Post on 28-Jul-2020
Fundamentals Of ElectricityFundamentals Of Electricity
Power Factor, contd :
C = ( Q1 - Q2 )2 π f V2
Where, C = Capacitance (F) required to reduce the
Reactive or Imaginary Power from Q1 to Q2 Q1 = Initial, higher Reactive Power, in VARsQ2 = Improved, lower Reactive Power, in VARsV = Voltage, in Voltsf = Frequency, in Hz
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Electrical Engineering Fundamentals for Non-EE's; © B. Rauf
Fundamentals Of ElectricityFundamentals Of ElectricityPF = ⏐P⏐/⏐S⏐ or
⏐S⏐= ⏐P⏐/ PFPower Factor Improvement Example:Problem:
An air compressor station is consuming 2,000 kW at a power factor of 0.8. The utility company charges a $4.00/kVa per month as demand charge for poor power factor. What would the annual, pre-tax, savings be if capacitors could be installed and power factor improved to 0.9?
Solution:Apparent Power or Billing kVa at existing Power Factor of 0.8 = 2,000 kW / 0.8
= 2,500 kVa
Apparent Power or Billing Kva at an improved Power Factor of 0.9 = 2,000 kW / 0.9 = 2,222 kVa
Demand Charge Savings = (2500-2222) kVa x $4.00/kVa x 12 Months/Year = $13,344
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Electrical Engineering Fundamentals for Non-EE's; © B. Rauf
Power Factor and Loss Calculation Power Factor and Loss Calculation Example:Example:
Power Factor and Loss Calculation
Load: 8,760,000 kVAHAssume, Losses = 5% of total load, in kW'sElectricity Cost: 0.06$ Per kWHOperating Time: 8,760 Hours Per Year
PF1 = 0.7PF2 = 1
kVA 1 = 1,000 => 700 kWkVA 2 = 700 => 700 kW
((I1- I2) / I1) * 100 30%I2 = (0.7) x I = ( 0.7) I New Loss = I x I x R = (0.7 x I)^2 x R => 49%
Loss Reduction (%) = 51%
Loss Reduction, in kWh = 156,366 kWH{0.05x700x8760x0.51}
Approx. Savings = 9,382$ Per Year{156,366x$0.06/kWh}
Equiv. to a 938 HP Motor
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Electrical Engineering Fundamentals for Non-EE's; © B. Rauf
Additional Comments / Discussion on Additional Comments / Discussion on Power FactorPower Factor
Some electric utilities penalize commercial and industrial customers for failing to maintain a power factor (PF) above a specified level. The average power factor, without correction, for a typical small commercial or industrial facility is about 82%.Some utilities base demand charges on kVAdemanded by a customer facility. In such cases, an approximate 10% demand reduction can be realized if a power-factor-correction capacitor bank is installed to improve the power factor from 82% to 90%. Such and investment has a typical payback of, approximately, two (2) years.
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Electrical Engineering Fundamentals for Non-EE's; © B. Rauf
Additional Comments / Discussion on Additional Comments / Discussion on Power Factor:Power Factor:
If the power factor of a facility is improved or increased by 10%, the demand (kVA) charges would decrease by 10%. Therefore, even if PF Penalty threshold is not met, real cost reduction is achieved through lower demand charges.Higher PF means lower kVA demand and lower “unproductive” current in the electrical system. This “unproductive” current is wasted, as heat, as it flows through conductors, protective devices, power monitoring devices, transformers and loads. Therefore, improving the power factor not only results in improved energy efficiency but it also extends service life and reduces maintenance cost of equipment.
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Additional Comments / Discussion on Additional Comments / Discussion on Power Factor:Power Factor:
Application of power factor correcting capacitors should be preceded by proper analysis and design. Improper application of power factor correcting capacitors can damage an electrical system. Improper application of power factor correcting capacitors can cause fuses to blow and can amplify system harmonics. After installation, capacitor banks must be included in the facility’s Preventive Maintenance Program. Loose connections and inherent defects, when ignored, can lead to unanticipated failures, faults and downtimes.
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Electrical Engineering Fundamentals for Non-EE's; © B. Rauf
Additional Comments / Discussion on Power Factor:Additional Comments / Discussion on Power Factor:If VAR contribution is from a distribution transformer, application of PF capacitor is recommended at the distribution bus feeding the transformer. When the volt-amp reactive (VAR) contribution is caused by large motors, the greatest PF corrective effect and energy loss reduction is realized when the capacitors are installed at each motor load (on line side), or between the motor starters and themotors. – However, the initial cost for a number of small banks of
capacitors would tend to be higher than the initial cost of a single, large, bank of capacitors, catering to several motor loads. In such cases, the higher initial cost must be weighed against gains in energy cost and PF correction benefits.
