Electrical Power Engineering Reference & Applications Handbook

Electrical Power Engineering Reference & Applications Handbook

K. C. Agrawal
B.Sc. (Engg.) Electrical, Senior Member IEEE, USA, Industrialist and Consultant

Copyright Page

Copyright 2007 by K.C. Agrawal

Dedicated
to my parents with

A Guilt of Neglect
Had I cared them a little more, Had I loved them a little more! My loving parents have gone, And so goes my heart! The memories would stay and So will the Guilt.

K. C. Agrawal

Contents
Preface to this edition Preface to the first edition Acknowledgements Technical support Introduction xi xv xvii xix xxiii

5 Starting and control of slip-ring induction motors

95

Part I Electric motors, drives and energy saving 1376

1 Theory, performance and constructional features of induction motors and energy saving 1
Introduction Brief theory of operation of a polyphase motor Motor output and torque Motor ratings and frame sizes Preferred ratings at different voltages Influence of service conditions on motor performance No-load performance Effect loading on motor performance Effect of steel laminations on core losses Circle diagram Types of induction motors Mounting of motors Enclosures Weatherproof (WP) motors Degree of protection Cooling systems in large motors Single phase motors Theory of operation Energy coservation, energy auditing and energy efficient motors (EEM)

Important features of a slip-ring motor Starting of slip-ring motors Hypothetical procedure to calculate the rotor resistance Speed control of slip-ring motors Moving electrode electrolyte starters and controllers

6 Static drives and energy saving

111

Speed control in squirrel cage motors Speed control through solid-state technology V/f control (speed control at constant torque) Phasor (vector) control Use of phasor control for flux braking Control and feedback devices Evolution of solid-state technology Conduction and commutation Circuit configurations of semiconductor devices Smoothing of ripples in the d.c. link Providing a constant d.c. voltage source Providing a constant current source Generation of harmonics, over-voltages and voltage surges in a static device switching circuit and to mitigate their effects PWM inverter drives causing shaft currents Energy conservation using static drives Application of static controllers Speed variation through variable-speed fluid couplings Static drive versus fluid coupling D.C. drives Retrofitting of EE motors and drives

2 Motor torque, load torque and selection of motors 41

Motor speed-torque curve NEMA rotor designs Special designs of rotors Effect of starting current on torque Load torque or opposing torque Selection of motors Time of start-up and its effect on motor performance Thermal withstand time Braking Inching or jogging Number of starts and stops

7 Special-purpose motors and induction generators 185

Textile motors Crane motors Determining the size of motor Sugar centrifuge motors Motors for deepwell pumps Motors for agricultural application Surface-cooled motors Torque motors or actuator motors Vibration and noise level Service factor Motors for hazardous locations Specification of motors for Zone 0 locations Specification of motors for Zone 1 locations Motors for Zone 2 locations Motors for mines, collieries and quarries Intrinsically safe circuits, type Ex. i Testing and certifying authorities Additional requirements for critical installations Motors for thermal power station auxiliaries Selection of a special-purpose motors Induction generators

3 Duties of induction motors

63

Duty cycles Continuous duty (CMR) (S1) Periodic duties Factor of inertia (FI) Heating and cooling characteristic curves Drawing the thermal curves Rating of short-time motors Equivalent output of short time duties Shock loading and use of a flywheel

4 Starting of squirrel cage induction motors

83

8 Efficient transmission of loads

Direct or rigid couplings Flexible couplings

221

Direct on-line starting (DOL) Reduced voltage starting

viii Contents

Delayed-action couplings Construction and principle of operation Belt drives Checking the suitability of bearings Suitability of rotors for pulley drives

9 Winding insulation and maintenance 255

Insulating materials and their properties Ageing of insulation Practices of insulation systems Procedure for vacuum pressure impregnation Maintenance of insulation Monitoring the quality of insulation of MV formed coils and resin-poor windings during manufacturing

switchgear assembly HV switchgear assemblies Protection schemes General guidelines during installation and maintenance of a switchgear or a controlgear assembly Power circuits and control scheme diagrams APPENDIX Painting procedure of switchgear and controlgear assemblies and treatment of effluent 461

14 Testing of a metal-enclosed switchgear assemblies 483

Philosophy of quality systems Use of environment friendly substances (RoHS) Recommended tests LV impulse test Procedure for type tests Procedure for routine tests Procedure for field tests Introduction to mechanical impact test, internal arc test and EMC/EMI (electromagnetic compatibility and emission) tests An introduction to earthquake engineering and testing procedure A passing reference to tsunami

10 Installation and maintenance of electric motors 267

Installation of bearings and pulleys Important checks at the time of commissioning Maintenance of electric motors and their checks Maintenance of bearings General problems in electric motors and their remedy Winding temperature measurement at site Analysis of insulation failure of an MV motor at a thermal power station

11 Philosophy of quality systems and testing of electrical machines

Philosophy of quality systems Transition to ISO 9001(2000) Testing of electrical machines Procedure for testing Load test No-load test Tolerances in test results Certification of motors used in hazardous locations

283

15 Instrument and control transformers: applications and selection 529

Introduction Types of Transformers Common features of a voltage and a current transformer General specifications and design considerations for voltage transformers Precautions to be observed while installing a voltage transformer Current transformers Short-time rating and effect of momentary peak or dynamic currents Summary of specifications of a CT Precautions to be observed when connecting a CT Test requirements Nonconventional methods of current measurement (sensors and transducers) Rogowski coils

12 Protection of electric motors and selection of components

317

Purpose Unfavourable operating conditions Fault conditions Protection Single-device motor protection relays Summary of total motor protection Motor protection by thermistors Monitoring of a motors actual operating conditions Switchgears for LV motors Selection of main components Fuse-free system Switchgears for MV motors Microprocessor based devices (IEDs) and intelligent starters APPENDIX Rule of thumb for everyday use 367

16 Captive (emergency) power generation 577

Introduction DG set Operating parameters Theory of operation Guidelines on the selection of a DG set Types of loads Starting of a DG set Protection of a DG set Parallel operation Procedure of parallel operation Fault levels and grounding of generators Recommended protection for a synchronizing scheme Load sharing by two or more generators Total automation through PLCs APPENDIX Selection of power cables PVC, paper insulated and XLPE and ampacity tables 617

