BEE2922

INDUSTRIAL INDUSTRIAL INSTALLATIONINSTALLATION

Syllabus1. Electrical Power Supply (T)• Institution of Electrical Engineers (IEE)regulation • Power Distribution

2. Main Switch Board-MSB (T)– Power factor correction – Switchgear and protective devices-RCCB,ACB,VCB– Over current protective devices-CT ratio, TMS(time

multiply setting) , relays– Standby generator

3. Sub-Switch Board-SSB (T)• Feeder pillar• Choose of cable size• Switchgear and protective devices-

MCCB,ACB,fuses• Meters

4. Distribution Board-DB (T)• Current carrying capacity• Cable sizing• Circuit breaker rating • Three phase and single phase supply• Assessment

5. Loads (T)– Total Connected Load(TCL)– Current carrying capacity– Voltage drop– Sensitivity – Balanced three phase circuit – Maximum demand– Tariffs

6. Project (P)• Configuration of tools and equipment• Schematic drawing-assignment• Conduit and trunks • Installation and wiring• Cables - Armoured cable • Inspection and Testing- Condition of equipment and materials,

continuity, insulation, termination, earth electrode

LEARNING OUTCOMESThis subject introduces student to three phase wiring.

The students will learn how to do electrical wiring involving three phase supply and also the safety

measures required.

The students should be able to:i. Differential between domestic and Industrial wiringii. Demonstrate the component and function of

distribution boardiii. Explain the flow of distribution power system.iv. Practice right installation and wiring technique.

CHAPTER 1

• ELECTRICAL POWER SUPPLY IEE

POWER DISTRIBUTION

IEE REGULATION

• The 16th IEE regulation (Institution of Electrical Engineers) currently is used in commenwealth countries

• It must be follow as practically in order to achieve/fulfill the safety and rule requirement

ELECTRICAL REGULATION 1994

• The rule to describe how the activities in generation, transmission, distribution, consuming, supervising, handling, license, competent person, importing, manufacturing, upgrading, etc is applied

COMPETENT PERSON

• Pendawai Elektrik (Wireman), PW1 to PW6• Penjaga Jentera Elektrik (Chargeman), A0 to A4• Penyelia Elektrik (Electrical Supervisor)• Pencantum Kabel (Cable Jointer)• Jurutera Elektrik Kompeten (Competent Engineer)• Jurutera Elektrik Perkhidmatan (Servising Engineer)• Jurutera Elektrik Kompeten Residen (Competent

Resident Electrical Engineer)

POWER STATION

ALTERNATOR

Main intake substation

POWER GENERATIONTNB 33kV/11kV

11kV/433kV substation

TRANSMISSION and DISTRIBUTION

CHAPTER 2• MSB (LV 415V)

• CHAPTER 2 :POWER DISTRIBUTION

TNB SUBSTATION

MAIN SWITCH BOARD

SUB SWITCH BOARD

DISTRIBUTION BOARD

LOAD

11 kV

415V

415/240V

415/240V

POWER DISTRIBUTION

MSB(415V)

SSB415V

SSB415V

SSB)415V

STANDBY GENSET

MSB

SSB SSB SSB SSB

DB DB DB DB

INSIDE SUBSTATION

Ring Main Unit (RMU) / Ring Main Unit (RMU) / Switchgear 11kVSwitchgear 11kV

Transformer (11/0.415kV)Transformer (11/0.415kV) MSBMSBFeeder pillarFeeder pillarHigh voltage & low voltage cableHigh voltage & low voltage cable

2.0:MAIN SWITCH BOARD(MSB)

2.1 CAPACITOR BANK• power factor correction

<= 0.85• Lowest PF – penalty

RESIDUAL CURRENT CIRCUIT BREAKER (RCCB)

• Automatic Circuit Breaker for current leakage to earth

• Current rating:40A and 60/63A

• Sensitivity of current leaking :10mA, 30mA, 100mA, 300mA

• Three phase and single phase type

2.3 AIR CIRCUIT BREAKER

• Current rating – 600A and above

• Add - Current Transformer, relay and shunt trip coil for operation

• Current trip be adjusted

2.3 CT, TMS, RELAY

CURRENT TRANSFORMER (CT)

2.4 STANDBY GENSET

3.0 SSB

3.1 SWITCH GEAR PROTECTION3.2 RCCB, ACB, VCB

Type of protection

• Over current (short circuit)• overload• earth fault• earth leakage• lightning• Overheating• unbalance phase• reverse phase sequence

3.0 SUB SWITCH BOARD (SSB)

EARTH FAULT RELAY

MOULDED CASE CIRCUIT BREAKER (MCCB)

• Function=MCB• For 60A and above usage• For three phase power supply• Replace switch fuse and fuse switch• ON- after Short circuit and over loading• Easy to operate

