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PERFORMED BY: MIDWEST ELECTRICAL CONSULTANTS, INC 18055 UPLAND DRIVE TINLEY PARK, ILLINOIS 60487 (708) 444-0001 fax: 444-0003
www.midwestelectrical.com.
POWER QUALITY TESTING & INSPECTIONS OF TRANE AIR CONDITIONING COMPRESSOR(S) ELECTRICAL SERVICE
PROJECT: C822
D.J. Sweeney Electric 6813 Hopson Valley Drive Woodridge, Illinois 60517
May 5, 2008
Re: Power quality testing & inspections of Trane compressor(s) electrical service Attention: Mr. Timothy Sweeney, Enclosed is the engineering report detailing the project that we recently completed at the XYZ Corporation 100 Anyplace Drive Chicago, Illinois 60613. MEC is a full service independent testing company and appreciates the opportunity to provide your system review, inspection, power quality testing and engineering support services. Our mission is to provide an independent technical service to enhance the safety, reliability and efficiency of electrical systems. Thank you for the opportunity to provide this service. Please contact us if you have any questions or wish to know more about our services.
Respectfully Submitted,
Cc: Mr. William W. Baird - XYZ Corporation Cc: Mr. Robert Rogers - Advantage Electric Cc: Mr. Timothy Fashing - Roberts Mechanical
ENGINEERING REPORT XYZ Corporation 100 Anyplace Drive Chicago, Illinois 60613
SCOPE; PURPOSE; PROCEDURE; APPRAISAL AND RECOMMENDATIONS POWER QUALITY MONITORING DATA (separate file) ADDITIONAL TESTING SUPPORT DATA (separate file)
ENGINEERING REPORT XYZ Corporation 100 Anyplace Drive Chicago, Illinois 60613
Power Quality Testing & Inspections of Trane Compressor(s) Electrical service APPRAISAL AND RECOMMENDATIONS: The Trane Heli Rotor air conditioning compressor(s) system was found to be installed according to manufacture and electrical standard practices. A digital power recorder was installed at the local compressor(s) disconnect and allowed to monitor during multiple starts of the unit. Compressor(s) disconnect location (240 volt compressor) 1) Utility/system voltage levels were found to be imbalanced during the monitoring period (approximately 4.7%). Average voltage levels were found to be 236 volts on A-B, 247 volts on B-C, 245 volts on C-A. Voltage magnitudes were consistent during compressor(s) starts, indicating the system is not overloaded. MEC recommends review of the electrical service voltage levels with the utility to determine if the voltage imbalance is caused by service entrance equipment (transformer(s), cabling, connectors, etc.) or utility distribution (grid) system voltage deviation caused perhaps by loading or other issues. 2) Compressor(s) motor currents (amps) were found to be severely imbalanced at the main disconnect panel. Average current for each phase was 28.6 amps- Phase A, 46.3 amps - Phase B, and 54.7 amps - Phase C per motor. Load imbalances greater than 4% (91% during the monitoring period) would typically indicate an internal motor problem. Further investigation indicates a different problem exists at this location. Motor leads were moved to accommodate proper rotation at the compressor(s) control board. Upon restart of the compressor(s) with exchanged phasing, the voltage and current imbalances followed the same phases to different motor windings (See two attached files, section 2 power quality monitoring data, and section 3 additional testing support data). Investigation of the electrical service voltage levels is recommended. 3) Overhead transformers providing service for the facility were inspected for proper installation and operation. Inspection of the transformers indicate that transformer bank A (East) is currently or was previously overloaded. Localized discoloration and corrosion of transformer tank components (secondary bushings) generally indicates an overloaded condition. MEC recommends investigation of the electrical transformers by utility personnel. 5
4) Voltage magnitudes at the utility transformer secondary locations were found to be identical to the voltage levels measured at the compressor(s) disconnect location. Due to similar voltage readings, we recommend a review of the utility distribution system. 5) We recommend that an adequately sized dedicated power source (e.g. diesel or natural gas generator) be used to support the compressor(s) load to confirm the existing utility source issue, and run the equipment until the problem is corrected. APPRAISAL AND RECOMMENDATIONS: General 1) MEC recommends REGULAR ELECTRICAL INSPECTIONS, CLEANING AND TESTING of electrical equipment to assist in identifying deteriorated insulation, abnormal operating temperatures and malfunctioning protective devices prior to equipment failure. 