25 Common Problems

for M&E Engineers

Armada Hotel , Petaling Jaya
26
th
May 2011
10 Common Electrical
Design Problems Part II
Ir. Looi Hip Peu
Hon Sec, ACEM (2010/11)
B.Eng (Hons) (Electrical)
P.Eng (5226), Jurutera Gas
hplooi@unifi.my
26
th
May 2011 hplooi@unifi.my
CONTENT
2
System Design Wiring Design Protection Installation
Objectives of this Workshop
1. Tariff selection
2. Generator sizing
3. Earthing system
4. PE cable
selection
5. Mains cable
sizing
6. Al vs Cu cables
7. RCD selection
8. Motor starting
9. Standards
10. Malaysian
wiring code
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Al umi num & Copper Cabl es 6
Cur r ent l y t he mar ket f or copper i s uns t abl e
and copper pr i ce has become hi gh. Thi s has
af f ec t ed t he demand f or copper cabl es wi t h
Cl i ent s and cont r ac t or s r equest i ng
des i gner s t o change f r om copper t o
al umi num cabl es .
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WIRING DESIGN AL & CU CABLES 4
6
What are the possible impact on design, cost and future
operation. Is AL cables a fire hazard?
Unfortunately professional engineers faced with such
request cannot brush them off easily due to the cost
implication neither can they satisfactorily answer their
clients.
6
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6
Propert i es of Mat er i al
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WIRING DESIGN AL & CU CABLES 7
6
Material Thermal
expansion, at
25 C
m-m
-1
K
-1
Volumetric
coefficient, ,
at 20 C
(10
6
/C)
Electric
Resistivity
[nm] at
20 C
Melting
Point
Aluminum 23.1 87 28.2 933 C
Copper 16.5 51 16.8 1084.6 C
Steel 17.3 51.9 ~ 100 ?? C
AL has hi gher c oef f i c i e nt of ex pans i on
AL has a hi gher el ec t r i c r es i s t i vi t y. Al c abl e s i z e wi l l
have t o be one s i z e l ar ger
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WIRING DESIGN AL & CU CABLES 8
6
Pos s i bl e haz ar d f or Copper Cabl es
Galvanic reaction between AL and copper terminals.
Proper AL-Cu terminals will be required.
Al has a higher coefficient of expansion. Cable
connections may loosen in the long run.
AL wiring not properly installed is a fire hazard mainly
due to loosening connections at terminals.
AL subject to galvanic reaction with copper and steel
terminals.
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Al l cabl es <70mm s houl d be copper. I ndi a
has t he most exper i enc e i n usi ng Al cabl e
sys t em i nbui l di ng. I n I ndi a t he r ul e of <
70mm t o be c opper hol ds .
Cabl es us ed out door may be AL .
Pr oper cabl e connec t or s at t er mi nal s s houl d
be us ed. Al cabl e t er mi nat i ons and
connec t or s ar e r ecogni s ed as a maj or caus e of
f i r e f r om over heat i ng.
Al cabl i ng syst em s houl d be s ubj ect t o annual
c hec k of cabl e t er mi nat i ons .
WIRING DESIGN AL & CU CABLES 9
6
Bes t Pr ac t i c e f or AL cabl i ng sys t ems
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Concl usi on
1. Engineers should ensure proper terminations and cable
bimetal joints/lugs are used.
2. Practitioners should properly advise client and property
manager on the need for regular check due to risk of fire
hazard from AL cable terminations.
3. Cost savings in AL cables may have consequences for
maintenance!
WIRING DESIGN AL & CU CABLES 10
6
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Resi dual Cur rent Devi ces ( RCD) 7
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Res i dual Cur r ent Devi c es ar e es s ent i al
i t ems i n wi r i ng des i gn. However wi t h t he
wi des pr ead us e of el ec t r oni c l oads ,
s pur i ous/i nt er mi t t ent t r i ppi ng by RCD ar e
a bane f or t he des i gn engi neer.
RCD
12
7
1. Understanding RCD.
2. RCD design for electronic
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RCD class of protection device measuring residual currents
ELCB Earth Leakage Circuit Breaker 2 types (i) Voltage ELCB & (ii)
Current ELCB.