3 PHASE ELCB CONSTRUCTION

R Y B N

Perintang uji

Punatekan uji

Teras besi ( Gelung secondary )

PLBB Tiga Fasa

Elemen sensitif

Suis 4 kutub jenis link

BEBAN

BALANCE CONDITION

R Y B N

BEBAN

20A 20A 20A

20A

UNBALANCE CONDITION

R Y B N

bocor ke bumi

BEBAN

20A 20A 20A

10A

3.2 FEEDER PILLAR

CABLE CONSTRUCTION

• conductor – Aluminium/Copper• insulator – Paper, PVC, XLPE• Lembar (strand) – helaian paling

kecil• core – himpunan helaian• Perisai (armour) – perlindungan

mekanikal• Salut (sheath) – kemasan luaran• Pengisi (filler) – mengisi ruang

kosong• Screen (thin copper foil) – stress

uniformity• Pengalas (bedding) – alas antara

bahagian keras dgn bahagian lembut

PILCDSTAS CABLE (PAPER CABLE)

VARIOUS TYPE OF CABLES

KABEL PVC/SWA/PVC

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3.3 CABLE SIZE vs CURRENT RATINGmm SQUAREmm SQUARE CURRENT (A)CURRENT (A)

11 13.513.5

1.51.5 17.517.5

2.52.5 2424

44 3232

66 4141

1010 5757

1616 7676

2525 101101

3535 125125

5050 151151

7070 192192

9595 232232

120120 269269

150150 300300

3.4 METERS

kWhour meter

CT meter

4.0 DB

CURRENT CARRYING CAPACITYFUSE/MCB (Amp)FUSE/MCB (Amp) CABLE SIZE (mmCABLE SIZE (mm²)²) MAX POWER(watt)MAX POWER(watt)

5/65/6 1.51.5 1000/12001000/1200

1515 2.52.5 1 x 13A s/s/o1 x 13A s/s/o

2020 2.52.5 2 x 13A s/s/o2 x 13A s/s/o

30 (gelang)30 (gelang) 2.52.5 10 x 13A s/s/o10 x 13A s/s/o

30 (jejari)30 (jejari) 4.04.0 6 X 13A s/s/o6 X 13A s/s/o

1515 2.52.5 1 x cooker 3 kW1 x cooker 3 kW

3030 4.04.0 1 x cooker 8 kW1 x cooker 8 kW

1515 4.04.0 1 x heater 1.5kW1 x heater 1.5kW

1515 4.04.0 1 x 1.5 HP air cond1 x 1.5 HP air cond

3030 6.06.0 1 x 2.5 HP air cond1 x 2.5 HP air cond

6363 16/2516/25 Kabel masuk utamaKabel masuk utama

4.0:DB-SINGLE PHASE

• CONTENT:ISOLATOR (63A)ELCB -4 poleLIVE TERMINALNEUTRAL TERMINALEARTH TERMINALMCB

CABLE SIZING• 1.25 / 1.5 mm square (lamp/fan circuit)• 2.5 mm square (socket 13A, radial)• 4.0 mm square (socket 13A, ring)• 6.0 mm square (socket 13A, ring)• 10.0 mm square (main cable)• 16.0 mm square (main cable)• 25 mm square (main cable)• 35 mm square (main cable)• 50 mm square (main cable)• 70 mm square( main cable)

MCB

Cable sizing sizesize No of core/No of core/

Core Core size(diametsize(diamet

er)er)

LOadLOad voltage voltage ratingrating

Size of Size of cable cable

(diameter)(diameter)

1.25 1.25 mmmm22

(7/0.53 (7/0.53 mm)mm)

lamp circuitlamp circuit 300/500 300/500 voltvolt

2.5 mm2.5 mm

1.5 mm1.5 mm22 (3/0.737 (3/0.737 mm)mm)

lamp circuit/ lamp circuit/ heaterheater

300/500 300/500 voltvolt

3.0 mm3.0 mm

2.5 mm2.5 mm22 (7/0.67 (7/0.67 mm)mm)

Power Power circuit/water circuit/water heater 5kW- heater 5kW- 20A20A

400/750 400/750 voltvolt

3.7 mm3.7 mm

4 mm4 mm22 (7/0.85 (7/0.85 mm)mm)

water heater water heater 7kW- 30A7kW- 30A

400/750 400/750 voltvolt

4.2 mm4.2 mm

INTERNAL MCB COMPONENT

MCB-internal design

Earth chamber & earth electrode

• Earth chamber & earth electrode

EARTH RESISTANCE MEASUREMENT

• The grounding system is an essential element for the electrical system security and it is required to:

• Allow for protective devices activation when there is an insulation fault.

• Equalize the potential of conductive parts that can be accessed simultaneously, with the potential in the surrounding soil in order to prevent people from being exposed to hazardous voltages.

• Allow the lightning strike energy to be safely dissipated.

