for thermal to be reached.

2) Short Time Duty (Duty Type S2)

Operation at constant load during a given time, less than that required to reach
thermal equilibrium, followed by a rest and de-energized period of sufficient

66 of 116
 duration to re-establish equality of temperature with the coolant. The recommended
values for short time duty are 10, 30, 60 and 90 minutes.

3) Intermittent Periodic Duty (Duty Type S3)

A sequence of identical cycles, each including a period of operation at constant load

and a rest and de-energized period, these period being too short to attain thermal
equilibrium during one duty cycle, and in which the starting current does not
significantly affect the temperature rise.

4) Intermittent Periodic Duty With Starting (Duty Type S4)

A sequence of identical duty cycles, each cycle consisting of a period of starting, a

period of operation at constant load and a rest and de-energized period, these periods
being too short to attain thermal equilibrium during one duty cycle.

In this duty the stopping of the motor is obtained either by natural deceleration after
disconnection of the electricity supply or by means of braking such as a mechanical
brake which does not cause additional heating of the windings.

5) Intermittent Periodic Duty With Electric Braking (Duty Type S5)

A sequence of identical duty cycles, each cycle consisting of a period of starting, a

period of operation at constant load and a period of electric braking, the period of
operation being too short to attain thermal equilibrium during one duty cycle.

6) Continuous Operation Duty (Duty Type S6)

A sequence of identical duty cycles, each cycle consisting of a period of operation at

constant load and a period of operation at no-load, these periods being too short to
attain thermal equilibrium during one duty cycle.

7) Continuous Operation Duty With Electric Braking (Duty Type S7)

A sequence of identical duty cycles, each cycle consisting of a period of starting, a

period of operation at constant load and a period of electric braking, the period of
operation being too short to attain thermal equilibrium during one duty cycle. There
is no rest and de-energized period.

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 8) Continuous Operation Duty With Related Load/Speed Changes (Duty Type S8)

A sequence of identical duty cycles, each cycle consisting of a period of operation at

constant load, corresponding to a pre-different speed of rotation, followed by one or
more periods of operation at other constant loads corresponding to different speeds
of rotation, each period of operation being too short to attain thermal equilibrium
during one cycle. There is no rest and de-energized period.

Unless otherwise specified, the duration of the duty cycles shall be 10 minutes.

The recommended values of cyclic duration factors are 15%, 25%, 40% and 60%.

9) Designation

The duty type is normally designated by the abbreviations S1, S2, etc, the
abbreviation is followed by an indication of the duration of the duty. For duty types
S3 and S6 the abbreviations are followed by the cyclic duration factor.

Examples : S2 60 min

S3 25%

S6 40%

3.2.2 SUPPLY VOLTAGE VARIATIONS

a) The motors are designed to operate satisfactorily for a voltage variation of  5% and
a frequency variation of  3%. However at extreme limits of voltage and frequency,
the performance figures will be different from those mentioned in name plate.

b) Table below describe the effects of variation of voltage and frequency on the
characteristics of the motors.

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 3.2.3 THE EFFECTS OF VARIATION OF VOLTAGE AND FREQUENCY ON
INDUCTION MOTOR

Alternating Current (Induction Motors)

Characteristics Voltage Frequency

110% 90% 105% 95%

Torque *
Starting and Increase 21% Decrease 19% Decrease 10% Increase 11%
maximum running
Speed **
Synchronous ... No change No change Increase 5% Decrease 5%
Full Load ... Increase 1% Decrease 1.5% Increase 5% Decrease 5%
Per cent slip ... Decrease 17% Increase 23% Little change Little change
Efficiency :
Full Load ... Increase 0.5 to 1% Decrease 2% Slight increase Slight decrease
¾ Load ... Little change Little change do do
½ Load ... Decrease 1 to 2% Increase 1 to 2% do do
Power factor :
Full load ... Decrease 3% Increase 1% do do
¾ Load ... Decrease 4% Increase 2 to 3% do do
½ Load ... Decrease 5 to 6% Increase 4 to 5% do do
Current :
Starting ... Increase 10 to 12% Decrease 10 to 12% Decrease 5 to 6% Increase 5 to 6%
Full Load ... Decrease 7% Increase 11% Slight decrease Slight increase
Temperatur rise ... Decrease 3 to 4o C Increase 6 to 7o C Do Do
Maximum overload Increase 21% Decrease 19% Do Do
capacity
Magnetic noise ... Slight increase Slight decrease Do Do

* The starting and maximum running torque of A.C. induction motors will vary as the square of the
voltage

** The speed of A.C. induction motors will vary directly with the frequency

3.3 INSULATING MATERIALS

3.3.1 TYPES OF INSULATING MATERIALS

INMACO motors are manufactured with class B insulation as standard. Class F and class
H motors are also offered against orders. The insulating materials used for various
classes of insulation are briefly described below :

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 1) Class E

The maximum operating temperature is 120o C. The insulating materials used are
mostly synthetics like Polyester films with trade names like Melinex, Mylar, etc.
Combination of Polyester film with other materials like terylene, presspahn, etc., are
also used. The copper wires are insulated with Polyester or Polyvinyl Acetate (PVA)
enamels.

This class of insulation is still commonly used by most motor manufacturers for
standard small motors.

2) Class B

The maximum operating temperature is 130o C. The insulating materials used are
varnished Fiberglass tapes and cloth, terylene compounds, fiberglass sleevings, mica
and mica-glass combination, etc.

The copper wires are insulated with Polyester enamels.

3) Class F

The maximum operating temperature is 155o C. The insulating materials used are
Nylon compound, with trade names like Nomex, combination of films using Nomex,
silicon varnished glass tapes, glass-resin composite strips, etc.

4) Class H

The maximum operating temperature is 180o C. The insulating materials used are
Nylon compounds, Nomex combinations, silicon varnished glass tapes and sleeving,
etc.

3.3.2 WHY INSULATION IS USED

All insulating materials used in the manufacture of electrical motors perform one or
more of the following functions :

1. Act as a dielectric medium to prevent occurrence of an electrical breakdown

2. To protect the conducting parts from moisture, abrasion, corrosion, etc.

3. To provide mechanical support to conducting parts

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 4. To withstand the heat which is present at their point of use during operation of the
motor. It is essential that the insulating properties of the materials used remain
unaffected at the operating temperatures

3.3.3 WHERE TO INSULATE

Listed below are four principal areas where a potential difference occurs and where,
therefore, insulation must be applied.

1. Between turns in a coil (turn-to-turn)

2. Between coils of the same phase (coil-to-coil)

3. Between coils of different phases (phase-to-phase)

4. Between coils and ground (phase-to-ground)

3.3.4 CROSS SECTION OF STATOR COILS AND INSULATION MATERIALS

3.4 DEGREE OF PROTECTIONS / INDEX OF PROTECTION (IP)

1) Enclosures for motors are designated by the letters ’IP’ followed by two numerals as
explained below :

a) The first numeral designates the degree of protection to persons against contact with live
or moving parts of the motor and to motors against entry of solid foreign bodies.