IEC coined the term RCD to refer to i-ELCB so as to differentiate it from v-
ELCB
RCCB Residual Current Circuit Breaker refers to RCD fitted with or to a
circuit breaker e.g. RCD fitted to socket outlet with breaker to
disconnect outlet woul be a RCCD.
RCBO Residual Current Breaker with Overcurrent refers to RCD fitted
with O/C device e.g. RCD fitted to MCB or MCCB.
GFI term used in North America for RCD.
Common terms confused with RCD:
RCD
13
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RCD
14
7
Types of RCD
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RCD
15
7
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RCD
16
7
Despite its reputation for protection; the biggest
problem afflicting RCD is spurious tripping.
Most spurious/intermittent tripping can be resolved
either due to choice of RCD or design issues in
network.
Common response:
remove/disable RCD;
Replace with a less sensitive RCD
BOTH METHODS ARE DANGEROUS AND SHOULD BE
AVOIDED!
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RCD
17
7
IEC 62350 GUIDANCE FOR THE CORRECT USE OF RESIDUAL
CURRENT OPERATED DEVICES (RCDs) FOR HOUSEHOLD AND
SIMILAR USE.
RCD
18
7
Best Practice RCD
Choose the right RCD for the right
kind of load:
Loads 1, 4, 5, 8 Type A
Loads 8 & 9 Type AC
Loads 1 - 9 Type B
Estimate leakage current of loads
and select sensitivity of RCD
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Mot or St ar t i ng 8
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PROTECTION MOTOR STARTING
20
Pr ot ect i on Rel ay keeps t r i ppi ng on
Mot or St ar t i ng
Many r easons can be at t r i but ed t o t hi s
phenomenon:
8
Mechanical system issues
Mismatch in protection device and motor starting surge.
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SELECT TRIPPING CURVE OF PROTECTION RELAY TO TAKE INTO
ACCOUNT STARTING SURGE.
PROTECTION MOTOR STARTING
21 8
IDMT CURVES
NORMAL INVERSE
VERY INVERSE
EXTREMELY INVERSE
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SELECT TRIPPING CURVE OF PROTECTION RELAY TO TAKE INTO
ACCOUNT STARTING SURGE.
PROTECTION MOTOR STARTING
22 8
IDMT CURVES
NORMAL INVERSE
VERY INVERSE
EXTREMELY INVERSE
Motor
starting
surge
Choose
curve 3
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Mal aysi an Wi r i ng St andards 9
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Currently specification of consultants are not updated to
reflect actual update. Some of the update are mandatory
under Malaysian laws.
INSTALLATION MALAYSIAN STANDARDS
24 9
L.V. Distribution System
MSIEC 60364 Electrical Installation in Building (Part 1 to Part 7).
(note: IEE 17
th
edition or BS7671 us NOT the preferred wiring code.
MS 1979:2007 "Electrical Installation of Buildings Code of Practice"
MS 1936:2006 :Electrical Installation of Building Guide to MS IEC
60364"
Malaysian Voltage is 400V 3phase/230V 1phase +10%, -6%
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INSTALLATION MALAYSIAN STANDARDS
25 9
Power Quality and EMC
PQ
MS1760:2004 and IEC 61000-2-8; Definition of PQ phenomenon (surge, dip,
transient).
MS-IEC 61000-4 Mitigating factor for PQ & immunity levels
EMC
IEC 61000-1-1; definition of EMC, classification of EMC phenomenon
(conducted LF, radiated LF field, conducted HF, radiated HF field, electrostatic
discharge, HEMP).
IEC 61000 introductory level only of Part 2 (EM Environment), Part 3 (emission
/immunity limits) and Part 4 (testing and measurement techniques).
IEC 61000- Part 5-1; Understanding EMC mitigating concepts under Part 5; EM
coupling, emitter and susceptor, mitigating EM disturbance (identifying EM
class, zone protection, earthing etc.) Part 5-2 mitigating EMC; earthing and
cabling.
26
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May 2011 hplooi@unifi.my
INSTALLATION MALAYSIAN STANDARDS
26 9
Power Quality and EMC
PQ
MS1760:2004 and IEC 61000-2-8; Definition of PQ phenomenon (surge, dip,
transient).
