Category: Blog

AQ: What is the Reactive Power?

For a “physical” interpretation, reactive current (power/KVA flow), in my opinion is best looked at from the perspective of a generator connected directly to an infinite bus (in LV generators this is the norm).

The generator when connected to the system, “see’s/feels” the parallel impedance combination of all other generators (circa 3 ohms each) with respect to ground – which basically parallel to equate to a zero impedance in terms of restriction to any current flow out of our generator.

Post initial synchronization, the system voltage prevents currents from flowing into or out of the generator due to pressure (voltage) balance of our generator matching that of the system voltage.

If you (as the generator operator), try to lift the generator voltage, the result will only be heaps of current output flowing into the system – but with no actual extra power generated!

This is due to the fact that to achieve the extra generator voltage setpoint you desired, the generator must send out enough current into the system impedance to create the back emf required to achieve the new desired generator terminal voltage setpoint.

But because the system impedance to ground is very low (as it actually is) – then despite the extra current sent out in that fruitless attempt, the generator is near impotent to make any substantial effect on raising the “system” voltage – “fruitless” current sent out.

In a DC sense you can equate this to a small DC generator trying to lift the voltage of a load system that has a zener diode installed across that system load.

Back to the AC world, ….that current sent out in the fruitless attempt to lift system voltage must flow through the parallel low impedance of the other connected generators (each of those working against you – lowering their own generator excitation, hell bent on keeping their own same old voltage set points), thwarting our futile attempt to achieve a raise in the system voltage.

All those generators, although collectively of low impedance, compose virtually no resistance, compared to their inductive reactance. Hence all our little generators current flow – in its futile attempt to lift system volts – is virtually purely inductive.

So we have heaps of current flowing out in our attempt to lift generator volts, but because the current is 90 degrees lagging the voltage, the only power imposed on the generator prime mover is that due to the resistance of the generator windings (circa 1% of the full load current rating – hence basically un-noticeable).

Hence the physical interpretation of VAR’s, is actually simply a look at the voltage balance perspective of an electricity network. It’s the collective attempt of many parallel-connected generators to influence the system voltage – either trying to raise the voltage at a particular node (positive VAR’s) or trying to reduce the voltage at a particular node (negative VAR’s flowing back through our generator due to our attempt to lower our generator setpoint – which “lets current in”).

Reactive Power is an electrical parameter that exist in a sinusoidal (AC circuits). It maybe zero or a certain magnitude. It maybe capacitive in nature or it maybe inductive nature. In the power triangle, it is the vertical power component (plus or minus / capacitive or reactive). It may be supplied from power sending end (grid or generator) on from the power receiving end (load). A capacitor bank connected on the grid provides capacitive reactive power. An inductor bank connected on the grid provides inductive reactive power. Both of them have magnitude. Reactive power also influences the between phase angle displacement between the voltage and the current. It is power but reactive power.

AQ: Is frequency inverter better than soft starter in motor control?

There are hundreds of applications for a frequency inverter. I use them on a pump to test pumps with voltages from 208-600VAC 3PH 50 and 60 HZ. You just have to size the frequency inverter to the largest 208 HP motor, so it can handle the current. Many people are installing them on pumps, fans and air compressors to get the energy savings of lowering the speed on the motor to maintain the pressure, temperature and flow. Frequency inverters also have the ability to ride through power dips, since the DC bus to store in a capacitor bank.

It is correct the frequency inverter will reduce the staring current of and induction Motor, but as all of you know that the motor have to drive a load the starting torque is related to starting current, also the main role of frequency inverter is to control the speed.
The starting current is related to the rotor conductor structure or classes because we can get direct starting currents within 1.5-4 times the full load depend on the squirrel cage design or construction.

The effect is, that at the reduced frequency during start, the full torque can still be developed at nominal current. As soon as the frequency hits the nominal slip frequency, the nominal torque will also be developed, at nominal full-load current. (The slip frequency is the nominal frequency multiplied by the full load slip percentage, i.e. around 2.5Hz for a 50Hz motor with a full load slip of 5%).

