Monday, September 30, 2013

Motor Service Factor (SF) Defined By NEMA

Motor Service Factor (SF) Defined By NEMA

Permissible horsepower loading

Motor Service Factor (SF) is the percentage of overloading the motor can handle for short periods when operating normally within the correct voltage tolerances. This is practical as it gives you some ‘fudge‘ in estimating horsepower needs and actual running horsepower requirements.
It also allows for cooler winding temperatures at rated load, protects against intermittent heat rises, and helps to offset low or unbalanced line voltages.
BALDOR Open Drip Proof C-Face Foot Mounted motor - 1/3Hp-100Hp NEMA 56C-404TC
BALDOR Open Drip Proof C-Face Foot Mounted motor - 1/3Hp-100Hp NEMA 56C-404TC

For example, the standard SF for open drip-proof (ODP) motors is 1.15. This means that a 10-hp motor with a 1.15 SF could provide 11.5 hp when required for short-term use. Some fractional horsepower motors have higher service factors, such as 1.25, 1.35, and even 1.50.
NEMA defines service factor as a multiplier, when applied to the rated horsepower, indicates a permissible horsepower loading, which may be carried under the conditions specified for the service factor at rated voltage and frequency.
This service factor can be used for the following:
  1. To accommodate inaccuracy in predicting intermittent system horsepower needs.
  2. To lengthen insulation life by lowering the winding temperature at rated load.
  3. To handle intermittent or occasional overloads.
  4. To allow occasionally for ambient above 40°C.
  5. To compensate for low or unbalanced supply voltages.
NEMA does add some cautions, however, when discussing the service factor:
  1. Operation at service factor load for extended periods will usually reduce the motor speed, life and efficiency.
  2. Motors may not provide adequate starting and pull-out torques, and incorrect starter/overload sizing is possible. This in turn affects the overall life span of the motor.
  3. Do not rely on the service factor capability to carry the load on a continuous basis.
  4. The service factor was established for operation at rated voltage, frequency, ambient and sea level conditions.
Most motors have a duty factor of 1.15 for open motors and 1.0 for totally closed motors.
Traditionally, totally enclosed fan cooled (TEFC) motors had an SF of 1.0, but most manufacturers now offer TEFC motors with service factors of 1.15, the same as on ODP motors. Most hazardous location motors are made with an SF of 1.0, but some specialized units are available for Class I applications with a service factor of 1.15.
The service factor is required to appear on the nameplate only if it is higher than 1.0.

Sunday, September 29, 2013

NEC Requirements for Emergency Systems

NEC Requirements for Emergency Systems (on photo Automatic Transfer Switch for Emergency Systems 240V 150A 3p)