2) All electrical protective equipment including ground fault relays, circuit breakers and fused disconnects should be tested, exercised and lubricated on a regular basis. Mechanical equipment may not operate properly when called upon if regular maintenance is neglected. 3) New OSHA requirements have been issued regarding Arc Flash recommendations and personnel safety. New Arc Flash requirements will require all facilities (industrial, commercial, institutional) to display information about the arc flash availability at each panel, switch or breaker where the equipment is accessible by maintenance/site personnel. The arc flash information on the panel fronts will indicate the level of clothing and level of training required to open and maintain the equipment within the panel or switchboard. See note #2 above; protective equipment which does not operate within specified tolerances (tripping time or magnitudes) will invalidate any Arc flash study results. 4) Transient voltage surge suppressor (tvss) units were not evident on any of the electrical distribution equipment we inspected or tested at. We recommend the installation of a properly sized high quality tvss unit on the main electrical switchboard. The main tvss unit will mitigate or remove any and all transient voltage spike and surge disturbances caused externally to the building (lightning, electrical storms, downed power lines, utility company switching, high winds, tree branches, ice/snow on utility lines and distribution equipment, other utility customers in close proximity, etc.) Also secondary sub panel or final point of protection tvss units should be installed on or at ALL critical equipment especially electronic loads (fire alarm, security, telephone, roof hvac, elevators, etc.) to address or clamp internally generated switching transient/surge events created by all electrical and electronic equipment being turned off and on or duty cycled within the building. The secondary level of protection would also act as back up protection should the primary tvss unit become damaged or sacrificial. 6
All plug in or corded electronic equipment (pcs, monitors, printers, modems, Fax, etc.) should be plugged into a quality corded power strip tvss unit. I would direct your attention to the documentation I left with you for a more detailed explanation on this subject. We would be happy to provide any engineering assistance in the selection or installation of any of the transient voltage surge suppressors outlined in this report.
delta setup #2 Trane compressor(s) service disconnect Three phase delta Unknown 04/29/08 11:06:38 240 Volts 60 Hz
Report Parameters
This report was prepared on 4/29/2008 by Midwest Electrical Consultants, Inc. 18055 Upland Drive Tinley Park, Illinois 60487 (708) 444-0001 fax: 444-0003 www.midwestelectrical.com The following limits were used in analyzing the results. Maximum Phase Voltage. Minimum Phase Voltage. Maximum Impulse Voltage. Maximum. Waveshape Voltage. Maximum Frequency Deviation. Minimum Power Factor. Maximum Voltage T.H.D. Maximum Current T.H.D Maximum Voltage Imbalance. Maximum Current Imbalance. 254 volts 208 volts 500 volts 10 volts .02 Hz .85 5% 20 % 2% 5%
Any values outside these limits are noted in the report. Values within the limits are considered to be within a safe operating range. These limits have been programmed by Midwest Electrical Consultants, Inc.
Value
229.2V 235.8V 240.4V 240.3V 247.2V 255.3V 239.5V 245.1V 252.2V
RMS. Currents
Phase A minimum Phase A average Phase A maximum Phase B minimum Phase B average Phase B maximum Phase C minimum Phase C average Phase C maximum
Value
549.3mA 11.93A 380.3A 3.662A 20.53A 487.2A 1.098A 23.14A 343.5A
Frequency
Phase A minimum Phase A average Phase A maximum Phase B minimum Phase B average Phase B maximum Phase C minimum Phase C average Phase C maximum
Value
42.12Hz 43.61Hz 44.69Hz 42.12Hz 43.61Hz 44.69Hz 42.12Hz 43.61Hz 44.69Hz
RMS. Voltage Summaries for XYZ Coporation:delta setup#2. Phase A Voltage Summary.
RMS. Current Summaries for XYZ Coporation:delta setup#2. Phase A Current Summary.
Value
2.83% 3.388% 5.68% 2.55% 3.039% 4.83% 2.95% 3.523% 5.38%
Current Distortion
Phase A minimum Phase A average Phase A maximum Phase B minimum Phase B average Phase B maximum Phase C minimum Phase C average Phase C maximum
Value
4.81% 34.15% 67.92% 4.06% 121.5% 308.2% 3.8% 30.55% 143.9%
Voltage Flicker
Phase A minimum Phase A average Phase A maximum Phase B minimum Phase B average Phase B maximum Phase C minimum Phase C average Phase C maximum
Value
N/A N/A N/A N/A N/A N/A N/A N/A N/A
10
Voltage T.H.D. Summaries for XYZ Coporation:delta setup#2 . Phase A Voltage Distortion.
