Ross Hill Controls, Variable Speed Motor Drives Applications Manual
Ross Hill Controls, Variable Speed Motor Drives Applications Manual
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IRI I FINMECCANICA
.• ""·
VARIABLE SPEED
MOTOR DRIVES
APPLICATIONS MANUAL
070794
QUICK FIND INDEX
OVERVIEW
WHAT IS A VFD?
ECONOMIC ANALYSIS
HARMONIC ANALYSIS
CONTROL ELECTRONICS
2. WHAT IS A VFD?
' HOW DOES IT WORK? . . . . . . . . . . . . . . . . . . . . . . . 2-2
ARE SPECIAL MOTORS REQUIRED FOR USE WITH A VFD? 2-3
WHAT APPLICATIONS FIT THE VFD? 2-4
APPLICATION EXAMPLES . . . . . . . . . . . . . . . . . . . 2-4
7. CONTROL ELECTRONICS
VFD DIGITAL CONTROL MODULE . . . . . . . . . . . . .
THE FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL ELECTRONICS - DISPLAY SCREENS . . . . . . . . . . . . . . . .
MAIN DISPLAY SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METER CONFIGURATION SCREEN . . . . . . . . . . . . . . . . . . . . . . .
ALARM DISPLAY SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRIP DISPLAY SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPLAY DEVICES SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . .
SETPOINT CHANGE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . .
DATE AND TIME UPDATE SCREEN . . . . . . . .
INDEX APPLICATIONS
24 HOUR SERVICE (713) 467-2523
iii
9. VARIABLE FREQUENCY MOTOR DRIVE GUIDE SPECIFICATION
(MEDIUM VOLTAGE)
5-1
5~7 1.0 GENERAL ............... . 9-1
5-1 2.0 MANUFACTURER RESPONSIBILITY . 9-1
5-d 3.0 QUOTATION REQUIIiEMENTS 9·2
5:-d 4.0 SPARE PARTS LIST 9-2
5.0 DRAWINGS .. 9-2
t 6.0 WARRANTY . . . . . 9-3
6-1
6-2
&-2
I
~
F
7.0 EXPERIENCE . . . .
8.0 REFERENCE CODES AND STANDARDS .
9.0 SERVICE CONDITIONS .
10.0 EFFICIENCY . . . . . . . . . . .
9··3
9-3
9-4
9-5
6=-2
n~3
11.0 HARMONIC STUDY .. . 95
12.0 TORSIONAL ANALYSIS . 9 5
13.0 INPUT LINE ISOLATION . 9-6
14.0 CONSTRUCTION . . . . . 9--6
72
15.0 WIRING AND EXTERNAL CONNECTIONS 9-7
-z.3
16.0 POWER BRIDGES . . . . . . . 9-8
7_5
17.0 DRIVE COOLING SYSTEM . . . . . . . 9-9
7_5
18.0 DC LINK REACTOnS (DCLR) . . . . . 9·10
7.-5
19.0 INSTRUMENTATION AND CONTROLS . 9·1 0
L-5
20.0 INPUT AND OUTPl JT INTERFACES . . . . . 9-12
J-6
,-6 21.0 MICROPROCESSOH DIAGNOSTIC SYSTEM 9-12
. -6 22.0 PRINTED ClflCUIT BOARDS . . . . . . . . . 9-13
23.0 OUTPUT FILTER (INDUCTION DRIVE) .. . 9 13
~
. -7
24.0 MOTOR FIELD EXCITATION (LCI synchronous drive) 9-1 Lj
25.0 SWITCHGEAn . . . . 9-14
26.0 TESTING . . . . . . . 9-15
27.0 START-UP SERVICr: . 9-15
-d-1 28.0 CONTROL HOUSE . . 9-16
~d-1
29.0 MOTOR . . . . . . . . 9-19
,d-1
ADJUSTABLE FREQUENCY MOTOR DI11VE SYSTEM EVALUATION SHEET . 9-22
d-2
VARIABLE FREQUENt~Y DRIVE . 9-22
J-2 THYRISTORS . . . . . . . . . . . . . . . . . . . 9-22
J-2 DC LINK REACTOR . . . . . . . . . . . . . . . 9-23
3-2 ISOLATION TRANSFORMER (WHEN 11EOUIRED) 9-23
OUTPUT TRANSFORMER (WHEN REOUIIlED) 9-24
MOTOR (IF SUPPLIED WITH DRIVE) . . . . . . . . 9-25
iv
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-v
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IROSS HILL CONTROLSI
IRI I FINMECCANICA I ANSALDO
•
l!l ROSS HILL CONTROLS CORPORATION
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• Supplier of Large HP I Variable Voltage I Variable Frequency Drives
L.
• Location - Houston, TX, USA
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• Manufactured Oil Well Drilling SCR Systems Since 1970
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- Industry Leader
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e 1984- Supplied First High HP I
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High Voltage Induction Motor
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Drive
=:- Industry Leader
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• Industries Served: - ":. ''
• ......_
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- Oil Well Drilling
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- Petrochemical
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- Electric Utility
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- Pulp & Paper
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- Pipeline
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- Water Utility
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- Marine
- General Industry
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Focused on Equipment & Industries
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l IANSALDOI
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EXPERIENCE
• World Leader in Large Induction Motor Dri\ms
• Manufactured:
- Over 5,000,000 HP - Rectifiers and Large SCR Drives
- Over 350 Systems 8!>0,000 HP - Large AC Drives
(Induction & Synchronous)
- Over 300 Systems 700,000 HP - Large Induction Motor Drives
• Voltages Supplied
6.9 kV
- 4.16 kV
- 2.3 kV
- 0.6 kV
• Drive Frequency - From 0- 300Hz
• Leader in Liquid Cooling Systems
.ot'"f
~
ROSS Hill COtJ!•:oLS CORPORATION
,OA MINERALS CORPORAL CUSTOMF P USF.R liST:
VARIABLE SPEFoD DRIVE SYSTEMS
1005)
scription:
,he Model Vr480 ·· SOOHP, 48<1V, 6/6 pulse, cap;\
tompressors. 60 Hz., hot transfer of rnotor for Rtt
;Minerals, Rocky Mountain ~huse, Central Alh•Jr\
( Delivered: June 1981 'i
I, SOUTHWEST PUBLIC SEllVICE I ··.i:
I, (#1013) /
\Description: ·
'\wo Model VF4000 - 2000IIP, 4161 tV, 616 pulo:
~
need draft fans Drives were selected over loa•·
tailed at Southwest l'ubli<; Service's Nich•
"!red: October 198•1
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~
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Most Experienced Variable Frequency Drive Supplier) ~ .,
~·
~·NSALDOf J
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_IN_Tf=lQ_QU(;TION _ _ _ _ _ __
(713) 467-2523
f1PPLICAriONS MANUAL~.·.
24 HOUR SERVICE
1
1-3
J FACILITIES
• Over 200,000 Sq. Ft. Manufacturing Facilities
~~/
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• Vertically Integrated _/~
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-I - Sheet Metal House Manufacturing
IANSALDOI
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• Reliability
- Eliminates Mechanical Flow Control Device
- Reduces Wear on Motor & Compressor/Pump/Fan
• Maintainability
- Minimum Maintenance Required
- Mean Time to Repair Less Than 1 Hour
""T""'"··+.·-···
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.•
IANSALDOI
II' I TRODUCTION
~ - - · · · - - - - - - · -·
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APPLICATIONS
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-
• Cost of Operation
- No Costly Rebuilds Required
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DC Link
l>rt--.--1
6-Pulse 6-Pulse Motor
T r ilter
INTRODUCTION
------~------·-- - ---- --- ---...,---- -~-
APPLICATIOiJS MANUAL
24 HOUB SERVICE (713) 467-2523
1-7
New
Converter Inverter Synchronous
Transformer Motor
r>r
6-Pulse
r>r
6-Pulse
. - -- - - - -- -
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IANSALDOJ
1-9
IRoss:j-ttLL cPNTROLsl
IAI I FINMECCANICA I ANSALDO
Multiple Motors
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IANSALDOI
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1-10
I
!ROSS HILL CONTROLS!
IRI I FINMECCANICA I ANSALDO
Synchronous New
Converter h··,rerter Synchronous
Transformer Motor
6-Pulse 6-Pulse
New
Converter Induction Inverter Induction
Transformer Motor
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6-Pulse
...
N'
6-Pulse T Motor
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(ANSALDQ)
RELIABILITY
• System
- MTBF Over 3 Years
- Conservative Rated Components
- Rated for 50° C
• Power Conversion
- Uses only SCR's - No GTO's
- Derated Thyristors -Temperature Margin
- N-1 Cell Redundancy
- Liquid Cooled System
• Control
- Mil Grade Devices for Critical Components -
JAN-TX (-55 to 125° C)
- Module 70° C Burn-In with Power On for 168 Hours·
- Comprehensive Computer Tested with Full Operations Testing
• Cooling
- Redundant Pumps
.
It
IANSALDOJ
1-12
MAINTAINABILITY I AVAILABILITY
• Designed for Easy Maintenance
IANSALDOI
24 HOUR SERVICE
(713) 45-7--2-52_3_ ~--~··-·~'
1-13
TESTING
e 1 00°/o Component Testing
IANSALDOI
1-14
COST OF OPERATION
• Minimize Maintenanr.e with Long MTBF I Short MTTR
IANSALDOI
FLEXI 81 LITY
• Project Engineering will Provide What You Need I Require
SERVICE
e DEDICATED Field Service
- 20 Engineers Supporting Equipment
- Available in Less than 24 Hours
- 24 Hour Service Line
MOTORS
INDUCTION I SYNCHRONOUS UP TO 35,000 HP
• Design Flexibility
- Ability to Meet Most Specifications
- Ability to Satisfy Demanding Customers
• Low Vibration
- Tight Interference Fit Rotor Bars (Induction)
- Dynamic Balancing At, or Near, Rated Speed
- Heavy Steel Frame & Stiff Shaft Design/Construction
- Double End Cooling for Even Temperature Distribution
• High Reliability
- Proven Insulation System (Cias~; F, r~1ica-Epoxy VPI System)
- Meets API Standards
• Quality
- ISO 9001
- Thorough In-Process Testing
... On-Time Response
IANSALliQ]
INTRODUCTION
------------------------------------~----- -- ---· -- ·------------------~--·- ----·-- ·--
APPLICATIONS MANUAL
---------------- -----~~--
GENERATORS
INDUCTION I S'YNCHRONOUS UP TO 35,000 KW
• High Efficiency
• On-Time Delivery
• High Reliability
- Proven Insulation System (Class F, Mica-Epoxy VPI System)
- Heavy Steel Frame Construction & Double End Cooling
.... Easy Maintenance
.... Low Vibration
• Quality
- ISO 9001
- Thorough In-Process Testing
- On-Time Response
IANSALDOI
This side of the page 1s intentionally left blank.
WHAT IS A VFD?
This side of the page 1s intentionally left blank.
----------------------------------------, .,l
2-1
WHAT IS A VFD?
VFD is an acronym for Variable Frequency 5. An Output Filter system is used to limit
Drive. A v a r i a b I e f r e q u e n c y d r i v e i s the voltage and current harmonics of
essentially a "black box" which is capable the output electrical waveform to the
of taking power from a cunstant, three induction motor. The filter also providos
phase, 50 or 60 Hertz, Alternating Current VAn's at speeds above approximat8ly
power source and convertinn it to variable 60% of rated motor speed, so that tl1e
voltage and variable frequency (Hertz) diverter circuit is not needed.
power. This variable voltage, variable
6. Control and Diagnostics Section to
frequency power is then used to operate
allow adjustments of certain operating
a standard squirrel cage induction motor,
parameters by the End User's
or a standard synchronous motor.
operating personnel and the ability to
The basic building blocks involved in a locate problems by means of "usor
variable frequency drive system are: friendly" indicating lights, display
1. A Rtlctifier Unit which converts utility screens, or plain English paper
powor from Alternating Current (AC) to printouts.
