Iacdrive|Automation Solution

Synchronous generator operating frequency

When synchronous generators (alternators) are connected in parallel with each other on an AC grid, they are all operating at a speed that is directly proportional to the frequency of the AC grid. No generator can go faster or slower than the speed which is proportional to the frequency.

That is, when a synchronous generator and its prime mover is operated in parallel with other synchronous generators and their prime movers, the speed of all of the generator rotors (and hence their prime movers if directly coupled to the generator rotors) is fixed by the frequency of the grid. If the grid frequency goes up, the speed of all the generator rotors goes up at the same time. Conversely, if the grid frequency goes down, the speed of all the generator rotors goes down at the same time. It is the job of the grid/system operators to control the amount of generation so that it exactly matches the load on the system so that the frequency remains relatively constant.

Isolated or is landed generators that are not in parallel with other generators have an added limitation in that keeping exactly 50Hz is somewhat difficult, or puts too much demand on controlling/governing systems. In such environments it is normal to accept some small deviation from the nominal frequency.

The vast majority of power for industry is supplied by large rotating AC generators turning in synch with the frequency of the grid. The frequency of all these generators will be identical and is tied directly to the RPM of the generators themselves. If there is sufficient power in the generators then the frequency can be maintained at the desired rate (i.e. 50Hz or 60Hz depending on the locale).

An increase in the power load is accompanied by a concurrent increase in the power supplied to the generators, generally by the governors automatically opening a steam or gas inlet valve to supply more power to the turbine. However, if there is not sufficient power, even for a brief period of time, then generator RPM and the frequency drops.

By operating transformers at higher frequencies, they can be physically more compact because a given core is able to transfer more power without reaching saturation and fewer turns are needed to achieve the same impedance. However, properties such as core loss and conductor skin effect also increase with frequency. Aircraft and military equipment employ 400 Hz power supplies which reduce core and winding weight. Operation of a transformer at its designed voltage but at a higher frequency than intended will lead to reduced magnetizing current. At a lower frequency, the magnetizing current will increase. Operation of a transformer at other than its design frequency may require assessment of voltages, losses, and cooling to establish if safe operation is practical. For example, transformers may need to be equipped with ‘volts per hertz’ over-excitation relays to protect the transformer from overvoltage at higher than rated frequency.

Stiff voltage sources

Stiff voltage sources are not problematic as long as they don’t get in the way of the solver’s attempts to linearize the behavior of the circuit matrix via step size reduction. It is the highly nonlinear stiff sources that are heavily fed back into the rest of the circuitry that can cause the solver to hang. Linear sources that are ground referenced or nonlinear ones that don’t feed back anywhere are not likely to cause problems.

In the initial versions of SPICE there were a few elements that could not be simulated directly with nodal analysis in the circuit’s admittance matrix, ideal inductors and voltage sources being the most common among them. However, starting with some version of SPICE 2 this deficiency was removed when modified nodal analysis (MNA) was added to the simulation engine (requiring an additional computational enhancement sometimes called the auxiliary matrix, I believe).

Modified nodal analysis is an extension of nodal analysis which not only determines the circuit’s node voltages (as in classical nodal analysis), but also some branch currents. This permits the simulation engine to crunch ideal inductors and voltages sources (true Thevenin circuit elements) but at a cost of incrementally increasing the matrix size and difficultly about twice as much as for when “easy” Norton type elements (e.g., resistors, capacitors and current sources) are added.

In other words, adding one ideal inductor slows down the simulation about as much as adding two ideal capacitors. However, there is a small additional silver lining to this, as it also comes with the possible advantage of “free” (whether you use it or not) automatic sensing of instantaneous inductor current.

LTspice (my simulator of choice) treats inductors in a special way in that they are normally given a default series resistance of 1 m-ohm unless a value of zero is explicitly entered for that parameter. Having a non-zero series resistance allows LTspice to “Nortonize” the inductor such that it can be processed as a normal branch within the circuit matrix, thereby allowing the simulation to run marginally faster. This also makes the inductor “look” like any other of the “easy” elements so that it is not a numerical problem to parallel it with a stiff voltage source. If a series resistance parameter is entered for a voltage source, it also becomes Nortonized by LTspice.

Nortonizing an inductor or voltage source comes at the cost of giving up free sensing of the instantaneous branch current, which is not a cost at all if this current is not being used elsewhere. However, as soon as you call out the inductor current in *any way* in any b-source behavioral expression, LTspice changes the default series resistance for that inductor back to zero ohms and reverts back to the standard MNA way of processing it within the circuit matrix so that it can get access to the inductor’s instantaneous current.