Systems that experience large load swings, throughout the day ormonth, are good candidates for automatic switching correction systems. These systems, automatically, correct the PF as load variations occur.
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Electrical Equipment and Electrical Equipment and InstrumentationInstrumentation
Bobby Rauf ©
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Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
Topics Topics
Size of Power Distribution Systems, by VoltageElectrical Equipment and Instrumentation
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Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
Power Distribution SystemsPower Distribution Systems
Low Voltage Systems:Up to and including 600 VAC or DC
Medium Voltage Systems:From 600 V up to 1,000 V, 1 KV
High Voltage Systems:From 1,000 V up to 800 KV
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Power Distribution SystemsPower Distribution Systems
MCC’s or Motor Control CentersAllen-Bradley Slide ShowOther Sources:
– Square-D– ABB– Seimens
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• 20” (508mm) wide standard
• 15” (381mm) or 20” (508mm) deep
• 90” (2286mm) high standard, – 71” (1790mm) high
available
• Front mounted or back-to-back
Front MountedBack-to-Back
SectionsSections
NEMA Enclosure TypesNEMA Enclosure Types
• Type 1
• Type 1 with gaskets
• Type 12 (also instainless steel)
• Type 3R
• Type 4 stainless steel
NEMA Type 4
NEMA Type 1
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Bus ConnectionsBus Connections• At least two bolts
– Horizontal-to-vertical– Horizontal splices – Extra bolt ensures integrity
• Front accessible
Horizontal to Vertical Connection
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Horizontal Ground BusHorizontal Ground Bus
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• 1/4” x 1” (6.4mm x 25.4mm) or 1/4” x 2” (6.4mm x 50.8mm)
• Unplated or tin-plated copper
• Located in wireway– Top or bottom– Top and bottom
Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
Vertical Ground BusVertical Ground Bus• Plug-in ground bus
– Steel (standard)– Copper (optional)
• Unit load ground bus optional– Copper– For easier
termination of ground wires
Unit Load Ground Bus
Plug-in Ground Bus
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Incoming Lug CompartmentIncoming Lug Compartment
• Top or bottom
• Straight pull for cables
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Main Fusible DisconnectMain Fusible Disconnect
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• Top or bottom
• Frame mounted
• 600A-2000A utilize “Bolted Pressure Switch”
• Visible blade
BoltedPressure
Switch
Main Circuit BreakerMain Circuit Breaker
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• Top or bottom
• Frame mounted
• Ground fault protection available
Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
Space Factors
78” (1981mm)
Space Factors13” (330mm)
• One space factor equals 13” (330mm)
• Six space factors per section
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Full Voltage NonFull Voltage Non--Reversing Starter Reversing Starter UnitsUnits
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1.5 Space Factor Dual Size 1
(8 starters/section)
1.0 Space Factor Size 1
(6 starters/section)
0.5 Space Factor Size 1
(12 starters/section)
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• Housing– Isolates incoming
phases acting as a fault barrier
• Stabs– Tin-plated– Rated 240A– Directly crimped– Steel spring backed– Free-floating and
self-aligning
Stab Assembly
Stab AssemblyStab Assembly
Unit Grounding ProvisionsUnit Grounding Provisions
• Unit ground stab– Used with unit plug-in
ground bus– Copper alloy (standard)– Solid copper (optional)
• Unit load ground connector– Used with unit load
ground bus– Solid copper– For easier termination of load
ground wire
Standard Plug-in Ground Stab
Optional Plug-in Ground Stab
Unit Load Ground
Connector
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Unit HandleUnit Handle
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• Remains in control of disconnecting means
• Positive status identification
• Interlocked with door
• Padlockable
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Unit InterlockUnit Interlock