Direct Current (DC). 7. Switchgear Section consisting of a11y
2. DC Link Reactors which are used to combination of input, output, atHJ
smooth DC current ripple. bypass contactors, switches, or circuit
breakers. The Switchgear Section
3. An Inverter Unit which converts the DC allows the VFD to be turned off (tripped)
power to variable frequency AC power. during a Fault condition, isolated from
4. A Diverter or Commutating Circuit, t h e m o to r ( s ) be i ng o p e rate d , o r
which is used to provide forced bypassed entirely for constant speed
commutation of the inve11er during low operation of the motor(s).
speed operation of the induction motor.
DIVEIHER I 4i
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SMOOTIIING
INPUT BREAKER
REACTOR
j OUTPUT BREAKER
INCOMINGAC
"(7
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·" AC-DC
flECTIFIER
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DC-AC
INVERTER
OUTPUT
LINE .
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FIXED FILlER \.MOTOR
FREQUENCY
( 1) (31 ( 5)
lI VARIABLE
16 .i
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AND
INSTBUMENTATION
6
ll!nFE PHASF
INPUT VOLTAGE
( ~- /!, __
OIFFf-nFNCF BETWEEN MOST POSiliVE AUP , .. l<:, I NFGATIVE
~-
CATHODE ~ '----GATE
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3000 AVERAGE VALUE
2000 AMPERES 7
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iE 2000 2000· ----------
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0 1000 0 1000
,_ --------- ~ --------------~------- __ ,_
TIME ---j 60' f-- TIME
------------ -------
Figure 2-4. Unfiltered and Filtered DC Waveforms
~--
lead to premature motor failure. This same
AMPS f type of failure will not occur with new motors
"designed" for operation with the drive.
(+) ()
t
DC tr!PUT
POWER
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(-) 0 --
BENEFITS OF VARIABLE
FREQUENCY DRIVES
This side of the page 1s intentionally left blank.
3-1
ECONOMIC ANALYSIS
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ECONOMIC ANALYSIS
VARIABLE VARIABLE
FREQUENCY - - - FREQUENCY
INVERTER CONVERTER
II
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POWER\
--~-;miNoL INDUCTION
MOTOR
-------- - - -
Figure 4-1
ECONOMIC ANALYSIS
4-2
ECONOMIC ANALYSIS
---~--~---~-- ~-~ ~·----~------~----- - - - - - - - APPLICATIONS M/\NU.A.'-
24 HOUR SERVICE (713) 467~2523
,...
4-3
EXAMPLE:
Note that the analysis results c:md the calculated values may not be exactly same
due to program approximations and rounding of numbers:
AIR HORSEPOWER = 0.000157 x Flow in ACFM x Head
in Inches of Water
I =
=
HORSEPOWER REQUIRED FHOM POWER CURVE
0.000157 X 256,000
277.33 HP
X 6.9
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Table 4-1
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6000 HP - 850 RPM - FD FAN - VANE CONTROL
--------
f-----·- -
PLANT PARAMETERS
POWER ANALYSIS
·-~--·--------
-·------
EXISTING
-----
---~- ~---
AVU - TUELHF1-900!:J::O:I
------
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# FLOW HEAD POWER UNIT MOT POWEH SPD UNIT MOT VFD POWER
ACFM IN HP EFF EFF KW RPM EFF ElF EFF KW
----- --·------~
- --- ------ -
1 256 6.9 282 15.0 92.8 1510 319 91.7 85.8 82.4 325
2 898 16.4 1035 42.1 93.9 1950 492 91.6 92 2 93.0 982
3 502 25.9 2045 G:J.8 9tl.6 2528 G19 91.6 93.9 96.6 1836
4 584 34.9 3184 l(l.4 94.9 3192 719 91.6 91.5 97.4 28111
------- ---------· ~--- -----------·-
fable 4-2
60 8000
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-CONSTANTEFFIClENCY(d-~shkd curve~) I .
I I I I : STATIC
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4-8
342
IN.
12.1
--
HP l'fl!YR
661
%
--~-------~--------
438 5.0
MW-111?
761
----1 MW-HR
288
MW-HR
473
2 393 16.0 995 438 5.0 84!) 415 429
3 449 20.8 1473 1752 20.0 3855 2387 1468
4 493 25.0 1939 1752 20.0 4322 3057 1264
5 656 44.0 4475 1\38 5.0 1735 1722 14
TOTALS 1\818 55.0 1151 B 7869 3649
-------~------------ ------
ECONOMIC ANALYSIS
Table 4-3
APPLICATIONS MANUAL
••
24 HOUR SERVICE (713) 467-2523 ~
~
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6000 HP- 850 RPM - FD FAN -VANE CONTROL
60 I ' 8000
---1-- CONSTANT EFFICIENCY (dashed curves) !
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42 I I 5600
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36 7
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12 ~ r=T J 7 ·i ~ 7\ /: HE~D-VS.-FLOyv''----i---___:__ __.__ _ _j 1600
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0 100 200 300 400 500 600 700 800 900 1000
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ECONOMIC ANALYSIS
·------
24 HOUR-SERVICE ____(713)
APPLICA !IONS MANU/
467-i523____ -------_ f~
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---------. --- --------
--·------------------- "-- .. -----:
4-1 t
NAME OF COMPANY:
ADDRESS: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
CITY: _____________ STATE: _ _ _ _ _ __ ZIP: - - - -
CONTACT NAME·
PHONE NO.: ___________ _ _ _ FAX NO.: _ _ _ _ _ _ _ __
ANALYSIS INFORMATION:
-------------------------
(OVER)
~
4-12 t!
INFORMATION TO BE SUPPLIED BY THE USER FOR FAN ECONOMIC ANALYSI::; t
(Cont'cf.) (
* If the performance curves are not available in units specified above, information
should be provided to convert tile <.Jata to the iJbove units for analysis.
* If performance curves arn not available, followinrJ infortnation is required to
generate default curves.
• Flow or Volume at maximum efficiency • Head offse at zero flow or zero volume
• Head or Pressure at maximurn efficiency • Maximum Efficiency
• Flow of Volume at Test Block
ADDITIONAL INFORMATION:
------------
---------. - - - - - - - - - - - - ----------
----------------------- -----------------------
- - - -----------
!
j_ VARIABLE VARIABLE
FREQUENCY
FREQUENCY
INVERTER CONVERTER
POWER\
--~--- /
- ---- - - - - - --~:0..
STANDARD
INDUCTION
MOTOFl
--~--·- ----·-- ---
Figure 4-5
4-14
OVERVIEW OF ECONOMIC The existing power in KW is the input power
ANALYSIS FOR PUMP SYSTEMS required at the motor terrninals taking into
account the motor and pump efficie• 1Cies.
Page 4-16 Summary of savings The power requirements for varia:Jie · peed
corresponding to the flow rates and number operation are tabulated in the laf~t C'llumn - j
of pumps operating is provided based on indicating power requirPd at the input of the
the results of the economic analysis. The variable frequency drive.
estimated payback time is calculated with
ENEflGY ANALYSIS: The inform,, t ion
reference to the cost of the system scope
provided by l11e power a11alysis is used along
of supply consisting of two variable
with duty cycle (hours of operation) to
freLJuency drives, two input isolation
genrrate tho data for energy consumrtion.
transformers.
Tho eneryy savings is the difference
Page 4-17 Customer furnishud pump between the energy consumed by e'<isting
curves for existing constant speed system and the energy used by v;1riable
operation. frequency drive system.
Page 4-18 Customer furnished load ECONOMIC ANALYSIS: The information
profile data. genorated by the energy analysis is ulilized
with the cost of ener~IY (cents per KWH)
Page 4-19 Results of the Power, Energy
infonnation ·Ill ovided by the cw: tomer. The
and Economic analyses for one pump
calcttlation mveal the cost of operation for
operation. The information generated is
existing system and for proposed variable
grouped into following three categories:
speed operation. The cost savings is the
1. Plant Parameters difference in the cost of operation of existing
2. Existing system and cost of vari;Jble speed operation.
3. Ross Hill Controls VFO
Page 4-20 Computer generated curves
for one pump operation based on input data
POWER ANALYSIS: The information under
derived from customer provided curves.
the PLANT PARAMETERS column indicates
the hydraulic horsepower requirement The Head vs. Flow curves are plotted for
corresponding to flow anrl head_ Thn flow differert spGeds in 10 percent decrements.
rates refer to the selected analysis points. The static efficiency curve, the power curve
and the sy:-;tem resistance or system load
The information under EXIS-llf'JG pertains
curve are plotted b:1sed on customer
to the constant speed operation. The
furnished information. The analysis points
information about the variable speed
are indicatt:d by small squares on systPm
operation is listed under f-lOSS HILL
load line.
CONTROLS VFD column. The unit
efficiency represents the efficiency of the Tho dashed curves originating from the
pump. The motor efficiencie~-; at constant origin are constant efficiency lines generated
speed and at variable speed operation are by the computer. The second power curve
estimated based on the motor efficiency (lower curve) is the power consump"tion
information supplied by the customor. curve of the variable frequency drive system.
= 70.35%
ASSUMING MOTOR EFFICIENC)' OF 95. 1%
6260 X 0.746
EXISTING POWER IN KW ==
0.951
= 4910.6 KW
EXISTING ENERGY IN MVVH == 4910.6 X 552 X 10-3
= 2710.65 MWH
EXISTING ENERGY COS1 = 2710.65 X 1000 X 0.021
.:: ::::f=: O'!'l.
= - --·~-- ...
----- -----
-·---- - ___ ]
- - - ·----- ---- --- - ------ - ---- ------------- - - ---
I
TOTAL COST OF TWO DHIVES: $ 1.1 06,00Q_()Q
Table 4-4
~- ,•
4-17
'-}
-- -~----··------------------
,----.-- --
-P,ER'C l~·NUF.FI €1 ENCY
0 0 0 C> Ci 0 0 0 0
m co ,-.~ (l) l1) o::t M N ,- 0
-- ......
- '-- -
0 0
0 0
0 0
BRAKE HP ,- tn 0
1--- f--
-- ~- r---
v
f-- f---
/
I~ ..J
~
<!J
~,~
~
q,
'If :;::> "'Oi
0
0
-~~ '~l
0
t--- t-1-~ r-c----0
I
0
M
II
I·
LiJ
f- --
a:
;l:-
~\ 9
h:
~ en 0
?o---*" f~-
I 0
f--- t-------- 1-------
~ ~
a.
::c
' r'-,f-- -
~
m
0
~ --
0
·o
......... ,-
I'- I
1---- t------ --
1.-.
0 0 0 0
0 0 0 0
0 0 0 0
0') ...... c.o tn
24.0%
22.0%
20.0%
~
UJ 18.0% -
16.2"n
UJ
16.3%
~ 16.0% --
15.0%
LL
0 14.0% -
1-
zUJ 12.0% -
(.)
a: 10.0% -
UJ
a.
8.0% --
6.0%
4.0%
2.0%
0.0%
0.0%
50 100 150 200 250 Jl)Q 350 400
. . MEGAWATTS
I~:
~
Figure 1-7
1 "!!