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 b) The second numeral designates the degree of protection to the motor against harmful
entry of water

c) A letter may appear after the 2 numerals which could be S (indicating that the motor was
rested while stationery) or M (indicating that the motor was tested while in operation)

2) Protection to persons against contact with motor parts and to motor against solid bodies

First
Short designation Degree of protection definition
Numeral
No special protection of persons against accident
Non-protected or inadvertent contact with love or moving parts.
0
machine No protection of machine against ingress of solid
foreign bodies.
Protection against accidental or inadvertent
contact with live or moving parts inside the
Machine protected enclosure by a large surface of the human body,
1 against solid bodies for example, a hand, but no protection against
greater than 50 mm deliberate access to such parts.
Protection against ingress of large solid foreign
bodies (diameter greater than 50 mm)
Protection against contact by finger with love or
Machine protected
moving parts inside the enclosure. Protection
2 against solid bodies
against ingress of small solid foreign bodies
greater than 12 mm)
(diameter greater than 12 mm)
Protection against contact with live or moving
parts inside the enclosure by tools, wires, or such
objects of thickness greater than 1 mm.
Machine protected Protection against against ingress of small solid
4 against solid bodies foreign bodies (diameter greater than 1 mm)
greater than 1 mm excluding the ventilation openings (intake and
discharge) of external fans and the drain holes of
enclosed machines, which may have degree 2
protection
Complete protection against contact with live or
moving parts inside the enclosure.
Machine protected Protection against harmful deposits of dust. The
5
against dust * ingress of dust is not totally prevented, but dust
cannot enter in an amount sufficient interfere with
satisfactory operation of machine

* The degree of protection against dust defined by this standard is a general one. When the
nature of the dust (dimensions of particles, their nature, for instance fibrous particles) is

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 specified, test conditions should be determined by agreement between the manufacturer
and the user.

For first characteristic numeral 2, 4, and 5 with machines cooled by means of an external
fan, the fan shall be so protected as to prevent contact of the blades or spokes of the fan
with the standard test finger. However, at the outlet of the fan the test finger is not inserted
past the 50 mm diameter guard.

3) Protection To Motors Against Harmful Entry Of Water

Second Degree of Protection

Numeral Short designation Definition
0 Non-protected machine No special protection
1 Machine protected Dripping water (vertically falling drops) shall
against dripping water have no harmful effect
2 Machine protected Drops of water falling at any angle up to 15 o
against drops of water from the vertical shall have no harmful effect
falling up to 15o from
the vertical
3 Machine protected Water falling as a spray at an angle equal to or
against spraying water smaller than 60o with respect to the vertical
shall have no harmful effect
4 Machine protected Water splashed against the machine from any
against splashing water direction shall have no harmful effect
5 Machine protected Water projected by a nozzle against the machine
against water jets from any direction shall have no harmful effect
6 Machine protected Water from heavy seas shall not enter the
against conditions on machine in a harmful quantity
ship’s deck
7 Machine protected Ingress of water in the machine in a harmful
against the effects of quantity shall not be possible when the machine
immersion is immersed in water under stated conditions of
pressure and time
8 Submersible machine Ingress of water into the machine in a harmful
quantity shall not possible when the machine is
immersed in water under a specified pressure
and for an indefinite time

NOTE : a machine is weather protected when its design reduces the ingress of rain, snow and
air bone particles under specified conditions to an amount consistent with correct operation.
This degree of protection is designated by the letter W (placed between IP and the numerals).
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 3.4.1 MAKING ENQUIRIES FOR MOTOR

a) When enquiring for an electric motor, specify the followings :

i. Type of induction motor (squirrel cage or slip-ring)

ii. Make

iii. Rated KW/HP

iv. Rated Volts

v. Rated Amps

vi. Rated Frequency

vii. Rated Speed

viii. Class of Insulation

ix. Type of Enclosure (Degree of Protection)

x. Type of Mounting

xi. Duty Type

xii. Service Factor

Note : Local Assembly by Syarikat Jasa Kita – up to 100 HP (Controlled items)

b) Calling for Quotations

3.5 MOTOR STARTERS

3.5.1 Types of Motor Starters

• Direct-On-Line (DOL)

• Star-Delta (SD or  - )

• Auto-Transformer (AT)

• Rotor Resistance (RR)

• Soft Starter (SS)

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3.5.2 Selection of Starters

a) 1 hp – 5.5 hp : Use DOL starter

b) 7.5 – 30 hp : SD starter

c) 40 hp and above : Use AT starter

d) 75hp and above : Use Soft Starter

e) Slip-Ring Induction motor : Use RR starter

3.5.3 Summary of Characteristics of Various Starting Methods

Squirrel – Cage Motor Slip-Ring Motor

Direct on Line Star Delta Primary Auto- Rotor Resistance
Starting Starting Resistance Transformer Starting
Starting Starting
1) Initial 4 to 8 In 1.3 to 2.6 In 4.5 In 1.7 to 4 In 2.5 In
Starting Current
2) Initial 0.6 to 1.5 Tn 0.2 to 0.5 Tn 0.6 to 0.85 Tn 0.4 to 0.85 Tn 2.5 Tn
Starting Torque
3) Usual 2 to 3 secs 3 to 7 secs 7 to 12 secs 7 to 12 secs 3 steps – 2.5 secs
Starting Time
4/5 steps – 5 secs
4) Typical Small Machines High inertia High power or Machine starting
Application machines even starting at no machine with high inertia at full load
starting on full load no special machine when
load torque or the reduction
Small fans, starting current of current peak
centrifugal problem is an important
pump consideration

In = Rated current Tn = Rated torque

3.5.4 Advantage and Disadvantage of Types of Motor Starters

TYPE OF ADVANTAGES DISADVANTAGES

STARTERS
Direct on Line a) Simple and Inexpensive a) High starting current
b) High Starting Torque b) Starting current cannot be
regulated
Star-Delta Relatively inexpensive a) Low starting Torque
b) 6 - terminal motor required
c) Break in Line supply when
change-over (arc and loss of
torque)
d) No adjustment of starting
current

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 Primary Resistance a) Possibility of adjusting a) Small reduction in starting
starting current current
b) No break in line supply b) Require resistor
during starting
Auto-Transformer a) Good torque Require a costly auto-
transformer
b) Possibility of adjusting
starting values
Soft Starter a) Torque can be adjusted a) Expensive
b) Starting current can be b) Electrical Assistance require
adjusted and limited training.
c) Immediate stop can be
avoided
d) Avoid water hammering at
pipeline
Rotor Resistance e) Very good torque a) Slip ring motor more
expensive
f) Low starting current
b) Requires additional resistor
g) Possibility of adjusting
bank
starting current
h) No break in line supply

3.5.5 POWER AND CONTROL CIRCUITS

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Operation

Manual Closing of Main Switch

Press START button
Closing of SC – Star Connection
Closing of MC – Line Connection
Timer is energized and counting
Motor Runs Up to 85% Rated Speed
Opening of SC – Opening of Star Connection
Closing of DC – Delta Connection
Motor now runs on Delta Connection

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 PRIMARY RESISTANCE STARTER
L1 L2 L3

Q1 TP ISOLATOR

F1 FUSE

KM11
KM1
u1 v1 w
R 1 RESISTANCE
u2 v2 w
2

F2 THERMAL
OVERLOAD

M
3~

Operation
Manual Closing of Q1 (Main Switch)
Closing of KM11 – Motor Energised and Run
Timer energised and counting
Closing of KM1 – Shorting of Resistances
Direct Connection of Motor to Line 3

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Power Circuit Operation

Manual Closing of Main Switch

Closing of KM1 – Star connection
Closing of KM2 – Starting of Motor
Opening of KM1 – Opening of Auto-Transformer Star Connection
Closing of KM3 – Motor connected directly to the supply
Opening of KM2 – Disconnection of Auto-Transformer

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80 of 116
 L1 N

240 V 50 Hz SUPPLY

C/F
MOTOR TRIP
1
O/L R 5
4
C
C-1 MOTOR RUN

INTERLOCK RELAY
R
2 3 4
REMOVE LINK WHEN USING
REMOTE START/STOP PUSH
BUTTTON

Control Circuit
Type C (Direct-on-Line)

L1 N

240 V 50 Hz SUPPLY

C/F
MOTOR TRIP
1
O/L TDR-1 D
4 R 5 6 7
C S
P
LC- SP-1
8 L
1
C
LC-2
5
2 3 4 TDR

REMOVE LINK WHEN USING

MOTOR RUN
REMOTE START/STOP PUSH
TDR-2 SP-2
BUTTTON 9 1 D
0 C
HRM
1
0 R INTERLOCK RELAY
Control Circuit
Type B (Star-Delta)