Part II Switchgear assemblies and captive (emergency) power generation 377642

13 LV switchgear and controlgear assemblies 379

Application Types of assemblies Conventional types of switchgear and controlgear assemblies (also referred to as switchboards) Compact switchgear assemblies Intelligent switchboards Design parameters and service conditions for a switchgear assembly Determining fault level of a system and its duration Energy based discrimination Deciding the ratings of current-carrying equipment, devices and components Designing a bus system Designing a

Part III Voltage surges, overvoltages, circuit interrupters and grounding practices 643822
17 Voltage surges causes, effects and remedies 645
Introduction Temporary over-voltages Voltage

Contents ix

surge or a transient Transient stability of overhead lines Causes of voltage surges Definitions Causes of steep rising surges Effect of steep-fronted TRVs on the terminal equipment (motor as the basis) Determining the severity of a transient Protection of rotating machines from switching surges Theory of surge protection (insulation coordination) LV surge protection and surge protection devices (SPDs)

gradients Determining the leakage current through a human body Measuring the average resistivity of soil Improving the performance of soil Determining the ground fault current Designing a grounding grid

18 Surge arresters: applications and selection

Part IV Power capacitors and reactive power controls 823980

23 Power capacitors: behaviour, switching phenomena and improvement of power factor 825
SECTION I

681

Surge arresters Electrical characteristics of a ZnO surge arrester Basic insulation level (BIL) Protective margins Protective level of a surge arrester Selection of gapless surge arrester Classification of arresters Surge protection of motors Pressure relief facility Assessing the condition of an arrester

827

19 Circuit interrupters and their applications

721

Circuit interrupters Theory of circuit interruption with different switching mediums (theory of deionization) Theory of arc plasma Circuit breaking under unfavourable operating conditions Circuit interruption in different mediums HV and LV vacuum contactors Current chopping Virtual current chopping Containing the severity of switching surges Comparison of interrupting devices Gas insulated switchgears (GIS) Retrofitting of old installations

Introduction Application of power capacitors Effect of low PF Other benefits of an improved power factor Behaviour of a power capacitor in operation Generation of triple harmonics in an inductive circuit Generation of harmonics by a power electronic circuit Resonance Effective magnitude of harmonic voltages and currents When harmonics will appear in a system Filter circuits: suppressing harmonics in a power network Excessive charging currents (switching inrush or making currents) Limiting the inrush currents Capacitor panel design parameters Capacitor rating for an induction motor Location of capacitors Automatic PF correction of a system Switching sequences PF correction relays
SECTION II 873

20 Temporary over-voltages and system grounding 759

Theory of overvoltages Analysis of ungrounded and grounded systems The necessity of grounding an electrical system Analysis of a grounded system Arc suppression coil or ground fault neutralizer Ground fault factor (GFF) Magnitude of temporary over-voltages Insulation coordination Application of different types of grounding methods (for MV, HV and EHV systems) Important parameters for selecting a ground fault protection scheme

Electromagnetic compatibility (EMC) Electromagnetic interferences (EMI)

24 System voltage regulation and improving power quality 881

Capacitors for improving system regulation Series capacitors Rating of series capacitors Advantages of series compensation Analysis of a system for series compensation Reactive power management Influence of line length (Ferranti effect) To optimize the power transfer through reactive control Transient stability Auto-reclosure scheme for transient stability Switching of large reactive banks Automation of power network for dynamic stability through SCADA system Serial data transmission and communication interfaces Introduction to communication protocols Security of SCADA system

21 Grounding theory and ground fault protection schemes

773

Protection of a domestic or an industrial single phase system Ground fault on an LV system Ground fault protection in hazardous areas Ground leakage in an HV system Core-balanced current transformers (CBCTs) Ground fault (G/F) protection schemes Grounding systems and their choices Grounding electrodes Resistivity of soil () Measuring the ground resistance Metal for the grounding conductor Jointing of grounding conductors Maintenance of grounding stations Grounding practices in a power generating station Tolerable potential difference at a location Voltage

25 Making capacitor units and ratings of switching devices 933

Making a capacitor element Special purpose capacitors A critical review of internally protected capacitor units Self-healing capacitors Making a capacitor unit from elements Making capacitor banks from capacitor units Rating and selection of components for capacitor duty Fast discharge devices

22 Grounding practices

797

x Contents

26 Protection, maintenance and testing of capacitor units 953

Protection and safety requirements Installation and maintenance of capacitor units Test requirements

30 Properties and ratings of currentcarrying conductors

1049

Physical and electrical properties of aluminium and copper conductors Ampacity tables of copper and aluminium conductors

27 Selection of power reactors

971 31 An isolated phase bus system 1067

An isolated phase bus (IPB) system Constructional features Special features of an IPB system Enclosure heating Natural cooling of enclosures Continuous rating Forced cooling Influence of a space field on the metallic structures Fault level Voltage drop Forming of sections for IPB systems Determining the section and size of conductor and enclosure Sample calculations

Introduction Types of power reactors Selection Design criterion and I characteristics of different types of reactors Applications

Part V Busbar Systems 9811100

28 Carrying power through metal-enclosed bus systems 983
Introduction Types of metal-enclosed bus systems Non-conventional compact and sandwich low loss bus systems for LV and HV systems Partially isolated bus systems for HV systems Design parameters and service conditions for a metal enclosed bus system Short-circuit effects Service conditions Other design considerations for aluminium and copper busbars Skin effect Proximity effect Sample calculation for designing a 2500 A non-isolated phase aluminium busbar system

32 Testing a metal-enclosed bus system 1091

Philosophy of quality systems Recommended tests Impulse test on LV bus system New safety measures and tests prescribed by IEC Procedure for type tests Routine tests Field tests Index 1101

29 Recommended practices for mounting buses and making bus joints 1039
Precautions in mounting insulators and conductors Types of joints Making a joint Bending of busbars

