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Contents

1 Introduction....................................................................................................................... 3
1.1 Problem statement ................................................................................................... 4
1.2 Project intention ........................................................................................................ 4
2 Company Details ............................................................................................................. 5
2.1 Company Logo .......................................................................................................... 5
2.2 Company’s Motto ...................................................................................................... 5
2.3 Company’s Vision ..................................................................................................... 5
2.4 Company’s Mission .................................................................................................. 5
2.5 Company Organization Chart ................................................................................. 6
2.6 Background Company ............................................................................................. 6
3 Design Planning .............................................................................................................. 7
3.1 Load Estimation Tool ............................................................................................... 9
3.2 Power Factor Correction ......................................................................................... 9
3.3 Transformer Sizing Tool ........................................................................................ 10
3.4 Cable Sizing and Conduit Design Tool ............................................................... 10
3.5 Protection Device Design Tool ............................................................................. 11
3.6 UPS System Sizing ................................................................................................ 11
4 Methodology................................................................................................................... 13
4.1 Load Estimation Tool ............................................................................................. 13
4.2 Power Factor Correction ....................................................................................... 14
4.3 Transformer Sizing ................................................................................................. 15
4.4 Cable Sizing and Conduit Design ........................................................................ 16
4.5 Protection Device ................................................................................................... 17
4.6 UPS System Sizing ................................................................................................ 18
5 Result and Discussion .................................................................................................. 19
5.1 Load Estimation ...................................................................................................... 19
5.2 Power Factor Correction ....................................................................................... 21
5.3 Transformer sizing .................................................................................................. 23
5.4 Cable Sizing and Conduit Design ........................................................................ 26
5.5 Protection Device ................................................................................................... 29
5.6 UPS System Sizing ................................................................................................ 30

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6 Energy Efficiency Strategies for Industrial Power System ..................................... 32
6.1 Pumping Systems................................................................................................... 32
6.2 General Motors ....................................................................................................... 33
6.3 Compressed Air Systems ...................................................................................... 34
6.4 Heating and Cooling Systems .............................................................................. 34
6.5 Lighting System ...................................................................................................... 35
6.5.1 LED tubes lighthing system ........................................................................... 35
6.5.2 Lighting control ................................................................................................ 36
7 Conclusion ...................................................................................................................... 38
8 Reference ....................................................................................................................... 38

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1 Introduction

The power system management is very important in any industry to have a good
energy management. Power system is a subfield of energy engineering and
electrical engineering that deals with the generation, transmission, distribution and
utilization of electric power and the electrical devices connected to such systems
including generators, motors and transformers. Although much of the field is
concerned with the problems of three-phase AC power, the standard for large-scale
power transmission and distribution across the modern world and a significant
fraction of the field is concerned with the conversion between AC and DC power and
the development of specialized power systems such as those used in aircraft or for
electric railway networks.

In this Industrial Power System subject, we have to plan an industrial visit to any
company that required the power system management. Our section have choosen
the Sharp Manifacturing Sdn Bhd, Batu Pahat as our visit destination. From the
visits, we will explore the power system management in the company. The porpose
of the visit is to expose the real industry power system management in real
company. We have got many information about the energy management of the
company.

In this project, we are required to construct a design tool for three-phase


industrial power systems using MS Excel and to discover the practical energy
efficiency improvement strategies for industrial buildings based on our experience in
our industrial visit. There are several tools that we need to design which are total
load estimation, power factor correction, transformer sizing, voltage drop and cable
sizing, protection device and UPS sizing. We also need to design the one line
diagram for the company that we visited.

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1.1 Problem statement

Power system plays a critical role in industrial section in order to ensure that
the daily operation of the industries can carry out smoothly. The industries will not be
able to produce any outputs if the power system has been interrupted or break down.
Therefore, it is important to select the suitable equipment that are used in the power
system such as the proper transformer sizing, suitable cable type and cable sizing,
the UPS system, protection devices, power factor compensators and so on
according to the need of industries itself. Besides, the proper selection of equipment
also eases in the future expansion of loads inside the industries[1]. To ensure that
the efficiency and the sustainability of the industrial power system is maintained at its
peak, tools that used to select the power system equipment are designed to enable
the selection process carry out accurately. The improvements that can be applied to
the industrial power system are also being suggested so that the electrical energy
can be fully utilized by the loads at the minimum power losses or minimum wastage
of energy. Hence, the power system that is being designed must also fulfil the
requirements such as the load demands in industries and enable the maintenance
and repair process to be carried out easily.

