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ELECTRICAL FAULTS
AFFECTING MILL OPERATION
AND
THE SOLUTION
Presenter :
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
Overload,
Over-current
Overheat
3.
Short-Circuit
4.
Earth-Fault
5.
Earth Leakage
FAULTS
CAUSES
EFFECTS
1.
Overload,
Over-current
2.
Overheat
3.
Short-circuit
Windings
insulation (of
motor)
degenerates, cracks
and flash-over
FAULTS
CAUSES
EFFECTS
4.
Earth Fault
5.
Single
Phasing
6.
Reverse
Power
Parallel generators at
wrong timing
7.
FAULTS
CAUSES
EFFECTS
11
FAULTS
CAUSES
EFFECTS
8.
Over-voltage
9.
Earth
Leakage
a.) Damage
electrical &
electronic
equipment
b.) Expedite aging
of electronic
components
FAULTS
10.
Contamination
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
FAULTS
PROTECTION
DEVICES
AVAILABLE
1.
Overload,
Over-current
a.) TOR
b.) Over-current relay
c.) MCCB, MCB
2.
Overheat
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
FAULTS
PROTECTION
DEVICES
AVAILABLE
4.
Earth Fault
Earth-fault relay
Yes
5.
Single
Phasing
6.
Reverse
Power
a.) Lack of
maintenance
b.) Single phase
detector
a.) Reverse power relay
b.) Synchronizing
check relay
7.
a.) Yes
b.) Yes
a.) Yes
b.) None
15
FAULTS
PROTECTION
DEVICES
AVAILABLE
8.
Over-voltage
9.
Earth
Leakage
a.) ELCB
b.) ELR
a.) Yes
b.) Yes
16
FAULTS
PREVENTIVE MEASURES
1.
Overload,
Over-current
2.
Overheat
3.
Short-circuit
4.
Earth Fault
FAULTS
PREVENTIVE MEASURES
5.
Single
Phasing
6.
Reverse
Power
7.
8.
Over-voltage
9.
Earth
Leakage
FAULTS
10.
Contamination
11.
Mechanicalrelated
Failure
PREVENTIVE MEASURES
19
21
.
22
4.0
5.0
10.
25
CLOSING
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