Knowledge is Power LOAD Sizing Phase II

Course Objectives At the end of this program, you will be able to Understand DG sizing methodology and utilize the procedure in day to day activities. Use the calculator and arrive at DG size for a given load list. Appreciate the severity of Non Linear Loads Appreciate the importance of its impact on DG sets and need for in depth study and Analysis for DG sizing

How do we intend to space the time !!!!

Objective Understand DG sizing Methodology DG Sizing Exercise Non Linear Load Charecteristics

No of Slides

Time mins

Program is structured to ensure that the participants actually size the DG set, Right First Time in this training program itself !!!!!

Size to Fit

Contents
RECAP OF DG SIZING KIP I DG SIZING EXERCISE NON LINEAR LOAD CHARACTERISTICS

Contents
NOT COVERED IN THIS SECTION ARE Size to Fit DEFINITION AND DISCUSSIONS ON ELECTRICAL PARAMETERS VOLTAGE, CURRENT, POWER FACTOR SWITCHGEAR SELECTION PARALLELING SCHEMES. PROTECTION SCHEME COMPLICATED UNBALANCED NON LINEAR LOAD ANALYSIS AND DG SIZING FOR SUCH APPLICATIONS.

Partly Covered in Controls

Size to Fit

RECAP OF DG SIZING KIP I

DG

Load

Load

DG

MATCH THE LOAD AND DG

Importance of DG Sizing
It enables Selection of Right DG for the load from our range of products. Assist customer to optimize his investment. Ensure optimum loading on the DG set thus enhances performance and improves fuel efficiency. It eliminates customer irritation due to mismatched DG set. Provide competitive advantage Finally a DELIGHTED CUSTOMER

Objective 2 and 3 KIP I Recap

Understand different loads Operating in the industry. Know Parameters of loads to be considered for DG sizing.

Voltage to other circuits and the pollution circulates

Non Linear Load

Linear Voltage applied Non Linear Loads draw non linear Current From a linear source

IHarmo

Loads and their Characteristics

Industrial Load

Non Linear Linear Motor Loads Lighting Loads Resistive Loads Furnace UPS Computers Invertors Rectifiers VFDs Regenerative Welding

Loads and their Characteristics

Industrial Load

Motor Loads

Single Phase

Three Phase

Loads and their Characteristics Starting Methods

Direct On line Start ( DOL ) Auto Transformer Start Rotor Resistance Start Reactance Start Star Delta Start Variable Frequency Drives

Starting Method is critical to understand the start kVA and also affects the Voltage dip during starting. This voltage dip will affect other loads.

Loads and their Characteristics

Impact of start kVA and PF due to starting methods

There are several methods available for starting threephase motors. Emphirical Multiplying Factors are as below.

DOL Starting : 6 times rated kVA Star Delta Starting : 2.75 / 3 time rated kVA Auto Transformer Starting : DOL start KVA X ( %Tap)2 You will use this multiplication factors in the DG sizing Exercise

Load Types and Characteristics

Load Types and Characteristics

SinglePhase Motor Design
Nominal std. values for single phase induction motors

SinglePhase Motor Defaults: EFF, SPF, RPF

Loads and their Characteristics

Loads and their Characteristics Industrial Load

Non Linear Furnace UPS Computers Invertors Rectifiers VFDs Regenerative Welding

Loads and their Characteristics

Uninterruptible Power Supply Loads: Research indicates that the alternator needs to be oversized as follows:
For 3 pulse: GkW = 2.50 x RkW, or 1.4 x RkW if equipped with harmonic input filter For 6 pulse: GkW = 1.40 x RkW, or 1.15 x RkW if equipped with harmonic input filter For 12 pulse: GkW = 1.15 x RkW, or 1.15 x RkW if equipped with harmonic input filter

For UPS loads you may assume RPF = 0.9, SPF = 0.9 and EFF = 0.9.

Loads and their Characteristics

Battery Charger Loads: A battery charger is a silicon-controlled rectifier (SCR) assembly used to charge batteries. A battery charger is a non-linear load requiring an oversized alternator.

Loads and their Characteristics Battery Charger Loads: Research indicates that the alternator needs to be oversized as follows: For 3 pulse: GkW = 2.50 x RkW For 6 pulse: GkW = 1.40 x RkW For 12 pulse: GkW = 1.15 x RkW

For battery charger loads GenSize 96 assumes RPF = 0.9, SPF = 0.9 and EFF = 0.9.