£Z
i
ECONOMIC ANALYSIS
24 HOUR SERVICE ---(7-1J-)-467-2523
1\PPLICATIONS MANUAL
______ j
~-
4-HJ
7000 HP - 3570 RPM - PUMP - THROTTLE CONTROL
POWER ANALYSIS AVB - FPLK1BP2-9:10113
------- ------ -~- ---- --- ------ --~--~--------- -----
- - - PLANTPARAMEniiis---, ----
EXISTING ROSS HILL CONTROLS VFD
---~ --·-----·----------·- ------------ ---·----- ---------------------- ---
FLOW HEAD POWEFI UNIT MOT POWER SPD UNIT MOT VFD POWER
GPM FT HP EFF- EfF KW RPM EFF EFF EFF f(W
2818 6861.9 4404 70.4 95 1 4096 3426 79.2 95.1 97.8 4465
2 2465 6726.4 3777 63.3 95.2 467B 3344 75.9 95.0 97.7 4001
3 2113 6609.4 3181 56.5 95.2 4410 327G 71.5 94.9 97.6 3fi86
4 1761 6510.3 2611 50.0 95.2 4097 3222 65.7 94.8 97.5 3210
!) 1409 6429.3 2063 43.2 95 1 3750 3182 58.2 94.7 97.3 2869
6 2113 6609.4 3181 56.5 95.2 4410 327f) 71.5 94.9 97.6 3586
7 1409 6429.3 2063 43.2 95.1 3750 318:> 58.2 94.7 97.3 2869
ENERGY ANALYSIS AVB - FPLK1BP2-030113
PLANT PARAMETE:RS EXISTING ROSS HILL CONTROLS VFD
----------------- ·---- --- -·------- --------- - -
- - - - --------------- --------------------
Table 4-5
'm
0
0
z
I 7000 HP- 3750 RPM- PUMP- THROTT~~~ONTRO:-------- - -- - -~ ~
0 . I
s: 9000 ! I 10000
0 --- . I I II J
1/ I I ·I co I· ' · ·I 00
~ SYSTEM~
I I
N 7200 I
A 1
I I I 80
' ' .
+::-
3570 RPM
:I: HEAD VS. FLOW
0 6300 !
~ ! 7000
c I
I
:0
' I
~I "':E
[ / HEADVS.FLO'f'
::z:
,. m ,/~ VFDiPOWER "'C
-m
<
() <0"
c
>
-z
0 4500
.
2ass RPM
5000
0
m
m
:r:
HEAD VS. FLOW
-:r::::0
-
.1>-
Co 3600 4000
-... -
N "'C
0 ,/ I
~ 2498 RPM
' -I ~ /, ~
HEAD VS. FLOW
-
w
+::-
en
2700
/'
I
I/
/
/
~
[ 2141 RI?M
HEAD VS. FLOW
3000
I ' Q
0
~
6 0 400 800 1200 1600 2000 2400 2800 3200 3600 4000
z
(j)
s:
)>
+- FLOW (GPM) -+
z lVB- co!..:<~SP:-:~c' ·3
I~ l_
::.~tMt·:emrb1WW»t~se ~··twi<t" ·n~r!f', e • .. ~ ...~·.·--.·i~">fV'~.~$~~~·f"""'""'"'"''''
t
B
'"
:!o:"
t 4-21
ANALYSIS INFORMATION:
PLANT OR STATION: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
APPLICATION: _ _ _ _ _ _ _ _ _ _ _ _ _ NO. OF UNITS: _ _ _ _ __
TYPE OF PUMP: - - -------------------
EXISTING CONTROL: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
MOTOR DATA: HP SPEED _________ VOLTAGE _ __
COST OF ENERGY: $ PER KWI ~
--- --- - - - - - - - - - - - - - - - - - - - -
(OVER)
ECONOMIC ANALYSIS
4-22
INFORMATION TO BE SUPPLIED BY THE USER FOR PUMP ECONOMIC ANALYSIS
(Cont'd.)
* If the performance curves ate not available i11 uni 1:> specified above, informatior.
should be provided to convert the data to the above units k1r analy:;is.
* If performance curves are not available, following it formation is required to
generate default curves.
• Flow or Volume at maximum efficiency
• Head or Pressure at maxitnum efficiency
• flow of Volume at Test 131ock
• Head offset at zero flow or zero volume
• Maximum Efficiency
ADDITIONAL INFORMATION:
- - - - - - - - - --·-· - - - - - - -
----·-- - - - - - -
-------
------··· ----------------
----------- ------------
ECONOMIC ANALYSIS
-=----- - - - - - - - · · - APPLICATIONS MANL --
24 HOUR SERVICE (713) 467-2523
HARMONIC ANALYSIS
J
HARMONIC ANALYSIS
Power system harmonics have plagued than the preceding Standard IEEE
electric utility companies for many years. 519-198 ·1. The 1992 Standard recommends
The utilities have customarily solved their limits on certain harmonic indices (current
harmonic problems by prescri!)ing a limit on and voltaue) at the point of common couplin\J
the harmonics that a manuf, 1cturiw1 plant to reduce harmonic effects at any point i11
or other users could impose on tho utility the system. Further harmonic limitations
system, and/or mandatinq corrective may be required by power utility
measures or imposing financial penalties. specificntions, company standards, and
local government regulations.
The widespread use of non linear loads has
increased harmonics on iJ tplant power In a thre(1 phase full wave bridge rectifier,
systoms with seriotts it'lplant problems. The the thyristors operate in pairs to convert AC
concerns include, but are not limited to, to DC by switching the load current among
transformer overheating, motor fililures, the variot lS thyristor pairs six times pu AC
cap;1citor fuse blowing, and misoperation of cycle. During commutation a brief short
electronic controls. These concerns cannot circuit ou:urs which produces notches in the
be :~olved by simply paying a penalty to line to linH voltage waveform. Commu1.1tion
_ the utility company. For utilities, harmonic produces two primary notches per eye!.' plus
distc:.rtion taxes the i :ntire distribution ~;ystem four secondary notches of lesser magnitudo
and reduces genet ating car·dCity. which ar& due to notch reflections fron 1 other
legs of the bridge. The line current
Tho harmonic di:.tortion h caused by
waveform is essentially a "quasi square
nonlinear loads including static power
wave" current pulse.
converters, arc fumaces, <tnd saturated
mannetic device:;. The ~;tatic power An analysis of these non sinusoidal
converters are the largest n1 1nlinear loads wavesh:tpes by Fourier transforms will
and are used in tlte industry for a variety resolve the waveshape down to a
of purposes such ci:> variable speed drives, fundamental sinusoidal wave plus a number
and uninterruptiblt: power supplie~>. The of higher frequency sinusoidal wavef()rms.
nonlinear loads chLmge the sinusoidal nature These high frequencies are harmonic
of tile AC power current and consequently multiples of the fundamental and are
the AC voltage drop, result it .g in t11e flow determint~d by h =
kp ± 1, where h is thv
of harmonic currt~nts in tlte AC power harmonic order, p is the number of pt llses
system. These l1armonic currents can (6, 12, etc) and k is any positive i11teger
cause interferencn with cummunication 1,2,3 etr:.
circuits and other types of equipment.
In other \t-JOrds, for a six pulse bridge rectifier
Further, when power factor correction
characteristic harmonics present are of the
capacitors are usc;d with those nonlinear
order of !!th, 7th, 11th, 13th, 17th, 19th, etc.,
loads, resonance conditions can occur
where as, for a twelve pulse bridge rectifier
resulting in high levels of hat monic voltage
the characteristic harmonics are of the order
and current disto11 ion.
of 11th, 13th, 23rd, 25th, 35th, 37th, etc.
The harmonic standards in the U.S. and
Calculation of system harmonic levels
worldwide recommend specific limits on
resulting from harmonic sources requires
harmonic distortion. In tho U.S., many
knowledge of the harmonic source
utilities will adopt the recommenda1ions of
characteristics and a representation of the
harmonic standard IEEE 519. The latest
system response characteristics. The
standard IEEE 51D-1992 is more stringent
' 5-2
important elements of the model used to The harmonic currents from a converte1 C?""'
perform these calculations include system flow into any part of an AC system to whicn
short circuit equivalent impedance, it is conner;ted, as determined by tt •...:
characteristics of lines and cables, load impedances of the sy[;tem at the ham :or.
characteristics and capacitor b;mks. frequcncie[:. Several techniques such r
s e r i o s r e <1 c t o r, s h u n t f i It o r s , p It a$ o
A computer simulation program is used to
multiplication catt be used to contwl the
determine the levels of harmonic distortion
harmonics. ·In reality, some harmonic effec •..,
in a given network. The computer analysis
are unavoidable at some points in tt .
will be performed with available system
system. Aho, economic factors ar 1
characteristic data to ensun~ that the
effecti 1enes~. of the harmonic control rnuct
harmonic distortion limits recom• nended by
be cot tsiderE·u in the selection of the c~~ntrol
the standards and/or requirod I ·y the user
scheP1e.
specification are not excee• led. The
analysis is performed at the point of The shunt filters used for 1ed11cti· •n of
influence or point of common coupling. The harmunic currents flowing into ;Jn i\C 1'OWe-(
interface between sources and load is syste1 n con~;ist of one or more tum·d cit ~:ui, .
described as the point of common coupling. The individual circuits consist tJf ~ ,;ri · ~
The analysis results provide information connucted i:1ductor ;md capacitor tun· ·d f·>r
about total harmonic distortion of current and speciiic harmonics e.g. 5th, 7th, 11th, 13m
voltage as well as individual harmonic levels etc.
of voltages and currents up tu the 49th
The basic 6 pulse C(Jnverter produces 5th,
harmonic. All the information is related to
7th, 11th, ! 3th, 17th etc harmon.~
the point of common coupling. It is
frequencies. I he use of 12 pulse conver. r
important to understand that any analysis
theorE:tically oliminatr:;s 5th, 7th, 17th, 1!"-·,
of system harmonics is dependrmt on the
etc. hmmoni ; frequencies reducing the totL)I
quality of the system network itlformation.
harmonic distortion. Further phase
The harmonic filter, if necessary, will be
multiplicati! )n will reduce other harmo,,.c
designed and selected to provido the best
currents an'l the total harmonic distortic ..
and optimum solution to meet the harmonic
distortion requirements.
3. Harmonic Traps
HARMONIC ANALYSIS
I 5-4
-- ---~---~-~~--~---- -----------
Ls } Source Impedance
Rs
Source XFMR
~
__) La} Added Reactor
or lndnctor
Ra
,--------1
I #6 #s #4 #3 #2 #1
:1111 JT-:
Harmonic Trap-:
La} Added Bridge
Ra
Reactor or Inductor
,;K---- lconv
___ ! Drive XFMR
----- or Bridge XFMR
(V3, 13)
Drive or Bridge
Parameters
(Ldc, Ide, Vdc)
Figure 5 1
Typical Ci:•:uil Configuration for Distortion Factor Analysis
-----------
Xfmr:
--------------
10000 I<VA
--------~--- -------
Z =-- .08 FL = .008065
- -- --- --------
1'-IL = --------------
.0015 Pri!Sec = 4160 I 3600
4800 VOLT HARMONIC FILTER COMPONENTS
Circuit # Capacitance Inductance Resistance Circuit Freq. Harmonic
(I<VAR) (~tH) (!.l) Q (Hz) #
---------------------------------· ---- -- ------ -------
C1 = 400 L1 = 6111.54 R 1 = . 1151 100 300 5
2 C2 = 400 L2 -= 311 n. 13 R2 = .0822 100 420 7
3 C3 = 1200 L3 = 420.9
--------- --------------------
R3 = .0174 100
-----------------------------
660 11
OJ>ERATING CONDITIONS:
Bridge # 1: 824 AfJC 331~) VDC A == 45.4" U = :l.47". Rc = .109 (12-Pulse)
-------- ·-----·---- --- ·------ ------ - -- ------------------------------
5 '/STEM FUNDAMENTAL COMPONENTS:
Input Bus: 4116 VAC @ .833° lac = 446.9 Amps @ -30.82° (V1, 11)
VFD Filter: 4116 VAC @ .833° lac = 446.9 Amps @ -30.82° (V2, 12)
Bridge #1: 3473 VAG @ -2.03° lac = 643.3 @ -47.1° (V3, 13)
29 2 163 1 -I 06 2 0 0 -
1
--- -- ---
0 0
---------- ----- - - -
-
0 ()
37 22 -33 6 57 11 0- - - - - 1 ---
4
-~--------
0 0 0
------------------
()
-----
41 2
------------- ----
1 48 0 0
--- ---- - -
0
-·------
0
---------
0
-----
0
------- -------
0
43 2 0 46 1 0 0 0 0 0 0 0
-------
47 19 -145 4 54 8 0 0 3 0 0 0 0
19 121 4 -149 7 0 0 3 0 0 0 0
-.--------
2377 447 561 45 4:3 137 0 0 0 0
---·---------
RESULTS: Bus Currt!nt OF== 4 86');,
----------- --------- ------ ---
Bus Potential OF= 2.34%
NOTES: 1. CUSTOMER NAME - PLANT NAME
2. TWO 5000 l-IP 4160 V BOILER FEED PUMP DRIVES AT 70% SPEED
3. CASE 1 - UNIT START UP WITH SOURCE TRANSFORMER
Analysis 5-1
5-6
Line 6 XFMR
Information on bridge trtnsformer or drive transformer is giVf'n.