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 L1 N

240 V 50 Hz SUPPLY

C/F
MOTOR TRIP
1
O/L TDR2- TDR1- LC-1
R 1 5 4 1 6 7 TSC

TSC 8 LC-2 9 L
4 C
SC
5 TDR
2 3 9 1
REMOVE LINK WHEN USING
REMOTE START/STOP PUSH TDR
2
BUTTTON TDR1-
2
1 1 LC
0 0
LC-3
HRM

MOTOR RUN
1
Control Circuit 0
R
Type D (Auto-Transformer)

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 L1 N

240 V 50 Hz SUPPLY

MOTOR TRIP

C/F
HRM
1
O/L 4 R 5 SC

SC-1 FR-1
5 TDR1

TDR1-1
6 A
2 3 4 R
REMOVE LINK WHEN USING TDR2
REMOTE START/STOP PUSH
BUTTTON TDR2-1
5 7 FR

FR-2 7 MOTOR RUN

R INTERLOCK RELAY

Control Circuit
Type A (Rotor Resistance)

3.5.6 SELECTION OF ELECTRIC MOTORS, STARTERS AND CABLES

MOTOR STARTER MCCB 3-CORE ARMOURED

ITEM
KW HP Amps TYPE (Amps) CABLE (Sqmm)

1 0.37 0.5 1.2 DOL 20 1 x 2.5

2 0.55 0.75 1.5 DOL 20 1 x 2.5
3 0.75 1 1.9 DOL 220 1 x 2.5
4 1.1 1.5 2.5 DOL 20 1 x 2.5
5 1.5 2 3.2 DOL 20 1 x 2.5
6 2.2 3 4.9 DOL 20 1 x 2.5
7 3.75 5.0 7.5 DOL 20 1 x 2.5
8 4.0 5.5 8.0 DOL 30 1 x 2.5

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9 5.5 7.5 11.0 SD 30 2 x 2.5
10 7.5 10 4.0 SD 30 2 x 2.5
11 11.0 15 20.0 SD 40 2 x 6.0
12 15.0 20 26.5 SD 40 2 x 10
13 18.5 25 35.0 SD 60 2 x 16
14 22.0 30 41.3 SD 60 2 x 16
15 30.0 40 52.4 AT 60 1 x 25
16 37.0 50 70.0 AT 80 1 x 35
17 45.0 60 82.0 AT 100 1 x 50
18 55.0 75 100.0 AT 125 1 x 50
19 75.0 100 135.0 AT 150 1 x 75
20 93.0 125 165.0 AT 200 1 x 95

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 4. POWER CABLES

4.1 TYPES OF CABLES

Common type of cables used in Palm Oil Mill :

Types Denotions
i) PVC Cables PVC or PVC/PVC
ii) PVC Insulated Armoured PVC/SWA/PVC
iii) Hard Drawn Stranded Aluminium Conductor HD AL
iv) Mineral Insulated Cable MICC
v) PVC Insulated Flexible Cords PVC FC

PVC  Polyvinyl – Chloride is a high Resistive material

a) Different Parts of Cables

i) The Conductor

ii) The Insulation

iii) The Mechanical Protection

b) Different Types Of Materials

i) For Conductor : Copper and Aluminium

ii) For Insulation : PVC, Paper, Powdered Mineral, Rubber

iii) For Mechanical : Lead Alloy, Galvanised Steel Wire, Steel Rod, Aluminum Sheath

c) Voltage Range

i) 250/440 volts

ii) 600/1000 volts

iii) 1900/3300 volts

iv) 3800/6600 volts

v) 6350/11000 volts

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 vi) Other higher ranges

d) No. Of Core

i) One Core

ii) Two Core

iii) Three Core

iv) Four Core

v) Multi-Core (Five and Above)

4.2 APPLICATIONS

a) PVC Cables

1. Lighting Point

2. Power Point

3. Motor Point

4. Main Cable for Generator Output

5. Internal Cabling for Main Switchboard and Sub-Switchboard (Motor Control Centre)

6. Overhead Distribution Power Line

b) PVC Insulated Armoured Cable

i. To link main switchboard with Motor Control Centre

ii. To link sub-switchboard with lighting distribution board

iii. To link main switchboard or sub-switchboard with other starter panels outside the main
processing building

iv. Starting and Termination of overhead distribution power line

v. Sometimes for motor point wiring

c) Impregnated Paper Insulated Cable

Similar Application as PVC Insulated Armoured Cable except it is not commonly used for
motor point wiring.

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 Paper insulated cable has higher Ampere rating than Armoured cable but more expensive.

d) Mineral Insulation Cable

i. Boiler House - Boiler Control Wiring

ii. Power Plant - Governor Control Wiring

iii. Steriliser - Process Control Equipment

iv. Pressing Station - Solenoid Valve installed at hot water pipe

v. Other areas with high ambient temperature

MICC cable can withstand ambient temperature of 150oC. Insulation material use is
Magnesium Oxide a Fire-proof material.

e) PVC Insulated Flexible Cord

i. Home Appliances like table fan, air-conditioner, electric kettle

ii. Hand Lamp

iii. Extension Socket

iv. Fractional Horse Power Motor Point Wiring

v. Electronic Equipment

f) Hard Drawn Stranded Aluminium Conductor

Mainly used for overhead distribution power line. For instance, chanelling electric power
from power house to workers quarters.

Common sizes used are :

i. 3/.132 inch

ii. 7/.122 inch No. of strands/wire diameter

iii. 7/.173 inch

g) Method of Installation

i. Laid direct in the ground

ii. Pulled through earthen ware duct or GI pipe

iii. Installed on cable tray or trunking

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 iv. Installed inside conduits

h) Points to Note

i. Cable Trenches

Cables laid direct in the ground shall be buried to a depth of 30 inches. 3 inch deep clean
sand shall be provided at the bottom and at the top of the cable. Good quality house
bricks shall then be laid length-wise along the route.

ii. Cable Ducts

At road crossing, the cable shall be protected with ducting eg G.I. pipe

iii. Cable Tray/Trunking

These shall be installed vertically or horizontally complete with support clips or

retaining clip respectively every 3 feet. The minimum height shall not be less than 7 feet.
20% spare volume and weight capacity should be provided for future use. All cable and
trunking should be painted orange.

iv. Conduits

All conduits shall be galvanized screwed steel type. Saddles shall be provided every 4
feet. Inspection elbows shall be provided at bend. Tee boxes shall be provided at branch-
off. All conduits shall be painted orange.

4.3 IDENTIFICATIONS

a) There phase wiring and busbars are coloured as follows :

Phase A – Red

Phase B – Yellow

Phase C – Blue

Neutral – Black

b) Single phase wiring are coloured as follows :

Live – Red (Brown)

Neutral – Black (Blue)

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 c) D.C. Wiring and bus-bars are coloured as follows :

Positive (+) – Red

Negative (-) – Black

d) Green is the standard colour for earth

4.4 VOLTAGE DROP

When current flows through a conductor, voltage is dropped along the conductor due to
resistance (DC power) or impedance (AC Power). The drop in voltage is in terms of
millivolts/amps/metres.