• Reduce electromagnetic interferences.

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Earth electrode• Standard Earth Electrode 6

inches length• Galvanised Iron (G.I) hollow

pipe with diameter 2 in• Wire mesh • Max resistance-for

domestic wiring=1 ohm• Max resistance-for

lightning=10 ohm

Down conductors

Air terminal

5.1: total connected load• TCL is a total load in

each electrical equipment it is need supply for project or installation

• These equipment – lamp, fan, power point, lift, water pump, and electrical equipment

• Exp:

loadload raterate

1 x 18 W1 x 18 W 30W30W

1 x 36 W1 x 36 W 50W50W

Ceiling Ceiling fanfan

65W65W

EmergencEmergency lampy lamp

20W20W

Socket Socket outlet outlet 13A13A

250 W250 W

Socket Socket outlet outlet 15A15A

500 W500 W

VOLTAGE DROP

• IEE regulation-• Voltage drop≤4% from voltage source• EXAMPLE :VOLTAGE SOURCE= 240VMAXIMUM VOLTAGE DROP =240 X 4% = 9.6V

• VOLTAGE SOURCE =415VMAXIMUM VOLTAGE DROP=415 X 4% = 16.6V

CHAPTER 6: size of trunks

cable sizecable size Cable factorCable factor

1.5 mm1.5 mm 8.18.1

2.5 mm2.5 mm 11.411.4

4 mm4 mm 15.415.4

6 mm6 mm 22.922.9

10 mm10 mm 36.336.3

• CABLE FACTOR

• Trunks factor

Trunks size (mm)Trunks size (mm) factorfactor50 x 3850 x 38 767767

50 x 5050 x 50 10371037

75 x 2575 x 25 738738

75 x 3875 x 38 11461146

75 x 5075 x 50 15551555

75 x 7575 x 75 23712371

100 x 25100 x 25 99.399.3

100 x 38100 x 38 15421542

100 x 50100 x 50 20912091

100 x 75100 x 75 31893189

100 x 100100 x 100 42524252

example• Calculate the size of trunks to carried the cable size as below:a. 12 x 1.5mm²b. 16x2.5mm²c. 8 x 4mm²d. 4x6mm²

solution

• define the cable factor:a. 12 x 1.5mm² =12 x 8.1=97.2b. 16x2.5mm²=16 x 11.4=182.4c. 8 x 4mm²=8 x 15.4= 123.2d. 4x6mm²= 4 x 22.9= 91.6

• 494.4

• Trunks size=75 x 25 mm

FLAXIBLE CONDUIT

TYPE OF TRUNKING

STARTING

4 cm

X

X

TRUNKING -90 °

XX

X

20cm 5cm5cm

X

XX

X

X

TRUNKING 45 °-1

XX

X

X

45

2cm 2cm

20 cm

20cm

X X

X

X

TRUNKING 45 °-2

X

X

X

45

2cm 2cm

X

=28.5cm

X

X

ENDING

5 cm

X

X

CAP

5 cm 5 cm20 cm

X

X

X

X

X

90˚

2 cm2 cm

2 cm 2 cm

X

45˚-2

45˚-1

20 cm

DOL

TO MOTOR

MCB 32 A

O/L

CONTACTOR

Inside DB (Three Phase)

MCCB(40A)

ELCB(40A)

CON(32A)

10A

20A

20A

32A

32A

TO DOL

TO SOCKET OUTLET

SPARE

SPARE

EN

INCOMING FROM ISOLATOR

E/S

CABLE SIZE: 4mm

A1

A2

SPARE

RING CIRCUIT

S/O 2S/O 1

S/O 3

MCB (20A)E N

Cable size:2.5mm

R BY N E

Moulded-Case Circuit Breaker

(MCCB)

Earth Leakage Circuit Breaker (ELCB)

Magnetic Contactor

(MC) Emergency Stop Button

Coils

A1

A2

Neutral Link

Neutral bar

Earth bar

Miniature Circuit

Breaker (MCB)

32A

32A

20A

20A

10A

to D.O.L starter

SPARE

SPARE

SPARE

to Outlet Socket

4mm Cable

From MCCB until MCB

2.5mm Cable

DOL Starter

Socket Outlet

One Way Switch

Socket Outlet

OVERALL LAYOUT

TRUNKING (2”X2”)

CONDUIT(3/4”)

DB

DOL

S/O 1

S/O 3

S/O 2

E/S

45°

45°

90°

90°

12”

7”7”

9”

9”

10”

10”16”

12”

10”

10”

45°

45°

Practical FLOW WORK

START

CONDUIT-measurement, cutting, bending and threading

TRUNKING (body & cap)–measurement, cutting, hole

Conduit fitting-clip

TRUNKING FITTING-screwing

WIRING

TESTING

TEORI

ASSESSMENT

• Quizzes (5%)• Test (10%)• Practical (35%)