It really depends on the application. If you are only interested in starting current, then soft start is what you need.

AQ: Circuit Breakers tests

1- For small circuit breakers we can do the test of Magnetic protection behavior by using “Injection Current Apparatus”, and suppose the CB’s results were good, do you think it’s enough? I’m sure not, because by this apparatus we can inject the necessary current with a very low voltage value (5-15V), so, do you think that the arc will be the same if we have the same current but with “400V”?

2- The same question for “Short Circuit Tests”

Personally, I done the tests of many MCBs for different manufactures by using “Injection Current Apparatus”, and I saw the same tests in laboratory in France for the same MCBs by injection the same currents values with 230V or 400V depending on the CB, be sure, the results weren’t the same, we found some differences for Magnetic protection tests, and big differences for Short Circuit tests.

AQ: How to select a breaker?

Before breaker’s selecting for your electrical system, you need to calculate value of expected short circuit current at the place of breaker’s installation. Then you need to calculate value of heat pulse and 1s current (expected value of current during one second). After that you need to calculate power of breaker and finally, after all, you can select appropriate breaker. Values of characteristics of selected breaker need to be higher from calculated values of characteristics of your power system.

You can calculate operational current of breaker using this expression:

Inp=SnT/((sqrt(3))*Un)

After that, you need to calculate expected value of surge current:

kud=1+e(-0,01/Tae)
Iud=(sqrt(2))*kud*I’

After that, you need to calculate expected value of heat impulse:

A=(sqr(I0″))*Tae*(1-e(-2*ti/Tae))+(sqr(I’))*(ti+Td”)

And finally, you need to calculate 1s current (expected value of current during 1s):

I1s=sqrt(A/1s)

So, current of interruption of your breaker and power of interruption of your breaker are:

Ii=I’
Si=(sqrt(3))*Un*Ii

Additional expressions that you can use during your calculation:

I0″=Un/((sqrt(3))*Ze”);
I”=1,1*Un/((sqrt(3))*Ze”);
I’=1,15*Un/((sqrt(3))*Ze’);

where are:

ti-time of interruption
Inp-operational current of breaker
SnT-rated power of transformer
Un-rated voltage
kud-surge coefficient
Tae-time constant of aperiodic component of short circuit current
Iud-surge current
A-heat impulse
I0″-short circuit current in subtransient period (generators are in no-load conditions)
I’-short circuit current in transient period
Td”-time constant of subtransient component of short circuit current
I1s-current during one second
Ii=expected value of current of interruption of your breaker
Si=expected value of power of interruption of your breaker
Ze”-equivalent impedance of power system in the place of fault (subtransient period)
I”-short circuit current in subtransient period (generators are in full-load conditions)
I’-short circuit current in transient period
Ze’-equivalent impedanse of power system in the place of fault (transient period)

For a branch circuit feeding a single pump, you would generally size the circuit at 125% of the pump’s full-load amperage. If you’re not using a variable frequency drive or soft starter (which have built-in overload protection), you would use a Motor-circuit protector (MCP) breaker that has both thermal and magnetic trip capability. Sizing would be according the breaker manufacturer’s recommendations for a motor of a given horsepower, but not larger than would be required to protect the circuit conductors.

“The total load of an area” is much too ambiguous to answer. If you have lighting and receptacles, you’re going to need a different type of breaker than if you have motors or mixed types of load. There is no general approach. Circuit breaker types are very specific to the application.

Safety should not be taken lightly. Installing the wrong type of breaker could result in equipment damage and/or physical harm.

There are instantaneous breakers as well as time delay breakers. For time delay breaker, for example, you go 250% maximum of the rated current based upon the HP of a motor (look in the NEC), not on the nameplate label. The nameplate current value is for overload protection. Also try to size the breaker so that the conductors are protected.

