SINAR MAS AGRIBUSINESS

Managers Conference 2002

24-28 March 2002

ELECTRICAL FAULTS
AFFECTING MILL OPERATION
AND
THE SOLUTION
Presenter :

Gan Saik Ngai

PROJECT AND ENGINEERING DIVISION

CONTENTS
1.0. Background
2.0. Objectives of Presentation
3.0. Types of Electrical Faults in Palm
Oil Mills
4.0. Causes and Effects of Electrical Faults
5.0. Types of Protection Devices to Isolate
Electrical Faults
6.0. Preventive Measures Against Electrical Faults
7.0. Recommendations to Improve Reliability of
Electricity Supply in Palm Oil Mills
8.0. Typical Drawings

CONTENTS
9.0 Guidelines To Minimize Injury To Persons or Damage To
Property Arising From Electrical Faults

1.0. BACKGROUND

Electricity is a very essential commodity today

It is consumed in factories, offices, schools, hospitals,

shopping centers, homes, public transport etc. These are the
places where there are high concentration of people

Without electricity the functions of all these buildings and

amenities will be badly affected

However, electricity can also be a very dangerous

commodity if it is not properly controlled or used

In fact, it can maim or kill a person very quickly without

warning. Every year thousands of people lost their lives due
to electrical faults
4

1.0. BACKGROUND ( continue )

In our case, if the generation or distribution of electricity is

interrupted due to an electrical fault, the mill processing
stops until the fault is identified and rectified

It implies expensive production downtime

This affects the revenue, profitability and cashflow of the

company

As a result, our competitive advantage can be affected due

to increase in unit cost of production

2.0. OBJECTIVES OF THIS PRESENTATION

To review the types of electrical faults affecting palm oil

mills

To understand the causes and effects of electrical faults

To determine the types of protection devices required to

isolate the electrical faults

To discuss on the preventive measures in order to avoid or

minimize electrical faults

To evaluate long term plans so as to increase the reliability

of electricity supply in palm oil mills

3.0. TYPES OF ELECTRICAL FAULTS IN

PALM OIL MILLS
1.
2.

Overload,
Over-current
Overheat

3.

Short-Circuit

4.

Earth-Fault

5.

Earth Leakage

Exceeding the rated current i.e. full

load current
Exceeding the permissible operating
temp. of insulation (class of insulation:
120 - 180 deg C - Class E, B, F & H)
Two or more conductors come into
direct contact (Large current)
Live conductor directly touching the
frame of an electrical apparatus (large
current)
Live conductor indirectly touching the
frame of an electrical apparatus (< 1
amps)
7

3.0. TYPES OF ELECTRICAL FAULTS IN

PALM OIL MILLS ( continue )
6.

Single Phasing Motor running on two phases

Reverse Power Alternator is motoring during

paralleling (reverse current)
8. Under-Voltage Electrical apparatus operating below its
rated voltage (<95% / 361V)
Induced voltage from external source
9. Over-voltage
like lightning
(Surge)
10. Contamination Ingression of contaminants into motors
like oil, grease and water
Cause by vibration or misalignment
11. Mechanicalrelated Failures
7.

4.0. CAUSES AND EFFECTS OF ELECTRICAL

FAULTS
NO
.

FAULTS

CAUSES

EFFECTS

1.

Overload,
Over-current

a.) Machine is over-fed a.) TOR trips

b.) Machine is jammed b.) Windings burn
c.) Excessive load on
c.) OCR trips
alternator

2.

Overheat

a.) Frequent start/stop

operations
b.) Cooling fan not
working
c.) Choked cooling fins

3.

Short-circuit

Insulation of cables or a.) Switchboards

windings damaged thus
trip
touching (large current) b.) Motor fails
c.) Flashing of
power cables
9

Windings
insulation (of
motor)
degenerates, cracks
and flash-over

4.0. CAUSES AND EFFECTS OF ELECTRICAL

FAULTS ( continue)
NO

FAULTS

CAUSES

EFFECTS

4.

Earth Fault

Direct contact between a.) EFR, ELR,

live wire and machines
ELCB trips
frame (large current)
b.) Endanger
operator

5.

Single
Phasing

one phase opens circuit a.) TOR trips

(run on 2 phases)
b.) Motor burns

6.

Reverse
Power

Parallel generators at
wrong timing

a.) RPR trips

b.) Endanger
operator &
alternator
10

4.0. CAUSES AND EFFECTS OF ELECTRICAL

FAULTS ( continue )
NO

7.

FAULTS

CAUSES

Under-voltage a.) Starting large

machinery
b.) Voltage drop along
cables

EFFECTS

a.) ACB trips

b.) Increase
running amps
(at external
pump houses)
c.) TOR, MCCB
trips
d.) Motor burns

11

4.0. CAUSES AND EFFECTS OF ELECTRICAL

FAULTS ( continue )
NO

FAULTS

CAUSES

EFFECTS

8.