Preface to this edition

Since time immemorial pursuit to knowledge has been a never ending process for the man. The man has always been capable of evolving new methods and techniques to overcome his difficulties. In earlier times the means were primitive but with the advancement of science and technology, applications of safety measures and mans own disciplines and controls, situation today is far more redeeming yet quite alarming in many fields. Of all fields, degeneration of environment is the most alarming, caused by emission of toxic gases and discharge of effluents and most importantly generation of excessive heat due to excessive loss of energy by all equipment and devices consuming energy in whatever form. Electromagnetic (EM) emissions also cause environmental pollution affecting performance of equipment and devices operating in their vicinity. The gradual rise in human awareness even about his own callousness towards contributing to the above causes, he is now getting intensely engaged in containing the causes and mitigating their effects as far as possible. Rigorous R&D in various fields around the world by those who are more aware and concerned is now the order of the day. Emphasis is on controlling all kinds of pollutions and all such emissions that contribute to global warming or health hazard at source itself. Similarly, energy and space saving. All such requirements can form the eco norms. These issues are discussed in this handbook to the extent related to the topics covered to keep the readers abreast with the latest technological philosophies and the disciplines that one is required to observe. For more information refer to Kyoto Protocol*. The present edition is a thoroughly revised and
* Kyoto Protocol was opened up for signature on Dec. 11, 1997 at Kyoto, Japan and came into force with effect from Feb. 16, 2005. In all 141 countries have presently ratified the protocol. It is an amendment to the United Nations Framework Convention to Climate Change (UNFCCC), an international treaty on global warming. It also reaffirms sections of the UNFCCC countries who have ratified this protocol and commit to reduce the emission of green house gases (GHG) (the major gases being water vapours (3670%), CO2 (9 26%), Ozone (37%), and minor gases being methane (CH4), Nitrous oxide (N2O), Sulphur hexafluoride (SF6), Chlorofluorocarbons (CFC 11 to 115, Section 13.10.1) and many more).

upgraded version of the earlier handbook Industrial Power Engineering and Applications Handbook. It accounts for technological changes, product developments and new applications that have taken place in the last one decade. This also takes account of upgraded and new national and international Standards that have become available in this period. Some of the new topics that have been added are noted in Table P-1. It has been done to keep the readers well informed of the latest technologies and practices being adopted worldwide in the field of Electrical and Electronic Power Engineering. Energy saving and space saving are buzzwords in todays world. All these aspects have been given due consideration in the present handbook and accordingly special thrust is laid on, Energy conservation Use of energy efficient electrical and electronic equipment and devices Environment and pollution controls Space saving

Energy conservation
All efforts have been made to identify areas, equipment and devices that can save energy. Some such areas discussed in this book are Energy efficient motors (EEM) Soft starters and energy feedback through static drives Energy efficient and space saver belt drives Fluid couplings for soft starting and energy saving Power cables, busbars and gas or fluid pipelines Air insulated and gas insulated switchgears (GIS) and general guidelines to save energy where possible. Compact and sandwich low loss busbar systems Retrofitting of old installations, equipment and devices with energy efficient and space saving equipment and devices It is suggestive that manufacturers and equipment suppliers, who deal with energy efficient products or technologies, as customary, provide repayment schedule to their users for encouraging them use energy efficient products and technologies and enable them take a more pragmatic decision while making the purchases.

xii Preface to this edition

Environment
Similarly, thrust is on environmental and pollution controls by way of effluent treatment of waste water and disposal of wastes. Also practising EMC/EMI norms to control electromagnetic and radiated field environmental pollutions. - Restrictions on the use of certain hazardous substances (RoHS) in the manufacture of electrical and electronic equipment (EEE) and their waste management (WEEE) (collection, treatment, recycling and disposal under controlled conditions).

given due reference. BS and IS Standards are gradually adapting to IEC Standards, their equivalent are also mentioned where possible. Similarly, more prominent ISO Standards are also mentioned.

Tables and data

All tables and data obtained from manufacturers are for general reference only. With continuous improvements and advancements in technology and product the data and applications may vary. The user must consult the manufacturer for accurate data.

Technical information
To compile all these details a lot of research and hard labour has gone into obtaining vital data and details from different leading manufacturers and users worldwide. The basic thrust of the book is to provide such information that is not easily available. All topics are backed up with extensive study and research by the author and information provided by leading manufacturers and consultants. Utmost care has been taken to ensure authenticity of text in technical discussions, inferences drawn and applications on a particular subject matter. All data provided and recommendations made are corroborated through relevant IEC and other Standards and generally accepted practices worldwide. Presenting all such Standards in a tabular form with their equivalent BS, IS, IEEE, NEMA and ANSI Standards, as practised by different countries, for each chapter and each topic is a unique feature of the handbook and shall greatly help a practising engineer, consultant or a design engineer, student or research scholar in their day to day working and handling of these subjects and machines. All this has been done to benefit the readers and provide them such vital data and details so handy. The language is simple and distinct and easily comprehensible. Those who like to learn and be abreast with the technological advances, modern practices and applications will find the handbook extremely informative and useful. Masters in their fields surely know all this. The topics added in the present addition are shown in Table P-1.

Mathematical and voltage systems

Endeavour is to provide as much information with as much clarity as possible. Different countries may adapt to different mathematical systems (like MKS or FPS), 50 Hz or 60 Hz and also different voltage systems (new voltage systems are mentioned in the Introduction). While MKS and 50 Hz system has been chosen in the book for all explanations, where possible data are provided for FPS as well as 60 Hz systems also. It has been done to help the readers find it easy to comprehend the subject matter and translate it to their system easily. Similarly, there may be variations in basic components and raw materials from country to country, but it would be easy to apply the practical approach of this book and use only the available raw materials and components. Cross-references The cross-references should not be hindrance to smooth reading. They are aimed to provide more details to the reader on a particular subject or its additional applications, and in the process providing more clarity on the subject. This is a unique feature of the handbook and it is hoped the readers will like it. Index The book contains enormous amount of rare and valuable information. To make it convenient for the reader to search out an information, we have tried to provide an exhaustive index to enable him locate his information promptly. It is hoped the readers will find the book unique and useful.