As we kn

AQ: Motor line starting and ramp starting with VFD

Variable frequency drives are important power electronic devices. When we start an electric motor, we are increasing from 0 speed to full operating speed. A VFD ensures that the motor accelerates (increases its speed) to its full speed in a smooth manner, without causing much irregularities. In other words, VFDs make the motor accelerate uniformly.
VFDs are also easy to install and use. VFD drives are not only for starting motors (like the normal starters), but for easy speed control as well.

The difference between line starting a motor and ramp starting the motor with a variable frequency drive is that the motor/load does not pull the 6-7 times rated current of the motor, because the motor winding are not saturated with the full EMF produced to get the motor to synchronous speed it is ramped to it. If you are not trying to control the motors speed from process control then a soft start will serve the same purpose. The VFD drive main purpose is to control the V/F of the motor.

You will have to adjust the ramp time on the VFD or soft starter to over the force required to turn whatever the motor is turning, this can be accomplished with both devices. Soft starter is less expensive than variable frequency drive, thus it has limitations.

AQ: Difference between ICCB, MCCB and MCB

The aforementioned types of Circuit Breakers are used in LV System and generally based on the same operating principle.
MCB and MCCB/ICCB have a bimetal heater for overload which releases the Contact s while for short circuit the trip / electromagnet hammers itself against moving contacts. The arc created by breaking contacts is extinguished in an arc chamber. Are defined as “Thermo-magnetic “ CBs , accordingly. It is operating characteristic addressing the overload by thermal action of the bimetal strip and instantaneously dealing with short circuit occurrences by electromagnetic action.

MCB – Miniature Circuit Breaker is suitable for domestic usage. Used to protect final circuits from O/C such as Overload & Short Circuit.
i- MCB is basically made in accordance to BS 3871, is now superseded by BS EN 60898 which recognizes type B, C & D.
Type B is suitable in domestic premises.
Type C is used in commercial & industrial applications.
Type D is suitable for application where a high in-rush current is expected.
ii- MCB is of low breaking / making capacity as well as low current rating compared with MCCB/ICCB. MCBs available in different number of poles (SP, DP, TP,,).

MCCB – Molded Case Circuit Breaker & Insulated Case Circuit breaker are also current limiting devices but with high making/ breaking capacity and current ratings compared with MCB. MCCB and ICCB are almost the same and both are manufactured in accordance to NEMA AB1/AB3 to suit industrial and commercial purposes.
The advent of electronic protection increased the use of them and the scope is widened like tolerances, range of time & current adjustment. By virtue of that a good discrimination can be achieved with accuracy about ±10%.
Eventually, MCCB/ICCB has advantages in the capability of accommodating further features which can be provided as
i. RCD.
ii. Under voltage device.
iii. A shunt trip coils that enabling remote tripping.
iv. Auxiliary switches for remote monitoring and/or control.

AQ: VFD PWM and PAM definition

PWM is shorted for Pulse Width Modulation, it’s a variable frequency drive (VFD) regulate way to change the pulse width according to certain rules to adjust the output volume and waveform.

PAM is shorted for Pulse Amplitude Modulation, it’s to change the pulse amplitude according to certain rules pulse amplitude pulse train to adjust the variable frequency drive output volume and waveform.

AQ: Can a VFD reduces motor starting kick?

At zero speed the motor requires torque which is flux (voltage) and current (mostly reactive). Only a little bit of active current to compensate for the motor power losses.
Only the power losses need to be drawn from the grid at that time, which means a very small amount of current. It may produce 200% current on the motor and pull only 10% current from the grid.

Of course, as the motor is accelerating, the motor will require kW and the current pulled from the grid will increase accordingly, as the active power consumed by the motor is increasing.

Regarding the kick of torque on the motor, it is controlled by the maximum current ramp limit or through the speed reference as the ramp rate defines the current and the derivative of that rate is the current rate. For this reason, many large machines will be started using an S-Curve speed reference where the S part will adjust the torque (current) rate to avoid stressing the mechanical components, especially if there is mechanical backlash in the gears.

Actually the starting method depends on the type of motor itself SR or SQ type the voltage supply, the motor capacity and motor function, for the MV Motor a liquid or oil starter was the best solution used before.