Introduction

Emergency systems are generally installed in buildings that are or can be occupied by 1000 or more persons or are more than 75 ft high.
These are buildings where artificial illumination is required for safe exiting and for panic control. Examples are hotels, theaters, airports, railroad stations, sports arenas, department stores, and hospitals.
Emergency systems are designed to power exit lighting, fire detection and alarm systems, elevators, fire pumps, and public safety communications systems. They might also power ventilation systems considered essential to preserving health and life, or industrial processes where power interruption would result in hazards to life or injury.
NEC 2012, Article 700, “Emergency Systems,” covers electrical safety in the installation, operation, and maintenance of emergency systems. These consist of “circuits and equipment intended to supply, distribute, and control electricity for illumination, power or both, to vital facilities when the normal electrical supply or system is interrupted”.
These are “systems legally required and classed as emergency by municipal, state, federal, or others codes, or by any governmental agency having jurisdiction”.
These systems are intended to automatically supply illumination, power, or both to designated areas and equipment in the event of failure of the normal supply or in the event of accident to elements of a system intended to supply, distribute, and control power and illumination essential to human life.”
The general subjects covered in Article 700 include:
  • Tests and maintenance of approved emergency system equipment
  • Capacity and rating of emergency system equipment
  • Power transfer equipment, including automatic transfer switches
  • Signals and signs for emergency systems
The circuit wiring provisions of Article 700 include:
  • Identification of boxes, enclosures, transfer switches, generators, etc.
  • Wiring independence and exceptions
  • Fire protection for high-occupancy and high-rise buildings
The section on sources of power gives the response-time requirements for the restoration of emergency lighting, emergency power, or both as “not to exceed 10 seconds” for the specific classes of buildings stated previously.
In selecting the emergency source of power, consideration must be given to the occupancyand type of service rendered in those buildings.
The occupancy classes are given as (1) assembly, (2) educational, (3)residential, (4) detention and correctional, (5) business, and (6) mercantile.
Article 700 requires that power sources be installed in rooms protected by approved automatic fire suppression systems (sprinklers, CO2systems, etc.) or in spaces with a 1-hr burn rating. (Fire can surround or be adjacent to the room for at least 1 hr before its fire-resistant integrity is lost and its contents begin to ignite spontaneously.)
The four emergency power systems approved by Article 700 are:
  • Storage batteries (rechargeable)
  • Generator sets
  • Uninterruptible power supplies (UPS)
  • Separate services (alternate outside utility or inside generation) in accordance with NEC Article 230
The section on emergency system circuits for lighting and power covers:
  • Approved loads on emergency branch circuits
  • Emergency illumination
  • Circuits for emergency lighting
  • Circuits for emergency power
The section on emergency control lighting circuits covers:
  • Switch requirements
  • Switch location
  • Exterior lights
The section on overcurrent protection covers accessibility of branch-circuit overcurrent devices (fuses and circuit breakers) and ground-fault protection of equipment.

Identifying The Primary And Secondary Phasor Polarities Of Transformer – Polarity Test

CPC 100 - Universal testing device for electrical diagnostics

CPC 100 - Universal testing device for electrical diagnostics on transformers, current transformers, voltage transformers, grounding systems, lines and cables, and circuit breakers (photo by www.omicron.at)

Polarity Detection

This is needed for identifying the primary and secondary phasor polarities. It is a must for poly phase connections. Both a.c. and d.c methods can be used for detecting the polarities of the induced emfs.
The dot method is used to indicate the polarities.
The transformer is connected to a low voltage a.c. source with the connections made as shown in the Figure 1 (a). A supply voltage Vs is applied to the primary and the readings of the voltmeters V1V2 and V3 are noted. V1 : V2 gives the turns ratio.
If V3 reads V1−V2 then assumed dot locations are correct (for the connection shown).
Transformer polarity test scheme
Figure 1 - Transformer polarity test scheme

The beginning and end of the primary and secondary may then be marked by A1 − A2 and a1− a2 respectively. If the voltage rises from A1 to A2 in the primary, at any instant it does so from a1 to a2 in the secondary.
If more secondary terminals are present due to taps taken from the windings they can be labeled as a3a4a5a6. It is the voltage rising from smaller number towards larger ones in each winding. The same thing holds good if more secondaries are present.
Figure 1 (b) shows the d.c. method of testing the polarity. When the switch S is closed if the secondary voltage shows a positive reading, with a moving coil meter, the assumed polarity is correct. If the meter kicks back the assumed polarity is wrong.

Condition Monitoring of Transformers

Condition Monitoring of Transformers (on photo: distributive tranformer; by Gazoogleheimer via Flickr )

Detecting early signs of deterioration

It is possible to provide transformers with measuring devices to detect early signs of degradation in various components and provide warning to the operator in order to avoid alengthy and expensive outage due to failure.
The technique, which can be applied to other plant as well as transformers, is called condition monitoring, as the intent is to provide the operator with regular information on the condition of the transformer.
By reviewing the trends in the information provided, the operator can make a better judgement as to the frequency of maintenance, and detect early signs of deterioration that, if ignored, would lead to an internal fault occurring.
Such techniques are an enhancement to, but are not a replacement for, the protection applied to a transformer.
The extent to which condition monitoring is applied to transformers on a system will depend on many factors, amongst which will be the policy of the asset owner, the suitability of the design (existing transformers may require modifications involving a period out of service – this may be costly and not justified), the importance of the asset to system operation, and the general record of reliability.
Therefore, it should not be expected that all transformers would be, or need to be, so fitted.
A typical condition monitoring system for an oil immersed transformer is capable of monitoring the condition of various transformer components (bushings, tank, tap changer, coolers and conservators) as shown in Table 1 below.
Condition monitoring for transformers
Table 1 - condition monitoring for transformers