Only true Thevenin type elements have the possibility of being used as the instantaneous current sense for a current controlled switch (or other similar current controlled devices). The SPICE standard is to only allow voltage sources for this purpose, but apparently LTspice accepts zero ohm inductors as well.

One last note, LTspice is indeed able to measure the current in any element, including Norton type devices, but for these devices the current measured will necessarily be a time delayed version that may not be suitable for tight feedback loops (there is a warning about this in the LTspice Help file section on b-sources).

Variable Frequency Drive Basics (Working Principle)

Variable Frequency Drive (VFD) Basic Configuration
The basic configuration of a variable frequency drive is as follows.
VFD Basic Configuration
Fig. 1 Basic configuration of variable frequency drive

Each part of a variable frequency drive has the following function.

Converter: Circuit to change the commercial AC power supply to the DC
Smoothing circuit: Circuit to smooth the pulsation included in the DC
Inverter: Circuit to change the DC to the AC with variable frequency
Control circuit: Circuit to mainly control the inverter part

Principle of Converter Operation
The converter part consists of the following parts as following figure shows:

Converter
Inrush current control circuit
Smoothing circuit

Fig. 2 Converter part

Method to create DC from AC (commercial) power supply
A converter is a device to create the DC from the AC power supply. See the basic principle with the single-phase AC as the simplest example. Fig. 3 shows the example of the method to convert the AC to the DC by utilizing a resistor for the load in place of a smoothing capacitor.

Fig. 3 Rectifying circuit

Diodes are used for the elements. These diodes let the current flow or not flow depending on the direction to which the voltage is applied as Fig. 4 shows.
Diode
Fig. 4 Diode

This diode nature allows the following: When the AC voltage is applied between A and B of the circuit shown in Fig. 3, the voltage is always applied to the load in the same direction shown in Table 1.

Table 1 Voltage applied to the load

That is to say, the AC is converted to the DC. (To convert the AC to the DC is generally called rectification.)

Fig. 5 (Continuous waveforms of the ones in Table 1)

For the three-phase AC input, combining six diodes to rectify all the waves of the AC power supply allows the output voltage as shown in Fig. 6.

Fig. 6 Converter part waveform

Input current waveform when capacitor is used as load
The principle of rectification is explained with a resistor. However, a smoothing capacity or is actually used for the load. If a smoothing capacitor is used, the input current waveforms become not sine waveforms but distorted waveforms shown in Fig. 7 since the AC voltage flows only when it surpasses the DC voltage.

Fig. 7 Principle of converter

Inrush current control circuit
The basic principle of rectification is explained with a resistor. However, a smoothing capacitor is actually used for the load. A capacitor has a nature to store electricity. At the moment when the voltage is applie

Different brushes at same ring

Recently I had to do a report explain why is impossible join brushes, at same time, from different companies, even with same characteristics.
I used the follow points:
1 – Even with same characteristics the final results is different because tue proportion of material and/or manufacturing process different lead to a different brushes;
2 – Guarantee, because our machine is new, and is a good practice use brushes recommended by Manufacturer;
3 – The film, that is formed on the rings by the brushes could change (but I don’t have any sure if chage for bad);

Unfortunately my report was based on experience for old engineer and recommendation of Manufacturer.

One
of the most important thing about brushes in high current density
environments is uniformity. If there are any variations in material
composition, manufacturing methods, dimensions, porosity, density,
surface hardness, friction coefficient, pig-tail attaching means, size
of pig-tail conductor, etc., there will be a variation in the current
division and/or wear.

Ultimately some brushes will carry more current than others and the increased current density in those brushes will lead to overheating, pitting, scoring, and ultimately costly repairs to the commutator/slip-rings. You might also accidentally mix brush grades when dealing with multiple vendors.

Although manufacturers publish data for brush materials which may prove to be very close to one another, mixing them on a collector surface is not a good practice. Any signs of undesirable performance would be difficult to identify the root cause for and small differences in electrical resistance can produce staggeringly varied performance from each brush.

While the materials used have good material data supplied with them, the manufacturing of the cable connection does not which can account for many times the resistivity differences of the material. Brush manufacturers do use a variety of materials here also and so some brushes, even of the same grade and from the same supplier but with different connection material, cannot be used together.

Mixing of grades is an uncontrolled practice which leads to variable surface conditions especially where the numbers of each grade used is not controlled.

Lower resistance brushes will “grab” the current possibly over filming the collector surface leaving the higher resistance brushes to run at lower than prescribed minimum current densities which results in higher coefficients of friction at the brush/collector interface. You would never know when your film is stable which endangers machine life.