1.2 Project intention

 To study about the industrial power system and the proper method to choose
suitable equipment in power system.
 To design tools based on the variables or parameters needed in the industrial
power system in order to ease the selection of equipment to be used in power
system.
 To study and propose on how to improve the efficiency and long term
sustainability of the industrial power system.

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2 Company Details

2.1 Company Logo

2.2 Company’s Motto

YOUR BUSINESS PARTNER

2.3 Company’s Vision

To Be A Leading Asian Electrical Consultant Company.

2.4 Company’s Mission

“ Improving electrical energy consumption is our core business. We will also


invest in complementary businesses which create value.”

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2.5 Company Organization Chart

2.6 Background Company

Multi Service Consultant Sdn Bhd is an engineering consultant company that


established in 2006. The board of director consist of seven people and four divisions.
The company is very well known among other engineering consultant that involve in
improving the building electrical energy consumption. The speciality of our company
also provide for reducing the power loses. Based on our company backgroud, we
also provide a low cost electrical device such as circuit breaker, relay, motor,
switchgear and etc. This is because some companies cant afford to buy high cost
and high quality electrical device due to short in budget especially in small
companies. Due to rapidly growth of clients of our company since our service is
among the highest quality, Multi Service Consultant Sdn Bhd have become a very
well known company even in oversea in the past few years.

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3 Design Planning

Figure 1: Designed Single line diagram.

Figure 2: Loads on MCCB 1

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Figure 3: Load in MCCB 2

Figure 4: Load in MCCB 3

In this project, there are 5 tools have been developed in order to calculate the
power system requirement. Each tool has different functions and purposes that can
solve the complexity in obtaining power system’s data information. These are the
tools that used in obtaining data in the proposed load line power system:-

 Load Estimation
 Power Factor Correction
 Transformer Sizing
 Cable Sizing and Conduit Design
 Protection Device
 UPS System Sizing
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3.1 Load Estimation Tool

Input Process Output

 Phases of the loads  Calculation for each  Total 3Φ load and


(single phase or load: 1Φ load (kVA)
three phase)
- 3Φ load and 1Φ load  Total full load
 Absolute load (kW) (kVA) current (A)

 Voltage (V) - Full load current of  Total starting


load (A) current (A)
 Demand factor
depend on duty of - Starting current of  Total estimated
load load(A) power

 Power factor - Estimated power

 Efficiency of loads

3.2 Power Factor Correction

Input Process Output

Input

 Collect load data connect to power factor correction.


 The input parameter includes types of power load and power factor values
before compensation.
Process

 Determine the rating of the required capacitor bank to compensate based on


the formulae of power factor correction.
Output

 Display the result of the power factor correction using required capacitor bank.

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3.3 Transformer Sizing Tool

Input:

 The voltage value, size of transformer used, maximum load demands,


maximum load currents are being calculated and inserted in the excel tools as
the input data to calculate whether the size of transformer is suitable to
support the total load demands of the industry

Process:

 The input data are being processed and calculated by using the excel tools

Output:

 The result whether size of transformer that are used in the proposed single
line diagram is suitable for the industry power system

3.4 Cable Sizing and Conduit Design Tool

INPUT
For the input, we will collecting the load data that related to the cable sizing. For
example, the power of the load, supply voltage needed, power factor, efficiency,
installation method, type of conductor, type on insulator and so on.
PROCESS
In process, we will designing the tools using Microsoft Excel that can be use to
designing the suitable cable sizing. It will including how to determine the full load
current of the load, the current rating, the cross-sectional area of the conductor need
to be use, the suggested maximum length of cable and so on.
OUTPUT
At the output, we should get the desired information that needed in order to
designing the proper cable sizing.

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3.5 Protection Device Design Tool

Input

 Collect load data connect to current rating.

 The input parameter includes types of voltage load and apparent power
values before compensation.

Process

 Determine the suitable protection device to compensate based on the


formulae of current rating.

Output

 Display the result of the suitable protection device using required the current
rating value.

Protection Device Current Ratings Value


Miniature Circuit Breaker, 5A – 100A
MCB
Moulded Case Circuit 125A – 3000A
Breaker, MCCB
Air Circuit Breaker, ACB 1250A – 6300A

3.6 UPS System Sizing

INPUT
Parameters :Collect load data connect to UPS system
Discription :The input data parameter includes of type of load, the power rating
of the load, the Nos of the load, and the operating time of the load system.

Parameters :Collect input parameter for load profile.


Discription :The data requires user to select type of UPS used in power
system, insert the output DC voltage, future load growth, and design margain.