In case the operation process required a change in the equipment speed the variable frequency drive (Air or water-cooling) based on the drive capacity is the optimum and reliable solution.

Definitely it reduces starting kick of the motor. Actually, the degree of starting kick of a motor is depending upon the starting speed of the motor. If you start your motor at low speed you will have a low starting kick but if started at high speed, you will have high starting kick. This is generally the condition for low and high kw motors. One factors of varying the speed of motors is by varying the frequency of the motors (from the formula N=120f/p) and VFD drive is use to vary the frequency, thus varying the speed of the motors. But if used for starting only, this is expensive as there is more cheaper way like using the Soft Starter or use a WRIM/Slip-ring motors with LRH/Resistor Starters or other. Normally, variable frequency drive is use on operation with speed reduction/varying requirements at required number of time or continuously.

AQ: Why transformer rating is shown in KVA?

Transformers are rated in {VA, kVA, MVA etc.} due to flows of active and reactive power through transformer. In case of transformer we have active power losses as consequence of existence inside resistance of windings (primary and secondary) and existence of active losses of ferromagnetic core and other side we have reactive power losses as consequence of existence losses of magnetic flux (primary and secondary) and existence of reactive power losses of ferromagnetic core.

[VA]=sqrt(sqr[W]+sqr[VAr])

Transformer is rated in kVA by the manufacturer to inform users about the maximum power (voltage and current) that support it, the reason for not rating it in KW is that the active power (kW) is depend on the loads (lighting, machines..)

The simple answer is: It is because the kVA (or MVA) rating is only rating that matters to express a transformer’s “capacity” to allow the “passage” of power. That capacity is the thermal capacity dictated by the current it can carry at a given ambient temperature, regardless of the power factor. So combined with its voltage ratings, kVA (or MVA) is the value that matters. kW rating does not matter as transformer can handle unity power factor or in other words, a transformer can handle kW equal to its kVA rating at any time.

Remember that a transformer, as the name suggests, is only a transformation device or a pass through device and not a power producing device like a generator or an UPS, where their capacity to produce real power (kW) is an independent limit from the thermal ( kVA) limit.

To take it a step further, if you have an ability to cool the transformer further, you can augment the kVA (or MVA) rating of a transformer. This would explain having multiple kVA/ MVA ratings on transformers with forced cooling aids installed on them.

If you think of it, this is not different from a cable or a conductor’s capacity expression. Except that a transformer can have more than one voltage levels and different ampacities on primary and secondary, but the kVA rating remains the same on either side. So that makes kVA a more convenient way to express its thermal capacity vs. the amperes alone.

AQ: Variable frequency drive key functions

Soft Starter, Auto Transformer, Electrolyte, series resistance – wound rotor- etc,). The starting factor of VFD drive is usually 1 up to 1.2 with respect to the rated load current while for Direct On line about 5-6.

Moreover and as you know the variable frequency drive can control the speed of the AC motors in accordance to the formula N=120f/P rpm
where f = the supply frequency and P = number of the Poles.
According to this formula, Motor Speed can be changed either by changing/control the frequency or by changing the number of Poles of the Motor by which step changed in the RPM will be given, while the former gives continuous variable speed as per application demand.

However, as per newly developed power Semi Conductor IGCT based on PWM VFD became the most smart, effective and efficient control device in Industries since is associated also with protective and monitoring means.

From my experience, I know that variable frequency drive plays around with the frequency which the motor operates. It starts at low speed and varies the frequency to attain maximum speed. This reduces the high starting torque usually experienced when motors are started on DOL, Star/Delta etc. When you are driving delicate materials through your conveyors or pumping liquid through pipes etc., VFD plays a useful role. It reduces hammering in pipes usually experienced when using DOL. In large hotel application, variable frequency drive could be used with pressure switches to regulate water flow and reduce hammering when guests are showing. The volume of water required will determine the speed at which the motor runs through VFD control. However, very large KW motors at high voltage level are usually started DOL due to the cost of ac drive but that is when one has enough (power) capacity otherwise it will impact on other users in the network.