Standards
There is a continuous upgradation of Standards and products. It is therefore advisable that the user of a product may consult the latest Standards for the latest specifications. The main thrust is on IEC Standards but NEMA, ANSI and IEEE Standards that are more prominent in many countries are also considered and

K.C. Agrawal (2007)

Preface to this edition xiii

Table P-1 Topics added Part I Part II Part III Part IV Part V

Electric motors, drives and energy saving

Energy saving Energy efficient motors (EEM) Developments in semi-conductor devices and their applications in ac/dc drives, HV dc transmission, SVCs and other power applications Shielding of signals and isolated or clean grounding of power electronic circuits Prevention from bearing currents caused by PWM inverters Transition from ISO 9000 (1994) to ISO9001 (2000) Energy efficient and space saver powertransmission belts Microprocessor based switching devices (IEDs) Intelligent starters

Switchgear assemblies and captive (emergency) power generation

Energy based discrimination of current limiting breakers Compact switchgear assemblies Protection schemes Intelligent switchboards Additional tests on switchgear assemblies like impact test, internal arcing test and separators for operational safety, glow wire test Impulse test on LV system Restrictions on use of hazardous substances (RoHS) Some new techniques of recording and predicting an earthquake Passing reference to tsunami warning systems Non-conventional methods of current measurement Hybrid current sensors Hall effect sensors, Rogowski coils and Digital optical instrument transformers EMC/EMI testing requirements Generator grounding and reactive load sharing

Voltage surges, overvoltages, circuit interrupters and grounding practices

Gas insulated compact sub-stations (GIS) LV surge protection and surge protection devices (SPDs) Metal oxide distribution class surge arresters HV and LV vacuum contactors Grounding systems

Power capacitors and reactive power controls

Special purpose capacitors Auto-reclosure scheme for transient stability and Use of Supervisory Control and Data Acquisition (SCADA) system for dynamic stability of a power network Serial data transmission, communication interfaces and protocols EMC/EMI (Electromagnetic compatibility and interferences) EMC/EMI norms

Busbar systems
Sandwich and compact low loss bus systems Partially isolated bus-systems More tables and details on copper busbar systems Designing of copper bus systems New safety measures and tests prescribed by IEC

And many more small and relevant topics

Preface to the first edition

The author has had a long association with the machines described in this book. The book is the result of this experience and the overwhelming help and support extended to him by his colleagues, friends and business associates over the last twelve years. The purpose of this book is to share the experience of the author with those in the field. It is an attempt to make these subjects simple and interesting. The book should provide an easy approach to answer the problems an engineer or engineering student may face when handling these machines. The author is sure that the readers will find ample opportunity to learn from his experience and apply this information to their field of activities. The book aims to provide a bridge between the concept and the application. With this book by his or her side, an engineer should be able to apply better, design better and select better equipment for system needs and ambient conditions. It should prove to be a handy reference to all those in the field of design and application, protection and testing, production, project engineering, project implementation or maintenance, in addition to the sales and purchase of these products. Devoted Engineers and Scientists have done an incredible job by inventing new technologies and bringing them, over the years to their present level. Research and development work by a dedicated few Engineers and Scientists has been a relentless and untiring journey which has provided us with more advanced forms of technologies from time to time. The credit for this book goes to these Engineers and Scientists throughout the world. The author is not an inventor, neither has he done anything new in these fields. He has only attempted to bring together such advances in a particular field in one book for their better applications and uses. The authors contribution is only appropriate selection and application of the available technology and products for their optimum utilization. All relevant aspects of a machine, including design, have been discussed but greater emphasis is laid on selection and application. Since this is primarily a reference book the basic theory is assumed to be known to a student or a practising engineer handling such machines and/or technologies, yet brief theory has been discussed wherever considered necessary to refresh ones memory.

In the academic world the derivation of a formula from fundamentals is regarded as most important. In practice, this formula matters more rather than its origin. But for those who wish to know more of the reasoning and the background of a formula, care is taken that such supportive information is also covered. The author hopes that readers will be satisfied to have most of their queries answered. The book has been written so that it refreshes and awakens the engineer within a reader. The author is confident that this is what readers will feel as they progress through this book. A cursory reading will bring them abreast with the subject and enable them tackle problems with ease and simplicity. The authors efforts will be defeated if this book falls short of this aim. The endeavour has been to provide as much information as possible on the application of available technology and products. It should help application engineers to select and design a more suitable machine or power system for their needs. As mentioned above, the text may not cover the full engineering derivations, yet all fundamentals have been provided that are considered relevant to engineer any machine or system covered in this book. To augment the information, Further Reading has also been provided to support the text and to answer queries that may arise on a particular subject. For detailed engineering, the manufacturers are still the best guide. Detailing and engineering must be left to them. In this book, the author has tried to make the subject comprehensive yet concise and easy to understand, so that one can easily refer to it at any time. The references drawn are brief, but pertinent, and adequate to satisfy a query. This book may prove to be a boon to young engineers entering the field. With it by their sides they can comprehend the theory of their classrooms with applications in the field. Whereas all aspects that were thought necessary have been considered, it is possible that some have been omitted. The author would be grateful to receive suggestions from readers for any additions, deletions or omissions to make the book even more useful and up-to-date next time.

K.C. Agrawal (2001)

Acknowledgements
The author acknowledges with gratitude the help extended to him by his colleagues and friends and for the catalogues and leaflets from various manufacturers. Also helpful have been a score of references and textbooks on the subject besides the product Standards such as IEC, IEEE, ANSI and NEMA, ISO, BS and IS and other national and international publications. The authors most sincere thanks are due to the following, who have given their whole-hearted support and help in compiling this book and making it up-todate. They have provided details and the latest practices followed by leading consultants, engineers and end users worldwide, as well as the national and international practices of the various manufacturers. Dr Abraham Verghese Anil Kamra Ashwani Agrawal Dr Ashok Kumar B. Raman D.K. Duggal M.R. Atter P.S. Gokhle S.D. Nandakishore S.P. Sharma Dr Subir Sen V.P. Sharma English Electric (now Alstom) Crompton Greaves ABB IIT Roorkee BHEL NTPC ECS Syntron Controls Areva/Alstom L&T Power Grid Corporation EIL Special thanks for formatting the book go to: Anjuna Agrawal Manish Chand Asad Mirza A.K. Shringhi The authors daughter for her unflinching support throughout Computer support and assistance Editing and proofreading Illustrations and drawing services

Besides the above, the following have been a source of encouragement and continued support: Bhanu Bhushan Power Grid Corporation Harbhajan Singh Crompton Greaves Indu Shekhar Jha Power Grid Corporation Dr Laxmi N Gupta RIT, USA N.K. Bhatia English Electric (now Alstom) Dr P.C. Tripathi BHEL P.K. Sehgal NGEF Dr Unnikrishanan RIT, USA Y. Pal Ex EIL as well as a number of friends and well-wishers in addition to those mentioned in the Technical Support list. I would like to apologise to my family and friends for neglecting them during the time it has taken me to write the book; in particular, my wife Madhu and my daughter Anjuna.