KVA Rating == 10,000 KVA
Impedance Z .08 P.U. or 8% on 10.000 KVA base
(transformer rated KVA base)
Total Loss - FL .008065 per unit
No Load Loss - NL = .0015 per unit
Primary/secondary voltage - Pri/Sec = 4 160/3600 V
NOTE: The transformer secondary voltn.ge for a tht' ~e winding transfor111er is the
sum of voltages of the two secondary windings.
The 4800 volt refers tt, the capacitor rated voltage and relates to the voltage of
the bus on which the traps are connected.
4800V = 4160V (Bus vultage) x 1.15
HARMONIC ANALYSIS
5-8
SYSTEM FUNDAMENTAL COMPONENTS (Cont'd.)
Table SYSTEM HARMONIC COMPONENTS
The table provides information on the harmonic content of bu:. voltage, bus current
and individual trap currents.
COLUMN 1 - HAilM - I
Lists individual harmo1 de numbers up to 49lh han nonic.
COLUMN 2 - Ebus --- Degrees
Represent phase to ground voltage of bus and n!lated angle, con ~~sponding to
I
listed individual harmonics.
COLUMN 3 - lbus --- Degrees
I
Represents bus phase cur rent and rela!ed aPgle, c~~rresponding to listed individual
harmonics.
COLUMN 4 - lconv
Represents input current at the primary of the br1dye or drive transformer conosponding
to listed individual harmonics. J
COLUMNS 5 throuyh 10 - # 1, #2, 113, #4, 115, 1/G i
Represents phase current in the corresponding trap circuits at listed individual
harmonics.
COLUMN 11 - Load
Represents phase current in the parallel load cor :11ected al the drive input.
The last row of the table gives RMS va.lue!C, of re!C.pective vnltages and currents.
RESULTS: Provides tol;ll harmonic voltage distortion and current distcrtion at the
bus.
Current Distoriion - Bu·; Current OF =- 4.86%
Voltage Distortion - Bus Potential OF = 2.34%
NOTES: Typically provides information related to:
1. Customer Name
2. Name of Plant
3. Rating of the Drive
4. Case Analyzed
COMMENTS:
1. lconv current is not equal lo lac bridge #1 currer 1t becm,se of the primary to secondary
voltage ratio of bridg•J 11 ;1nsformer.
PRI (Vp) /SEC (Vs) = 4160/360')
=- 1.155
konv = 557 A
lac Bridg!' 1f·t = 643.3 A
IGonv = 643.3/1 .155
= 556.96 A
2. The secondary voltage of ! 'ridge? transformer or drive transformer i~, optimized to provide
better power factor at n''' input with allowable alpha angle margin.
3. The impedance of tile ckve transformer is lyrically selected b(3tween 6S~ to 9%.
Case 3 (Figure 5-9) - Drive with input transformer and harmonic filter.
Note that harmonic filter is not required to meet the distortion requirements.
ca~;e included to show effect of harmonic trap addition.
5-10
Bus Adder: Ra == 0 PU La == 0 PU ( 0 !2 + 0 pH )
____§~~~[~_!f_1~- _ ---~f_= _9__ f=>U u__~_?__~U_LOE2_+ -~J~~ !_'::_?~_ ~---~2_~2~_1::1e_n~ ________________ _
OPERATING CONDITIONS:
Bridge # 1: 609 ADC ~")99 VDC A = 33.4" U == !:>.75°.' Rc == .0859 (6-Pulse)
--------·-~---~---- ---------· - - - - - - - --~-------·--·
77
-----------------------------
-129 41 -39
41 . . -00 - 0
-0 -()-
0 0
0 ---0-
0
0 .... ---0- --,
0
---- -----·-- -·--·- -------
------- ---- ---·-·----- -- -- ------ -- ------- -- ------------------- ---------
13 68 159 30 - t 11 30 0 0 u 0 0 0 0 I
17 70 -166 24 -76 24 0 0 I) 0 0 -- - -0- 0 I
--·-·---------------~ ----~----- ---------- -- -------- - - - --- --~---
19 64 121 19 -148 19 0 0 0 0 0 0 0
--- ---------- · - - - - - - - - - - - _j_
23 62 156 16 -113 16 0 0 0--- 0 0 0 0
--------- - ---------- --- ------ ----- ------. ---1
25 57 84 1J 174 13 0 0 0 0 0 0 0
---------·-------- - --- - - ---- --- ---- -------
29 53 119 10 -151 10 0 0 0 0 0 0 0
-- ---------
31 49 47 9 137 9 0 0 0 () 0 0
. I-
35 43 ------------------
82 7 172 7 0 0 0 0 0
- - --~----- -------·-- - ~ --- -----
37 40 ----------- 9 6 99 6 0 0 () 0 0
-- ----- - ~------ - -------- . - -·-- ·---- -- -- --- -~ ------- -------·---·--
41 32 44 5 134 5 0 0 --- 0 0 0 0
--- ----- ----- -- -- -------- --- ---------------
4~3 30 -28 4 62 4 0 0 0 0 0 0 0
47 22 7 3 97 3 0 0 ------ 0 0 0 0 0
- - -------- - ----
41) 20 -66 2 25 2 0 0 0 0 0 0 0
RMS 1351
--------- ------ --- ------- - - - - · - - · - - ----------
494
----- --
494 0 0 0 0 0 0 0
RESULTS: Bus CtmPnt OF::: 28.3% Bus Potential DF= 16.9%
1. 2000 HP 2400 VOLT VARI/\BLE FREQUENCY DRIVE
2. 6 PULSE CONVEfHER
3. CASE 1
_j
J
-------------------- ------------ ~----------.J
Analysis 5-2
'I
!NPUT BUS:
...---_..________,__ _____ ,
h
i·!
I
MAX SCALE POTENTIAL: \,,
5000 Volts ~ 't" 1'
I
)>
:II
s:
0
z +a 2 CYCLES AT 60 HZ +
0
)>
·~
\~
ICJ)
#930416AVB EXAMPLE-1 CASE 1
-----------------~'~
I!
5-12
#930~1-~VB_-__ ~X_A~PL_~_-!_____ ___ _ __ ___ _______ ____________ ______ - 't
2400 VOLT CIRCUIT ELEMENTS (5000 KVA BASE)
Source: As == .015 PU Ls == .15 PU ( .01728 U + 4:,8.4 11H
Bus Adder: Ra == 0 PU La = 0 PU ( 0 l..l. + 0 ~LH )
-~~~-g~-Jt_~: ____ !1_1_=:: ~?O_G_ _PU_ Lf "' ---~- ~~L-00_691_~_u _:':_~11J~!__ !:~~___l L~~ -==-~~ 322_f~e~-
OPERATING CONDITIONS:
Bridge # 1: 609 ADC 2599 VDC A == 26.W U == 17.
-·---------------------~-~---------~---- - - - - - · - - - - - - - - - - ·-~-- ------ ------
r Rc == .0699 (6-Pulse)
---------- - - - - - - - ~-~-- --
-161 46 -70 46 0 (l 0 0 0 0 0
7 56
I
44 -123 23 -32 23 0 () 0 0 0 0 0
11 - -- - -·--- ------------------ · - - - ---
---------- ---------
35 166 15 -104 15 0 0 0 0 0 0 0
~
13 - ------- - - -
19 8 132 2 -138 2 0 0 0 0 0 0
- -- ·------------- ----·---------- - - - - - - - - · - · - -·----·- - -··----·-
11 -11 3 79 3 0 0 0 0 0 0 0
23 -- ----
3 8 3 0 0 0 0 0 0 0
25 11 -82 - ·--· ·---
-45 3 45 3 0 0 0 0 0 0 0
29 17 . -· -·- -. ---- - ·-·- ···-- ·-·-----
31 16 -116 3 -26 3 0 0 0 0 0 0
·-·- - - - · - · - · - ---- -------·-
10 -79 2 11 2 0 0 0 0 0
35 ---------·
37 8 -150 1 -60 1 0 0 0 0 0
41 2 67 0 157 0 0 0·-·----------
0 0 0 0
-- - - - - - - - - - - - - - - - - - -
43 3 -4 0 86 0 0 0 0 -- ---
0 0 0
------· --- ----- - - - - - -----------
0
-·-· ·-.---·- -··-- - - ----
47 9 33 123 0
----- ----
0
0 - - - · -0 ·-- ------ 0
-- --
0
·--------
0
------------- ---
49 9 -38 1 52 - --
0- - - 0
--- ----
--
0 0 ---
()---- 0
---·- - - -
0
-·--- - - - - - - - -
RESULTS: Bus Current OF== c' \''~ Bus (lotential Dl""" 8.93%
----- -- ----- --
. ·-·---- ·--·-··-- --·· -·--···- -··-···-·· ·--· ---
Analysis 5·3
HARMONIC ANALYSIS
24 HOUR SERVICE (713) 467-2523
\ SCR BRIDGE SYSTEM WAVEFORMS
I
INPUT BUS:
1893 KVA @ .84 PF l .;.
• .;.
_..-{,
- '/L.r-..
PLOT PARAMETERS: [(<r ~( \ ~
\ F
Input Current
i1
((S"
c
L-L Bus Volts vr rn ~i/
!~ ;'\l /l :
ro
(J1
i'
{
w MAX SCALE CURRENT: \ )
~ \'-}
2000 Amperes
.1-
I
)>
JJ
$::
0
z
+a 2 CYCLES AT 60 HZ +
o
)>
z)>
S( #930416AVB EXAMPLE-1 CASE 2
(/)
IC/5 -~----- ~-----
...-
U1
I
f
-""
5-14
#930416AVB - EXAMPLE-1
2400 VOLT CIRCUIT ELEMENTS (5000 KVA BASE)
Source: Rs = .015 ~>U Ls = .15 PU ( .0172!1 Q + 458.4 pH )
Bus Adder: Ra = 0 PU La = 0 PU ( 0 U + 0 11H )
Bridge #1: Rf = .006 f'U Lf ,- .3 PU ( .006912 n + 916.7 11H ) Ldc = .01322 Hen
-~----~-----~---~~--------------
Xfmr: 10000 KVA
-----
Z = .08- - - -FL
-------
= .008065 NL = .0015 Pri/Sec = 4160 I 3600
- - - - - - · - - · - - - - -------- -------------· - - - - - - - - - - - - - - - - - · -
2770 VOU HARMONIC FILTER COMP0NENTS
Circuit # Capacitance Inductance Resistance Circuit Freq. Harmonic
(KVAR) (pH) (!:2) Q (Hz) #
C1 = 800 II = 1017.64
-·---- -·--. ---------
R1 = .0191
---- - -~~
100 300 5
OPERATING CONDITIONS:
Bridge # 1: 608 ADC 2599 VDC A = 2(J.JD U :- 15.2" f{c = .0171 (6-Pulsn)
- - - - - - - - - - - - - - - - - - - - - - ·---- ------- ------------- -~- --- ·------------~-- ---
svsr:M FUNDAMENTAL COMPONENTS:
Input Bus: 2349 VAC @ -2.7" lac 409.1 Amps ro -20.04°
VFD Filter: 2349 VAC @ -;!.T' lac = 409.1 Amps '11 -20.0 11°
Bridge #1: 2195 VAC @ -BJ3" lac = 474 -37 l"
0
Load
--·- - - - -
0
----- ·---- -- --~----------·--- -·-·---- -------- ------~-------- ---- ------ -----~-
5 2 175
------------------------------- ----------
2 -- ----
-94 97
--------------
97
------
0
-----
0 0 ()
------
0
--- -----
7 31 -172 -----
2.5 -81 49 23 0 0 0 --+--
0 0
-·-·---· ----
---·-~- --~-----~-------~- --------- ---~---- ~-·.