Over-voltage

a.) External source :

lightning surge
b.) Internal source :
start/stop large
machinery

9.

Earth
Leakage

a.) Defective insulation a.) ELR trips at

(of conductors)
MSB
b.) Apparatus is wet or b.) ELCB trips at
damp
MCC or DFB
c.) Endanger
operator
12

a.) Damage
electrical &
electronic
equipment
b.) Expedite aging
of electronic
components

4.0. CAUSES AND EFFECTS OF ELECTRICAL

FAULTS ( continue )
NO

FAULTS

10.

Contamination

a.) End covers loose

b.) Opening at cable
terminal box

11.

Mechanicalrelated
Failures

a.) Vibration
a.) Bearing fails
b.) Misalignment of
b.) Motors stator
drive and machinery
and rotor rub.
Winding
flashover

CAUSES

EFFECTS

a.) Flashover
between
motors
winding
b.) Short to motors
frame

13

5.0. TYPES OF PROTECTION DEVICES TO

ISOLATE ELECTRICAL FAULTS
NO

FAULTS

PROTECTION
DEVICES

AVAILABLE

1.

Overload,
Over-current

a.) TOR
b.) Over-current relay
c.) MCCB, MCB

2.

Overheat

a.) Cause by operator

b.) Lack of
maintenance
c.) Heat detector

c.) None

a.) TOR
b.) Over-current relay
c.) MCCB, MCB

a.) Yes
b.) Yes
c.) Yes

3.

Short-circuit

a.) Yes
b.) Yes
c.) Yes
Due to human
element

14

5.0. TYPES OF PROTECTION DEVICES TO

ISOLATE ELECTRICAL FAULTS ( continue )
NO

FAULTS

PROTECTION
DEVICES

AVAILABLE

4.

Earth Fault

Earth-fault relay

Yes

5.

Single
Phasing

a.) Due to human

element
b.) None

6.

Reverse
Power

a.) Lack of
maintenance
b.) Single phase
detector
a.) Reverse power relay
b.) Synchronizing
check relay

7.

Under-voltage a.) Under-voltage coil

b.) Under-voltage
detector

a.) Yes
b.) Yes
a.) Yes
b.) None
15

5.0. TYPES OF PROTECTION DEVICES TO

ISOLATE ELECTRICAL FAULTS ( continue )
NO

FAULTS

PROTECTION
DEVICES

AVAILABLE

8.

Over-voltage

a.) Surge protectors for a.) Some mills

power lines & signal
line (W/B)
b.) Lightning arrestors b.) Yes
at OHPL

9.

Earth
Leakage

a.) ELCB
b.) ELR

a.) Yes
b.) Yes

16

6.0. PREVENTIVE MEASURES AGAINST

ELECTRICAL FAULTS
NO

FAULTS

PREVENTIVE MEASURES

1.

Overload,
Over-current

a.) Avoid over-feeding machinery - NT

b.) Ensure machine is not jammed - NT

2.

Overheat

a.) Do not start/stop machine frequently - NT

b.) Remove fiber at motors cooling fins NT
c.) Ensure motors cooling fan is working NT
d.) Select heat resistant cable at hot areas - T

3.

Short-circuit

Protect cables from physical damage (use

GI conduits/trunking) - T

4.

Earth Fault

Protect cables from physical damage (use

GI conduits/trunking) - T
17

6.0. PREVENTIVE MEASURES AGAINST

ELECTRICAL FULTS ( continue )
NO

FAULTS

PREVENTIVE MEASURES

5.

Single
Phasing

Service motor starters components regularly

-T

6.

Reverse
Power

Follow synchronizing procedures - T

7.

Under-voltage a.) Proper sizing of cables - T

b.) Use power transformers - T

8.

Over-voltage

Install external & internal surge protectors &

lightning arrestors - T

9.

Earth
Leakage

Ensure good insulation & dryness in

electrical equipment - NT
18

6.0. PREVENTIVE MEASURES AGAINST

ELECTRICAL FULTS ( continue )
NO

FAULTS

10.

Contamination

Tighten motor covers & cable terminal box

with rubber gasket - NT

11.