Disclaimer statement for used material

The International Electro-technical Commission (IEC): The author thanks the IEC for permission to use their material. All extracts are copyright IEC Geneva, Switzerland. All IEC publications are available from www.iec.ch. IEC takes no responsibility for and will not assume liability for damages resulting from the readers misinterpretation of the referenced material due to its placement and context in this publication. The material is reproduced or written with their permission. Manufacturers: Since most information contained in the handbook is obtained from manufacturers or is based on their catalogues/product details obtained from them or their various outlets it has authenticity and reliability. Nevertheless while every care has been taken to ensure accuracy of information no liability shall be accepted by the manufacturers or the author for any loss or damage direct, indirect or consequential arising out of the information contained in this handbook.

Technical support
Part I Electric motors, drives and energy saving
The author gratefully acknowledges the following companies and individuals for providing him invaluable technical support. Chapter 1 R.K. Gupta, NGEF Ltd, New Delhi; J.R. Mahajan, Voltas Ltd, Mumbai; Anil Kamra, Crompton Greaves Ltd, New Delhi; B. Raman, BHEL, Bhopal; S.K. Sharma, GE Motors India Ltd, Faridabad; Anirudh Singh, S.M. Patil, BHEL, New Delhi; Rajnish Sharma, Satish Talwar, Siemens, New Delhi; A.K. Varshney, BHEL, Bhopal Chapter 2 Bal Gopal, Dynaspede Integrated Systems (P) Ltd, Tamil Nadu Chapter 3 R.K. Gupta, Bhartia Cutler Hammer Ltd, Faridabad Chapter 10 Chapter 5 Y.H. Kajiji, AOYP Engineering Company, Mumbai; Ram Chandran, Bhartia Cutler Hammer Ltd, Faridabad; N.M. Shah, Pioneer Electrical Works, Mumbai; A.K. Varshney, BHEL, Bhopal Chapter 6 Sanjay Sinha, Hemant Agrawal, Vijay Arora, Munish Sharma and Ajay Kumar, Allen Bradley India Ltd, Sahibabad; Shasidhar Dhareshwar, ABB, New Delhi; Ashwani Kaul, Kirloskar Electric Co. Ltd, New Delhi; Siddhartha Ghosh, Siemens Ltd, New Delhi; S.D. Nanda Kishore, Cegelec (India)/Areva/Alstom, Noida; Arun Gupta, EISA Lifts, New Delhi; Rajiv Manchanda, Usha (India) Ltd, Faridabad; Kapil Grover, Allen Bradley Ltd, New Delhi; Ashok Jain, Fluidomat Ltd, Dewas (MP); A.K. Advani, Greaves Ltd, New Delhi; L.V. Buran, A.K. Nagpal, Rajeev Agrawal, Sony Chacko, Bhartia Cutler Hammer; Anant Narain, A.K. Tikkoo, EIL, New Delhi Soman Dhar, Castrol India Ltd, New Delhi; Chandra Kumar, National Engineering Industries, Jaipur; B.B. Rao, SKF Bearings India Ltd, Mumbai; B. Raman, BHEL, Bhopal; Anil Kamra, Crompton Greaves Ltd, New Delhi; S.D. Nanda Kishore, Areva/Alstom Chapter 11 Y.D. Dosaj, Crompton Greaves Ltd, Ahmed Nagar; Y. Pal, Formerly with EIL (GG-1/13-A, Vikaspuri, New Delhi); A.K. Varshney, BHEL, Bhopal Chapter 12 P.B. Dabholkar and Indrajit Jadhav, ABB, Vadodara; Sanjiv Bahl, ABB, Delhi; Pankaj Sachdeva and Balamourougan, Alstom (India), Chennai; V. Mohan, Rajiv Tandon, Prem Kumar and Chand Chadha, Larsen & Toubro, New Delhi; Kapil Grover, Allen Bradley, Sahibabad; S.P. Sharma, L & T, Mumbai; B. Raman, BHEL, Bhopal, T.K. Modak, Jyoti Ltd., New Delhi; Ashish Trivedi, Schneider Electric Chapter 8 Pembril Fluidrives Ltd, Aurangabad; Ashok Jain, Fluidomat Ltd, Dewas; Eddy Current Controls (India) Ltd, Kerala; A.K. Advani, Greaves Ltd, New Delhi; V.K. Sharma, Prasun Chakraborty, Sunil K. Kaul and K. Sukhija, Fenner (India) Ltd, Hyderabad/New Delhi; S. Kumar and P.K. Das, Dunlop (India) Ltd, Kolkata/ New Delhi Chapter 9 B. Raman, BHEL, Bhopal, India; A.K. Varshney, BHEL, Bhopal Chapter 7 Y.I.P. Sehgal, International Pumps and Projects, Noida; S.U. Submersible Pumps, Noida; V.P. Sharma, EIL, New Delhi; Nitin Sen Jain, Kirloskar Electric Co. Ltd, New Delhi; M/s Subhash Projects India Ltd; Sarvesh Kumar, Vestas RRB India Ltd, New Delhi; A.K. Varshney, BHEL, Bhopal