11 34 -141 18 -50 28 10 0 0 () 0
-- ------- ---· - - ------·-- ----
28 145 -125 19
--··--- ----
7
------
0 0 0 0 0
16 176 5 -94 8 3 0 0 0 0- 0
----------
- - - - - · - - - - · - - - ---· --·-- ----- ---.- --- .
13 101 ~ -169 6 2 0 0 0 0
--- -·---------------·---- -------- - --·------- -- -
0 -48 0 42 ---------
0
·------ -
0
--- --
0 0 ----------0
--
0
25 1 -123 0 -33 0 0 ' 0 0 0 () 0
'--·--- ------------- - - - - - - - - - - -
?9 10 -92
----
2
- -~2-- -- --i- 1 - -1- -
0 0 : 0 I 0 I
--- ----------
0
:Jl 10 -167 2 -76 3 0 0 0 0 0
35
------------ ----
11
--~-·---·
-136
----------- -·----
2 -46 3 0 0 -- -- 0
- -
0--- --
0
-~--·---·
37
----------·----
10 150
---------------- -----------
2 -120 2 0 0 0 0
41 7 -180 I -89
--~--- ----------
1 0 0 0 0 --
0
---------
43 6
------------------------------------
106 1 164 1
-------------
0 0 0 0 0 0
47 0 -43 0 47 0 0 0 0 0 () 0
49 -118 0 -28 0 0 0 0 0 () 0
--------------------------------------- ------- - ----- - -- -- --·--
---- --- ·-- -
RMS 1358
-~------~------------------------
411 -- - --
488
----------
178
----------
0 0 0 0
--------------·---·---· - - - - -
0
-~--
0
RESULTS: Bus Current DF= 8.37% Bus Potential DF=c 4.53%
------------- --------------------- --·------ ---------------·--
NOTES: 1. 2000 HP 2400 VOLT VARIABLE FREQUENCY DRI'/E
2. 6 PULSE C0NVUHER - INPUT REACTOR AND llt\RMONIC TRAP
3. CASE 3
Analysis 5-4
INPUT BUS:
[email protected] ~ + • +
)>
JJ
s:
0
z
~ 2 CYCLES AT 60 HZ -+
(")
)>
z
)>
S( #930416AVB EXAMPLE-1 CASE 3
(!)
Cii ....
\tfl
()1
·~---'
5-16
#9:30416AVB - EXAMPLE-2
4160 VOLT CIRCUIT ELEMENl S ( 10000 KVA BASE)
Source: Rs = .01 PU Ls = .1 PU ( .01731 U + 459 11H )
Bus Adder: Ra = 0 PI J La = 0 PU ( 0 l.l + 0 pH )
Bridge #1: Rf = 0 PU Lf = 0 PU ( 0 u + 0 pH ) Ldc = .01972 Hen
Xfmr: 4000 KV/1. Z = .06 FL = .01 NL = .0025 Pri/Sec = 4160 I 4160
---- -----·-- ------- ---- -- ----- ----.--- ------ ---- ---- --~- -------- -----·----------- ----~---
OPERATING CONDITIONS: ·
Bridge # 1: 708 ADC 4473 VDC A = 31.1 o U = 9.71 a fk = .0805 (6-Pulse) ______ !
------ -------------~----------~---- ··---~·-- ---~----------- ------- ------- -· -------·-
SYSTEM FUNDAMENTAL COMPONENTS:
Input Bus: 4045 VAC @ -1.7:J" lr-lC = 564.8 Amps @! -37.59"
VFD Filter: 4045 VAC @ -1.Y," lac = 564.8 Amps (<V -37.59"
Bridge #1: 3886 VAC @ -4.5' lac = 552 @ -36° - - - -------j
-- ~------------------
7 76 -163 63 -72 63 0 0 0 0 0 0 0
---- ---- --- --
11 80 -126 42 -36 42 0 0 0 0 0 0 0
----- -- ··-· --- ---------------- - - - - - ------· ---·
13 69 162 J1 -108 31 0 --
0 0
------------- --
0
~-~-
0 0
------- - - -----·-
0 -~
----------------------- --·· ------·-------- ------------ ---·-·-- -
17 62 -162 21 -72 21 0 .. ()_ - . 0~- ___()__ _9__ _Sl__ 0 ___ ]
19 55 126 17 -143 17 0 __()____ 0 0 0 .. ___q__ .____9_ ----:!
- - ------ -- --------
----,
- -- --- ----------------- ----
23 41 162 10 -107 10 0 0 0 0 0 0 0
----- ----- -- --- ----- ------ -·-- ----
25 37 90 8 -179 8 0 0 0 0 0 0 0
29 21 127 4 -143 4 0 0 0--- 0 0 0 0
----- - -· ----
0 f)
31 18 55 3 145 3 0 0 0 0 0
-- ------ ---- - --------· -----
43 11 163 -107 0- - --
0
------
0
-----------
u 0 0 ---
0
~-- ------j
47 17 -161 2 -71 2 0 0 0 0 0 0 0
49 17 127 2 -143 2 0 0 0 0 0 0 0
- ----------- ~- ~- ·--· --- ----·· -
NOTES: 1. 4000 HP 4160 VOLT VAniABLE FREOUENCY DRIVE WITf I INPUT TRANSFORMEFI 1
2. 6 PULSE CONVL 11TER
3. CASE 1
Ancllysis ;;.5
INPUT BUS:
3957 KVA @ .81 PF . ... .;.
..
~fAA~
'
PLOT PARAMETERS:
Input Current (
~~
VOLTAGE
\\
CJ1
.,.
~ .
.,. :vj
I
)>
:IJ
s;:
z
o +- 2 CYCLES AT 60 HZ ~
(")
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#930416AVB - EXAMPLE-2
----- ------ ----------·------------~---------- -~------·---~
I HARM
------
1
5
7
2371
-----------·-·-
4 -156
-2
---~-----------------~-------------·-
47
-------------------·--
-132
-·-·-
468
39
SYSTEM HARMONIC COMPONENTS
. -~~b_ll~_=~ Q~~L- __!l:>_us -~ £:>!9___._ -~~~"'-~ _l!_~ _ _ . #2 ____ _!_~--
----------~---
-------------
-65
-41
-18 517
----~-
107
59
·---
150
--·------ ------
107
21
----·-·--··
--0
0
0
-----
0
-----
---~---
0
--··-
0
#4
0
Load
0
0
0
------·-
11 53
----~--------
-78
~--··--·-
28
----------
13 37
---~----- -··--·-
9
- - - ·----
0
-~-
0 0
13 46 -141 21 -51 27 G 0 0 0 0 0
---- ---- --·-- -----
17 38 -87 13 3 17 4 0 0 0 0 0 0
-------·--·-------- -··------ ---- ----------· ------
19 ----- - - -
-1 50
33 -- ----·-------·-· 10 -60 13 3 0 0 0 0 0 0
-------~-- ·--- ---- - - - - ---~-
23 20 -97 5 -7 6 1 0 0 0 0 0 0
- ---·---- - --------- ----- ----···- --------------- -- . -- ---·--
25 16 -160 4 -70 5 1 0 0 0 0 0 0
--------------
29 4 -106 -16 0 0 0 0 0 0 0
31 - -
2
--·------- -- -----
-169
··--·------- ---
0 -79 0 0 0 0 0 0----- ---·-
----
0 0
------
35 ·-- -------
8
·-------
64
-------- ------
1 154
·-- ---- --
2
-·---·--- --- --
0 0 0 0 0 0 0
37 9 1 1 91 2 0 0 0 0 0 0 0
--- ·- --~------- -·---·-------- -- ~----~-- --- ---- -- - - - - ------- - - - - -
41 14 55 2 145 2 1 0 0 0 0
---------
0
---- --
0
43 14 -8 2 82 2 0 0 0 0 0 0 0
47 14 45 2 135 2 0 0 0 0 0 0 0
--------··------------------ --·---- ---- --·------ ------- --·- --- -·- -·
--·-
49
------ ------------
13 -18 · -
---------------
2
---------- ---
72 2 0 0 (l
-
0
-------
0 -·-
0
----
RMS 2373 471 534 186 0 0 0 0 0
RESULTS: Bus Current DF=-·--·
· - ------------ --- -·------·-· -------------·-
11.7% Bus Po!t 11tial OF= 4.47%
------ -----·-- ---- __ --- ---- ---~---------- ---------~----- _, -- -----~--
NOTES: 1. 4000 HP 4160 VOLT VARIABLE FREQUENCY DRIVE WITH INPUT TRANSFORMEn
2. 6 PULSE CONVERTER - WITH HARMONIC TRAP
3. CASE 2
HARMONIC ANALYSIS .
APPLICATIONS MANUAL
24 HOUR SERVICE (713) 467-2523
''.::..;:·,v
r---------------~ -- -~
I
SCR BRIDGE SYSTEM WAVEFORMS
I
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IJ
s:
0
z
~ 2 CYCLES AT 60 HZ +
0
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(/)
#930416AVB EXAMPLE-2 CASE 2 Cf
.... p-:"
i"
~--~-,c,· j
(/) --------- ~
-------.----~- ~
5-20
#930416AVB - EXAMPLE-3- - - - - -
--------~---- ----------~ ------------ ---------------··- -·- ------- - --------- -----~~--~-~--
HARM__ -~-~':1_~~-l?~-~---
2336 -2
lbu~_~__r:>ejJ._
561
lconv #1
-38
#2
tt~ ------· - - - -
552 0 0
--~4- I #: #6
0
-~--- o~ 1·_-o-•~~
--------------·--- ----------
---- --------
5 10 -91 11 0 11
---------
0 o o
7 8 -162 7 -72 -------
7 0 0 -- ~--- - 0 . -- Q ___(:)__ . ----~~-
11 81 -126 42 -35 42 0 0 () 0 0 0 0
I------ ----------1
13
17
72
--------- --------------
6
162
-161
32
2
-107
-71 -- -
---------
-
32
2
--·---- ----
0
------
0
0
0
~ ~ I ~ - --5-- --{-
-----
19 6 127 2 ·143 2 0 0 0 o I o o o
'2
- -··-------
23 42 163 10 -107 10 0 0 0 0 i 0 0
25 36 91 8 -179 8 0 0 0 0 0 0 0
------------
00 0 0 0
29 2 127 0 -'142 0 0 -0- - - - ----- - - ------- -
31 2 56 146
0 --------·- 0 0 0 0 0 0 0
--. ---------· - ---·- ------- --- ~ ---
35 2 92 0 -178 0 0 0 0 0 0
37 -160 0 -70 0 0 0 0 0 0
------- -
41 -124 0 -34 0 0 0 0
------
0 0
t13 164 0 -106 0 0 0 0 0 0
47 18 -160 2 -69 2 0 0 0 0 0 0
49 --·- -------
19 129 2 -141 2--- -------
0 --
0 0 o 1
_o 0
RMS 2339 567 555 0 0 0 0 0 0
RESULTS: Bus
------------ ----·-------------
Cmrent OF= 10%
-------
Bus PotPntial
----·--···-- ---·------·------
----- -----------~·
OF= 5.37'/o
----------- - - - - - - - - - - - - - - - - - - -
NOTES: 1. 4000 HP 41GO VOLT VARIABLE FREQUENCY DRIVE WITH INPUT TRANSFORMER
2. 12 PULSE CONVERTER
3. CASE 1
Cf
-....;
r
:'- l\ v '-J
~i ..;nr\A r:: C 'u,f RuC'ur::
Q, vt\,_,_
l\ 1 .... ~"~:""'·
i.
I
!;
,J
2000 Amperes I
.\ 'l.f---1 + +
\,
/
MAX SCALE POTENTIAL: l ... '-,.JY
. ...
- .