4.5 CONSTRUCTIONAL VEWS

Single Core Cables

PVC Insulated (B.S. 2004)

250/440 Volts Grade

Reference No. 4491X

Single Core Cables

PVC Insulated and

PVC Sheathed (B.S. 2004)

250/440 Volts Grade

Reference No. 4181Y

Single Core Cables

PVC Insulated (B.S. 2004)

660/110 Volt Grade

Reference No. 5491X

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 Single Core Cables

PVC Insulated and

PVC Sheathed (B.S. 2004)

660/1100 Volt Grade

Reference No. 5181Y

Metric Armoured Cables

PVC/SWA/PVC Two, Three

and Four Core Cables

PVC Insulated and Bedded

Galvanised Steel Wire Armoured,
PVC Sheathed (B.S. 6346)

600/1000 Volt Grade

Flat Two Core Cables

PVC Insulated and

PVC Sheathed (B.S. 2004)

250/440 Volt Grade

Reference No. 4192Y

4.6 Three core cable, single wire armoured and PVC oversheathed

1. Solid aluminium conductor

2. PVC insulation

3. Taped bedding

4. Galvanized steel wire armour

5. PVC oversheath

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4.7 Four core cable, single wire armoured and PVC oversheathed

1. Shaped stranded copper conductor

2. PVC insulation

3. Extruded bedding

4. Galvanized steel wire armour

5. PVC oversheath

4.8 Single core sectoral cable

The conductor consists of four sector shaped solid aluminum conductors laid up together and
bound. Extruded PVC insulation is applied over the conductor followed by a PVC oversheath. A
similar armoured version is also available.

1. Solid aluminium conductor

2. Conductor binder

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 3. Extruded PVC insulation

4.9 Four core cable, aluminium strip armoured, PVC oversheated

Conductors of shaped, solid aluminium are insulated with PVC. The cores are laid up and bound
with PVC tapes, followed by a single layer of aluminium strips and and overall PVC sheath.

1. Solid aluminium conductor

2. PVC insulation

3. Taped bedding

4. Aluminium strip armour

5. PVC oversheath

92 of 116
4.10 Construction of Aluminum Stranded Conductor

7 Strands 19 Strands

37 Strands 61 Strands

91 Strands 127 Strands

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4.11 CURRENT RATINGS

a) Daftar Pembebanan Penghantar Kontinu untuk Tembaga Penampang Persegi

Pembebanan Kontinu (A)

Arus Bolak-balik Arus searah
Penam-
Ukuran Berat Dilapisi lapisan Telanjang Dilapisi lapisan Telanjang
pang
konduktif (Jumlah Batang) konduktif (Jumlah Batang)
(Jumlah Batang) (Jumlah Batang)
mm mm2 kg/m 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
12 x 2 24 0.23 123 202 - - 100 182 - - 123 202 - - 108 210 - -
15 x 2 30 0.27 148 240 - - 128 252 - - 148 240 - - 128 255 - -
15 x 3 45 0.40 187 316 - - 162 282 - - 187 316 - - 162 305 - -
20 x 2 40 0.36 205 350 - - 185 315 - - 210 370 - - 190 330 - -
20 x 3 60 0.53 237 394 - - 204 384 - - 237 435 - - 203 395 - -
20 x 5 100 0.89 325 470 - - 290 495 - - 330 570 - - 300 515 - -
25 x 3 75 0.67 287 766 - - 245 412 - - 287 530 - - 275 485 - -
25 x 5 125 1.11 385 670 - - 350 600 - - 400 680 - - 360 620 - -
30 x 3 90 0.80 350 600 - - 315 540 - - 448 630 - - 325 570 - -
30 x 5 150 1.34 448 760 - - 379 672 - - 475 800 - - 425 725 - -
40 x 3 120 1.07 460 780 - - 420 710 - - 470 820 - - 425 740 - -
40 x 5 200 1.78 576 952 - - 482 836 - - 576 1030 - - 550 985 - -
40 x 10 400 3.56 865 1470 2060 2800 715 1290 1650 2500 865 1550 2180 - 800 1395 1950 -
50 x 5 250 2.23 703 1140 1750 2310 588 994 1550 2100 703 1270 1870 - 660 1150 1700 -
50 x 10 500 4.46 1050 1720 2450 3330 852 1510 2200 3000 1020 1900 2700 - 1000 1700 2400 -
60 x 5 300 2.67 825 1400 1983 2650 750 1300 1800 2400 870 1500 2200 2700 780 1400 1900 2500
60 x 10 600 5.34 1230 1960 2800 3800 985 1720 2500 3400 1230 2200 3100 3900 1100 2000 2800 3500
80 x 5 400 3.56 1060 1800 2450 3300 950 1650 2700 2900 1150 2000 2800 3500 1000 1800 2500 3200
80 x 10 800 7.12 1590 2410 3450 4600 1240 2110 3100 4200 1590 2800 4000 5100 1450 2600 3600 4500
100 x 5 500 4.45 1310 2200 2950 3800 1200 2000 2800 3400 1400 2500 3400 4300 1250 2250 3000 3900
100 x 10 1000 8.90 1940 2850 4000 5400 1490 2480 3600 4800 1940 3600 4900 6200 1700 3200 4400 5500
Catatan :

- Suhu sekitar 30-35o C

- Suhu penghantar tembaga maksimum 65o C

b) Daftar Pembebanan Penghantar yang diperbolehkan untuk Aluminium Penampang

Persegi

Pembebanan Kontinu (A)

Arus Bolak-balik Arus searah
Penam-
Ukuran Berat Dilapisi lapisan Telanjang Dilapisi lapisan Telanjang
pang
konduktif (Jumlah Batang) konduktif (Jumlah Batang)
(Jumlah Batang) (Jumlah Batang)
mm mm2 kg/m 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
12 x 2 24 0.06 100 180 - - 84 142 - - 105 185 - - 80 145 - -
15 x 2 30 0.08 125 215 - - 100 166 - - 130 225 - - 95 175 - -
15 x 3 45 0.12 150 265 - - 126 222 - - 155 270 - - 115 220 - -
20 x 2 40 0.11 165 280 - - 120 220 - - 170 295 - - 125 225 - -
20 x 3 60 0.16 245 425 - - 159 272 - - 200 350 - - 150 280 - -
20 x 5 100 0.27 325 550 - - 195 350 - - 270 460 - - 200 370 - -
25 x 3 75 0.20 240 410 - - 190 322 - - 245 430 - - 185 340 - -
25 x 5 125 0.34 310 535 - - 230 430 - - 320 550 - - 235 440 - -
30 x 3 90 0.24 280 480 - - 205 3385 - - 290 500 - - 220 400 - -
30 x 5 150 0.40 360 625 - - 295 526 - - 380 645 - - 275 520 - -
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 40 x 3 120 0.32 370 630 - - 280 500 - - 380 660 - - 285 525 - -
40 x 5 200 0.54 460 800 - - 376 658 - - 485 830 - - 360 660 - -
40 x 10 400 1.08 670 1200 1650 2250 557 975 1350 1800 700 1240 1750 - 540 1000 1420 -
50 x 5 250 0.67 560 970 1400 1850 455 786 1120 1500 590 1020 1500 - 445 815 1220 -
50 x 10 500 1.35 820 1440 1960 2660 667 1250 1600 2160 850 1520 2140 - 655 1220 1730 -
60 x 5 300 0.81 670 1160 1600 2120 500 900 1300 1730 700 1210 1700 2200 530 960 1420 1850
60 x 10 600 1.62 960 1680 2280 3040 774 1390 1900 2500 1000 1790 2500 3150 770 1430 2030 2600
80 x 5 400 1.08 880 1500 2000 2600 680 1170 1650 2230 910 1600 2200 2800 700 1260 1850 2400
80 x 10 800 2.16 1250 2140 2860 3800 983 1720 2360 3150 1300 2300 3200 4100 985 1840 2640 3400
100 x 5 500 1.35 1080 1880 2450 310 820 1440 2000 2600 1120 2000 2700 3400 855 1550 2220 2900
100 x 10 1000 2.70 1520 2550 3400 4300 1190 2050 2800 3700 1580 2800 3900 5000 1200 2240 3200 4200
Catatan :