Loads and their Characteristics

Regenerative Loads: Examples : Elevators, cranes and hoists Excessive regenerative load can cause a generator set to overspeed and shut down due to overspeed protection. Applications that are most susceptible to this type of problem are small buildings where the elevator is the major load on the DG. Harbor Cranes are other example.

Loads and their Characteristics

Regenerative Loads: Generally, the regeneration problem can be solved by making sure there are other connected loads which can absorb the regenerative power. For example, in the building with the elevator, transfer the lighting load to the generator first before transferring the elevator. Occasionally an auxiliary load bank with load bank controls is needed to make sure that the regenerative power is absorbed without affecting DG Set.

Readings are in milliseconds..

Under regenerative Conditions Overvoltage relay trips,Reverse Power Relay trips Engine Speed goes up, Freq Shoots up.

kW negative ,Engine Speed Raises, Voltage Raises, pf goes to leading Under regenerative load conditions.

Loads and their Characteristics

Regenerative Loads: Generally reverse power protection is provided for parallel operation. Regenerative power is sort of reverse power for a DG. Do you need a reverse power protection for a solo running DG powering Regenerative Load ???? Yes. It is safe to have reverse power protection for even solo DG for such application. How much regenerative power a DG can take without overspeeding ???? 5% of rated kW.

Understand DG sizing methodology and utilize the procedure in day to day activities.

Size to Fit

DG SIZING EXERCISE

DG Sizing Methodology

Having gone through the load characteristics we will now move on to DG sizing

DG Sizing Methodology The sized DG should be capable of meeting the following conditions 1. To be able to meet the single step kW and kVA loading 2. To maintain the allowable voltage and frequency dips during step loading conditions 3. To operate at a load factor of 80 -90 % of its kW capacity.

DG Sizing Methodology

The sized DG should be capable meeting the following conditions 4. To meet the non linear load content without any problem. 5. To deliver reliable power under stated site conditions like ambient temp, Humidity, altitude 6. To operate at a rated power factor as specified by the alternator manufacturers.

DG Sizing Methodology

Most importantly the DG should be installed to specifications ( Please refer installation guidelines provided by Cummins India Limited).

DG Sizing Exercise This example is based on a load list given by a customer prospect and hence is a real life situation. All of you are given a load list in hard copy. DG Sizing Calculator has been loaded in your computer Desk Top. We need to size the DG for the given load list using the calculator. All you need to do is to enter the load particulars and at the end, DG sizing will be given by the calculator.

DG Sizing Exercise

DG Sizing Calculator.xls

Size to Fit

NON LINEAR LOAD CHARACTERISTICS

Non Linear Load Characteristics Understand the Hidden Depth Understand the Hidden Depth

In the forthcoming slides we will show you the hidden depth of non linear loads

Load Characteristics

Load characteristics of the following non linear loads are presented in the forthcoming slides for reference 1. Welding Seam Welding Spot Welding Hermitic Welding Butt Welding 2. 3. 4. 5. 6. Furnace VFD UPS Injection Moulding Wire drawing Machines

These peaks appear for 20 ms

Hermitic Welding Load Waveforms

About 20 % of Line Current is Harmonic current

Unbalanced Seam Welding Loading Pattern

Maximum recorded kVA 385

Unbalanced Seam Welding Waveforms

This is Unbalanced BUTT WELDING LOAD WAVEFORM

Unbalanced Spot Welding Waveforms

Loading Pattern of Inductotherm Furnace

Maximum recorded kVA 2800

This is a Inductotherm furnace load waveform

Furnace Load Impact on PF

Note: PF drops to near zero in one phase calling for unbalanced phase to Phase cycle to cycle compensation

Furnace Waveforms

Injection Moulding Machines Waveforms

Waveforms of Wire Drawing Machines

The impact:

Notching observed probably due to Thryristerised Switching of microprocessors

UPS Loading Pattern

UPS Harmonics Peaks

Current Harmonic Spikes repeat at regular short intervals

Charging of Transformer using DG SETS Some times you may have to use 415 v DG set to charge a Transformer, to step up the voltage to 11 kV. General Thumb rule could be Size the DG, at least two times the rating of the transformer i.e for charging 1000 kVA Transformer you need 1 x 2000 kVA DG set. It is at best an approximation only.

Hope you enjoyed the session. Thank You