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• Prevents inserting or withdrawing unit with handle in ON position
• Padlockable
Bulletin 2100 Unit ComponentsBulletin 2100 Unit ComponentsBulletin 500 NEMA Contactor
Fusible Disconnect or Circuit Breaker
Bulletin 1492 Pull-Apart Terminal Blocks
Bulletin 592 Melting
Alloy or Solid-State
Overload Protection
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Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
Pilot DevicesPilot Devices
• Generally housed in control station
• Bulletin 800T – up to 3
• Bulletin 800MR – up to 8
Bulletin 800T
Bulletin 800MR9/23/2008
200.5 Space Factor Unit
with Pilot DevicesElectrical Engineering Fundamentals for Non-EEs; © B. Rauf
Variety of UnitsVariety of UnitsFull Voltage Non-Reversing Starters
Full Voltage Reversing Starters
Feeders
Lighting Transformers
Plus: Full Voltage Contactors, Two-Speed Starters,Reduced Voltage Autotransformer Starters
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Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
9/23/200822
Bulletin 1305
Bulletin 1336 PLUS or Bulletin 1336 PLUS II
Variable Frequency Drives Variable Frequency Drives -- Up to Up to 250HP250HP
Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
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SMC-2SMC Dialog Plus
Smart Motor Controllers (Smart Motor Controllers (SMCsSMCs) ) -- Up to Up to 500A500A
Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
PLC I/O ChassisPLC I/O Chassis
SLC-500
Bulletin 1771 Full Section
Bulletin 1771
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Metering UnitsMetering Units
Analog Metering Unit Powermonitor II Metering Unit
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Bulletin 2400 UnitsBulletin 2400 Units
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• Application-rated• IEC components• Reduced space• IEC standards
– Units – IEC 60947– Sections – IEC 60439-1– Witness tested by:
KEMAASTA
– CE rating upon request
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Bulletin 2400 ComponentsBulletin 2400 Components
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Bulletin 100 IEC Contactors
Bulletin 193 IEC Overload RelayFusible
Disconnect or Circuit Breaker
Bulletin 800E IEC Pilot Devices
Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
National Electric Code and National Electric Code and Safety SystemsSafety Systems
Bobby Rauf ©
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Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
Topics Topics Introduction to NEC & Outline – Art. 90.Definitions, Including Enclosure Ratings –Art. 100 & Table 1.1.Conductor Sizes, AWG and Circular Mils. Art. 110.6.Clearances and Working Space Requirements. Art. 110.26.Load Configurations and Voltages in Branch Circuits. Art. 210 and Exhibit 210.4Autotransformers. Art. 210.9.Branch Circuit Ampacity Determination & Over current Protection. Art 210.20.
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Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
Topics, contd.: Topics, contd.: Over current Protection. Art. 240.Circuit Breaker and Fuse Types. Art. 240.50 – 240.101.Importance of Coordinated OC Protection. Art. 240.86 & Exhibit 240.14.Grounding. Art. 250, Table 250.3, Exhibits 250.1 – 250.56.Conductor Insulation Rating. Art. 310 & Table 310.13.Conductor Ampacity. Art. 310.15 & Tables 310.16 – 310.21.Conduit and Cable Trays. Art. 358 – 392 & Exhibit 392.1.Panel Boards. Art. 408.13 – 408.35.
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Industrial Safety and Safety Industrial Safety and Safety SystemsSystems
Bobby Rauf
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Topics Topics
Safety Certifications in Industrial EnvironmentSafety Products and Common Applications
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Safety Certifications in Industrial Safety Certifications in Industrial Environment:Environment:
Look for the following safety related certifications, tests or labels on “off the shelf” equipment:– UL, Underwriters Laboratories– IEC, International Electrotechnical Commission– IEEE, Institute of Electronic and Electrical Engineers– NEC, National Electrical Code– IP Rating– CE Certification
On custom engineered systems or equipment, look for Safety Compliance Statement from the manufacturer, engineering firm, general contractor or system integrator.
