Power Factor, contd - CED Engineering for Non EE...monitoring devices, transformers and loads....

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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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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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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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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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 ©

9/23/20081

Electrical Engineering Fundamentals for Non-EEs; © B. Rauf

Topics Topics

Size of Power Distribution Systems, by VoltageElectrical Equipment and Instrumentation

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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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9/23/2008Electrical Engineering Fundamentals for Non-EEs; © B. Rauf5

• 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


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


• 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


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


0.5 Space Factor Size 1




• 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


Unit InterlockUnit Interlock


• 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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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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Bulletin 1305

Bulletin 1336 PLUS or Bulletin 1336 PLUS II

Variable Frequency Drives Variable Frequency Drives -- Up to Up to 250HP250HP


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SMC-2SMC Dialog Plus

Smart Motor Controllers (Smart Motor Controllers (SMCsSMCs) ) -- Up to Up to 500A500A


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


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


National Electric Code and National Electric Code and Safety SystemsSafety Systems

Bobby Rauf ©

9/23/20081


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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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.

9/23/20083


Industrial Safety and Safety Industrial Safety and Safety SystemsSystems

Bobby Rauf

9/23/20084


Topics Topics

Safety Certifications in Industrial EnvironmentSafety Products and Common Applications

9/23/20085


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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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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SafeShieldSafeShield DeviceNetDeviceNet


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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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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Electrical Engineering Fundamentals for Non-EEs; © B. RaufBACK

Lifeline 4

Cable Pull SwitchesCable Pull SwitchesLifeline 3

Lifeline 2

LRTS

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BACK


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

9/23/200817


GuardEdgeGuardEdge™™ Safety EdgesSafety Edges

Profiles/Rails and Controllers

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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)


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

BACK9/23/2008

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

Power Factor, contd - CED Engineering for Non EE...monitoring devices, transformers and loads....

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Transcript of Power Factor, contd - CED Engineering for Non EE...monitoring devices, transformers and loads....