There can be some overlap with the measurements available from a digital/numerical relay.
By the use of software to store and perform trend analysis of the measured data, the operator can be presented with information on the state of health of the transformer, and alarms raised when measured values exceed appropriate limits. This will normally provide the operator with early warning of degradation within one or more components of the transformer, enabling maintenance to be scheduled to correct the problem prior to failure occurring.
The maintenance can obviously be planned to suit system conditions, provided the rate of degradation is not excessive.

Total Losses in Power Distribution and Transmission Lines

Total Losses in Power Distribution and Transmission Lines (1)
Total Losses in Power Distribution and Transmission Lines (on photo: Power sunset over Kampala City, Uganda)

Introduction

Power generated in power stations pass through large and complex networks like transformers, overhead lines, cables and other equipment and reaches at the end users. It is fact that the unit of electric energy generated by Power Station does not match with the units distributed to the consumers. Some percentage of the units is lost in the distribution network.
This difference in the generated and distributed units is known as Transmission and Distribution loss. Transmission and Distribution loss are the amounts that are not paid for by users.
T&D Losses = (Energy Input to feeder(Kwh) – Billed Energy to Consumer(Kwh)) / Energy Input kwh x 100
Distribution Sector considered as the weakest link in the entire power sector. Transmission Losses is approximate 17% while Distribution Losses is approximate 50%.
There are two types of Transmission and Distribution Losses:
  1. Technical Losses
  2. Non Technical Losses (Commercial Losses)

1. Technical Losses

The technical losses are due to energy dissipated in the conductors, equipment used for transmission line, transformer, subtransmission line and distribution line and magnetic losses in transformers.
Technical losses are normally 22.5%, and directly depend on the network characteristics and the mode of operation.
The major amount of losses in a power system is in primary and secondary distribution lines. While transmission and sub-transmission lines account for only about 30% of the total losses. Therefore the primary and secondary distribution systems must be properly planned to ensure within limits.
  • The unexpected load increase was reflected in the increase of technical losses above the normal level
  • Losses are inherent to the distribution of electricity and cannot be eliminated.
There are two Type of Technical Losses.

1. Permanent / Fixed Technical losses

  • Fixed losses do not vary according to current. These losses take the form of heat and noise and occur as long as a transformer is energized
  • Between 1/4 and 1/3 of technical losses on distribution networks are fixed losses. Fixed losses on a network can be influenced in the ways set out below
  • Corona Losses
  • Leakage Current Losses
  • Dielectric Losses
  • Open-circuit Losses
  • Losses caused by continuous load of measuring elements
  • Losses caused by continuous load of control elements

2. Variable Technical losses

Variable losses vary with the amount of electricity distributed and are, more precisely, proportional to the square of the current. Consequently, a 1% increase in current leads to an increase in losses of more than 1%.
  • Between 2/3 and 3/4 of technical (or physical) losses on distribution networks are variable Losses.
  • By increasing the cross sectional area of lines and cables for a given load, losses will fall. This leads to a direct trade-off between cost of losses and cost of capital expenditure. It has been suggested that optimal average utilization rate on a distribution network that considers the cost of losses in its design could be as low as 30 per cent.
  • Joule losses in lines in each voltage level
  • Impedance losses
  • Losses caused by contact resistance.

Main Reasons for Technical Losses

1. Lengthy Distribution lines

In practically 11 KV and 415 volts lines, in rural areas are extended over long distances to feed loads scattered over large areas. Thus the primary and secondary distributions lines in rural areas are largely radial laid usually extend over long distances.
This results in high line resistance and therefore high I2R losses in the line.
  • Haphazard growths of sub-transmission and distribution system in to new areas.
  • Large scale rural electrification through long 11kV and LT lines.