Most machine manufacturers select a grade of carbon to use which is useful at the machines fully rated capacity. However, manufacturing tolerances, specifications etc can produce a machine vastly over rated for your application. Running the manufacturers supplied brushes at reduced load can be very damaging. Most Manufacturers will accept that you need another brush grade for your specific use and will maintain warranty provided they have been consulted regarding any changes.

Many overlook that by moving a machine from one position in their plant to another, that they well need to consider the brush grade at that time also. Sometimes a simple and cost effective reduction of brushes (of the same grade) within the machine can increase plant reliability and longevity dramatically. Other times a consultation with a brush expert can lead to an alternative grade to produce better performance.

The cause of harmonics in variable frequency drive

Before you attempt to dissipate causative factors of harmonics verbally, you take a look at several studies done by NEMA regarding such, and look into variable frequency drive (VFD) a bit better. You can view articles and studies by subscribing to the NEMA newsletter, and find other sources quite readily through NEMA. It’s an easily accessible place for many current dissertations on this and other electrical topics, with excellent subject matter.

Categorizing all VFDs into the same bucket doesn’t get it. You can also look at EPRI reports done better than 15 years ago on this and other VFD oriented subjects. Of course, all VFDs use Pulse Width Modulation to create the AC type wave form output (AKA ‘Sinusoidal Flows) and of course all have rectifiers at the top end, as do all computers, PLCs, and many solid state control components. The differences of transient creation on the outputs of variable frequency drives depend upon the quality of the wave form output. The more transients or ‘spikes’ in the wave form, the more disruption potential. The quality of outputs of variable frequency drives can clearly be seen in testing with oscilloscopes. Several VFDs on the market significantly reduce this effect with chokes up front, and on the output. It really is a garbage in/garbage out situation that lesser drives don’t bother to address.

Anytime AC is rectified to DC a field is created, and this is at best an elementary statement. The solution is good grounding to bleed it off. It isn’t a problem to do so as long as the grounding pathway is adequate, a simple and proven fix. All drives employ capacitors. Motor field generation, field collapse of any wound coil has the potential of creating conductive/inductive reactance, and capacitors create capacitive reactance. To claim otherwise flies in the face of electrical fact. Phase balancing capacitor banks serve to bring about the same effect. As far as ‘putting drives on a pedestal’, you seem far more inclined to pursue a defensive posture than to take a better look at the correlation between capacitive and inductive/conductive reactance. Again, when these two factors meet the same frequency is when the distortion issue is brought to a peak, with these harmonics becoming the face of disruption.

I successfully remedied these situations by working with engineers in DOD and DOE facilities, as well as with a host of different independent companies, Iacdrive, General Electric, Shaw Nuclear, being a few among them.

Renewable Energy in India

Holistic and Combined i.e Hybrid Renewable Energy Generation per Taluka / District of Each state with Energy Potential study with Investment seeking proposal with land (barren) identified with Revenue department clearances and also with a clear MAP of Evacuation with existing Transmission lines and future lines to planned, which shall be appended to RfP and not ask each developer to identify the location and struggle with Government Administration (which will increase time and Costs (read wrong costs)) complying to Land Acquisition bill and also eliminate the real estate babus to relinquish 5000 acres of land per state, which is BENAMI now…..I do not know how this excess land in BENAMI exist when we have Land ceiling Act!!

In order to do an extensive and credible study to explore renewable energy potential in each Taluka, State and Central Government Can hire international Consultancies with Video Documentation with GPRS MAPS to know the real truth and there shall not be much difference between reports and the ground reality, otherwise, hold these agencies responsible with necessary punitive clauses.

These costs can be recovered in the form of Bid document charges, which any serious developer will pay. However, the Equity selling proxy promoters, who have access to the power corridor and bid with Net worth Financial capacity, but, not worthy of any Renewable energy promotion as we saw in JNNSM wherein a large corporate bought equity from the other bidders and later an investigation took place…..

Following is the excerpts of the Mail written to MNRE and KREDL, in Jan 2012 (now we see their web site showing Biomass study is under progress):

For Power evacuation, we need to know the following (as we can’t use the existing data):

a). Distance from the Power generation site, which normally comes under KREDL (single window agency) i.e where one can put up the plant by undergoing NA or KREDL has identified land bank in Yadgir, but, how many km is the Substation from these sites, which we verified, was difficult to ascertain due to patch lands and the distance was over 10 km in certain cases.

b). Whether these substations can accept 20 MW or 10 MW or 5 MW of intermittent Solar PV load (non firm power which at times may create grid related disturbances etc). Biomass power is firm power as long as Firm biomass feed stock is available.