Parameters :Collect information to design the battery system.


Discription :In order to determine the number of cell connected for the
batteries, the tool requires user to insert the minimum and maximum load
voltage tolerance, the cell charging voltage, and the end of discharge voltage.
For determine the minum size of the battery, user need to insert the depth of
discharge, battery aging factor, temperature, and capacity rating factor.

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Parameters :Collect information to design the rectifier system.
Discription :In this section, the system requires only recharge effieciency factor
and minimum recharge time according to user need.

PROCESS
Parameters :Determin the battery capacity
Discription : Formula of Minimum battery capacity,
𝑬𝒅 (𝟏 + 𝒌𝒂 )(𝟏 + 𝒌𝒄 )𝒌𝒕
𝑪𝒎𝒊𝒏 =
𝑽𝑫𝑪 × 𝒌𝒅𝒐𝒅

Parameters :Determine the minimum DC rectifier current.


Discription : Formula of DC load current,
𝑺 𝑪(𝒌𝒍 )
𝑰𝑫𝑪 = +
𝑽𝑫𝒄 𝒕𝒄

Parameters :Determine rating for the static switch and inverter


Discription : Formula of AC rated load current,
𝑺 𝑺
𝑰𝑳 = 𝒇𝒐𝒓 𝟑∅ 𝒐𝒓 𝒇𝒐𝒓 𝟏∅
√𝟑 × 𝑽𝑶 𝑽𝑶

OUTPUT
Parameters :Display the result of the for the UPS sizing.
Discription : in this section, the user will prompted with result of the load
profile, battery sizing, rectifier system sizing, and inverterter or static switch
system sizing.

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4 Methodology

There are several steps involve in developing the system tools. Each steps are
differences according to the desired output. In order to complete develop the system,
it is crucial to follow the design plan. Below is the flowchart and the explanation for
each tools:-

4.1 Load Estimation Tool

Design Flow Chart

Figure 5 shows the flowchart for


the load estimation tool. In load
estimation tool, firstly we need to
collect all of the data required for this
tool. Eg. absolute load(kW), demand
factor, voltage, power factor and
efficiency. Then, we will calculate all
of the parameters that involve using the
Microsoft Excel to creat the tool. Lastly
we should get the output which contain
all of the information that needed using
the tool.

Figure 5: Flowchart of Load estimation tool

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4.2 Power Factor Correction

There are several step to develop


the system tools. Firstly, the design of
interface for power factor correction
must be easy to use and understand by
user. Secondly, the input data need to be
choosed to determine the type of power
load and power factor before
compensation. Third, apply the
mathematical equation to determine the
output result. After that, the technique in
microsoft excell been utilise according to
the requirement of the system. Lastly, the
output result will be appeared to the user.

Figure 6: Flowchart of power factor correction


tool

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4.3 Transformer Sizing

The input data such as the voltage


value, proposed transformer size, total
load demands, maximum load current,
allowable voltage drop and others are
keyed in to the excel tools that is being
designed. The input data are then being
analysed and calculate to check
whether the size of transformer
proposed in the single line diagram is
suitable to for the industry power
system or not. The result of
interpretation is then produced to
determine whether the size of
transformer is enough to support the
total load demands and needs of the
industry or not. If no, the new proposed
transformer size need to be inserted to
Figure 7: Flowchart of transformer sizing tool
the data and re-analyse the data again.

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4.4 Cable Sizing and Conduit
Design

Desribtion
Step 1: we start with designing the
user-friendly cable sizing tool and
collecting the relatable data needed.

Step 2: inserting the data collected


into the tool based on requirement

Step 3: used the suitable


mathematical expression that needed
for the sizing process

Step 4: we are using Excel software


to perform the tool

Step 5: Produce the desired outcome


from data collected using tool
designed.

Figure 8: Flowchart of cable sizing tool

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4.5 Protection Device

Start

Collect data which is


the voltage, the
apparent power Describtion
From the flow chart as shown, it is
Search the equation of
about the flows of the protection
current ratings
device which are from starting go
through input, process and the end.
Firstly, this flow should be have the
Calculation of voltage, the apparent power to
calculate the current ratings. After that,
current ratings
this flow will process for the suitable
protection device based on the value
of current rating that calculated from
the excel tools.

Choose the suitable


protection device
(circuit breaker)

End

Figure 9: Flow chart of protection device tool

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4.6 UPS System Sizing

Design Flow Cart:


Table 1: Discription of the UPS sizing
methodology

START Discription

Step 1: The interface prompt to the


Step 1: Design the interface for the UPS user should be easy to be
system tool.
understand and user-friendly.