- Suhu sekitar 30-35oC

- Suhu penghantar maksimum 65o C

- Untuk pemasangan 4 lapis dibagi dua kelompok dengan suhu udara 50 o C

c) P.V.C. non-armoured single-core (1.0 mm2 to 36 mm2)

(COPPER)

Single-circuit current ratings and associated volt drops for single-core p.v.c. Insulated
cables, non-armoured, with or without sheath (copper conductors)

1.0 mm2 (1/1.13 mm) to 35 mm2 (18/1.83 mm)

Conductor Bunched and Enclosed in conducts or Clipped direct to a surface or on a cable tray,
trunking bunched and unenclosed
2 cables, single phase 3 or 4 cables three- 2 cables, single phase 3 or 4 cables three-
Nominal a.c., or d.c. phase a.c a.c., or d.c. phase a.c
No. and
cross- Current Volt drop Current Volt drop Current Volt drop Current Volt drop
dis (m) of
sectional rating per rating per rating per rating per
wires
area ampere ampere ampere ampere
per metre per metre per metre per metre

mm2 A mV A mV A mV A mV
1.0 1/1.13 11 40 9 35 13 40 12 35
1.5 1/1.38 13 27 11 23 16 27 15 23
2.5 1/1.78 18 16 16 114 23 16 20 14

4 7/0.85 24 10 22 8.8 30 10 27 8.8

6 7/1.04 31 6.8 28 5.9 38 6.8 34 5.9
10 7/1.35 42 4.0 39 3.5 51 4.0 46 3.5

16 7/1.70 56 2.6 50 2.2 68 2.6 61 2.2

95 of 116
 25 7/2.14 73 1.6 66 1.4 89 1.6 80 1.4
35 18/1.53 90 1.2 80 1.0 109 1.2 98 1.0

d) P.V.C., non-armoured single-core (50 mm2 to 630 mm2)

(COPPER)

Single-circuit current ratings and associated volt drops for single-core p.v.c. Insulated cables,
non-armoured, with or without sheath (B.S. 6004 or B.S. 6346) (Copper Conductors)

(50 mm2 to 630 mm2)

Nominal Bunched and enclosed in conduit or Clipped direct to a surface or on a cable Con-
Defined conditions
cross trunking tray, bunched and unenclosed duc-
sectional tor
area of Flat or vertical (2 cables,
2 cables, single-phase 3 or 4 cables, 2 cables, single phase 3 or 4 cables, (3 cables,
conductor single-phase a.c., or d.c., or 3 or
a.c. or d.c three-phase a.c. a.c., or d.c. three-phase a.c. three phase)
4 cables three-phase)
Cur- Volt drop per Cur- Volt Cur- Volt drop per Cur-rent Volt Cur- Volt drop per ampere Cur- Volt
rent ampere per rent drop rent ampere per rating drop rent per metre rent drop
rating metre rating per rating metre per rating ra- per
ampere ampere ting ampere
per per Single Three- per
a.c d.c a.c d.c d.c
metre metre -phase phase metre

mm2 A mV A mV A mV A mV A mV mV mV A mV mm2
50 145 0.97 0.91 125 0.84 175 0.93 0.91 160 0.82 195 0.95 0.91 0.85 170 0.80 50
70 185 0.71 0.63 160 0.62 220 0.65 0.63 200 0.59 240 0.68 0.63 0.62 210 0.59 70
95 230 0.56 0.45 195 0.48 270 0.48 0.45 240 0.45 300 0.52 0.45 0.49 260 0.42 95

120 260 0.48 0.36 220 0.42 310 0.40 0.36 280 0.38 350 0.44 0.36 0.43 300 0.34 120
150 - - - - - 355 0.34 0.29 320 0.34 410 0.39 0.29 0.39 350 0.29 150
185 - - - - - 405 0.29 0.24 365 0.30 470 0.35 0.24 0.36 400 0.25 185

240 - - - - - 480 0.24 0.18 430 0.27 560 0.36 0.18 0.38 480 0.22 240
300 - - - - - 560 0.22 0.14 500 0.25 660 0.33 0.14 0.35 570 0.19 300
400 - - - - - 680 0.20 0.12 610 0.24 800 0.30 0.12 0.33 680 0.17 400

500 - - - - - 800 0.15 0.086 710 0.23 910 0.28 0.066 0.31 770 0.16 500
600 - - - - - 910 0.17 0.068 820 0.22 1040 0.26 0.068 0.30 880 0.15 600

96 of 116
 e) P.V.C., non-armoured twin and multicore (1.0 mm2 to 35 mm2)

(COPPER)

Single-circuit current ratings and associated volt drops for twin and multicore p.v.c.
Insulated and sheathed cables, non-armoured (B.S. 6004 **) (Copper Conductors)

1.0 mm2 (1/1.3 mm) to 35 mm2 (19/1.53 mm)

Conductor Enclosed in conduits or Clipped direct to a surface or Defined conditions Conductor

trunking on cable tray an unenclosed
Nomi No. and One twin One three-core One twin One three-core Onde twin One three-
nal dia. cable, woth or cable, with or cable, with or cable, with or cable, with or core cable,
cross (mm) of without earth without earth- without earth- without earth without earth with or
sectio wires continuity continuity continuity continuity continuity without earth
nal conductor, conductor or conductor, conductor or conductor, continuity
areas single-phase one four-core single-phase one four-core single-phase a.c conductor or
of a.c., or d.c. cable, three- a.c. or d.c. cable, three- or d.c one four-core
con- phase phase cable, three-
duc- phase
tor
Cur- Volt Cur- Volt Cur- Volt Cur- Volt Cur- Volt Cur- Volt
rent drop rent drop rent drop rent drop rent drop rent drop
rating per rating per rating per rating per rating per rating per
ampere ampere ampere ampere ampere ampere
per per per per per per
metre metre metre metre metre metre

mm2 A mV A mV A mV A mV A mV A mV mm2
1.0 1/1.13 11 40 9 35 12 40 10 35 - - - - 1.0
1.5 1/1.38 13 27 12 23 15 27 13 23 - - - - 1.5
2.5 1/1.78 18 16 16 14 21 18 18 14 - - - - 2.5

Flat
4 7/0.85 24 10 22 8.8 27 10 24 8.8 - - - - cables
only
6 7/1.04 30 6.8 27 5.9 35 6.8 30 5.9 - - - - 4
10 7/1.35 40 4.0 37 3.5 48 4.0 41 3.5 - - - - 6

16 7/1.70 53 2.6 47 2.2 64 2.6 54 2.2 - - - - 10

05 7/2.14 60 1.7 53 1.5 71 1.7 62 1.5 86 1.7 72 1.5 25 Circular
85 19/1.53 74 1.2 65 1.0 87 1.2 72 1.0 105 1.2 92 1.0 35 cables

* For twin and multicore non-armoured cables to B.S 6346/1969

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 f) P.V.C., non-armoured twin and multicore (50 mm2 to 300 mm2)

(COPPER)

Single-circuit current ratings and associated volt drops for twin and multicore p.v.c. -
Insulated and sheathed cables, non-armoured (B.S. 6004 ) (Copper Conductors)

50 mm2 to 300 mm2

Clipped direct to a surface or on a cable tray and

Defined conditions
unenclosed
One three or four One three or four-
One twin cable, single phase One twin cable, single-phase
Nominal core cable three- core cable three-
a.c., or d.c. a.c., or d.c.
cross phase phase Conductor
sectional Current Volt drop per Current Volt drop Current Volt drop per Current Volt drop
areas of rating ampere per metre rating per rating ampere per metre rating per
conductor ampere ampere
a.c. d.c. per metre a.c. d.c. per metre

mm2 A mV mV A mV A mV mV A mV mm2
50 140 0.94 0.93 125 0.81 170 0.94 0.93 145 0.81 50
70 175 0.66 0.64 155 0.57 215 0.66 0.64 190 0.57 70
95 215 0.49 0.46 190 0.42 260 0.49 0.46 230 0.42 95