[
>
,.D
)
7
E- 2 CYCLES AT 60 HZ -+
::;
>
:::
>
<
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#930416AVB EXAMPLE-3 CASE 1 !tn
~~..;
·~'·
Ul
' "
.l
5-22
---------- ------ ------------· ---- ----- · - -
#9:J0416AVB - EXAMPLE-3
--------~---~---·------------~---·-- -- --------------- -~-- -- --------· - - - - - - - -----·- -----------
4160 VOLT CIRCUIT ELEMENTS ( 10000 KVA BASE)
Source: Rs = .0 t I'U Ls =- .1 PU ( .01731 U + 459 11H )
Bus Adder: Ra =0 Pl J La =0 PU ( 0 n + 0 11H )
Bridge #1: Rf = 0 PU Lf = 0 PU ( 0 .n + 0 11H ) Ldc = .019n Hen
Xfmr: 4000 KVA Z = .08 FL = .01 NL = .0025 Pri/Sec = 4160 I 3900
- - - - - - - - - - - - - - - - - - - - - - - · - - - - - -------- ---------------- --- -------------------- - - - - - - - - - - - - -------
--------
OPERATING CONDITIONS:
Bridge # 1: 708 ADC '1473 VDC A = 23.9° U = 13o Rc = .0289 (12-Pulse)
-- - -·--- - - - · · · - - - - - - - · - - - - ·------
SYSTEM FUNDAMENTAL COMPONENTS:
Input Bus: 4064 VAC @ -1. 77" lac -, 527. rl Amps @ -32.32°
VFD Filter: 4064 VAC @ -1.77" lac =- 527 9 Amps @ -32.32"
Bridge #1: 3655 VAC @ -5.54" lac ,.,. 551.1 @ -30.5°
- · - - - - - - - - - - - - - - - - - - - - - --------------- --- - - · - - - - - - - - - - --- ------ . ----
13 58 -126 26 -3G 26 0 0 0 0
---------------------- ---- . ---- - - - - - - - - -··---~ ~---- ~-- -
17 4 -68 1 2 ')
L. 1 0 0
·--·-------~.
0··- ---
0
19
------ --·-----
23
------·--
16
3
~------·-
-129
---- --·-
-71
---
1
-------·----
4
-- -
-3!1
·-- --
Hl
1
----------
0 0 0
0
0
0 0
!?.___ -----
0
-l
4 0 0 ------------ -1
25 10 -132 2 -41 2 0 0 0 0 0 0
29 0 -16:3 0 0 0
0 ---1
0
-~------·-
----~
31 0 131) 0 0 0 --------
35--- 17
-----------~---·-----
104 3 -166
-------
3 0
---- -- ---
0
----- --- -- --
0 0 _ _j
37
---~-- -----~-
18 43
------------------------
3
-- -----·-- -
133 3
-------------
0 0 - -- ____o -1
41 2 101 0 -169 0 0 0 0
---·-·----~- -------~ --------- - -I
43------ ----·---2 40
------~-
0 130 0 0 0 ------ --- -------· ------0 -I
47 13 98 2 -171 2 0 0 0 . 0 0 0
49
---·----~-- --·-----
10 ----·------~---
37 128
-------·--
1 0 0
- - - --·- ------
0 I~~--~--_ CI.. -~-~~-() - --l
RMS 2348 530 519 0 0 0 0 0 0 0
RESULTS: Bus Current DF= -8.64%
- - - - - - - - - - - - - - - - - - - - - --··----·-- ----- ----~-
Bus Potential
--------------·---·
OF · ·--------
-------
---
4.09% ------------
NOTES: 1. 4000 HP 4160 VOLT VARIABLE FREQUENCY DRIVE WITH !NPUT TRANSFORMER 1 __
2. 12 PULSE CONVERTER
3. CASE 2 I
-------- - - - - -- --------'
Analysis 5-8
INPUT BUS:
3716 KVA @ .86 PF . ... ...
PLOT PARAMETERS:
Input Current
rI~ ~~\ :
) ~\
r"'-\ - , """
L-L Bus Volts
11
I'
)
tCi" . .I \ \\
c
a; I
'
.r
Cf
CP, MAX SCALE CURRENT:
2000 Amperes
.,
~~~ \ \\t1
MAX SCALE POTENTIAL: ... v ... ...
~/
10000 Volts 't
.,. 't
)>
::0
~
0
z ~ 2 CYCLES AT 60 HZ ~
R
)>
z)>
!:<
(/) #930416AVB EXAMPLE-3 CASE 2 I~
~
(j)
k------------------------------------------------------------------------------------------------------- ~
--------------·-·-··· -·---
.·A-
5-24
#930416AVB - EXAMPLE-3
----------- ~ --------~-------- - -----------
4160 VOLT GIHCUIT ELEMENTS ( WOOO KV/\ [lASE) L
1
SYSTEM HARMONIC COMPONENT~;
~
11
-~-=~~~i-= - - -
1 -161
:.1 -1-~i- -- ~
-7 I
1
38
1
~
0
~
0 l8
~~ ~ci_l ~t
0 ! -----
0
(}
0
0
. J
·- ------. ·- ----·-cd.
0
--- --- - -- . - - - - ·----j
1:3 21 -136 9 -46 29 0 1 18 0 0 0
- --- -·--·-- ·--- -----··- --------- -------·- -----
11 3 -80 1 10 2 0 0 1 0 0 () 0 .L
-··---- --··---- ----------- - --·--·------ -- --------- -~- -·
19 2 -142 -52 1 0 0 1 0 0 (\ 0
- -·--- ----
23 17 -87 4 4 8 0 0 3 0 0 u--- 0
--·--·- ---
1
2G 14 -149 3 -59 6 0 0 2 0 _o__ _ o__ o -~
29 1 -93 0 -3 0 0 0 0 0 0 0 0 --1
31 0 -156 0 -66 0 0 0 0 0 0 0
- ---·-- - -·- . -:J
35 4 80 170 1 0 0 0 () 0 0 0
0 --.l
37 6 17 - - - ---- --- -
108 2 0 0 1 0 0 - -
0
---·
41---- 1- - - - - - ----------
73 0 163 0 0 0 0 () 0 0 0 J
----- -·----- -- ---
43 11 0 101 0 0 0 0 0 0 0 0 .l
--- -- -·------·------·----- -------
47 11 66 1'16 2 0 0 0 0 0
49----- ---------
11 - - ---- --
4 l4 2 0 0 0 0 -----0 --- --·---.
-·-- 0 -.J
RMS 2364 4B3 519 24 22 75 0 0 0 0
RESULTS: Bus Current DF= 2.37% Bus Pc tential DF"' 1.48%
NOTES: 1. 4000 HP 4160 VOLT VARIABLE f-=HEOUENCY DRIVE WITH INPUT TriANSFo'RMEPJ.
2. 12 PULSE CONVERT! .R - WITH IIARMONIC TRA!'S .J
3. CASE 3
~'
- - - - - - -------- -----'
Analysis 5-9
I
)' '-
I!
SCR BRIDGE SYSTEf\11 VVAVEFORrV\S
~- -·-~ - - -·
-~ ~ ~- ---l
'"··~r-;~ r - ~! 'C'~
~~.. ~ v, c._,-.:,.
.. ~ .;.
PLOT PARAMETERS:
Input Cu:-rent
r/i/~
~. ., CURRENT l \ .
/\~ f
,· / -......
L -L Bus Volts I \\\\
"T1
f I ' ~ I
<.0' I
~I
Cll]
()11
0: I
1
I
MAX SCALE CURRENT:
2000 Arr-iperes
~
'\ '-,y \... /J
+ -' ... .. -.
MAX SCALE POTENTIAL:
10000 Volts .,. 't
.,.
:
>
.
D
..
:
+- 2 CYCLES AT 60 HZ +
:;
~
,.
>
C( EXAMPLE-3 CASE 3
I~
#930416AVB
/)
(J1
75
- G1 '•
I
f
-
I
fc
~
5-26
• NOMINAL FREQUENCY: H~
• SOURCE IMPEDANCE Al FU JDAMENTAL FHEQUENCY
AND ASSOCIATED X/Fl l \fl! ·, IF KNOWN.
a) SHOFl CIHCUIT MVA
b) --~---+j , , ;1_ UASE MVA IN PFR UNIT
OR PERCENT OR 01--'lv'l' ··
• PROVIDE SYSTEM ONE 1 .lr\1' (PREFERRED) WITH IMPEDAf\lCE INFORMATION. -
• MAXIMUM DEMAND LOA J C. IRHENT AT POINT OF COMMON COUPLING
COMPLIANCE TO STANDAI D: ~------------
TOTAL HARMONIC DISTOr\! 10 J LIMITS: VOLTAGE ______
CURRE.NT _ _ _ _ _ __
NO. OF VFD DRIVES OPC !Al·NG AT A GIVEN TIME
(FOR WORST CASE ANAL 'SI; ·): _ __
OPERATING POINTS AT \J\il~IU-1 THE HAHMONIC ANALYSIS IS REQUIRED
(SPEED AND OUTPUT HO· !Sl POWER):--~-~ ~-----~-
-----~---~-----
--------- -- ----------
-------------
------ - - - - - - - -
The heart of any variable frequency drive • The Peak Inverse Voltage rating of t11e
is made up of the components which convert SCR's is 200% with one devico failed
AC power to DC and then from DC to AC in a bridge leg.
power in order to operate /\C ind1rction or
• The bridges are designed such that the
synchronous motors. The power
thyristor junctions operate at a cool 95''C
conversion sections of a Ross Hill Controls
temperature at a 5oac ambient
variable frequency drive sy~>tem nre made
temperature.
up of identical rectifier and inverter ~;ections.
For induction motor drives, <'t divertHr bridge • Fluid cooling with a remote heat
section and output filter arn adele• t; these exchanger produces low heat loss in H1e
features will be discussed later. equipment room for clean, quiut
operation.
Whether the drive provided is an induction
• Filtering of the output current and voltaue
motor drive or an LCI synchronous motor
waveforms produce near sinusoidal
drive matters little with Ross Hill Controls.
The rectifier and inverter bridges for the two waveforms in RHCC induction motur
systems are the same within a volta! 1e class. drives; thus, allowing retrofit to a11y
A Ross Hill induction motor drive may be existing induction motor without deratit iSJ
thought of as an "LCI" for induction motors. of the motor.
··-,1
')
j
'
'
'
CONTROL ELECTRONICS
7-2
CONTROL ELECTRONICS
..J ___ -
-
·-----
----
---
0
POWER
SUPPLY ON
u
PROCESSOR
()
OK
50
FREQUENCY CONTRCJL
I•
• .~
VARIABLE FREQUENCY
,- MOTOR CONTflOL
_.-,
,-
,-
I ,.....
IRl I FINMECCANICA I ANSALDO
CHANGE
ENABLE
" II
" I
,.....
7-6
TRIP DISPLAY SCREEN
Selecting this ::creen allov s tl iO use -
to display the status of t:1e rnoduiP
and system tt ips. All ai munr:iuteu_
shutdowns arn highlighted. Tht-
number precedi·1g the highligllied tri 1
conc:Jition indic0tes the srJquence c~
trip events.
SETPOINT ~;HANGE
SCREEN
The user cu 1 change sever~.
setpoints US( I by the module .-
control the vat 1ble frequency < lriv,...
The "RAISE V \LUE" push button .-.
used to updatf the selected setpoi~•
value. Pushin! the "RAISE VALUF:-"
button cycle: the change value::;
within the pre~~"t range. The chan!:J..J
operation is inl Jrlocked with the frc ~-:
panel change r.;nable key.
CONTROL ELECTRONICS
--·- ------·---·-~-·--~--------- ---~----~---~----- --------- '\PPLICATIONS MANU -
24 HOUR SERVICE (713) 467-2523
7-/
DATE AND TIME UPDATE
SCREEN
The: user can reset the time and datl;
display using the Date and Tirnu
Update Screen.
The Raise and Lower push button:,
are used to change the value of the:
selected item. When set, the clock
waits until the start of the next secon~ l
to reset.