Step 2: Insert input data Step 2: Input data been inserted to


according to the UPS the interface. The input data used
system requirement. to determine the load profile,
battery sizing system, rectifier
sizing system, and inveter sizing
system
Step3: Design the mathematical equation
according to the input data provided in
the interface.
Step 3: Apply the mathematical
formula use in determine the
output result. For the cell correction
Step 4: Utilise the Microsoft Excel factor, the temperature have been
format/rule/technique to perform the refered to the standard IEEE Std
calculation. 485-1997

Step 4: The format/technique/rules


Step 5: Design the output interface to in Microsoft Excel been utilise
show the result of the system.
according to the need of the
system. Below are the technique
been apply in the system:
 if then statement
Test and check  vlookup statement
the design tool. Are the tool  apply a GUI function such
perform according to expected
form control in Developper.
result?

Step 5: The output result been


prompt to the user. The data
provided should be correct and
FINISH
relevant to the user in determine
the UPS system sizing.
Figure 10: Flow chart of developping the UPS
sizing system

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5 Result and Discussion

In this section, the tools that been develope can be use in determine the
proposed load line as shown in Figure 1 . The results from the tools systems can
determine the suitable parameter according to the load data connected in the
industrial power system. below is the detail discussion for the result on each tools.

5.1 Load Estimation

The value of absolute load, demand factor, voltage on load, power factor and
efficiency of loads are required as input data to calculate total loading. Demand
factor of each load is corresponding to their duty operation. Demand factor usually
less than 1.0. Demand factor for continuous, intermittent and standby operation are
1.0, 0.5 and 0.1 respectively.

Motor input power is computed by using operating motor power, power factor
and efficiency of each load.

K= Power factor x Efficiency

Operating motor power


Motor input power (kVA) =
K

Full load current is the largest current that a motor or other device is designed
to carry under particular condition. Full load current is calculated based on the phase
of the load.

For three phase,

Motor input power


FLA =
√3 × V × Power factor × Efficiency

For single phase,

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Motor input power
FLA =
V × Power factor × Efficiency

Starting current is computed based on the motor code letter. We stated the
code D of locked rotor which used to determine starting current of load. Maximum
current of motor code D is 4.5.

Starting current = 4.5 × Full load current

Figure 11: the result of total load

Based on the calculation, total load which followed by appendix A is


2894.142kVA. Total load is sum of all loads in three phases and single phase which
is R phase, Y phase and B phase. Total full load current and starting current can be
used to calculate for voltage transformer, cable sizing and so on. Estimated powers
are computed for whole system which is 2283.30kW and 2894.142kVA.

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5.2 Power Factor Correction

Power Factor Correction using Static Capacitor

In power factor correction, the improvement of power factor is required to


increase in available power, reduction of voltage drop and etc. Figure 1 shows power
factor values assumption before compensate and power load based on the data
given.

Figure 12: Load and power factor data

After that, the system requires input parameters as shown in figure 2 to


determine the power load, power factor value before compensation and target power
factor value. These parameters are need to be inserted in order to get desired output
results. As the result, we obtain the required capacitor bank rating to compensate.

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Figure 13: parameter need to br insertd and result of required capacitor bank

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5.3 Transformer sizing

For the tools that used to determine whether the proposed transformer sizing is
suitable to be used in the line diagram or not, there are several information that we
need to take into account. First, we need to insert all the information about the
transformer and load details in order to proceed with the calculation. The proposed
size of transformer and the secondary voltage of the transformer which connect to
the loads need to be filled in the tools. The total load demand in kW, kVA and total
load current can be obtained from the results that interpret by the tools that
determine the total load demand in the single line diagram. Then, the total power
factor and the motor inrush kVA in starting are calculated by using the formula as
shown below:

𝐴𝑝𝑝𝑎𝑟𝑒𝑛𝑡 𝑃𝑜𝑤𝑒𝑟
Cos θ = 𝑅𝑒𝑎𝑙 𝑃𝑜𝑤𝑒𝑟

√3 𝑋 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑋 𝑇𝑜𝑡𝑎𝑙 𝐿𝑜𝑎𝑑 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑋 𝑀𝑎𝑥. 𝐿𝑜𝑐𝑘𝑒𝑑 𝑅𝑜𝑡𝑜𝑟 𝑀𝑢𝑙𝑡𝑖𝑝𝑙𝑖𝑒𝑟