120 250 0.40 0.37 215 0.34 300 0.40 0.37 265 0.34 120
150 285 0.33 0.30 250 0.29 340 0.33 0.30 300 0.29 150
185 325 0.28 0.24 280 0.24 385 0.28 0.24 340 0.24 185

240 385 0.24 0.19 335 0.20 450 0.24 0.19 400 0.20 240
300 445 0.21 0.15 390 0.18 520 0.21 0.15 460 0.18 300

 For twin and multicore non-armoured cables to B.S. 6346/1969

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 g) P.V.C., armoured (1.5 mm2 to 35 mm2)

(COPPER)

Single-circuit current ratings and associated volt drops for twin and multicore armoured
p.v.c. - Insulated cables (B.S. 6346) (Copper Conductors)

(1.5 mm2 to 35 mm2 )

Clipped direct to a surface or on a cable tray and

Defined conditions
unenclosed
Nominal
cross One twin cable, single One, three or four-core One twin cable, single- One, three or four core
sectional phase a.c. or d.c cable, three-phase phase a.c. or d.c. cable, three phase Conductor
areas of
conductor Current Volt drop Current Volt drop Current Volt drop Current Volt drop
rating per ampere rating per ampere rating per ampere rating per ampere
per metre per metre per metre per metre

mm2 A mV A mV A mV A mV mm2
1.5 14 28 13 24 - - - - 1.5
2.5 20 17 17 15 - - - - 2.5
4 26 11 22 9.1 - - - - 4

6 32 7.0 28 6.0 38 7.0 32 6.0 6

10 45 4.1 38 3.6 52 4.1 44 3.6 10
16 58 2.6 50 2.2 68 2.6 58 2.2 16

25 76 1.7 66 1.5 91 1.7 77 1.5 25

35 93 1.2 80 1.0 112 1.2 94 1.0 35

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 h) P.V.C., armoured (50 mm2 to 400 mm2)

(COPPER)

Single-circuit current ratings and associated volt drops for twin and multicore armoured
p.v.c. – Insulated cables (B.S. 6346) (Copper Conductors)

(50 mm2 to 400 mm2 )

Clipped direct to a surface or on a cable tray and

Defined conditions
unenclosed
Nominal One, three or four- One, three or four-
One twin cable, single phase One twin cable, single-phase
cross core cable three core cable three
a.c., or d.c. a.c., or d.c.
sectional phase phase Conductor
areas of
conductor Current Volt drop per Current Volt drop Current Volt drop per Current Volt drop
rating ampere per metre rating per rating ampere per metre rating per
ampere ampere
a.c. d.c. per metre a.c. d.c. per metre

mm2 A mV mV A mV A mV mV A mV mm2
50 150 0.92 0.92 125 0.81 180 0.92 0.92 155 0.81 50
70 180 0.65 0.64 155 0.57 220 0.65 0.64 190 0.57 70
95 225 0.48 0.46 190 0.42 270 0.48 0.46 230 0.42 95

120 260 0.40 0.36 220 0.34 310 0.40 0.36 270 0.34 120
150 290 0.32 0.25 250 0.29 355 0.32 0.25 310 0.29 150
185 340 0.29 0.23 290 0.24 410 0.29 0.23 350 0.24 185

240 400 0.25 0.18 350 0.20 485 0.25 0.18 420 0.20 240
300 460 0.23 0.14 400 0.18 550 0.23 0.14 475 0.18 300
400 520 0.22 0.11 460 0.17 620 0.22 0.11 550 0.17 400

100 of 116
 i) Bare circular copper conductors (risers)

Single-circuit current ratings and associated volt drops for bare or lightly-covered solid
copper conductors of circular cross section

Installed in vertical trunking with a spacing of 75 mm between conductors

Conductor 2 conductors, d.c. 2 conductors, single-phase a.c. 3 or 4 conductors, three-phase a.c.

Diameter Approxima Current Volt drop Current Volt drop ampere per Current Volt drop per ampere
te cross rating per ampere rating metre rating per metre
sectional per metre
area p.f. = 1.0 p.f. = 0.7 p.f. = 1.0 p.f. = 0.7

mm mm2 A mV A mV mV A mV mV

10 79 270 0.55 270 0.55 0.66 270 0.48 0.60

12.5 120 370 0.35 370 0.35 0.51 370 0.31 0.45
16 200 510 0.22 510 0.22 0.39 510 0.19 0.36
20 315 700 0.14 690 0.14 0.32 690 0.12 0.30
25 490 940 0.088 920 0.092 0.27 920 0.081 0.25

j) Flexible Cords

Current ratings and associated volt drops and masses supportable, for flexible cords insulated
with p.v.c.

(B.S. 6500)

Nominal cross No. and diameter Current rating d.c. Volt drop per ampere per metre Maximum mass
sectional area of (mm) of wires or single-phase a.c., d.c. or single- Three-phase supportable by twin
conductor forming conductor or three-phase a.c. phase a.c. a.c. flexible cord

mm2 A mV mV Kg

0.5 16/.20 3 83 72 2
0.75 24/.20 6 56 48 3
1.0 32/20 10 43 37 5

1.5 30/.25 15 31 26 5
2.5 50/.25 20 18 16 5
4 56/.30 25 11 936 5

 28/.15
For p.v.c. parallel-twin non-sheathed cords
42/.15

101 of 116
k) For impregnated paper insulated lead alloy sheathed cables

Single core cables – Textille served or PVC oversheathed

Multicore cables – armoured and served

STRANDED COPPER CONDUCTORS

Run in single – way Approximate volt drop per ampere

Direct in ground Run in air
Nominal ducts per metre
area of
Single core
conductor Single core 4 core Single core 4 core Single core 4 core 4 core
Ground/air Duct

mm2 amp * amp amp amp amp * amp mV * mV mV

16 - 105 - 66 - 91 - - 2.5
25 - 135 - 115 - 120 - - 1.6
35 - 165 - 135 - 150 - - 1.1

50 220 195 190 160 215 180 0.81 0.86 0.82

70 270 240 230 200 275 230 0.58 0.65 0.58
95 320 290 275 240 335 280 0.43 0.53 0.43

120 365 335 310 275 390 325 0.35 0.46 0.35
150 410 375 345 315 445 375 0.30 0.42 0.28
185 460 425 385 355 520 430 0.26 0.39 0.24

240 530 490 440 410 620 510 0.22 0.35 0.20
300 600 550 490 460 710 590 0.20 0.32 0.18
400 680 620 550 530 820 680 0.18 0.30 0.17

500 760 - 600 - 940 - 0.17 0.28 -

630 850 - 660 - 1080 - 0.16 0.27 -
80 940 - 720 - 1220 - 0.15 0.25 -
1000 1010 - 760 - 1350 - 0.15 0.24 -

* 3 cables run in close trefoil formation Maximum conductor temperature

All types – in ground and in air 80oC
 3 cables in single-way ducts in trefoil formation Single core – in ducts 60oC
Multicore 80oC

102 of 116
 l) Stranded Aluminium Conductors ( BS 215/1/170)

Current Rating Capacity in Amperes for Bright

Nominal Copper Stranding and wire Conductors Exposed to Sun with 1 MPH Wind
Sectional area
Area * diameter
and 30o C temperature rise

Sq. in mm2 No./in. mm Sq. in mm2 A

0.022 - 7/.081 7/2.06 0.03607 23.33 106
0.025 - 3/.132 - 0.04104 - 116
0.025 - 7/.087 - 0.04162 - 115
0.035 - 7/.102 - 0.05720 - 139
0.05 50 7/.122 7/3.10 0.08183 52.83 172
0.06 60 7/.134 7/3.40 0.09870 63.55 193
0.075 - 7/.149 - 0.1221 - 218
0.10 100 7/.173 7/4.39 0.1646 106.0 260
0.15 150 19/.128 19/3.25 0.2445 157.6 327
0.20 200 19/.149 19/3.78 0.3314 213.2 390
0.25 250 19/.166 19/4.22 0.4112 265.7 441
0.30 300 19/.183 19/4.65 0.4997 322.7 493
0.35 - 37/.141 - 0.5776 - 533
0.40 400 37/.149 37/3.78 0.6453 415.2 567
0.45 - 37/.161 - 0.7533 - 618
0.50 - 37/.168 - 0.8203 - 648
0.60 - 37/.183 - 0.9731 - 710

* This item denotes in round figures the area of a solid hard-drawn copper rod of resistance
approximately equal to that of stranded aluminum conductor.