Mechanicalrelated
Failure

a.) Minimize vibration - T

b.) Maintain good alignment - T

PREVENTIVE MEASURES

19

7.0. RECOMMENDATIONS ( TO IMPROVE

RELIABILITY OF ELECTRICITY SUPPLY
IN PALM OIL MILLS )
1. Prepare an effective and comprehensive preventive
maintenance program
2. Conduct periodic calibrations of OCRs and EFRs
3. Provide training for maintenance team at training institutes
4. Conduct training for operators on the danger & proper
operations of electrical installations
5. Management to ensure preventive works are planned &
completed on time and conduct spot checks
6. Provide right tools & equipment . Purchase correct types of
spares
20

7.0. RECOMMENDATIONS ( TO IMPROVE

RELIABILITY OF ELECTRICITY SUPPLY
IN PALM OIL MILLS ) ( continue )
7. Maintain a safe & conducive working environment
8. Form a Group Technical Support Team to assist
maintenance team

21

8.0. TYPICAL DRAWING

Single Line Diagram of Main Switchboard

4-Line Diagram of Main Generator Board

Single Line Diagram of Motor Control Center

Overhead Distribution Power Line

Lightning Protection System

.
22

Guidelines To Minimize Injury To Persons or

Damage To Property Arising From Electrical Faults
1.0
2.0
3.0

4.0
5.0

Use good workmanship

Use approved materials and equipment
Ensure that the correct type, size and
current-carrying capacity of cables are
chosen
Ensure that the equipment is suitable for the
maximum power demanded from it
Make sure that the conductors are insulated
or protected or placed in a position to
prevent danger
23

Guidelines To Minimize Injury To Persons or

Damage To Property Arising From Electrical Faults
6.0 Always provide over-current protection for
every circuit in an installation and ensure that the
protection devices are suitably chosen.
7.0 Where there is a chance of metal work becoming
live owing to a fault, the metal work should be
earthed and the circuit concerned should be
protected by a residual current device
8.0 All single-pole switches must be wired in the
phase conductor
24

Guidelines To Minimize Injury To Persons or

Damage To Property Arising From Electrical Faults
9.

10.

All motors must have a readily accessible

means of disconnection like the provision of
Emergency Stop push-button
Before adding to or altering an installation
ensure that such work will not change the
performance of any part of the existing
installation

25

CLOSING

THANK YOU FOR

YOUR ATTENTION

26

OVER-LOAD, OVERCURRENT

Over-feeding
Over-flow

NormalLevel

Over-load,Over-current

27

OVERHEAT

R un

T r ip

S ta rt

S t op

O v er he at

28

SHORT-CIRCUIT

2 E x p o s e d C o n d u c to r s
D i re c t ly T o u c h i n g E a c h O th e r

R
S
T

S h o r t - c irc u it
29

R
S
T

EATH-FAULT

E
VeryHighCurrent
-DirectContact
-DamagedInsulation
-ExposedConductor

Earth-fault

30

SINGLE
PHASING

B r o k e n C o n d uc t o r a t 1 P h a s e

R
S
T
M otor

S in g l e P h a s in g
31

REVERSE
POWER

M a in b u s b a r

G e n e r a t in g

Gen -s et A

M o t o r in g

Gen -s et B

R e v e rs e P o w e r
32

UNDERVOLTAGE

BrightLight

DimLight

R
R
380VS LongDistribution S 330V
P
o
w
e
r
L
i
n
e
T
TMINIMUM=360V
N
N
SendingEnd
ReceivingEnd

Under-voltage

33

OVERVOLTAGE
(SURGE)

LightningStrike
O
v
e
rh
e
a
d
PowerLine

ControlPanel
EM
leocto
tric
r
PumpHouse

Over-voltage(Surge)

34

EARTH LEAKAGE

R
S
T
E
S
m
a
l
C
u
rre
n
t
<1Am
p
--In
d
i
r
e
c
t
C
o
n
ta
c
t
D
a
m
a
g
e
d
In
s
u
la
ti
o
n
-ConductorExposed/NotExposed

EarthLeakage

35

CONTAMINATION

Waterenters
cableterminalbox

Contamination

36

MECHANICA
L FAILURE

iM
M
s
a
l
i
g
n
m
e
n
t
o
f
o
t
o
r
a
n
d
M
a
c
h
i
n
e
BearingFails

M
echanicalfailure

37

MAIN SWITCHBOARD
(sheet 1)

.S
IY
S
Y
N
W
T
C
H
N
.P
C
O
EVF2V

P
FR
38

MAIN SWITCHBOARD
(sheet 2)

S
Y
N
.S
W
ITC
H
S
YN
.PEVF2V
C
O
39

MAIN
SWITCHBOA
RD (sheet 3)

40

MAIN GENERATOR
BOARD (sheet 1)

O
C
R
E
F
R
R
P
U
.V
V
O
E
LV
C
R
O
N
ICU
D
ITE
T

K
A
A
K
WK
W
HP
FK
V
/SH
V
zH
R

41

MAIN GENERATOR
BOARD (sheet 2)

O
C
R
E
F
R
P
U
V
.
O
LD
E
IV
C
T
R
O
N
C
IEU
V
T
42

MOTOR CONTROL
CENTRER (sheet 1)

43

MOTOR CONTROL
CENTRER (sheet 2)

44

OVERHEAD POWER
LINE (sheet 1)

45

OVERHEAD
POWER
LINE (sheet
2)

46

LIGHTNING
PROTECTIO
N (sheet 1)

47

LIGHTNING
PROTECTIO
N (sheet 2)

48