Motor Inrush kVA in starting = 1000

In order to determine whether the proposed transformer can be used or not,


the calculations that used to calculate the full load current of transformer, short circuit
current of transformer, voltage drop due to inrush and maximum kVA of transformer
at short circuit are calculated as following:

𝑃𝑟𝑜𝑝𝑜𝑠𝑒𝑑 𝑇𝑟𝑎𝑛𝑠𝑓𝑜𝑟𝑚𝑒𝑟 𝑆𝑖𝑧𝑒 (𝑘𝑉𝐴)


Full Load Current of Transformer =
√3𝑋 𝑆𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑜𝑓 𝑇𝑟𝑎𝑛𝑠𝑓𝑜𝑟𝑚𝑒𝑟

𝐹𝑢𝑙𝑙 𝐿𝑜𝑎𝑑 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑜𝑓 𝑇𝑟𝑎𝑚𝑠𝑓𝑜𝑟𝑚𝑒𝑟


Short Circuit Current of Transformer =
𝐼𝑚𝑝𝑒𝑑𝑎𝑛𝑐𝑒

Maximum kVA of Transformer at Short Circuit


𝑇𝑟𝑎𝑛𝑠𝑓𝑜𝑟𝑚𝑒𝑟 𝑆𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝑉𝑜𝑙𝑡𝑎𝑔𝑒
𝑋 𝑆ℎ𝑜𝑟𝑡 𝐶𝑖𝑟𝑐𝑢𝑖𝑡 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑜𝑓 𝑇𝑟𝑎𝑛𝑠𝑓𝑜𝑟𝑚𝑒𝑟
=
1000

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Voltage Drop of Transformer Due to Inrush = 𝑀𝐴𝑥𝑖𝑚𝑢𝑚𝑀𝑜𝑡𝑜𝑟 𝐼𝑛𝑟𝑢𝑠ℎ 𝑘𝑉𝐴 𝑎𝑡 𝑆𝑡𝑎𝑟𝑡𝑖𝑛𝑔
𝑘𝑉𝐴 𝑜𝑓 𝑇𝑟𝑎𝑛𝑠𝑓𝑜𝑟𝑚𝑒𝑟 𝑎𝑡 𝑆ℎ𝑜𝑟𝑡 𝐶𝑖𝑟𝑐𝑢𝑖𝑡
𝑋 100%

After the requirement had been calculated, the excel tools will check whether
the total full load current is smaller or equal to 65% of transformer full load current
and the voltage drop is smaller than 10% or not. If both criterions meet the
requirement, it means that the proposed size of transformer can be used.

Figure 14: transformer 1 sizing

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Figure 15: transformer 2 sizing

Based on the results on Figure 14 and Figure 15 that interpreted by using the
excel tools, the proposed transformer size for 415V and 6.6kV with rating value of
11kV is suitable to be used in our project. The proposed sizing of transformer meet
the criteria which the load current is less than or equal to 65% of the total load
current of transformer and the voltage drop of the system based on the information
that are being inserted is less than 10%.

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5.4 Cable Sizing and Conduit Design

For the cable sizing for the loads in the factory, we use the designed tool using
Microsoft Excel. To use it, we need to insert the data needed such as power load,
supply voltage, power factor, efficiency and so on in to the data input section.

Figure 16: Data input of tool

Then we will get the results straight away after inserting data required. We will get
the cross-sectional area for conductor, cable current rating, voltage drop, suggested
cable length and so on.

Figure 17: Data Output of the tool.

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Figure 17 shows the data output of the tools. This is the equation that invole for
these output:-

 Total Derating Factor (Ktotal) = refer to the table at the ‘correction factor’
worksheet in tool.
𝑡𝑜𝑡𝑎𝑙 𝑙𝑜𝑎𝑑 𝑝𝑜𝑤𝑒𝑟 (𝑘𝑊)𝑋 𝑙𝑜𝑎𝑑 𝑑𝑢𝑡𝑦
 Maximum apperent power = 𝑝𝑜𝑤𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟 𝑋 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
𝑀𝑎𝑥 𝐴𝑝𝑝𝑒𝑟𝑒𝑛𝑡 𝑃𝑜𝑤𝑒𝑟 (𝑘𝑉𝐴)
 Full load current, I (A) =
√3 𝑋 𝑆𝑢𝑝𝑝𝑙𝑦 𝑉𝑜𝑙𝑡𝑎𝑔𝑒
 Load duty is based on the duty of the load. If the load is in continuous duty,
the load duty is 1, Intermittent 0.5 and standby is 0.1.
 Cross-sectional Area of conductor (𝑚𝑚2 ) in depend on type of cable
conductor, cable installation method, and full load current over derated factor.
Then, refer to the table ‘cable ampacity’ worksheet in the tool.
 The based cable current is also based on the ‘cable ampacity’ worksheet in
the tool.
 Installed cable current rating, I (A) = Ktotal X based cable current rating, I (A).
√3 𝑋 𝐹𝐿𝐴 [(𝑅𝑐 cos 𝜃)+(𝑋𝑐 sin 𝜃)] 𝑋 𝐿
 The voltage drop = 1000
1000 𝑋 𝑛𝑜𝑚𝑖𝑛𝑎𝑙 𝑉𝑜𝑙𝑡𝑎𝑔𝑒
 Suggested cable length =
√3 𝑋 𝐹𝐿𝐴 𝑋 (𝑅𝑐 𝑐𝑜𝑠 𝜃)+(𝑋𝑐 𝑠𝑖𝑛 𝜃)