4.12 VOLTAGE DROP CALCULATION

Example :

Cable used is 50 sq.mm 4 Core Armoured copper

Cable voltage drop is 0.81 mV/A/m

Total length of cable = 40 metres

Load = 100 Ampere

0.81
Therefore voltage drop =  100  40 volts
1000
103 of 116
 = 3.24 volts

If supply voltage = 415 voltage

3.24
% of voltage drop =  100%
415

= 0.78%

This should not exceed 2.5% as specified in IEE Regulations.

104 of 116
 MULTI CORE CABLE

Pemasangan tidak rapat

Jumlah [Jarak antara permukaan kabel = diameter kabel (jarak dari Pemasangan berhimpit
Penyusunan
pengangga dinding ke permukaan kabel ≥ 2 cm)]
Kabel
kabel Jumlah kabel yang dipasang Jumlah kabel yang dipasang
Tata letak kabel Tata letak kabel
1 2 3 6 9 1 2 3 6 9
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Di atas lantai 0,95 0,90 0,88 0,85 0,84 0,90 0,84 0,80 0,75 0,73
(Above the
floor)

Di atas 1 0,95 0,90 0,88 0,85 0,81 0,95 0,84 0,80 0,75 0,75
penyangga
kabel tertutup 2 0,90 0,83 0,83 0,83 0,80 0,95 0,80 0,76 0,71 0,69
(sirkulasi 3 0,88 0,83 0,83 0,79 0,78 0,95 078 0,74 0,70 0,68
udara 6 0,86 0,81 0,79 0,77 0,76 0,95 0,76 0,72 0,68 0,66
terhindar)

(Enclosed
cable trench)

Di atas 1 1,00 0,98 0,96 0,93 0,92 0,95 0,84 0,80 0,75 0,73
penyangga 2 1,00 0,95 0,93 0,90 0,89 0,95 0,80 0,76 0,71 0,69
kabel terbuka 3 1,00 0,94 0,92 0,87 0,88 0,95 0,78 0,74 0,70 0,68
6 1,00 0,93 0,90 0,87 0,86 0,95 0,76 0,72 0,68 0,66

105 of 116
 MULTI CORE CABLE (lanjutan)

1 2 3 4 5 6 7 8 9 10 11 12 13 14
Dipasang 1,00 0,93 0,90 0,87 0,86 0,95 0,78 0,73 0,68 0,66
pada
konstruksi
besi atau
dinding

Pemasangan Jumlah kabel yang dipasang Jumlah kabel yang dipasang

yang faktor tidak ditetapkan tidak ditetapkan
koreksinya
dapat
diabaikan

106 of 116
 SINGLE CORE CABLE

Jumal Pemasangan tidak rapat Pemasangan 3 kabel diikat

Penyusunan
penyangga Jumlah kabel Jumlah ikatan kabel
kabel Tata letak kabel Tata letak kabel
kabel 1 2 3 1 2 3
1 2 3 4 5 6 7 8 9 10
Di atas lantai 0,92 0,89 0,88 0,95 0,80 0,88

Di atas 1 0,92 0,89 0,88 0,95 0,90 0,88

penyangga 2 0,87 0,84 0,83 0,90 0,85 0,82
kabel tertutup 3 0,84 0,82 0,81 0,88 0,83 0,81
(sirkulasi 6 0,82 0,80 0,79 0,86 0,81 0,79
udara terhindar

Di atas 1 1,00 0,97 0,96 1,00 0,98 0,96

penyangga 2 0,97 0,91 0,93 1,00 0,95 0,93
kabel terbuka 3 0,96 0,93 0,92 1,00 0,95 0,93
(sirkulasi 6 0,94 0,91 0,90 1,00 0,93 0,90
udara tak
terhindar)

107 of 116
 SINGLE CORE (lanjutan)

1 2 3 4 5 6 7 8 9 10
Kabel dipasang satu di atas 0,94 0,91 0,89 Penyusunan kabel
yang lain pada rangka besi yang faktor
atau dinding koreksinya boleh
diabaikan

Dipasang pada konstruksi 0,94 0,91 0,89

besi dan dindng

108 of 116
 5. COMMON ELECTRICAL FAULTS IN PALM OIL MILLS

5.1 TYPES OF ELECTRICAL FAULTS

Common electrical faults :

 Overload/over-current

 Overheat

 Short Circuit

 Earth Fault

 Single Phasing

 Reverse Power

 Under Voltage

 Over Voltage

5.2 CAUSES AND EFFECTS

No Faults Causes Effects

1. Overload-Over-Current a) Machine over-feeding Motor burnt
b) Machine jam
2. Overheat a) Constant start/stop operations Motor burnt
b) Cooling fan not working
c) Blocked coolings fins
3. Short circuit Insulation of cables/windings are a) ACB trips
damaged
b) Motor failure
4. Earth Fault Direct contact between live wire and Endanger operator
machine’s frame
5. Single Phasing Open circuit on one phase Motor runs on
overload
6. Reverse Power Parallel generator at wrong timing Endanger operator
and machine
7. Under-Voltage a) Starting large machine a) ACB trips
b) Voltage drop along cables b) Increase running
amps

109 of 116
 8. Over-Voltage a) External-lightning a) Damage
electronic
b) Internal-mill machineries
equipment
(start/srop operations)
b) Expedite aging of
electronic
components
9. Earth-leakage a) Poor insulation Endanger operator
b) Presence of moisture

5.3 TYPES OF PROTECTION DEVICES

No Faults Protection Devices Available

1. Overload/Over-current a) TOR a) Yes
b) Over-current relay b) Yes
2 Overheat a) Cause by operator Due to human
element
b) Lack of maintenance
3. Short-circuit a) TOR
b) Over-current relay
c) ELCB Yes
d) ELR
e) Earth-fault relay
4. Earth-Fault a) Earth-fault relay
b) ELCB Yes
c) ELR
5. Single Phasing Lack of maintenance Due to human
element
6. Reverse power Reverse power relay Yes
7. Under-voltage Under-voltage coil Yes
8. Over-voltage Surge protectors for power lines and None
signal lines
9. Earth Leakage ELCB/ELR Yes

110 of 116
 6. SHORTCOMING IN MAINTENANCE, OPERATION AND CARE
OF ELECTRICAL EQUIPMENT AND MACHINE

6.1 MAINTENANCE

1. Alternator

a) Insulation resistance of windings are not checked and recorded. Deterioration of

windings cannot be ascertained.

b) Cable terminal box is seldom opened up to inspect for loose connections and heating.

c) Electric heater or carbon lamp is not used to heat up windings to remove moisture when
alternator is not in operation.

d) Blowing of windings is only done at the overhangs. Little attempts are made to remove
dust and dirt in other areas of alternator’s windings.

e) Lubrication of bearings are not properly recorded to maintain standard time for greasing.

f) Diode connections to rotating disc are not checked by torque wrench and as such under
and over tightening occur. Both can lead to failure of rotating diode assemblies.