Therefore, we have been writing to many agencies involved to come out with a common approach, wherein the bidding documents identify clearly the SLDCs where the Project Developer can upload (evacuate) the energy generated with an in principle approval (with location MAP with transmission distances etc) from SLDC and ESCOM to accept such Renewable energy as the States are bound to buy the RE under RPO.

If the investor or RE Generator has to run around to know the fundamentals, then, please try to imagine how many man hours will be wasted and how much money gets drained from many participants for the same location? Instead, these data is available with KPTCL / KREDL / KERC / ESCOMs or such multiple organisation, but, Single window agency KREDL does not produce such VITAL information in their bid documents, hence, we as entrepreneurs are trying to tie the loose ends and make things happen for the good of our state.

I hope you understand our concern and append the finer details of evacuation, project site, land bank, the maximum capacity of MWh the substation can take or any upgrade is needed etc be appended in the bidding documents or even in your web sites also.

Further, any new substations are under development, the same with a clearly identified MAP with distances will help the people to understand the grid network to ensure the grid sustainability, reduction in transmission lines and hence the losses can be planned while making the bids, which otherwise will be a

Variable Frequency Drive Load Types

The potential for variable frequency drive (VFD) energy saving from slowing down the load depend on the characteristics of the load being driven. There are three main types of load: variable torque, constant torque and constant power.

Variable torque load
Variable torque loads are typical of centrifugal fans and pumps and have the largest energy saving potential controlled by variable frequency drives. They are governed by the Affinity Laws which describe the relationship between the speed and other variables.

The change in flow varies in proportion to the change in speed:

Q1/Q2 = (N1/N2)

The change in head (pressure) varies in proportion to the change in speed squared:

H1/H2 = (N1/N2)²

The change in power varies in proportion to the change in speed cubed:

P1/P2 = (N1/N2)³

Where Q = volumetric flow, H = head (pressure), P = power, N = speed (rpm)

The power – speed relationship is also referred to as the ‘Cube Law’. When controlling the flow by reducing the speed of the fan or pump a relatively small speed change will result in a large reduction in power absorbed.

Constant torque load
Typical constant torque applications controlled by variable frequency drives include conveyors, agitators, crushers, surface winders and positive displacement pumps and air compressors.

On constant torque loads the torque does not vary with speed and the power absorbed is directly proportional to the speed, this means that the power consumed will be in direct proportion to the useful work done, for example, a 50% speed reduction will result in 50% less power being consumed.

Although the variable frequency drive energy savings from speed reduction are not as large as that with variable torque loads, they are still worth investigating as halving the speed can halve the energy consumed.

Constant power load
On constant power loads the power absorbed is constant whilst the torque is inversely proportional to the speed. There are rarely any energy savings opportunities from a reduction in speed. Examples of constant power applications include center winders and machine tools.

Why designing an ethernet network IP scheme?

Depends on the size of the network (# of devices planned on connecting), for medium to large corporate networks go 10.x, for home and small business 192.168.x, or to 172.16.x. I would think the IP plan would be looking at least 10 – 20 years out. Changing IP schemes is hard, especially on a controls LAN, you wouldn’t want to undertake this task to frequently. Also consider any routing / firewalling / DMZing that you may want to do between the controls LAN and the business network (ideally these are separated networks).

Here’s some things to consider:

Number of devices or potential devices on the network
You may want to use a Class A subnet when you have or will have a large number of devices or a Class C when you have or will have a small number of devices.

Amount of traffic
A large subnet will more likely expose devices to more traffic. A smaller network may be employed to segment and/or control the amount of data that must be handled by a device.

Security
A large network (e.g., Class A) network may be more difficult to restrict access to or exposure of devices.

Simplicity
A Class A network is a flatter architecture and may be simpler to manage because you don’t have to worry about routing, gateways, and/or firewalls as much. This has to be balanced with security and traffic issues though.

Others
There are other considerations too…

In my experience, connecting with the “business” side of things is not technically difficult with an appropriate firewall/router. However, I have often found that the political challenges are more difficult. I have often butted heads with IT folks who have a fortress mentality and don’t understand the constraints, limitations, restrictions, and special considerations needed for industrial control systems. Many times, the best solution is to have a well defined line of demarcation where the IT folks take care of their side and the control guys take care of the control side. Most IT folks are OK with that as long as they can quarantine the control side to their satisfaction.