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Figure 18: Result of all loads

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Figure 18 shows the result of all loads that involve in our one line diagram load
design. From the Figure 18 we can see the cross-sectional area of conductor that
suitable, the rated current, the voltage drop, suggested cable length and so on. We
are using the copper type cable and XLPE/EPR instead of PVC as insulation of the
cable. This is because it is easy to troubleshoot electrical system and for
maintainance of the cable if something happen. Cross-connected polyethylene
(XLPE) is broadly utilized as electrical protection as a part of force links of all
voltage goes yet it is particularly appropriate to medium voltage applications. It is the
most well-known polymeric protection material.

5.5 Protection Device

In protection device, to determine the value of current rating, the voltage of load
description must know before using the tool as well as to determine the value current
rating. The voltage of load description as shown in Figure 19.

Figure 19: Voltage of load description

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After that, the system requires input parameters as shown in figure 20 to
determine the value of current rating by choose the voltage of load description and
enter the apparent power in KVA unit as shown in Figure 20. So that, the suitable
protection device will appear at that blue box as shown in Figure 20.

Figure 20: Parameter need to be inserted and the suitable protection device will shown

5.6 UPS System Sizing


In the UPS system design, the proposed line diagram required an Offline
(standby) UPS system. In normal operation, the load is supplied with power directly
to the line. The loads that been connected to the UPS system are shown in Figure 1
.

Figure 21: Load data connected to the UPS system

Then, the system requires another input parameter as shown in Figure 21 to


determine the load profile, battery sizing system, rectifier sizing system, and inveter
sizing system. These parameter is crucial to be inserted in order to get the desired
output results.

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As the result, we obtain the UPS system sizing information data as shown in
figure 22. The total load power and current rating for the UPS also can be obtain.
This will help to fulfil the load line data required for the proposed system.

Figure 22: Result of the UPS system sizing.

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6 Energy Efficiency Strategies for Industrial Power System
6.1 Pumping Systems

Pump systems consist of pumps, driver, pipe installation and controls (such as
ASDs or throttles) and are a part of the overall motor system. Below some of the
energy efficiency opportunities for the pumping system are presented.

1. Maintenance
Inadequate maintenance lowers pump system efficiency, causes pumps to
wear out more quickly and increases costs. Better maintenance will reduce
these problems and the most important – to save energy.
Proper maintenance includes the following:
 Replacement of worn impellers, especially in caustic or semi-solid
applications.
 Bearing inspection and repair.
 Bearing lubrication replacement, once annually or semiannually.
 Inspection and replacement of packing seals.
 Inspection and replacement of mechanical seals.
 Wear ring and impeller replacement.
 Pump/motor alignment check.
 The largest opportunity is usually to avoid throttling losses.
Typical energy savings for operations and maintenance are estimated to
be between 2% and 7% of pumping electricity use for the U.S. industry. The
payback usually is less than one year.

2. Monitoring
Monitoring in conjunction with operations and maintenance can be used to
detect problems and determine solutions to create a more efficient system.
Monitoring can determine clearances that need be adjusted, indicate
blockage, impeller damage, inadequate suction, operation outside
preferences, clogged or gas-filled pumps or pipes, or worn out pumps.
Monitoring should include:

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 Wear monitoring
 Vibration analyses
 Pressure and flow monitoring
 Current or power monitoring
 Differential head and temperature rise across the pump (also known
as thermodynamic monitoring)
 Distribution system inspection for scaling or contaminant build-up

3. Control
The objective of any control strategy is to shut off unneeded pumps or to
reduce the load of individual pumps. Remote controls enable pumping
systems to be started and stopped relatively quickly and accurately, and
reduce the required labor with respect to traditional control systems.