2. Main Switchboard

a) Arrangement is not made to re-calibrate the overcurrent and earth fault relays
periodically.

b) Defective meters, indicating lights, switched and lighting fittings are commonly found.
This shows lack of maintenance.

c) Cleaning of trench is not done. Water, debris, cockroaches and rats are common sight.

d) Front, side and back covers are not close tightly. Gaps are left behind inviting the entry
of vermin.

e) Defective power and control fuses are not replaced but instead shorted with ‘copper
wire’. This can lead to fire hazard.

f) Main switchboard is seldom being opened up to check for loose connections and
excessive heatings.

111 of 116
 g) The top of main switchboard is dirty and couple with rain water through leaking roof has
caused rust to set in. This leads to entry of water inside main switchboard and probably
short-circuit.

3. Motor Control Panel (MCP)

a) Externally, most MCPs are messy with peeled paint, oil and dirt.

b) Internally, the control wirings and power cables are not strapped and routed properly.

c) MCPs are usually set upon by water, oil and fibre. Little is done to improve the situation.

d) Screw are usually not complete or totally absent from front and back covers. As such
many covers are seen ajar.

e) Contractors are not opened up for servicing. They are left to operate until failures set in.

f) Power fuses are sometimes replaced not according to connected load but what are
available in stock. This can lead to single phasing.

g) Defective indicating lights and start/stop push buttons are commonly found.
Replacement are normally by cannibalizing from spare starter boards.

4. Electric Motor

a) Motors laden with oil, dirt and fibre are easily sighted. The roots of these problem are
not being attended to.

b) Bearings are not lubricated sufficiently but are left to run till failures. Shafts are at times
affected as well.

c) Missing fan covers are not replaced thus damage to fans have occurred.

d) Failures due to alignment, overheat, overload, short-circuit, water ingression etc are
common. These causes can be controlled with proper maintenance.

e) Missing screws from cable terminal box can be found. This can lead to short-circuit due
to ingreesion.

f) In the past. Wound rotors have failed due to defects of spring tension and carbon brushes
being too short. Scouring and arcing at slip rings are bad signs.

g) Many times after a motor is opened up and re-assembled the coil terminals are not
installed in the right order. This shows poor maintenance technique.

112 of 116
 h) The loading on each phase of an electric motor should be periodically checked.
Unbalanced loading is a sign of imminent failure. If the problem is identified in the early
stage, the motor could be saved by just cleaning and revarnishing.

5. Lighting Fitting

a) A large proportion of existing fittings are without bulbs and tubes. These forgotten
fittings are being left alone to ‘rot’.

b) Fittings in use are usually dirty or covered with cob-webs. This points to lack of
maintenance again.

c) Reflector which is an important part of a lighting fitting in terms of light intensity

emmission is not maintained clean and shiny.

d) Control box has been neglected to such an extend lizards have claimed habitat over it.
Since the choke acts as a current limiter, short-circuit by lizard can cause failure to these
fittings.

e) At times bracket has come loose and fittings are left dangling by the wire. Beside the
danger of falling on someone’s head, it can cause nuisance tripping of ACB due to earth
leakage.

6. Earthing

a) Earthing is one of the most neglected part of the electrical system in our palm oil mill.
Many times difficulty is encounter trying to locate these points and sometimes they are
not found at all.

b) Ironically, earthing is a very important part of any electrical system where providing
protection to electrical installations and operators are concerned.

c) Electrocution or explosion can happen if a fault is not isolated quickly due to defective
earthing. Maintenance of earth leads and earth electrodes must not be neglected but
instead given the same treatment like other important installations.

d) Periodic checking of earth resistance is important for effective operation of protection

relays. This is rarely done by Mill maintenance team.

e) Broken chamber and cover are not replaced.

f) Conceal earthing points are not attended to but are left alone to be forgotten.

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 g) Clamping of earth leads to earth electrodes is not being checked. Good connection is
important to effective earthing.

h) The reason for not maintaining this earthing system is mainly because of non-availability
of earth tester. Arrangement should be made with wiring contractor to perform the test
once a year.

7. Overhead Lines

a) Rotting poles and heavily sagged lines are just a few signs of poor maintenance.

b) Leaning poles are nor corrected but left to fall.

c) Tension on stay wires are not checked and retightened.

d) No arrangement is made to do maintenance at pole top like checking cracked shackle

insulators and bindings.

e) Anti-termite paint is not renew at pole bases thus deterioration of wood poles are
expedited.

f) Connection through line taps between service line and main lines are never checked.

8. Instrumentation/UPS

a) Field equipment like solenoid valves, actuator, regulator and transmitter are usually
cover with oil and dirt.

b) Removing water from air regulator is normally forgotten.

c) Lubricating the moving mechanism of control system is neglected.

d) Dust and dirt accumulation inside UPS is not attended to. When these inter-act with
moisture, a conductive path is formed where shoort-circuit and mal-function can happen.

e) Maintenance of UPS batteries is totally lacking. Some mills have already reported
battery failure.

6.2 OPERATIONS

1. Alternator

a) Operating at above or below rated value is undesirable.

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 b) High excitation will be introduced into the alternator operating at below rated speed.
This can lead to failure of windings.

c) Loading is not progressive but are buil up in short duration. Shock loading can lead to
failures.

d) The sharing of load between alternators in parallel are not proportional to their ratings.
This does not comply with manufacturer’s request.

e) Under-speed and over-voltage protection is not periodically checked to confirm these are
in good working condition.

f) Paralleling procedures are not strictly followed by all engine drivers and electrical
workers. The generated voltages are not adjusted to equal magnitude and in phase when
the main air-circuit breaker is closed.

g) Defective synchronoscope has been seen in used for months and no arrangement is made
to replace the defective unit. Only the synchronising lights are taken as guide to
synchronise alternator sets. This metode is highly dangerous.

2. Electric Motor

a) The most common mal-treatment of electric motor is frequent running and stopping in
short durations leading to winding failure. This particularly true for screw-press drive.

b) The setting of thermal overloads relay does not usually match the rated current of the
electric motor. There are adjusted just to prevent frequent trippings and thus stoppages of
machinery but at the expense of the electric motor.

c) Electric motor emitting excessive heat should be identified and checked. Very often no
one pays any attention to these motors.

d) Checks should be done to compare the running and rated amperes to prevent
overloading.

e) When replacing electric motor ensure the correct size and type are used. This is not
always the case and as result the original designs are all upset.

f) When the floors are being cleaned by hosing, the motors are not spared at all. The mill
management does not spared at all. The mill management does not make any effort to
stop such practice but only watch with astonishment.

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 3. Uninterruptible Power Supply System (UPS)

a) Additional loads are seen to be connected to the UPS without looking into the designed
capacity. Problems have been reported in these mills.

b) Operating procedures are not strictly complied with. Loads are not switch on and off
individually as instructed but the switch at the UPS is used. High surge is generated by
this manner of switching which can cause damage to UPS or electronic equipment.

c) Food and container have been seen placed on top of UPS for warming. The UPS is also
conveniently used as table top to keep files and number tags. These must be stopped
immediately to avoid problems.

6.3 CARE

Generally care of equipment is lacking at mill level. More interest and thought should be given
to equipment by mill personnel. The shortcomings are as following :

a) Spare equipment are not kept in clean, dry and cool place.

b) Spare equipment are not oiled to prevent rust

c) Most electrical workshop are messy without proper compartment for storing electrical
components. Instead everything is being thrown at one corner, more damage is done.

d) Before handling any equipment care must be taken to ensure they are securely fasten.

e) Loading and unloading of equipment shall be gradual and not being thrown off suddenly.

f) Care must be taken to comply with manufactures instructions on installation, operation and
maintenance.

g) When dismantling any equipment do not throw parts around but instead should be kept in
container or box.

PREPARED BY : GAN SAIK NGAI

PROFESSION : ELECTRICAL CONSULTANT

DATE : 02 MAY 2017

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