2. Inadequate Size of Conductors of Distribution lines

The size of the conductors should be selected on the basis of KVA x KM capacity of standard conductor for a required voltage regulation, but rural loads are usually scattered and generally fed by radial feeders. The conductor size of these feeders should be adequate.

3. Installation of Distribution transformers away from load centers

Distribution Transformers are not located at Load center on the Secondary Distribution System.
In most of case Distribution Transformers are not located centrally with respect to consumers. Consequently, the farthest consumers obtain an extremity low voltage even though a good voltage levels maintained at the transformers secondary.
This again leads to higher line losses. (The reason for the line losses increasing as a result of decreased voltage at the consumers end therefore in order to reduce the voltage drop in the line to the farthest consumers, the distribution transformer should be located at the load center to keep voltage drop within permissible limits.)

4. Low Power Factor of Primary and secondary distribution system

In most LT distribution circuits normally the Power Factor ranges from 0.65 to 0.75. A low Power Factor contributes towards high distribution losses.
For a given load, if the Power Factor is low, the current drawn in high  And  the losses proportional to square of the current will be more. Thus, line losses owing to the poor PF can be reduced by improving the Power Factor.
This can be done by application of shunt capacitors.
  • Shunt capacitors can be connected either in secondary side (11 KV side) of the 33/11 KV power transformers or at various point of Distribution Line.
  • The optimum rating of capacitor banks for a distribution system is 2/3rd of the average KVAR requirement of that distribution system.
  • The vantage point is at 2/3rd the length of the main distributor from the transformer.
  • A more appropriate manner of improving this PF of the distribution system and thereby reduce the line losses is to connect capacitors across the terminals of the consumers having inductive loads.
  • By connecting the capacitors across individual loads, the line loss is reduced from 4 to 9% depending upon the extent of PF improvement.

5. Bad Workmanship

Bad Workmanship contributes significantly role towards increasing distribution losses.
Joints are a source of power loss. Therefore the number of joints should be kept to a minimum. Proper jointing techniques should be used to ensure firm connections.
Connections to the transformer bushing-stem, drop out fuse, isolator, and LT switch etc. should be periodically inspected and proper pressure maintained to avoid sparking and heating of contacts.
Replacement of deteriorated wires and services should also be made timely to avoid any cause of leaking and loss of power.

6. Feeder Phase Current and Load Balancing>

One of the easiest loss savings of the distribution system is balancing current along three-phase circuits.
Feeder phase balancing also tends to balance voltage drop among phases giving three-phase customers less voltage unbalance. Amperage magnitude at the substation doesn’t guarantee load is balanced throughout the feeder length.
Feeder phase unbalance may vary during the day and with different seasons. Feeders are usually considered “balanced” when phase current magnitudes are within 10.Similarly, balancing load among distribution feeders will also lower losses assuming similar conductor resistance. This may require installing additional switches between feeders to allow for appropriate load transfer.
Bifurcation of feeders according to Voltage regulation and Load.

7. Load Factor Effect on Losses

Power consumption of customer varies throughout the day and over seasons.
Residential customers generally draw their highest power demand in the evening hours. Same commercial customer load generally peak in the early afternoon. Because current level (hence, load) is the primary driver in distribution power losses, keeping power consumption more level throughout the day will lower peak power loss and overall energy losses.
Load variation is Called load factor and It varies from 0 to 1.
Load Factor = Average load in a specified time period / peak load during that time period.
For example, for 30 days month (720 hours) peak Load of the feeder is 10 MW. If the feeder supplied a total energy of 5,000 MWH, the load factor for that month is (5,000 MWh)/ (10MW x 720) =0.69.
Lower power and energy losses are reduced by raising the load factor, which, evens out feeder demand variation throughout the feeder.
The load factor has been increase by offering customers “time-of-use” rates. Companies use pricing power to influence consumers to shift electric-intensive activities during off-peak times (such as, electric water and space heating, air conditioning, irrigating, and pool filter pumping).
With financial incentives, some electric customers are also allowing utilities to interrupt large electric loads remotely through radio frequency or power line carrier during periods of peak use. Utilities can try to design in higher load factors by running the same feeders through residential and commercial areas.