CONTROL ELECTfiONICS
This side of the page 1s intentionally left blank.
r
-t
I
l
_ _ _j
r
ROSS HILL CONTROLS CORPORATION
t
·~ COOLING SYSTEM OPTIONS
1
I t
OVERVIEW
I
I
~
't
8-2
system will assure safe operating airbome contarninant: , such as dust and
temperature margins for power devices. dirt, are not blown into the system.
The thyristors used in RHCC drive syst<?rn~; TherPfore, "fOil are tssured of cleaner
are rated for operating junction temperatures opernting oquipmet t without requiring
of 125°C. The RHCC cooling system, air filtered ambient air or lhe cle8nliness of an
or liquid, is designed to provide device air cunditionocl envi11 nment.
junction temperature, at full lo<~d, of 95°C Sinco large uir conditi ners ure not required
or less. Since the life of a thvristor is directly for tho liquid cooled ~ {stem, overall system
related to the operating junction efficif:ncy is much be 1er. Typically, a 5000
temperature, the conservative 1' ~rnpemlure HP drive will requ!e three 15 ton air
marqins designed into the HHCC systems conditioning unils (h •J operating, one for
<1ssure you, the customer, the highest level redundancy). C )mpare the power
of reliability. consumed by litis ai• conditioning load to
FORCED VENTILATED the two horsopow r pump and two
horsepower l1eat exct· mger fan used by the
COOLING SYSTEM liquid cooled system
Forced air cooling is stand;ud ·:;upply with Drives featuriny the : ~HCC liquid cooling
the flHCC low voltage (480V or GOOV) drive system feature bett• r reliability than air
systems. Designed to allo··.N the safe cooled units of com ·arable horsepower.
temperature margins previously discussed, With the liquid c:oolin1 system, operation is
the forced ventilated cooling ';yst0m will no Iunger tied to 1 1eration of the air
assure long term reliability with the low conditioning svste1 Since the active
voltage drive systems. compunents of :he liq •cl co~) ling system are
CLOSED LOOP LIQUID isolatod fro111 high v· ilage compartments,
and I 00% rC'dw tdanc of the cooling system
COOLING SYSTEM components is provicf, I, maintenance of the
Closed loop liquid cooling is stan lard supply cooli119 systern can · : performed without
for the RHCC medium voltage drive shutduwn of tl 1e VF system.
systems. The typically higher power rt1tings The combination of q' 1et, clean and efficient
of rnodium voltage systems have higher heat operation makrJs li• :Jid cooling the only
loss than their low voltage counterparts. sensible methu•l of c oling medium voltage
Liquid cooling provides a more quiet, clean drive systems. Cour 'e these benefits with
and efficient means of cooling tl mse higher the reliability built intt our closed loop liquid
power drives. cooling system :md y u can clearly see why
The liquid cooled system uses n deionized Ross Hill Conl1 liS Cc poration continues to
water/ethylene glycol mix to carry heat from be the leader iJ 1 variai e frequency AC motor
the VFD power components (SCRs) to the drive systerns.
outside atmosphere. Since most of the heat
COOLif'-lG SYSTEMS
------- Ar' LIGATIONS MANUAL
------ ------
.... ----------
24 HOUR SERVICE (713) 467-2523
-· '"~~ """_.,.,.,-~~"·-~"'"'~ .
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30 GAL
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VALVE ~=£ALARM ""BLEED" -
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PROBE
RESISTIVITY \ CELLS
LAMP
SHUTOFF VALVE
10% BYPASS QUICK
~ DISCONNECT.___-.-J ......,__---l
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EXCHANGER
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.:I Vt\RIABLE FREQUENCY
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9-1
I required)
• SCR bridge ct •. icle
• Control cabinel
• Pump cabinet
• DC link reacto: cabinet
• Output filter c1 :: d~le (induction drive)
• Field supply C<1: ,jnet (LCI 'synchronous
drive)
• Switchgear cui •!de(s)
• Heat exchang11 cubicle (outdoor)
• Squirrel cage i1 1duction or
synchronous n i ltor (optional)
9-2
Indoor/Outdoor
9.5 Driven Equipment
14.8 NEMA cl :.trances shall be 15.1 All internal wiring shall be colcJI
maintaine< i in all cubicles. The coded or tagged with permane11t
cubicles sh. :1 be holtt)d tognther to labels at each termination, junctio11
form a C• :llint,ou~; switchgear box, and device. Wire label
assembly. (Jesignations and/or color coding
shall correspond to the schr:matic
14.9 Power and • . ~ntrol ter1ninations shall
and wiring diagrams furnished witlt
be easily a1 :essil 1le for cable entry
the unit. All control wiring shall bt3
in the cubic: : top nr l1ottom. Power
stranded copper conductors, hi~Jil
termination· ~;hall tJe ~:uitablu for bolt
tnmperature, abrasion resi:;tald,
on lugs. C. 1lrol rerlllinatiOJlS shall
r::xane wiring.
be screw i. pe I· :rminal blocks.
15.2 All control wiring shall be isolakd
14.10 The powe1 .~onvnrsi.,n eqt~ipment
from power wiring and all AC
shall be h. qsed in free-standing,
voltages shall be isolated frnm cdl
ventilated I . : :'MA 1, 14 gaw.Je steel
DC voltages via separation 11r u~;e
enclosure witl1 12 gaurJO steel
of shielded cables.
bolted fran. worl·. l loors ·;hall be
lockable .tnd hinged. The 15.3 Insulated compression (crit npod)
enclosure ~ . 1all btJ ck:e1ned. primed, ring tongue type lugs shall I.Je
and finishi . 1 with elc:ctro~.tatically provided for all wiring terminating un
applied pol; :ste1 paint to a 111inimum terminal blocks. Soldered termin<tls
dry film th! lme~;,; of 3 mils. The are not acceptable for conrtection
color shall :le J\i~SI b1 li~Jht gray. to terminal blocks.
14.11 Audible n .ise uenlHated by the ·15.4 All external wiring including input,
controller ir, .ide :t building under any output, grounding, controls, .:ontrol
condition . , f opora lion shall not signal, and alarms shall be wirod
exceed a uund prnssure level of to functionally identified screw type
80 dBA m(. lSUrc:d five (5) f,;et from terminals within the enclosure. All
any surfa, of the enclo~:ure. interconnection terminal blocl<s sl1dll
include 20% spares. A maximum
of two wires per point should l>e
permitted.
;)
15.5 All line and load power connections
YAF~IABLE F_REQUENCY DRIVE SPI CIFIQf\.:fiONS _---· ---~ ___ ___ 1PPLICATIOf\jS MANUAL
24 HOUi~ SERVICE (713) 467-/523
-------------------------------
r
!
16.7 SCR's sl1 ,!1 ho of a mature 17.1 The power bridges shall utilize .1
I manufactu1
allow repla•
•19 todmcJiogy which will
. :menl of individual failed
closed loop liquid cooling systnm lur
optimum efficiency, increased
I
: -
devices wit:
to replace
,)ut rt:sorting to I he need
dl d(;vicos in a bridge
reliability and to minimize tho si.::tJ
of and dependence on <.:tir
! leg. conditioning units. Bridge coolittU
shall be accomplished using d
16.8 The syste: ; sh; dl bo desiuned to
mixture of deionized water ar.d
continuous: - provide rated power in
ethylene glycol which shall have dll
a 50°C an. ~ient at 7500 ft. altitude
ambient operating range from -30'\_:
with a m1 imttin ~;cR jttnction
to +50°C.
temperatt ,o c,f D5°C without
I 16.9
derating tl, sy~.tem.
II
redundant close coupled centrituwd
tho phase ell L )r uperatot" safety
pumps, a liquid to air (or liquid tu
in the regu: -!or c. ;mpartment. Gate
water) heat exchanger and a mix(:d
pulses shcc1o be 1: ansmitted utilizing
bed resin filter to maintain the punt y
fiber optic '"chniquos to rninimizo
of the deionized water/ethyle11u
noise probl- ms. The regulator shall
qlycol solution.
monitor inc 1 tidu;d SCR's to insuro
they receiv, their gate sign; 11 at the 17.3 Either pump shall be capable tJt
proper tin., and that each SCFl running as the primary. Tho
conducts '' , I bl( •cks at the; proper back-up pump shall automatically
times. Sh( dd either the g<tle firinu start if the primary pump shuts dow11.
or SCR co1 -lucti, ill be impt oper an The cooling system shall bo
alarm in die :ion <tnd <mnunciation of designed with a separate low volta~JLl
the individt d failed device ~;hall be cubicle to allow resin bed filtur
provided. replacement or pump servicinq With
the drive completely operati,mal
16.10 Each leg c: ihe flOWer bridqe shall
contain se;: :s SCR's which have a 17.4 All hoses shall be comprised of
minimum p. · 1k inverso voltaqe (PIV) hi-dielectric, flexible material
rating of ; ·10% with all devices pressure rated to a minimum of 150
operatin~J Tho failure of one PSIG. The hose shall have an
device, in : ty 0118 k:g or ; ill legs, operating range of -40 degrHes F
shall not c. -1se :~ shutdown. With to 250 degrees F. The hose shall
one device :lwrJ,:d, the PIV rating t >e Hi Pot tested to 50KV.
of the po• .:r bridge sh;:tll be a
minimum o: 195°,. All SCR's in the
VrO shall : , ; te~iled to inSlll"e they
have simil;., char:lcteristics so they
will share L;.; power reliably durin~J
turn-on, 01. ratio11 and turr1-off.
9-10
18. I Two DCLR's shall be provided. One 19.1 The in: trui 1entation shall be
for the positive and one rot the designe1: for ·r1se of operation and -
negative DC side of the power mainten; nee I the equipment and
bridges to properly control current shcill as a n· ·1imum include:
flow during normal operation and
Output :. oqu· ncy meter
any fault condition.
Output ·oltn 1 Jer
·t8.2 The reactor shall be desinned to limit
Output •rnm '11r
the peak to peak DC ripple to
approximately 15%. "Local- · ~em1 e" selector switch
Local s1•eed 10tentiometer
18.3 The reactor shall !Je dry type,
air-core convection cooled w1th Motor "'·tart op" control
Class H insulation not to m ceed Cooli1 g I' mp and blowe-
Class B temperature ri:::;o Tlte "Hand-Cff-Al' •" switch
reactor enclosure sholl be NlMA 1 Red mol· q· ou 1ut contactor "Closed"
indoor or NEMA 3R outdoor with light (in lucli· 1 drive)
screened or louvere<J C1lJGninqs.
Greon :not· r output contactor
18.4 The enclosure shall be provided with "Open" 1ighl induction drive)
a ground bus. Grenn ' l"riv- OK" light
Green ·· t\lan > OK" light
Logic p •wer illl
Motor 'Driv· Off-Bypass" contro 1
(option< d)(ind .;lion drive)
Red in1 >~Jt c' ·tactor "Closed" lighL
(optionnl)
Green i tput ')ntactor "Open" lighl
(option;.!)
Red by! ass -lased" light (optiona,,
(inductic 111 ell ·e)
Greon I ;pa~. "Open" light (optiona.,
(inducti· ·n d! o) -
~ ..
9-12
20.1 Each output shall be an isulnted 21.1 The contr, dan' regulation functions -
contact rated 10 amps at 600 Vf\C. shall be S( pam ·1 from the protection .
The following minimum VfD status and anrl,rnci. ion functions to _
indication shall be provided: enswre l11at U '} integrity of one
function i~ ma i tained in the event
• Alarms OK
of a faillJ· e of !he other.
• Trips OK
21.2 rhe rwr~ro: ocessor based
• Local Control
diagnnsti< sy.:.l m shall monitor all -
• Remote Control trip and <Y<~rm ; :nctions and display
• Output Contactor Opon (induction them 0n ; ' fror, l panel for indication
drive) by mean:·. of ei 11er LED light display _
• Output Contactor Closed or a con '!)Ute; display.
(induction drive) 21 .3 A RS23~' or I )422 port shall be_
• Spare provided :ur cc · 1munication with the
• Spare User's n·onil ring system. Tht-
syster n sl all b· · capable of remote I) -
20.2 The following 4-20 mA UC output
transmith1g ;1 um conditions, trir
signals shall be provided:
condition: , di~r al signals and analog-
• Output Voltage signals ':sin~ modbus protocol.