MS-IEC 61000-4 Mitigating factor for PQ & immunity levels
EMC
IEC 61000-1-1; definition of EMC, classification of EMC phenomenon
(conducted LF, radiated LF field, conducted HF, radiated HF field, electrostatic
discharge, HEMP).
IEC 61000 introductory level only of Part 2 (EM Environment), Part 3 (emission
/immunity limits) and Part 4 (testing and measurement techniques).
IEC 61000- Part 5-1; Understanding EMC mitigating concepts under Part 5; EM
coupling, emitter and susceptor, mitigating EM disturbance (identifying EM
class, zone protection, earthing etc.) Part 5-2 mitigating EMC; earthing and
cabling.
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Energy Efficiency
MS1525 Energy Efficiency for Electrical Engineer
Lightning Protection
MS IEC 62305 Protection Against Lightning
MS IEC 61662 ; Assessment of the Risk of Damage Due to Lightning.
Fire Protection For Electrical Engineers
MS 1745 Fire Alarm and Detection System
BS5839 Part 8 and 9 (Emergency call system)
Voice and Data Networks (telecom works)
Technical Standards, Infrastructure Requirements (TSIR, issued by
MCMC).
INSTALLATION MALAYSIAN STANDARDS
27 9
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MS 1979 Mandator y Wi r i ng Code 10
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Many practitioners are still unaware of Malaysian Standards
pertaining to Wiring Installation which are mandatory.
Common citation in specifications is the IEE 17
th
(and even
16
th
edition (correctly known as BS7671)
INSTALLATION MS 1979
29 10
The structure of MS1979 is a simple distillation of all the important
prescriptions contained in MSIEC60364 which have direct relevance to
wiring in residential buildings.
Rule-based conditions are set-out in the MS1979 where only
performance-based requirements are listed in the MSIEC60364. The
final product is a very simple booklet containing individual "COP"
(Code Of Practice) numbered COP1 to COP91.
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Briefing summary of prescription
INSTALLATION MS1979
30 10
COP05 All metal enclosures of electrical appliances must be connected
to a protective conductor. Water, gas pipes, strucutural metal parts of the
buildings and ductings of airconditioning system must also be connected
to the main equipotential bonding.
COP06 Isolation on fault. Protection using RCD, fuse, CB etc. must
comply with Ra x Ia < 50V
Ra = Resistance of earth electrode & protective conductor;
Ia = operating current of protective device (sensitivy of RCD and 5s
current trip for inverse time relay).
50V is the safe contact voltage defined by IEC60749-1.
COP07 Earthing resistance must be less than 10 for operation of RCD
but resistance of less than 1 is targeted.
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INSTALLATION MS1979
31 10
COP08 Electrical equipment must be mounted within materials that can
withstand temperatures produced (by the equipment).
COP10 Water heaters or forced air heaters or steam generators must be
equipped with over heating devices (i.e. use o/t cut-out etc.).
COP12 In > I
B
,
COP13 Iz > In
COP14 I
2
< 1.45 x Iz
In = nominal current of protective device; I
B
= design current; Iz = current
capacity of cable ; I
2
= tripping/effective operation current of protective
device.
COP16 Requires determination of short circuit current within the installation.
Effectively this requires every TNB district engineer to issue information on
short circuit at the point of common coupling (PCC) at the locality of
installation.
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COP10 to COP 14
INSTALLATION MS1979
32 10
(1) I
B
< In < Iz
(2) I
2
< 1.45 x Iz
Calculate
current from
load
Select
protective
devices,
In > I
B
Calculate cable size
based on:
Iz > In
I
B
decide current
rating of circuit
I
B
> load current
Check I
2
< 1.45 Iz
Electrical load
Iz = current capacity of cable.
Cables
Protection devices
In = nominal
current rating of
protective devices
I
2
= current ensuring effective
operation within time prescribed of
protective device
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COP19 Surge Protection Device (SPD) is RECOMMENDED for supply from
overhead lines.
COP26 Bending radius of 12 times diameter of cable is mandated. This
effectively requires that elbows and junctions be used where cable changes
direction.