8. Transformer Sizing and Selection

Distribution transformers use copper conductor windings to induce a magnetic field into a grain-oriented silicon steel core. Therefore, transformers have both load losses and no-load core losses.
Transformer copper losses vary with load based on the resistive power loss equation (P loss = I2R). For some utilities, economic transformer loading means loading distribution transformers to capacity-or slightly above capacity for a short time-in an effort to minimize capital costs and still maintain long transformer life.
However, since peak generation is usually the most expensive, total cost of ownership (TCO)studies should take into account the cost of peak transformer losses. Increasing distribution transformer capacity during peak by one size will often result in lower total peak power dissipation-more so if it is overloaded.
Transformer no-load excitation loss (iron loss) occurs from a changing magnetic field in the transformer core whenever it is energized. Core loss varies slightly with voltage but is essentially considered constant. Fixed iron loss depends on transformer core design and steel lamination molecular structure. Improved manufacturing of steel cores and introducing amorphous metals (such as metallic glass) have reduced core losses.

9. Balancing 3 phase loads

Balancing 3-phase loads periodically throughout a network can reduce losses significantly. It can be done relatively easily on overhead networks and consequently offers considerable scope for cost effective loss reduction, given suitable incentives.

10. Switching off transformers

One method of reducing fixed losses is to switch off transformers in periods of low demand. If two transformers of a certain size are required at a substation during peak periods, only one might be required during times of low demand so that the other transformer might be switched off in order to reduce fixed losses.
This will produce some offsetting increase in variable losses and might affect security and quality of supply as well as the operational condition of the transformer itself. However, these trade-offs will not be explored and optimized unless the cost of losses are taken into account.

11. Other Reasons for Technical Losses

  • Unequal load distribution among three phases in L.T system causing high neutral currents.
  • leaking and loss of power
  • Over loading of lines.
  • Abnormal operating conditions at which  power and distribution transformers are operated
  • Low voltages at consumer terminals causing higher drawl of currents by inductive loads.
  • Poor quality of equipment used in agricultural pumping in rural areas, cooler air-conditioners and industrial loads in urban areas.

Special Transformers for Industrial Applications

Special Transformers for Industrial Applications
Special Transformers for Industrial Applications

Specific Industrial Transformers

A number of industry applications require specific industrial transformers due to the usage of power (current) as a major resource for production.
  1. Electric arc furnace transformers (EAF)
  2. DC electric arc furnace transformers (DC EAF)
  3. Rectifier transformers
  4. Converter transformers
  5. Line Feeder
Electric arc furnaces (EAF)ladle furnaces (LF) and high-current rectifiers need a specific design to supply the necessary power at a low voltage level.
These transformer types, as well as transformers with direct connection to a rectifier are called special-purpose or industrial transformers, whose design is tailor-made for high-current solutions for industry applications.

1. Electric arc furnace transformers (EAF)

Electric arc furnace transformer
Figure 1 - Electric arc furnace transformer

EAF and LF transformers are required for many different furnace processes and applications. They are built for steel furnacesladle furnaces and ferroalloy furnaces, and are similar to short or submerged arc furnace transformers (figure 1).
EAF transformers operate under very severe conditions with regard to frequent overcurrents and overvoltages generated by short-circuit in the furnace and the operation of the HV circuit breaker.
The loading is cyclic. For long-arc steel furnace operation, additional series reactance is normally required to stabilize the arc and optimize the operation of the furnace application process.

Specific items

EAF transformers are rigidly designed to withstand repeated short-circuit conditions and high thermal stress, and to be protected against operational overvoltages resulting from the arc processes.
The Siemens EAF reactors are built as 3-phase type with an iron core, with or without magnetic return circuits.

