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BEE2922

INDUSTRIAL
INSTALLATION
Syllabus
1. 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 OUTCOMES
This 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 wiring
ii. Demonstrate the component and function of
distribution board
iii. 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 GENERATION
TNB 33kV/11kV
11kV/433kV substation
TRANSMISSION and DISTRIBUTION
CHAPTER 2
• CHAPTER 2 :POWER DISTRIBUTION

TNB
SUBSTATION
11 kV
MAIN SWITCH BOARD
415V
SUB SWITCH BOARD
415/240V
DISTRIBUTION
BOARD
415/240V
LOAD
POWER DISTRIBUTION

MSB
(415V)

STANDBY GENSET

SSB SSB SSB)


415V 415V 415V
MSB

SSB SSB SSB SSB

DB DB DB DB
INSIDE SUBSTATION
Ring Main Unit (RMU) /
Switchgear 11kV
Transformer (11/0.415kV)
 MSB
Feeder pillar
High 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 PROTECTION


3.2 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
PLBB Tiga Fasa

R Y B N

Elemen sensitif

Suis 4 kutub jenis link

Perintang uji

Punatekan uji

Teras besi
( Gelung secondary )

BEBAN
BALANCE CONDITION
Keadaan yang seimbang

R Y B N

20A 20A 20A


20A

BEBAN
Keadaan yang seimbang
UNBALANCE CONDITION
R Y B N

20A 20A 20A


10A

BEBAN

bocor ke bumi
3.2 FEEDER PILLAR
CABLE CONSTRUCTION

• conductor – PILCDSTAS CABLE


Aluminium/Copper (PAPER CABLE)
• 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
VARIOUS TYPE OF CABLES
KABEL
PVC/SWA/PVC
02/19/10 zailini@kuktem.edu.my 45
3.3 CABLE SIZE vs CURRENT RATING
mm SQUARE CURRENT (A)
1 13.5
1.5 17.5
2.5 24
4 32
6 41
10 57
16 76
25 101
35 125
50 151
70 192
95 232
120 269
150 300
3.4 METERS
CT meter

kWhour meter
4.0 DB
CURRENT CARRYING CAPACITY
FUSE/MCB (Amp) CABLE SIZE (mm²) MAX POWER(watt)

5/6 1.5 1000/1200


15 2.5 1 x 13A s/s/o

20 2.5 2 x 13A s/s/o

30 (gelang) 2.5 10 x 13A s/s/o

30 (jejari) 4.0 6 X 13A s/s/o

15 2.5 1 x cooker 3 kW

30 4.0 1 x cooker 8 kW

15 4.0 1 x heater 1.5kW

15 4.0 1 x 1.5 HP air cond

30 6.0 1 x 2.5 HP air cond

63 16/25 Kabel masuk utama


4.0:DB-SINGLE PHASE
• CONTENT:
ISOLATOR (63A)
ELCB -4 pole
LIVE TERMINAL
NEUTRAL TERMINAL
EARTH TERMINAL
MCB
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
size No of core/ LOad voltage Size of cable
Core rating (diameter)
size(diameter
)
1.25 mm2 (7/0.53 mm) lamp circuit 300/500 2.5 mm
volt
1.5 mm2 (3/0.737 mm) lamp circuit/ 300/500 3.0 mm
heater volt

2.5 mm2 (7/0.67 mm) Power 400/750 3.7 mm


circuit/water volt
heater 5kW-
20A
4 mm2 (7/0.85 mm) water heater 400/750 4.2 mm
7kW- 30A volt
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.

02/19/10 zailini@kuktem.edu.my 61
Earth electrode
• Standard Earth
Electrode 6 inches
length
• Galvanised Iron (G.I)
hollow pipe with
Air terminal
diameter 2 in
• Wire mesh
• Max resistance-for
domestic wiring=1 ohm
• Max resistance-for
lightning=10 ohm Down conductors
5.1: total connected load
• TCL is a total load in load rate
each electrical 1 x 18 W 30W
equipment it is need
supply for project or 1 x 36 W 50W
installation Ceiling fan 65W
• These equipment –
lamp, fan, power
point, lift, water Emergency 20W
pump, and electrical lamp
equipment Socket 250 W
• Exp: outlet 13A

Socket 500 W
VOLTAGE DROP
• IEE regulation-
• Voltage drop≤4% from voltage source
• EXAMPLE :VOLTAGE SOURCE= 240V
MAXIMUM VOLTAGE DROP =
240 X 4% = 9.6V

• VOLTAGE SOURCE =415V


MAXIMUM VOLTAGE DROP=
415 X 4% = 16.6V
CHAPTER 6: size of trunks
• Trunks factor
Trunks size (mm) factor
cable size Cable factor 50 x 38 767
50 x 50 1037
1.5 mm 8.1 75 x 25 738
75 x 38 1146
2.5 mm 11.4
75 x 50 1555
4 mm 15.4 75 x 75 2371
100 x 25 99.3
6 mm 22.9
100 x 38 1542
10 mm 36.3 100 x 50 2091
100 x 75 3189
100 x 100 4252
example
•a. Calculate the size of trunks to carried the cable size as below:
12 x 1.5mm²
b. 16x2.5mm²
c. 8 x 4mm²
d. 4x6mm²
solution
• define the cable factor:
a. 12 x 1.5mm² =12 x 8.1=97.2
b. 16x2.5mm²=16 x 11.4=182.4
c. 8 x 4mm²=8 x 15.4= 123.2
d. 4x6mm²= 4 x 22.9= 91.6
• 494.4

• Trunks size=75 x 25 mm
FLAXIBLE CONDUIT
TYPE OF TRUNKING
STARTING

4 cm
TRUNKING -90 °

X
X

X
X

X X X
20cm 5cm 5cm
TRUNKING 45 °-1
X
X
X
X
X
X
X X

2cm 2cm
20cm

20 cm
4
5
TRUNKING 45 °-2

X
X

X
X

X
=28.5cm 2cm 2cm

4
5
ENDING

5 cm
CAP
90˚
X

X
20 cm 5 cm 5 cm

X
X
45˚-
1

2 cm 2 cm
20 cm

45˚-2
X
X

2 cm 2 cm
DOL

MCB 32 A

CONTACTOR

O/L

TO MOTOR
Inside DB (Three Phase)
N
E

32A TO DOL

32A SPARE

20A TO SOCKET OUTLET

20A SPARE
E/S
CABLE 10A SPARE
SIZE: A1
4mm A2

MCCB CON
ELCB
(40A) (32A)
(40A)

INCOMING FROM
ISOLATOR
RING CIRCUIT

E MCB (20A) N

S/O 2
S/O 1

S/O 3

Cable size:2.5mm
OVERALL LAYOUT S/O 2

S/O 1
10”

9”
10”
90°
12
45° ”
10 45°
10”
16 ” 9”
90° ” 7”
45° 7”
S/O 3

45°
12

DB TRUNKING (2”X2”)

DO E/S CONDUIT(3/4”)
L
Practical FLOW WORK
START

TEORI

CONDUIT-measurement, cutting,
bending and threading

TRUNKING (body & cap)–


measurement, cutting,
hole
Conduit fitting-clip

TRUNKING FITTING-screwing

WIRING

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

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