In Malaysia, many wiring installation WILL FAIL THIS CRITERION.
COP27 Space factor for conduit shall be 40% and for trunking shall be 45%.
COP28 Cables installed behind walls (i.e. embedded in concrete) shall be
horizontal or vertical parallel to the edges of the room and within 150mm from
top and 150mm from edge of wall.
In Malaysia, many wiring installation WILL FAIL THIS CRITERION as cables are
commonly installed diagonally fully and in many cases partially (picture 1).
INSTALLATION MS1979
33 10
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COP28 Cables installed behind walls (i.e. embedded in concrete) shall be
horizontal or vertical parallel to the edges of the room and within 150mm from
top and 150mm from edge of wall.
INSTALLATION MALAYSIAN STANDARDS
34 9
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COP30 Wiring within ceiling space (under roof) must be provided with
mechanical protection (i.e. installed within APPROVED conduit). In addition
they must be installed either parallel or perpendicular to the edges of the
wall.
COP31 Water heater circuits shall have 2-pole switch installed at suitable
location. At the vicinity of the heater a socket outlet is required (unswitched
is acceptable).
COP32 Air Conditioner circuits shall have socket outlet (unswitched type is
accepable) at vinity of unit.
COP35 Size of neutral conductor must be same size as phase conductor.
COP36 Size of neutral conductor may be reduced (reference to COP35) at
the discretion of the Professional Design Engineer (i.e. only a P.Eng can
decide).
COP39 Minimum cable size shall be 1.5mm copper or 2.5mm aluminum.
Therefore the practice of using 1.25mm copper cables is illegal!
INSTALLATION MALAYSIAN STANDARDS
35 9
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COP41 Allowable voltage drop is 4%. Voltage drop for motor starting may
be 10%.
COP42 Soldered connections to connect or terminate cables ARE NOT
ALLOWED (see COP43 below).
COP43 Connections of 2 lengths of conductors shall be by sockets and
crimping.
COP44 Cables for final sub circuit shall NOT BE JOINED.
COP51 RCD (or current type ELCB) for single phase installation shall not
exceed 100mA (the previous quoted in the regulations was 30mA).
COP52 RCD for 3-phase installation shall not exceed 100mA. Three units of
single pole type RCD instead of a 3-phase RCD may be used PROVIDED no 3-
phase load(s) is/are served.
COP53 Hand-held equipment shall have RCD not exceeding 30mA.
INSTALLATION MALAYSIAN STANDARDS
36 9
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COP54 RCD not exceeding 10mA shall be installed for special location
(places of public entertainment; wet places; protection of electric water
heaters).
COP56 Requires RCD to be regularly tested, at least twice a year.
COP59 It is recommended to place SPD before RCD (on the supply side), see
figure 2.
COP61 SPD should be rated not less than 5kA.
COP64 The minimum earth connection from SPD to main earth terminal
shall be not less than 10mm copper and shall be as short as possible (0.5m).
INSTALLATION MALAYSIAN STANDARDS
37 9
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COP83 - Supervision of work on LV 3-phase installations shall be under direct
responsibility of Wireman (3-phase restriction). The Wireman shall be
required to certify completion under Form G.
COP 84 Testing for single phase installation shall be by Wireman (single-
phase or 3-phase restriction) under Form H.
COP 85 Testing for 3-phase installation shall be by Wireman (3-phase
restriction) under Form H.
COP86 Other installation at higher than low voltage shall be tested by a
Electrical Services Engineer under Form H.
COP87 Electricity SHALL NOT BE CONNECTED until Forms G & H are
submitted by the owner or building operator.
COP88 Insulation measurements shall be carried out on LV installation
using dc voltages. Where 500Vdc is applied, the insulation resistance shall be
more than 1M.
COP91 Every completed installation shall have as-built electrical diagrams
prominently displayed. Diagrams shall be endorsed by the professional
design electrical engineer.
INSTALLATION MALAYSIAN STANDARDS
38 9
25 Common Problems
for M&E Engineers
Armada Hotel , Petaling Jaya
26
th
May 2011
5 Common Contract
Management Problems
Ir. Looi Hip Peu | hplooi@unifi.my