6.2 General Motors

1. Maintenance

The purposes of motor maintenance are to prolong motor life and to foresee a motor
failure. Motor maintenance measures can therefore be categorized as either
preventative or predictive. Some of these measures are further discussed below.
Note that some of them aim to prevent increased motor temperature which leads to
increased winding resistance, shortened motor life, and increased energy
consumption.

Preventive measure include voltage imbalance minimization, load consideration,


motor aligment, lubrication and motor ventilation.

2. Motor management plan

A motor management plan is an essential part of a plant’s energy management


strategy. Having a motor management plan in place can help companies realize
long-term motor system energy savings and will ensure that motor failures are
handled in a quick and cost effective manner.

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3. Proper motor sizing

It is a persistent myth that oversized motors, especially motors operating below 50%
of rated load, are not efficient and should be immediately replaced with appropriately
sized energy-efficient units. In actuality, several pieces of information are required to
complete an accurate assessment of energy savings.

6.3 Compressed Air Systems

 Implement a industrial-wide compressed air management policy to eliminate


unnecessary uses, fixing leaks and synchronizing use with supply and
demand
 Reduced compressed air cost by analysing compressor operation and
reducing leaks
 Use a system approach while operating and maintaining a compressed air
system
 Smaller compressor can be used to operate during unoccupied period.

6.4 Heating and Cooling Systems

HVAC system is used to deliver consistent cooling and precision control to


overall operation of facilities load. In order to improve energy efficiency, the uses of
facilities load should reduce. The existing system may operate less frequently and
reduce the heat energy produced. A proper energy management system should be
implementing in company. This energy management system can monitor the load
performance and control the temperature to enhance energy efficiency on HVAC
system.

Besides, the energy recovery ventilation system is implementing to recover the


exhaust energy and use it to control the incoming air. HVAC system can combine
with dehumidification components which reduce the level of humidity in the air.
Insufficient dehumidification affect working condition and contribute to moisture
problem in any building. The relative humidity can control and maintain through the
dehumidification process [2].

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6.5 Lighting System

During the industrial visit at SHARP Manufactiring (M) Sdn Bhd,the


illumination system used was using the fluorescent lights that are commonly use in
domestic. Throughout the estimtation during the visit, we can see that the energy
amount used are qiuite huge due to the indoor operation takes about 8 hours on
average maximum usage. In that case, we would like to propose a new method that
will reducing or improving the energy usage to the building by using LED tubes
lighthing system and Lighting control.

6.5.1 LED tubes lighthing system

Nowadays, the use of LED (Light Emiiting Diode) technology give a huge
impact to global for illumination system. Researchers and electrical engineers more
likely start proposing these technology into domestic and industrial usage to replace
the common illumination system. This is because, the LED illuminaton systems are
proven to be more benfical to the energy usage, cost and environment.

LED tubes are a solid-state alternative for the fluorescent light tubes
commonly found in recessed troffers, signs, walk-in coolers, and other commercial
applications. They are pin compatible with standard fluorescent fixtures, and
frequently available to replace T8, T10, and T12 for fluorescent lighting system [3].
LED tubes are usually considered in these applications for one or more of the
following reasons:

Reason Description.
Long-lasting LED bulbs last up to 10 times as long as compact fluorescents, and
far longer than typical incandescents.
Durable Since LEDs do not have a filament, they are not damaged under
circumstances when a regular incandescent bulb would be broken.
Because they are solid, LED bulbs hold up well to jarring and
bumping.
Cool These bulbs do not cause heat build-up, LEDs produce 3.4
btu's/hour, compared to 85 for incandescent bulbs [4]. Common
incandescent bulbs get hot and contribute to heat build-up in a
room. LEDs prevent this heat build-up, thereby helping to reduce air
conditioning costs in the home.
Mercury-free No mercury is used in the manufacturing of LEDs.
More efficient LED light bulbs use only 2-17 watts of electricity. LED bulbs used in
fixtures inside the home save electricity, remain cool and save
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money on replacement costs since LED bulbs last so long. Small
LED flashlight bulbs will extend battery life 10 to 15 times longer
than with incandescent bulbs.
Cost-effective Although LEDs are initially expensive, the cost is recouped over
time and in battery savings. LED bulb use was first adopted
commercially, where maintenance and replacement costs are
expensive. But the cost of new LED bulbs has gone down
considerably in the last few years. and are continuing to go down.
Today, there are many new LED light bulbs for use in the home,
and the cost is becoming less of an issue [4].

