Basic Electrical Theory
Mohd Shafril Baharudin
Total Productive Maintenance
Role of TPM Champion
TPM Champion
as key person
to liaise with
Management
TPM Champion as
coordinator of TPM
program i.e. monitor
& report the progress
TPM Champion
preferably a strong
leader at mill either
senior executive or
Maintenance Engineer
2
Table of Contents
1. Basic Electrical Theory
2. AC/DC Circuit
3. Introduction Electronics
4. Basic Concept Of Control System &
Its Components
5. Control System Application in Palm
Oil Mill
6. Programmable Logic Control (PLC)
3
Basic Electrical Theory
Scope
1. Electrical Safety
2. Basic Electrical
3. AC / DC Circuit.
4. Equipment & Measurement.
4
Basic Electrical Theory
5
Basic Electrical Theory
6
Basic Electrical Theory
7
Basic Electrical Theory
8
Basic Electrical Theory
9
Basic Electrical Theory
10
Basic Electrical Theory
11
Basic Electrical Theory
12
Basic Electrical Theory
13
Basic Electrical Theory
Electrical Safety
14
Basic Electrical Theory
Electrical Safety
15
Basic Electrical Theory
Electrical Safety
16
Basic Electrical Theory
17
Basic Electrical Theory
18
Basic Electrical Theory
Electrical Safety
19
Introduction
Question #1
What is Power Factor?
Question #2
What causes Low Power Factor?
Question #3
Why should I Improve My Power Factor?
Question #4
How Do I Correct / Improve my Power Factor?
Question #5
How Long Will It Take My Investment in Power Factor Correction To Pay For Itself?
Question #6
What is The Next Step?
What is Power Factor?
Teh Tarik = Real / Active Power (kW)
Foam = Reactive Power / Loss (kVAR)
kVAR Glass Capacity = Apparent Power / Total (kVA)
kVA Power Factor = Teh Tarik / Glass capacity
kW
Capacitor help decrease the foam, freeing up Teh Tarik Glass Capacity so you don’t need
to buy larger mug and/or so you can pay less for your the Tarik.
What is Power Factor?
22
What causes Low Power Factor?
Inductive Load
23
Why should I Improve My Power Factor?
Reducing peak kW billing
demand
Eliminating the power factor
penalty
24
Why should I Improve My Power Factor?
Cost saving
System Capacity Voltage Revenue
level
System
Losses
Maintenance
cost CO2 emissions
Eliminating low power
factor
25
How Do I Correct / Improve my Power Factor?
Install Power
Capacitor
Install High Install Active
Efficiency Harmonic Filter
motor
How Long Will It Take My Investment in Power Factor
Correction To Pay For Itself?
27
KKS : KEMPAS MPLAN Total Saving RM 77,216.19
TITLE : ELECTRICITY USAGE JUL15/JUN16 Potential Saving RM 158,262 9677.9684 ###
MILL FBB TNB RM-Cost (Old tariff) Saving (EWE) RM-Cost (New tariff) Saving from new tariff PF PF
Month
(KWH) (PROCESS) (KWH) KVARh 0.435 0.509 37,482 RM % 0.38 0.441 RM % Mill Actual
Jan-15 325,510 17,392.56 74,548 12,020 87 37843 37,930 76 32,787 32,863 0.99 0.99
Feb-15 313,290 19,129.21 104,033 23,365 87 52851 52,938 76 45,790 45,866 0.99 0.98
Mar-15 497,660 28,065.37 94,085 21,577 87 47787 47,874 76 41,403 41,479 0.99 0.97
Apr-15 563,380 32,689.50 99,061 23,703 87 50320 50,407 76 43,598 43,674 0.99 0.97
May-15 544,940 31,766.75 100,497 23,049 87 51051 51,138 76 44,231 44,307 0.99 0.97
Jun-15 495,360 26,931.59 65,139 11,821 87 33054 33,141 76 28,638 28,714 0.99 0.98
Jul-15 530,440 29,367.20 46,136 6,058 87 23381 23,468 14,013 37 76 20,258 20,334 0.99 0.99
Aug-15 538,870 27,960.12 53,346 8,905 87 27051 27,138 10,343 28 76 23,437 23,513 3,625 15 0.99 0.99
Sep-15 518,070 29,652.03 50,603 7,900 87 25655 25,742 11,740 31 76 22,228 22,304 3,438 15 0.99 0.99
Oct-15 485790 27,003.19 60,732 10,954 87 30811 30,898 6,584 18 76 26,695 26,771 4,127 15 0.99 0.98
Nov-15 368990 19589.7 56,313 9,424 87 28562 28,649 8,833 24 76 24,746 24,822 3,827 15 0.99 0.99
Dec-15 346510 18752.33 60,791 16,740 87 30841 30,928 6,554 17 76 26,721 26,797 4,131 15 0.99 0.96
Jan-16 0 0 0 0 0 0 0 0 0 0 0 0 0.00
Feb-16 0 0 0 0 0 0 0 0 0 0 0 0 0.00
Mar-16 0 0 0 0 0 0 0 0 0 0 0 0 0.00
Apr-16 0 0 0 0 0 0 0 0 0 0 0 0 0.00
May-16 0 0 0 0 0 0 0 0 0 0 0 0 0.00
Jun-16 0 0 0 0 0 0 0 0 0 0 0 0 0.00
58,068 19,148.38
TNB Cost
MPLAN Yearly Actual RM Budget RM Var RM RM/month Total invest (RM) 21112.5 Unit cost 41 RM/kVAR
2014/15 449,782 75,000 (374,782) 37,482 Total kVAR 510
2015/16 154,644 510,240 355,596 25,774 Total motor 21 Total Power Recuction 132 kW
kW vs VAR Save in New Tariff
140000 4,500
4,000
120000
3,500
100000
3,000
80000 2,500
RM
60000 2,000
1,500
40000
1,000
20000 500
0 0
Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15 Jul-15 Aug-15 Sep-15 Oct-15 Nov-15 Dec-15 Aug-15 Sep-15 Oct-15 Nov-15 Dec-15
Remarks
Actual Cost Vs Energy Saving
60,000
50,000
40,000
RM
30,000
20,000
10,000 28
0
Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15 Jul-15 Aug-15 Sep-15 Oct-15 Nov-15 Dec-15
What is The Next Step?
Increased
awareness
Minimizing operation of Avoiding operating of
idling or lightly loaded equipment above its
motor rated voltage
Manage the
demand
Basic Electrical Theory
Assignment 3
Accuracy
Calibrate
Error
Input/output
Instrument
Range
Span
Transducer
Transmitter
30
Thank You
“Betulkan yang biasa,
Biasakan yang betul”