• Output Current This c a 1-" 1b iIi : ; s h a II inc I u de t h G
voltage <':ld ( urrent waveforms o.
• Output Frequency
the molt r, tl 1~ input voltage anc'
20.3 The variable frequency drive shnll current l< · the; -irive, and regulator
be configured to accept following analog f1 •!Jctit· s.
user provided inputs as a tninimum:
21.4 The regui.ttor lmll be designed tr-
• Input speed reference S;Jnal (~~-20 operate n·mTI; :y with input controL
mA frequency command) voltage frot: 75% to 125% oL
• Remote Start - dry contact nominal.
• Remote Stop - dry cor1tact :.->1.5 The foil< ·winu Diagnostic Option~
• Input Breaker Open-dry contact (If may be · lros' 1 (select one option
furnished by User) only):
• User Alarm - dry conlact a. Tho d1 ;ve : .111 be supplied with
• User Trip - dry contact an evt r1t w !Hder and printer to_
record the !entity of the drive,
date <'' 1d ti 1e of occurrence 01
any t1 :. ' or Iarm. The recorde1
shall I"~ in' died at the drive o,
at a re•, 1ote .mtral control station.
Ii
,·.,
9-13
,
l- 22.4 After ali .:ompon<:nts have been
I
mounteti and wave soldered, the
L PCB sh;.IJ be ~;outed willl a solder
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9-14
I!
;
j
1
The motor shall be of squirrel cage induction Thrust Requirements (for vertical
or LCI synchronous (as required by the drive motors only)
- type) design suitable for variable speed
- operation. If bypass is specified, the motor shall
~ Following shall be specified for motor bid: be designed suitable for across the
line start.
Dual Winding (LCI synchronous)
Output Power
Voltage (specify per winding for LCI
dual winding machine)
Manufacturer shall provide data applicable to each type drive system proposed. Write N/A
in spaces not applicable to a particular drive system type. Estimated quantities shall be
given and indicated as such when actual requested quantities are not known.
THYRISTORS
Manufacturer
Model No. or Type
Rated Current
Peak Inverse Voltage Rating
No. of thyristors per 3 phase bridge
Converter
Inverter
Peak Inverse Voltage Design Margin
Peak Inverse Voltage Design Margin
with one failed thyristor
Operating Design Junction Temperature
at 40°C ambient
DC LINK REACTOR
Manufacturer
Model No. or Type
Rated Current
Rated Voltage
Reactance Value
ENCLOSURE TYPE
Indoor Equipment
Outdoor Equipment
;:
r
ESTIMATED DIMENSIONS
Indoor Line-up
DC Reactor Enclosure
ESTIMATED WEIGHTS
Indoor Line-up
DC Reactor Enclosure
.,.
~-·
MOTOR SPECIFICATION
CONCERNS
r~ l
I V Neutral
c
DC· I I I
1flJlJ1Jlfl e
MOVES Mt-M:? MJ ANO
OENF.rlA IES n 11n0 I!NlMONIC
WJl TS TO NEUTAAL..
THE OC+ & DC- BUSES
JOV\ HA't{: A ()QMMON UCO:
loOt.TAGE.
4) speed range, and 5) starting considerations. 30 deogrees
- -·----
eo degntes 90 dngreee
Every Cycle of Input Ff'&quency - ---
e THE MAGNITUDE OF lHE
COMMON MOO(: CHANGES
V't'm-i rnE BRIDGE RAING
NIIGLE.
·-1
(Figure 10-1a).Figure 10-1b illustrates a --]l~~c----{)f-mn_~
- cotAM0N MODE VOLTAGE 1
ACROSS INPUT TRANSFORMER .
three-phase bridge which is the motor power
source of an adjustable frequency drive. In
operation, only two phases conduct at any
time, hence, the vectors do not sum to zero. Figure 10-1
The DC link center moves and has positive
and negative voltage values (the so-called Such motors may be expensive since the
"common mode" voltage) relative to ground, higher voltage requires additional insulation
the magnitudes of which vary with the bridge thickness, meaning larger stator slots,
firing angle. The magnitude of the common ultimately translating into larger, more costly
mode voltage in each bridge can be equal motor frames, especially on motors rated
to half the rated line-to-neutral voltage. 4kV and greater. Another solution is to use
Thus, the total voltage stress on motor an input or output transformer and connect
phases with an ac-ac converter (with input the neutral of the motor to ground (Figure _
and output bridges) can be Vl-n + 0.5 V1-n 10-1 d). A transformer can be insulated for
+ 0.5 Vl-h, or two times rated line-to-neutral higher voltage levels without significant
voltage (Figure 10-1c). performance compromise or cost penalty.
This is a concern since motors are not With an output transformer between the
normally designed to operate at twice-rated drive and motor, the common mode voltage
voltage. One approach to solving this is isolated from the motor and placed on
problem is to specify motors with sufficient the drive-side transformer winding. -
insulation to handle twice the rated voltage. Applying an input transformer and
--3~
~-~--L.___fJ
>1- 'il- )1.
t VOLTS
---
-
·----~---
f------
lr -
-- ALTER f----
Q
:¥
--- r£=-\=;
Q
AMPS
_::VOLTS~
r
1TS
--j(---- - - - -
-- ,_ ALTER
~~--- ~-
---
- - ---------- - - - - -
-
lr r AMPS~
--------- --------
- ---.---- __ , ________ ---- ------------
-
It VOLTS~-
ALTER -- 1- t-r--r--
1"'\J
1- ~
1~--...:L
1 AMPS
- - - - '-------- '--
--
-
r-- FILTER - I-- FILTER
r---l/1\\ f& I
~v WJ \x
f-
1-
v
-- ~-
Figure 10-2
10-4
HARMONICS (Cont'd.) OUTPUT WAVEFORMS I-
The value of voltage and current harmonics AT VARIOUS SPEEDS I-
varies tremendously with different drive
configurations. Many of the large
horsepower, medium voltage induction drive
systems (such as those offered by Ross
Hill Controls) are of a type which has low
harmonic currents at rated load and speed.
While the harmonics almost always increase
dramatically at reduced frequencies/speeds,
the typical pump/fan/compressor application
has such a significant reduction in load at 100% TORQUE AT RATED SPEED
reduced speed that the total current
(fundamental plus harmonics) will be well
below the motor's rated value and within T
-\-
the motor's self-cooling capability.
Harmonic currents are additive to the
fundamental current and thus generate
additional heat in the motor windings. If
har:-nonics are negligible, there will be v
negligible additional heating in the motor.
Even a value of thirty percent current 100% TORQUE AT 75% RATED SPEED
distortion in a motor is unlikely to generate ,-·------
more than about 8% additional heating.
However, since the type of drive and the
allowable harmonics will be specified in a
separate specification, the motor
specification must consider the entire range
of possible drives that may provide motor
power. It is necessary for the drive supplier
v \/ o_/
250% l
This "soft starting" is very beneficial to all - Molor Cap. - - - Dnve Cap.
elements of the drive-train, as well as the 200% ····Pump Load n Aclual Oulpul
:!?.
motor. Because an adjustable speed drive 0
Hence, starting is easier on a motor if a if the motor is NOT required to start the
drive is used. The decision is whether to load across-the-line, the motor should be
specify starting only with the drive. A motor braced for full voltage starting to allow future
that is always soft-started can be optimized shifting of the motor to an alternate
for efficiency and steady-state operating application.
characteristics. When across-the-line
starting is required and the specified load
has high inertia (typical of fans and some CONCLUSIONS
compressor/gear trains), this will require
compromises in other performance areas Despite the fact that motors have been with
and greater expense. There are two us for more than a century, they serve the -
important negatives in specifying soft-start needs of a new world that values cleanliness
only: ( 1) it may not be possible to start the and efficiency. AC motors are simple in
motor across-the-line (bypass the drive) in operation, reliable, efficient and clean.
the event of a drive failure and (2) the motor Making use of the added flexibility and energy
may not be capable of being shifted to savings that are possible with adjustable
another use without a soft-start control. The frequency drives is easy when four basic
benefits of specifying "soft-start only" are issues are addressed at the specification
optimized motor design and elimination of stage: (1) common mode voltage, (2)
mechanical flow control methods. Hence, harmonics effects, (3) switching frequencies
better efficiency, reduced initial cost, less and standing waves, (4) speed range
maintenance and fewer mechanical flow concerns and (5) starting considerations.
losses. The decision must be based on By supplementing existing motor
the type of drive purchased (reliability/ specifications to address these topics, one
confidence level, redundancy, fault tolerance, can be confident that a specified motor will
etc.) and the nature of the application perform reliably, meet the requirements of
(is this a critical service machine?). This the application and give the user long
decision should be a "bullet" item, requiring operating life.
purchaser input, on the data sheet. Even
"
.. -
This side of the page 1s intentionally left blank.
11-1
TECHNICAL PAPERS
Ross Hill Controls has compiled the following 3. Variable Frequency Drive Retrofits on
reading material from various magazines F-D Fans at Texas Utilities Lake
and IEEE technical papers that discuss case Hubbard and Valley Station Power
stu?ies and relative concerns with applying Plants
vanable frequency drives today. Copies are By Jack H. Smith and Steve Stewart ,
available at the Houston plant and can be Utility Engineering Corp. (Utility
sent out upon request. Engineering, Amarillo, TX).
1. Benefits of Variable Speed Drives
Emphasized at Very Low Loads SUMMARY: Two (2) 6900 HP VFD's
By Larry Randel, San Diego Gas & were placed in service at Texas
Electric Co. (Power, June 92). Utilities's Lake Hubbard Plant and One
(1) 5750 HP VFD at the Valley Station.
SUMMARY: Case study retrofitting This article discusses the design,
two 4000 HP starters using inlet guide benefits, considerations, and careful
vanes for control with two (2) variable planning needed when adding VFD's.
frequency drives controlling forced- Reasons for retrofit consist of:
draft fans. Inlet guide vanes were improved unit heat rates, soft start
opened and the efficiency was reduction in motor starting stresses,
increased substantially. Results show energy savings, and an increase in
more than a $1-million/yr savings and spinning reserve capability.
a payback period of just over two (2)
years. Reasons for retrofit consist of: 4. Application of a 5500 RPM, High
efficiency was dropping below 50% at Speed Induction Motor and Drive in a
tow loads, and cracks in the rotor bars 7000 HP Natural Gas Compressor
of the motor were caused because the Installation.
motors were started repeatedly with no By Stephen C. LaGrone, Miles C.
"soft-start" capability. Griggs, and Maurizio Bressani (IEEE
Paper No. PCIC-92-42).
2. Payback Enormous for Variable
Frequency Motor Drives SUMMARY: This paper describes the
reasons for choosing, and some of the
By 0. C. Smith, City Utilities of
considerations in implementing, high
Springfield, Edited by Steven Collins
(Power, February 93). speed induction motors and variable
frequency drives for the Princeton
SUMMARY: The City Utilities of compressor Station in Lawrenceville,
Springfield, Missouri added 4500 HP NJ which is comprised of two 7000
variable frequency drives to both the HP, 5500 RPM compressors. The
induced-draft (i-d) and forced-draft (f-d) selection options relevant to the
fans at their 200-MW plant. The facility application reviewed are: gas turbine
reports a $800,000 savings per year. vs motor driver, high speed motor vs
Reasons for retrofit consist of: conventional motor, induction vs
reducing parasitic load, improving synchronous. Design features of the
combustion control, obtain better major system components discussed
efficiency, and increasing overall plant are: power system, compressor
reliability. motor, and variable frequency drive.
11-2
5. The Steps to Select a High Horsepower 6. Avoid Pitfalls in Economics of Boiler
Variable Frequency Fan Drive System Feed Pump Variable Speed
By W. H. Beck, J. L. Ascher! (IEEE By Eugene Kempers (Power, March
Paper No. PCIC-88-21). 1984).
NOTES
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11-4
NOTES
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