xx Technical support

Part II Switchgear assemblies and captive (emergency) power generation

Chapter 13 M.R. Atter, ECS, Noida; S.P. Sharma, L&T, Mumbai; D.K. Duggal, NTPC, Noida; N.K. Agrawal and P.K. Garg, BHEL, Haridwar; Bhupinder Badiya, Siemens, New Delhi; Abid Hussain, Consultant, New Delhi; P.H. Kakade, Vinayak Corp., Mumbai; Shalini Bhateja, Sanjeev Sharma, Schneider Electric, New Delhi; Satpaul Goel, Mohit Atter, Atoz Power Systems, New Delhi APPENDIX Dr V.K. Anand, Anand CIS India, New Delhi; Stat-field Systems (Coating) Pvt. Ltd; Mitsuba Electricals (P) Ltd, India; Sajal Srivastava, Berger Paints Ltd, New Delhi; Sajjathe Sulthan, SBA Enviro Systems, New Delhi; R.R. Bagri, Clear Water Ltd, New Delhi; P.H. Kakade, Vinayak Corp., Mumbai; Arvind Mathur, Jasper Engineers, New Delhi Chapter 14 Dr. Ashok Kumar Mathur, Department of Earthquake Engineering, IIT Roorkee; Dr H.K. Chand, formerly Professor of Geography, Bhagalpur University; S.P. Sharma, L&T, Mumbai; V.N. Nandakumar, CPRI, Bangalore; Arvind Mathur, Jasper Engineers, New Delhi Chapter 15 S. Raghavan, Indcoil Transformers (P) Ltd, Mumbai; P.U. Patwardhan, Prayog Electricals (P) Ltd, Mumbai; Dr Abraham Verghese, English Electric Co. now Alstom (India), Sharjah UAE, N.C. Bhatnagar, Power Grid Corporation, New Delhi; Puneet Banga, Schneider Electric, New Delhi Chapter 16 Kamal Singhania, Crompton Greaves Ltd, New Delhi; Ashawni Kaul, Sharad Agarwal, Kirloskar Electric, New Delhi; Chandralekha Bhaskar, Bhaskar Power Projects; I.D. Qureshi, Kiran Engineering Enterprises; Atul Khanna, AVK-SEGC & Controls (India) Ltd, New Delhi; N.K. Mittal, Abett Consultants, New Delhi; A.K. Tikkoo, EIL New Delhi; V.K. Chaudhary, B. Sridhar Rao, Hemant Sharma, Cable Corporation of India Ltd, New Delhi; O.P. Kwatra, Havells India Ltd, New Delhi

Sharma, Consultant, Mumbai; Rajender Mohan, Moeller HPL, New Delhi; Neeraj Garg, Schneider Electric, New Delhi Chapter 18 Anil Poddar, V.M. Belsare, Elpro International Ltd, Chinchwad Gaon, Pune; Station Surge Arresters and Thyrite Magne Valve Station Lightning Arresters, IGE (India) Ltd; TransiNor As, Norway, through Vijay Khanna, New Delhi; N. V. Anantha Krishnan, W.S. Industries (India) Ltd, New Delhi; A. S. Kushwaha and Arvind M. Khurana, Power Grid Corporation of India Ltd, New Delhi; V.P. Singh, Elpro International Ltd, New Delhi; Ashwani Agrawal, ABB India Ltd, New Delhi; Dr S. Mukhopadhyay, A.K. Rajput, S.K. Ray Mohapatra, CEA, New Delhi; Dr Ram Nath, BHEL, New Delhi; T.P.R. Sharma, Consultant, Mumbai Chapter 19 V. Raghavan, BHEL, Bhopal; N. Biswas, Alstom, New Delhi; P.P. Sreekanth, Sanjay Bhambhani, Alstom, New Delhi; Manjeet Singh and Manoj Misra, ABB, New Delhi; Sandeep Mathur, Siemens India, New Delhi; Dr Ram Nath, BHEL, New Delhi; C.K. Bhagat, Voltas Switchgears; T.K. Modak, Jyoti Ltd., New Delhi; Dr H.S. Jain, BHEL, Hyderabad. Chapter 20 Y.K. Sehgal, Power Grid Corporation of India, New Delhi Chapter 21 P. U. Patwardhan, Prayog Electricals (P) Ltd, Mumbai; Dr Abraham Verghese, Alstom (India), Sharjah, UAE; Dr Girish Chandra, KGMC, Lucknow; Sanjeev Sharma, Schneider Electric, New Delhi Chapter 22 V. P. Sharma, EIL, New Delhi; C.S. Kore, Vinai Rai, L&T, Mumbai

Part IV Power capacitors and reactive power controls

Chapter 23 M. R. Attar, ECS; P. S. Gokhle, Niranjan Gokhle, Syntron Controls, Mumbai; N. P. Singh, Sigma Control, New Delhi; Vijay Jain, Neutronics Manufacturing Co. Ltd, Mumbai; S.P. Sharma, L&T, Mumbai; Y. P. Likhyani, Crompton Greaves Ltd, New Delhi; M. K. Pandey, Kapsales Electricals (Khatau Junker), New Delhi; A.S. Kushwaha, Power Grid Corporation of India, New Delhi; P. K. Mittal, Indian Railways Telecommunication, New Delhi; V.N. Nandakumar, CPRI, Bangalore Chapter 24 S. P. Singh, CEA, New Delhi; Dr Subir Sen and Indu

Part III Voltage surges, over-voltages, circuit interrupters and grounding practices
Chapter 17 Ashwani Agrawal, ABB, New Delhi; T.K. Modak, Jyoti Ltd, New Delhi; Atul Shrivastava, P.V. Ekande, NTPC, New Delhi; Dr Ram Nath, BHEL, New Delhi; T.P.R.

Technical support xxi

Shekhar Jha, Power Grid Corporation of India Ltd, New Delhi; Brajesh Malviya, ABB India Ltd, New Delhi; M. Hanif, Dr Ram Nath, P.K. Srivastava, D. Ravi, BHEL, New Delhi/Bangalore; Mata Prasad, Ex NTPC/ABB; Deepak Malhotra, Bhupinder Badiya, Siemens, New Delhi; Bhanu Bhusan, CERC, New Delhi; Ramesh Jha, Reliance Energy, Noida; Preeti Dhaundiyal, Flextronics Software Systems Ltd., Gurgaon Chapter 25 M. K. Pandey, Kapsales Electricals (Khatau Junker), New Delhi Chapter 26 M. K. Pandey, Kapsales Electricals (Khatau Junker), New Delhi Chapter 27 P. T. Pandyan, Western High Voltage Equipment, Jaisinghpur, Maharashtra Part V Busbar systems