There are two type LED tubes system that can be propose in this project
which are LED tubes that are designed to drop directly into an existing fixture with no
rewiring, while others require the prior removal or bypassing of the ballast [5]. In this
case, we prefer a ballast-compatible approach saves the cost of having to rewire the
fixtures, which can drastically reduce conversion costs.

6.5.2 Lighting control

Use lighting controls to automatically turn lights on and off as needed, and
save energy. You can save energy by turning off lights when they're not needed, but
sometimes we forget or don't notice that we've left them on. [6]

The most common types of lighting controls include:

Control Description
Dimmer Dimmer controls provide variable indoor lighting. When you dim
control lightbulbs, it reduces their wattage and output, which helps save
energy. Dimmers are inexpensive and provide some energy savings
when lights are used at a reduced level. They also increase the service
life of lightbulbs significantly. Some light-emitting diode (LED) lightbulbs
can be used with dimmers. LED bulbs and fixtures must be designed
for dimming, and you may need to replace existing dimmer switches
with ones that are compatible with an LED lighting product.

Motion Motion sensors automatically turn lights on when they detect motion

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sensor and turn them off a short while later. They are very useful for outdoor
control security and utility lighting.
Occupancy sensor control detect indoor activity within certain area.
They provide convenience by turning lights on automatically when
someone enter the room, and save energy by turning light off soon after
the last occupants has left the room. Occupancy sensor must be
located at where it can detect the occupants activity. [7]

Timer Timers can be used to turn on and off outdoor and indoor lights at
control specific times. There are two types of timers: manual timers, which plug
into an electrical outlet for controlling objects such as lamps or light
strings; and in-wall programmable digital timers (which look like digital
thermostats), which automate indoor or outdoor lighting. Manula timer
compatible with LED lightbulb, as they not interrupt the circuitry.

We can conclude that, by implementing LED technologies is beneficial for a long


term usage. Besides that, it also help in maintaing our ecosystem safe from pollution
of mercury substance inside the fluorescent tubes. There are some real safety and
environmental concerns with fluorescent bulbs. Fluorescent bulbs contain mercury,
which is harmful to a person or the environment when the bulb breaks in a room or in
the landfill, and can also be harmful to you or your coworkers if the bulb breaks in the
office. LED bulbs, on the other hand, are safe to use and easier to dispose of, with
no risk of poisoning, because these bulbs have no mercury or other toxic materials in
its design. This may lead as one of the green technologies that recommended in
preserve of world from pollutions

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7 Conclusion

From this project, we can conclude that we have improved our knowledge about
the industrial power system and the proper method to choose suitable equipment in
power system based on designed one line diagram. We also successfully designed
user-friendly tools based on the variables or parameters needed in the industrial
power system in order to ease the selection of equipment to be used in power
system. Lastly, based on this project, we have proposed proposed several methods
on how to improve the efficiency and long term sustainability of the industrial power
system. All of our group members have been passionally involve in order to
complete this project.

8 Reference

[1] Wikipedia (October 13, 2016) [online]


https://en.wikipedia.org/wiki/Power_engineering

[2] Ingersoll Rand. (Nov 11, 2010). Dehumidication solutions [Online]. Available:
https://www.trane.com/content/dam/Trane/Commercial/global/products-
systems/equipment/air-handling/air-handler-options/PROD-SLB014-
EN_1110_Dehumidification.pdf

[3] The Engineering Toolbox. (2012). Electrical Motor- Locked Rotor Indicating
Code letters [Online]. Available: http://www.engineeringtoolbox.com/locked-
rotor-code-d_917.html

[4] Eartheasy. (2014). Energy Efficient Lighting [Online]. Available :


http://eartheasy.com/live_energyeff_lighting.htm

[5] Premier Lighting (July 3, 2015) Should You Replace Your T8 Fluorescent
Lamps with T8 LED Tubes? (updated) [Online]. Available :
http://www.premierltg.com/should-you-replace-your-t8-fluorescent-lamps-with-
t8-led-tubes-2/

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[6] Philips Lighting Malaysia. (2016). Product Catalog [Online]. Available:
http://www.lighting.philips.com/main/prof/lamps/led-lamps-and-systems/led-
tubes

[7] Craig DiLouie, Advanced Lighting Controls. Indian Trail, Lilburn: The Fairmont
Press, 2006.

[8] Craig DiLouie, Lighting Controls Handbook.[journal] Indian Trail, Lilburn: The
Fairmont Press, (2006)

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