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Safety ProductsSafety Products
Bobby Rauf
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Safety ProductsSafety ProductsSafety
Contactors & Control Relays
Safety Relays
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Safety PLC Safety Buttons
Network Communications
Safety Mat + Controller
Safety Light Curtain
Key / Solenoid Interlock Switches
Cable PullSwitches
Trapped Key
Safety Laser Scanners
Safety Limit Switches
Safety Guard Edges
Safety EOI
Safety ESafety E--stop Devicesstop Devices
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Series 800T/800E & Self Monitoring Contact Blocks
E-Stops– Available in 30mm & 22mm sizes– Metal and plastic construction– Meet EN418 and IEC 60947-5-5
standards– Push-pull, push-pull/twist release, illuminated,
or key-operated devicesSelf Monitoring Contact Blocks– For use with 800T & 800E E-Stops– Patented technology improves reliability and safety– If contact block becomes separated from E-stop,
monitoring circuit automatically opens and shuts down the controlled process
– Essentially eliminates contact separation concernsfrom improper installation, damage or high-vibrationapplications
ZeroZero--ForceForceTMTM Touch ButtonsTouch Buttons
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Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
800Z GP (General Purpose) Line800Z HI (Heavy
Industrial) Line
Global Mounting OfferedExclusive 22.5 mm line & standard 30.5 mm line
Superior Rigid GuardsLargest ergonomic interface NEMA and IP rating remain when guard is usedOptional Guard Colors -
Black, Red, Green and Yellow
BACK
Safety Light Curtain SystemSafety Light Curtain System
TRANSMITTER RECEIVER
Safety Light Curtain System Consists of:– Transmitter/Receiver– Control Reliable Controller– Interface Cables– Optional Power Supply– Optional Muting Blanking
control
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Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
SafeShieldSafeShield DeviceNetDeviceNet
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DNet module can be interfaced to any SafeShieldproduct at any timeDiagnostic information can be transferred via DeviceNet(Output status / EDM active / Restart required / Device faulted / Weak signal / Blanking selected)DNet Communication via DNet Module (Black)SCD Software for L.C. Configuration only, not for DNet
DCPowerSupply
PAC (Perimeter Access Control)PAC (Perimeter Access Control)
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Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
Enclosure rating IP 6524Vdc Two box DesignComplies with requirements for type 4Meets CE requirements as pr EN 50 100Ambient operating temperature 0 ... + 55 °CResponse time - 20 msScanning range 0.5 – 70mMin. resolution 73 mmNumber of beams 1-42 OSSD PNP Semiconductor outputsMini Style connectorsIntegral Muting Module availableMargin Indication
An output turns on when lens are dirty
AAC (Area Access Control)AAC (Area Access Control)
Long Scan Range up to 70M (230Ft.)
Die Cast Aluminum Housing
Two Ranges available
- .5M to 18M (19.5” to 59”)
- 15M to 70M (4’ to 230’)
Easy Installation
Heated Front Screen, I.e. can be used in outdoor applications
Fast response time 22ms
24vd/115vac standard / 230vac (special order)
Built in monitored safety relays
- 2 NO/1NC / 2A Max switching Current
IP 65 enclosure rating
Operating temp. -25°C to 50°C
PG connector IP 67
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Lifeline 4
Cable Pull SwitchesCable Pull SwitchesLifeline 3
Lifeline 2
LRTS
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BACK
Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
Key Interlock Solenoid SwitchesKey Interlock Solenoid SwitchesAtlas 5 w/Trap Key
TLS GD2
Atlas 4
Atlas 5 w/Key
Spartan
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GuardMatGuardMat™™ Safety MatsSafety Mats
Mats
Controllers
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Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
GuardEdgeGuardEdge™™ Safety EdgesSafety Edges
Profiles/Rails and Controllers
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Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
Safety Safety PLCsPLCsGuardPLC 2000 and 1200 shipping since August
– TÜV Certified (Entire System) - IEC 61508 SIL 3, DIN VDE 19250 AK6, EN 954-1 Category 4,
– UL Listed– Primary Target Market - Machinery Safety
GuardPLC 2000 - 6 I/O slot, modular design– 24 Input / 16 Output digital – 8 Channel Analog Input & Output (12 bit resolution)– 2 Channel HSC (100kHz, 24 bit)
Guard 1200 - packaged design– 20 Inputs / 8 Outputs + 2 HSC Inputs (100khz, 24 bit)
Communications – Proprietary GuardPLC Ethernet + ASCII– Peer to Peer Safety Communications
RSLogix Guard Software (2 versions)– Lite and Professional Versions– Windows NT/2000– RSLogix “Look & Feel”– IEC 1131 Function Block Programming – User Defined Function Block Capabilities (1755-PCS)
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Emergency Stop Relays– Monitors the E-stop Circuit– Monitors Safety Gate Limit
Switches– Monitors Light Curtains– Monitors Rope Pull
Switches
2-Hand Control & Safety Gate Monitors
– 2-Hand Anti-tiedown & Anti-repeat relay
– Controls machine from safety gate limit switches
Provides additional safety contacts
Two Hand Controllers
Safety RelaysSafety Relays Single Channel
Dual Channel
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20Electrical Engineering Fundamentals for Non-EEs; © B. Rauf
Electrical Drawings and Documentation
Bobby Rauf ©
9/23/20081Electrical Engineering Fundamentals for Non-EEs;
© B. Rauf
3-HP; 460VAC, 3-Phase: 4.8 Amps; 125%: 6 Amps; 115%: 5.52 Amps; Starter Size: “0”
40-HP; 460VAC, 3-Phase: 52 Amps; 125%: 65 Amps; 115%: 60 Amps; Starter Size: “3”
9/23/2008 2Electrical Engineering Fundamentals for Non-EEs; © B.
Rauf