When it comes to selecting the firewall/router, you will need to take into consideration the protocols passing through it. If it’s the nominal business protocols like http, ftp, rdp, ssh, etc., then any business class device will typically work. However, if industrial protocols like CIP, Ethernet/IP, or OPC will be passing through, you will need to confirm that the firewall/router supports them specifically. When making the link, the important thing is the type of packet filtering and address translation rules that are configured in the firewall router. The IT folks might be more happy if they can setup a VLAN just for the controls.

The noise of variable frequency drive fed motors

The rotating electrical machines have basically three noise sources:

The ventilation system
The rolling bearings
Electromagnetic excitation

Bearings in perfect conditions produce practically despicable noise, in comparison with other sources of the noise emitted by the motor.

In motors fed by sinusoidal supply, especially those with reduced pole numbers (higher speeds), the main source of noise is the ventilation system. On the other hand, in motors of higher polarities and lower operation speeds often stands out the electromagnetic noise.

However, in variable frequency drive (VFD) systems, especially at low operating speeds when ventilation is reduced, the electromagnetically excited noise can be the main source of noise whatever the motor polarity, owing to the harmonic content of the voltage.
Higher switching frequencies tend to reduce the magnetically excited noise of the motor.

Criteria regarding the noise emitted by motors on variable frequency drive applications
Results of laboratory tests (4 point measurements accomplished in semi-anechoic acoustic chamber with the variable frequency drive out of the room) realized with several motors and variable frequency drives using different switching frequencies have shown that the three phase induction motors, when fed by VFDs and operating at base speed (typically 50 or 60 Hz), present and increment on the sound pressure level of 11 dB(A) at most.

Considerations about the noise of variable frequency drive fed motors

NEMA MG1 Part 30 – the sound level is dependent upon the construction of the motor, the number of poles, the pulse pattern and pulse frequency, and the fundamental frequency and resulting speed of the motor. The response frequencies of the driven equipment should also be considered. Sound levels produced thus will be higher than published values when operated above rated speed. At certain frequencies mechanical resonance or magnetic noise may cause a significant increase in sound levels, while a change in frequency and/or voltage may reduce the sound level. Experience has shown that (…) an increase of up to 5 to 15 dB(A) can occur at rated frequency in the case when motors are used with PWM controls. For other frequencies the noise levels may be higher.
IEC 60034-17 – due to harmonics the excitation mechanism for magnetic noise becomes more complex than for operation on a sinusoidal supply. (…) In particular, resonance may occur at some points in the speed range. (…) According to experience the increase at constant flux is likely to be in the range 1 to 15 dB(A).
IEC 60034-25 – the variable frequency drive and its function creates three variables which directly affect emitted noise: changes in rotational speed, which influence bearings and lubrication, ventilation and any other features that are affected by temperature changes; motor power supply frequency and harmonic content which have a large effect on the magnetic noise excited in the stator core and, to a lesser extent, on the bearing noise; and torsional oscillations due to the interaction of waves of different frequencies of the magnetic field in the motor air gap. (…) The increment of noise of motors supplied from PWM controlled variable frequency drives compared with the same motor supplied from a sinusoidal supply is relatively small (a few dB(A) only) when the switching frequency is above about 3 kHz. For lower switching frequencies, the noise increase may be tremendous (up to 15 dB(A) by experience). In some circumstances, it may be necessary to create “skip bands” in the operating speed range in order

Low impedance fault

A low impedance fault is usually a bolted fault, which is a short circuit. It allows a high amount of fault current to flow, and an upstream breaker or fuse usually senses the high current and operates, ending the event. A high impedance fault, usually an arc fault, is a fault of too high of an impedance for overcurrent protection to detect and operate, so the fault exists for long period of time without tripping upstream protection. Examples of arc faults are: A high or medium voltage distribution utility wire falling to earth in a Y grounded system and arcing to earth where no breaker or fuse will clear; another example is any fault tracking through a substance such as cable insulation or even air….this could be wiring within a building wall with a fault that lasts long enough to ignite the building wall it is installed in, which happens all the time somewhere (sometimes called “arc through char”). Another high impedance fault is one within a transformer secondary coil, arcing through the coil insulation and transformer oil (oil cooled units)…the arc will boil the oil into component gases such as acetylene and hydrogen and if the arc fault lasts long enough and gets to the gases, the gases may explode…and the primary fuse protection will likely not detect this for some time. There are many other examples of high impedance faults. One way to tell a high impedance fault or arc fault is if there is a protecting breaker or fuse that did not operate for a fault…if the breaker or fuse are correctly sized and working properly and did not operate that usually indicates a high impedance fault….a short circuit usually generates high enough current to trigger breaker/fuse operations (assuming normal circuit impedance is low). Another way to look at it is any fault in a power circuit with an impedance such that less than “available” fault current flows.