Chapter 29 Russy N. Master, L&T, Mumbai; J. K. Joneja, Sanjay Joneja, M/s J. K. Plastics, Noida; P.H. Kakade, M/s Vinayak Corporation, Mumbai Chapter 30 Regie Paul, Indian Aluminium Co. Ltd (Indalco), Cochin, Kerala; Mahesh Khandelia, Om Prakash, Electro Copper and Alloy Mfg. Co., Kolkata Chapter 31 B. S. R. Patnaik, Best & Crompton Engineering Ltd, Chennai; D. K. Chaturvedi, NTPC Ltd, Noida; V. K. Mehta, BHEL, Jhansi; R. N. Khanna, Controls and Switchgears Ltd, New Delhi Standards ANSI BS IEC IEEE American National Standards Institute USA British Standards UK International Electro Technical Commission Switzerland The Institute of Electrical and Electronics Engineers USA Indian Standards India International Standards Organisation Switzerland National Electrical Manufacturers Association USA

Chapter 28 Gautam Kumar, A.P. Singhal, Tricolite, New Delhi; Roger Housey, MGC Technology AG, Schweiz; Anil Saboo, Elektrolites, Jaipur; Puneet Banga, Schneider Electric, New Delhi; P.B. Bellary, Mumbai IS ISO NEMA

Introduction
This book is built into five parts. A summary of each part follows. an introduction to quality assurance systems and application of ISO 9001(2000). Special coverage of impulse testing of resin-rich formed coils and their in-house testing requirements. In Chapter 12 a detailed analysis is made of all unfavourable operating conditions and their effect on the performance of the motor and its protection for optimum utilization. The precautions also cover surge protection for MV motors. The details provided cover the smallest-influence that a particular parameter can have on the machine. Microprocessor based switching devices (IEDs) and intelligent starters.

Part I

Electric motors, drives and energy saving

This part deals with three- and single-phase a.c. machines, and their protective switchgears. However, reference is made to and comparisons drawn of a d.c. motor with an a.c. motor, to assist a user make a proper choice of machine. Energy conservation, energy auditing and energy efficient motors (EEM). However simple a motor is, it requires careful handling to ensure optimum performance and long years of trouble free operation. A small drive, failing while in operation, may bring the entire process to a halt. One can visualize the loss of production that can result. Power plants, chemicals, fertilizers, petrochemicals, paper and cement mills all require careful selection of equipment to avoid breakdown or malfunctioning during operation. Motors and their controlgears are core components that require special attention: It deals with the specifications, performance, characteristics and behaviour of motors under different operating conditions, their application and selection. It also covers aspects such as shock loading, motors for hazardous locations and open transient conditions in MV motors during a switching sequence. This part-also deals with static controls and drives, soft starting and process control through solid-state technology (phasor and field-oriented controls) using IGBTs, IGCTs, SGCTs. Energy conservation. Developments and applications of solid state technology. Grounding practices and shielding of signals. Prevention from bearing currents. There is special coverage of fluid couplings for soft starting and speed control. A comparison between static drives and variable-speed fluid couplings is made. Windmills (induction generators) as an unconventional energy source, vertical hollow shaft motors and submersible pump sets, selection of energy efficient and space saver belts for transmission of load, the phenomenon and remedy of shaft currents. The text especially covers testing requirements and

Part II Switchgear assemblies and captive (emergency) power generation

The subjects covered aim at providing methods to form specifications and design a switchgear assembly for all power distribution needs. The text covers compact assemblies and intelligent switchboards. It also provides coverage of draw-out assemblies. Establishing the fault level of a system is described including the electrodynamic and electromagnetic forces that arise. Protection schemes and energy based discrimination of current limiting breakers. An introduction to RoHS (restrictions on use of hazardous substances) Testing procedures are informative and elaborate Introduction to EMC/EMI testing Seismic effects and earthquake engineering is covered in this part to study the behaviour of an object under seismic conditions and its suitability for critical installations. The formation of the earth and movements of tectonic plates that cause earthquakes, tsunamis and volcanic eruptions are described Instrument transformers (CTs, class PS CTs, VTs and CVTs, etc.) form important components of a switchgear assembly for measurement and protection. They are covered for their specifications, selection and application. Design of class PS CTs, non-conventional current measurements, current sensors and transducers. Rogowski coils (RCs) Captive (emergency) power generation covers the

xxiv Introduction

application of a diesel generating set, its starting, protection, grounding, synchronizing and load sharing. This forms an important part of power distribution at any installation to provide a standby source of supply. The entire painting procedure and effluent treatment is covered for those in the field of manufacturing such assemblies and to also save environment. In an attempt to provide as much information on the related subjects as possible and to make the book more complete for a project or a design engineer we have provided data and tables on PVC, paper insulated and XLPE cables and described in detail the procedure for selecting the type and size of LV and HV power cables.

Grounding practices of industrial installations and power generating stations.

Part IV Power capacitors and reactive power controls

Reactive control is an important tool for voltage regulation and for optimizing available power utilization. It can also be used for attaining better stability of the system. It has therefore become a very important technique to improve an old distribution network that is being overutilized and is ailing with recurring problems such as flickering of voltage, frequent system outages and a normally low voltage at the consumer end. The author has attempted to apply reactive control to improve power distribution networks which are over-loaded and are ailing with such problems. In this part the author provides all relevant aspects of a reactive control and carries out an exhaustive analysis of a system for the most appropriate control. Harmonic effects and inductive interferences as well as use of filter and blocking circuits are covered. EMC/EMI (Electromagnetic compatibility and interferences). Capacitor switching currents and surges and methods of dealing with these are also described. This part considers reactive power control with the use of shunt and series capacitors. The controls may be manual or automatic through electromagnetic or static devices. Protection of capacitors and capacitor banks as well as design, manufacturing and test requirements, installation and maintenance are also covered, the main thrust being on the application of power capacitors. Application of series capacitors and analysis of an uncompensated transmission line and the capability of power transfer and system regulation with and without series compensation are also presented. Autoreclosure scheme for transient stability and SCADA system for dynamic stability of a power network. Serial data transmission, communication interfaces and communication protocols. To clarify the subject the basics and the behaviour of power capacitors in operation are also discussed. This part also briefly describes different types of power reactors required to control inrush currents, suppress systems harmonic disorders, limit system fault level and absorb the excessive charging currents on an EHV system.