11
12
13
14
15
16
Power Summaries
Power measurements for XYZ Coporation:delta setup#2 from 04/29/08 11:16:18 through 04/29/08 11:31:18. Imbalance
Minimum Voltage Imbalance Average Voltage Imbalance Maximum Voltage Imbalance Minimum Current Imbalance Average Current Imbalance Maximum Current Imbalance
Value
2.68% 2.840% 3.37% 2.17% 48.58% 154.8%
VA Power
Phase A minimum Phase A average Phase A maximum Phase B minimum Phase B average Phase B maximum Phase C minimum Phase C average Phase C maximum Total minimum Total average Total maximum
Value
97.69VA 1.660kVA 51.31kVA 512.7VA 2.868kVA 65.88kVA 179.5VA 3.346kVA 48.39kVA 925.0VA 7.874kVA 77.57kVA
VARS Power
Phase A minimum Phase A average Phase A maximum Phase B minimum Phase B average Phase B maximum Phase C minimum Phase C average Phase C maximum Total minimum Total average Total maximum
Value
-3.482kVAR 1.457kVAR 49.95kVAR -4.439kVAR 1.475kVAR 26.88kVAR -13.10kVAR 2.845kVAR 46.66kVAR -3.962kVAR 5.777kVAR 68.11kVAR
17
Watts Power
Phase A minimum Phase A average Phase A maximum Phase B minimum Phase B average Phase B maximum Phase C minimum Phase C average Phase C maximum Total minimum Total average Total maximum
Value
-11.75kW 737.8W 15.35kW -97.99W 2.118kW 19.78kW -3.091kW 1.706kW 20.38kW -98.06W 4.563kW 36.85kW
Demand Power
Phase A minimum Phase A average Phase A maximum Phase B minimum Phase B average Phase B maximum Phase C minimum Phase C average Phase C maximum Total minimum Total average Total maximum
Value
645.8W 707.4W 788.7W 1.806kW 1.982kW 2.214kW 1.434kW 1.570kW 1.750kW 3.887kW 4.260kW 4.753kW
Power Factor
Phase A minimum Phase A average Phase A maximum Phase B minimum Phase B average Phase B maximum Phase C minimum Phase C average Phase C maximum Total minimum Total average Total maximum
Value
0.968 Lead 0.271 Lag 0.000 Lag 0.000 Lead 0.608 Lag 0.004 Lag 0.003 Lead 0.344 Lag 0.000 Lag 0.861 0.270 0
18
19
20
21
Phase B VA Summary.
22
Phase C VA Summary.
23
Total VA Summary.
24
VARS Power Summaries for XYZ Coporation:delta setup#2. Phase A VARS Summary.
25
26
27
28
WATTS Power Summaries for XYZ Coporation:delta setup#2. Phase A Watts Summary.
Min.
-11.75kW
737.8W
Max. 15.35kW
29
30
31
32
Power Factor Summaries for XYZ Coporation:delta setup#2. Phase A Power Factor Summary.
0.968 Lead Apr 29 2008 11:19:49 0.271 Lag 0.000 Lag Apr 29 2008 11:21:22
33
0.000 Lead Apr 29 2008 11:21:22 0.608 Lag 0.004 Lag Apr 29 2008 11:17:46
34
0.003 Lead Apr 29 2008 11:16:43 0.344 Lag 0.000 Lag Apr 29 2008 11:16:43
35
0.861 0.270 0
36
MIDWEST ELECTRICAL CONSULTANTS, INC. 18055 UPLAND DRIVE TINLEY PARK, ILLINOIS 60487 (708) 444-0001 fax: 444-0003
www.midwestelectrical.com
SECTION 3
Trane Heli Rotor compressor motor power supply testing : Tests performed during the monitoring period at the XYZ Coporation 100 Anyplace Drive Chicago, Illinois 60613, consisted of rotation of the phases to test the compressor(s) equipment for problems. Amperage readings are taken on each phase, then the phases are rotated and a second set of amperage readings are taken. Comparing the two sets of readings indicates if the problem is located in the motor or power supply system. The following example in figures 1 and 2 illustrates the procedure per motor: Step 1: Measure all three legs A phase - 28.6 amps B phase - 46.3 amps C phase - 54.7 amps
Figure 1
Page 2
Figure 2
Step 3: Measure amperages again C phase - 54.7 amps A phase - 28.6 amps B phase - 46.3 amps Notice that the amperages rotated with the wires. This indicates the problem lies within the utility electrical supply to the facility, had the amperages remained with the motor windings when the wires were rotated, the problem would have been in the motor windings.
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