Design options

  • Direct or indirect regulation
  • On-load or no-load tap changer (OLTC/NLTC)
  • Built-in reactor for long arc stability
  • Secondary bushing arrangements and designs
  • Air or water-cooled
  • Internal secondary phase closure (internal delta)

Main specification data

  • Rated power, frequency and rated voltage
  • Regulation range and maximum secondary current
  • Impedance and vector group
  • Type of cooling and temperature of the cooling medium
  • Series reactor and regulation range and type (OLTC/NLTC)

2. DC electric arc furnace transformers (DC EAF)

Direct-Current Electric Arc Furnace (DC EAF) Transformer
Figure 2 - Direct-Current Electric Arc Furnace (DC EAF) Transformer

Direct-current electric arc furnace (DC EAF) transformers are required for many different furnace processes and applications (figure 2).
They are built for steel furnaces with a Thyristor rectifier. DC EAF transformers operate under very severe conditions, like rectifier transformers in general but using rectifier transformers for furnace operation. The loading is cyclic.

3. Rectifier transformers

Rectifier transformer for an aluminum plant
Figure 3 - Rectifier transformer for an aluminum plant

Rectifier transformers are combined with a diode or Thyristor rectifier. The applications range from very large aluminum electrolysis to various medium-size operations.
The transformers may have a built-in or a separate voltage regulation unit. Due to a large variety of applications, they can have various designs up to a combination of voltage regulation, rectifier transformers in double-stack configuration, phase-shifting, interphase reactors, transductors and filter-winding (figure 3).

Specific items

Thyristor rectifiers require voltage regulation with a no-load tap changer, if any. A diode rectifier will, in comparison, have a longer range and a higher number of small voltage steps than an on-load tap changer.
Additionally, an auto-connected regulating transformer can be built in the same tank (depending on transport and site limitations).

Design options

  • Thyristor or diode rectifier
  • On-load or no-load tap changer (OLTC/NLTC)/filter winding
  • Numerous different vector groups and phase shifts possible
  • Interphase reactor, transductors
  • Secondary bushing arrangements and designs
  • Air or water-cooled

Main specification data

  • Rated power, frequency and rated voltage
  • Regulation range and number of steps
  • Impedance and vector group, shift angle
  • Type of cooling and temperature of the cooling medium
  • Bridge or interphase connection
  • Number of pulses of the transformer and system
  • Harmonics spectrum or control angle of the rectifier
  • Secondary bushing arrangement

4. Converter transformers

Converter transformer
Converter transformer - The drive systems in which Converter Transformers are used can drive all kinds of applications such as pumping stations, rolling stock for the mining industry and wind tunnels as well as blast furnaces.
Converter transformers are used for large drive application, static voltage compensation (SVC) and static frequency change (SFC).

Specific items

Converter transformers are mostly built as double-tier, with two secondary windings, allowing a 12-pulse rectifier operation. Such transformers normally have an additional winding as a filter to take out harmonics. Different vector groups and phase shifts are possible.

Main specification data

  • Rated power, frequency and rated voltage
  • Impedance and vector group, shift angle
  • Type of cooling and temperature of the cooling medium
  • Number of pulses of the transformer and system
  • Harmonics spectrum or control angle of the rectifier

5. Line Feeder

Line feeder transformer
Line feeder transformer

This kind of transformer realizes the connection between the power network and the power supply for the train.
Transformer is operating in specific critical short circuit condition and overload condition in very high frequencies per year, higher reliability is required to secure the train running in safety.

Main specification data

  • Rated power, frequency and rated voltage
  • Impedance and vector group
  • Overload conditions
  • Type of cooling and temperature of the cooling medium
  • Harmonics spectrum or control angle of the rectifier

Design options

  • Direct connection between transmission network and railway overhead contact line
  • Frequence change via DC transformation (e.g. 50 Hz – 16,67 Hz)
  • Thyristor or diode rectifier
  • On-load or no-load tap changer (OLTC/NLTC)/filter winding
  • Secondary bushing arrangements and designs
  • Air or water-cooled.