Part III Voltage surges, over-voltages, circuit interrupters and grounding practices
This part is complementary to Part II and provides technical support to switchgear assemblies and machines fed by them for surge and over-voltage protection. It is a very useful part for all those handling HV and EHVpower systems and their surge and over-voltage protection. The part deals with the BIL of a system, protective margins and insulation coordination. LV surge protection and surge protection devices (SPDs) It also deals with electric motors as they are typical for their surge behaviour and protection. It also covers the steepness of TRVs, their significance and methods of taming them. Reflections of travelling waves and surge transferences are also described. This part specifically considers the application and selection of surge capacitors and surge arresters. Since the internal causes of surge generation are a consequence of switching operation and type of interrupter, this part provides details of the various types of interrupters in use, their switching behaviour, current chopping and quenching of arc plasma. It also makes a detailed comparison of the various types of interrupters available in the market to facilitate their selection and adaptation to a more appropriate surge protection scheme. Gas insulated switchgears (GIS). HV and LV vacuum contactors. Temporary over-voltages are different from surges as are their causes. Therefore temporary over-voltages also form an important parameter in a system design and its grounding method. This topic is therefore complementary to surge protection and has been dealt in detail to make a practising engineer or engineering student more aware of the behaviour of an HV system, particularly on a ground fault. Exposure of a human body to touch and step voltages and methods to deal with these are also covered. Grounding and ground fault protection schemes are described in detail with illustrations to help an engineer select the most appropriate grounding method and ground fault protection scheme for a machine or a system. The use of CBCTs is covered. Grounding systems, their choice and protection from transferred surges and over-voltages

Part V Busbar systems

Power transfer is a very important area of a power system. In this part it is dealt with in detail for both LV and HV systems and for all current ratings. For large to very large ratings, skin and proximity effects are also discussed to arrive at a design to transfer large amounts of power, without great loss, voltage drop or voltage unbalance. Technical data and current ratings for various sizes and sections of copper and aluminium are provided. The text provides material to design, engineer, manufacture and test a bus system of any current and voltage rating.

Introduction xxv

This part specifically deals with Design parameters Sandwich, compact and partially isolated low loss bus systems Short-circuit effects Electrodynamic and electromagnetic forces Effects of proximity and reducing this by phase interleaving or phase transposition Designing a reactor for the middle phase to balance a large unbalanced current-carrying system Recommended practices to mount buses and make bus connections A detailed discussion on the isolated phase bus system concentrating on continuous enclosures and their design aspects Sample calculation to design an IPB Testing of bus systems.

IEC 60038 New voltage systems

In pursuit of bringing more uniformity in voltage systems and promoting international understanding and business amongst various countries, IEC in consultation with experts of many countries has made an attempt to club dissimilar voltages practised by different countries into just a few slabs to narrow down this disparity for the advantage of all. The new voltage systems are noted in the Table I-1 for LV and Tables I-2 and I-3 for HV and EHV systems. These voltage systems are to be followed
Table I-1 IEC 60038 New voltage systems

by all member countries who follow international practices in design and manufacture of their products to facilitate better understanding and business relations with other countries. With a view to making transition easier, higher voltage variations (as noted in the tables) are now prescribed for all new equipment and devices manufactured as per the new voltages to facilitate easy retrofitting of the old equipment and devices with the new ones without calling for two designs to meet the situation. All countries following international Standards were required to follow the revised voltage systems by 2003. But many of them have not been able to do so as yet, because of practical problems. Although the maximum change is only in LV voltages, it too demands for change in design and change of existing equipment and devices besides the change of supply voltage in the existing distribution networks and all that is not an easy task. Nevertheless most countries are endeavouring to fall in line sooner or later. We have therefore retained our earlier tables. They will stand modified in proportion to the change in voltages. For exact details, one may refer to the relevant Standards. To identify the voltage level, the nomenclatures used by us are shown in Table I-4.
Table I-2 Series I or II (50 Hz or 60Hz)

Series I (50 Hz) Highest voltage for equipment *Vm kV 3.6 7.2 12 (17.5) 24 36 40.5 Nominal system voltage (**Vr ) kV( 10%) 3.3 6.6 11 22 33 3 6 10 (15) 20 35

Series II (60 Hz) Highest voltage for equipment Vm kV 4.40 13.2 13.97 14.52 26.42 36.5 Nominal System voltage (Vr ) kV (+5%, 10%) 4.16 12.47 13.2 13.8 24.94 34.5

Nominal voltages (Vr ) Series I (50 Hz) * 230/400 *400/690 1000 Series II (60 Hz) 120/208 240 277/480 480 347/600 600

* The manufacturers and users shall endeavour to change over by 2003 from the existing 220/380 V and 240/415 V systems to the new voltage system of 230/400 V (+6%, 10%) or (+10%, 6%) respectively. The first step shall be taken by the electricity supply authorities of a country to adjust their voltages to the revised level to be followed suit by the manufacturers and users of equipment and devices.

* Vm represents the dielectric strength of an equipment, device or power system for which it is designed. ** Vr nominal or rated system voltage at which an equipment, device or power system shall usually operate.

xxvi Introduction Table I-3 Series I or II (50 Hz or 60 Hz) Table I-4 Nomenclatures used to represent different voltage levels

Highest voltage for equipment *Vm kV (52) 72.5 123 145 (170) 245 (300) 362 420 550 (or 525) 800 (or 765) 1050 (or 1100) 1200

Nominal system voltage (**Vr ) kV (45) 66 110 132 (150) 220 69 115 138 230

System LV MV HV EHV UHV

Nominal voltage (Vr) kV Vr 1 1 < Vr 35 35 < Vr 230 230 < Vr 800 Vm = 1050 or 1200 kV (practised in USA)

(i)

(iii) (iv)

(ii)

Note For all voltages above LV we have used the nomenclature as HV unless where the voltage range is specific such as for motors and generators we have used MV. Similarly we have identified, Transformer voltages as: Lower voltage side LV Higher voltage side HV

(v)

1. Values in parentheses are not the preferred values. 2. Wherever two voltage systems for one Vm have been prescribed a country may adopt to any one of them. 3. For more details refer to IEC 60038 * Vm represents the dielectric strength of an equipment, device or power system for which it is designed. ** Vr nominal or rated system voltage at which an equipment, device or power system shall usually operate. Notes i, ii, iii, iv For one country one must choose only one voltage system from one group v Countries using 1050 kV should not use 800 or 1200 kV.

Electrical Power Engineering Reference & Applications Handbook

Revised and upgraded edition of

Industrial Power Engineering and Applications Handbook ISBN: 0-7506-7351-6