VENTILATION AND AIR- CONDITIONING OF ELECTRICAL EQUIPMENT ROOMS

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1 Handbook of Industrial Air Technology Applications VENTILATION AND AIR- CONDITIONING OF ELECTRICAL EQUIPMENT ROOMS Second, revised edition Kim Hagström Jorma Railio Esko Tähti February 2003

2 PREFACE This document is the revised version of the first pilot Application booklet for the Handbook of Industrial Air Technology. This text is based on INVENT project "Design Criteria for Ventilation in Electrical Equipment Rooms", done in Finland in , reported in Finnish as INVENT Reports 36 to 39. It has been re-structured to follow the basic structure of the Design Methodology for industrial ventilation, also in order to test the methodology in practice. After being published as a draft manuscript in 1996 (INVENT Report 52), the text has been reviewed by Mr Martti Lagus (Nokia Telecommunications, Finland) and by Mr Peter Kiff (British Telecom). In addition, the described design methodology has been validated by several Finnish companies who actively apply the results of the INVENT project, either as end users of equipment rooms, or as suppliers of air-conditioning systems and equipment. The text has been revised after review by Mr Jan Gustavsson (Camfil, Sweden), Dr Paolo Tronville (Politecnico di Torino, Italy) and Dr David Shao (Ericsson Radio Access, Sweden). The English language of the revision has been checked and corrected by Mr Eric Curd (U.K.) Helsinki, December

3 VENTILATION AND AIR-CONDITIONING OF ELECTRICAL EQUIPMENT ROOMS CONTENTS PREFACE... 2 CONTENTS... 3 SUMMARY INTRODUCTION Classification of environmental parameters for electrical equipment Typical environments of electrical equipment located in ventilated indoor facilities Application scope DESIGN CRITERIA Given data Process description Building layout and structures Target level assessment Source description Load calculations SYSTEM PERFORMANCE Selection of system Selection of equipment Implementation design COMMISSIONING The construction schedule Checks Spare parts Documentation APPENDI 1 - BASIS FOR DESIGN FOR VENTILATION IN ELECTRICAL EQUIPMENT ROOMS, CLIMATIC CONDITIONS APPENDI 2 - THE MEASURING PRECONDITIONS OF GASES APPENDI 3 - REFERENCES

4 SUMMARY There has been a lack of "common language" for the design, construction and operation of air-conditioning of industrial electric-, electrotechnical- and control rooms. Requirements for the equipment and its environmental conditions are presented in different standards and guidelines in such a way that many interpretations are possible. For example, a given temperature limit can have been regarded by the end user as an absolute maximum, while the equipment supplier could allow it to be exceeded (within another range) for a short period. As a result of this, in some rooms the environment is too severe, resulting in operational errors and equipment failures, which really can be worth more than the whole equipment some rooms are conditioned unnecessarily well in relation to the actual environmental requirements, resulting in high investment costs, due to oversized (or unnecessarily double) air-conditioning equipment, or in high operation costs. An INVENT project was done in to tackle this problem area. The participants in the project represented different supplier and user groups such as: HVAC equipment manufacturers and suppliers, HVAC consulting engineers, electrical equipment manufacturers, process automation- and -control system manufacturers, and end-users from different trades of process-industry: pulp and paper, chemical industry, metal industry. A service product was also developed, in order to analyze the state of existing equipment rooms. This work was done in 1995, and the results can be utilized in commercial basis now, and several project references already exist. The knowledge gained in these actions has been the basis of this application. Modern electrical equipment containing electronics is very sensitive to their environmental conditions: temperature and humidity, chemically and mechanically active substances etc. In highly automated process industry a failure in process control equipment may cause losses in production that are many times worth of the equipment itself. Just to mention one example: a paper machine breakdown can cost up to or USD/hour. Minor improvements can be also done with low costs. Very often the tightness of the room can be improved so that the ventilation rate for maintaining over-pressure can be adjusted to a much lower level. A typical pay-back time for sealing the room properly is 0,5-0,7 years and investment less than 1000 or USD/room respectively. The benefits from proper design, construction and use can be summarized as follows: better operating conditions prolonged lifetime for electrical equipment improved reliability of the systems efficient use of the systems improved knowledge of the condition of the systems improved skills of he maintenance personnel 4

5 1. INTRODUCTION 1.1. Classification of environmental parameters for electrical equipment The basis of the environmental classification for electrical equipment is covered in EN standard. International recommendations for environmental conditions in electrical equipment rooms are covered by the European standard EN To standardise design practice the above should be used in ventilation systems design. Environmental factors covered in EN have been divided in the following groups. Climatic conditions (K) Climatic special conditions (Z) Biological conditions (B) Chemically active substances (C) Mechanically active substances (S) Mechanical conditions (M) The environmental conditions in EN for electrical equipment room are covered in various classes. Electrical equipment manufacturers define the special requirements of each device according to EN in the following manner: A definition such as the following 3K1/3Z1/3Z4/3B1/3C1/3S1/3M1: The code -3K1 Defines climatic conditions. In class 3K1, the target temperature value is o C in the range o C. The relative humidity target value is % in the range % and the absolute humidity ranges from 3,5-15 g.kg 1-3Z1 Z-class describes the special climatic conditions, including the surroundings thermal radiation. -3Z4 shows the permitted air velocity if different from the K-class value. In this case it is 5 m.s -1. With special condition classes, it considers how a device reacts to water. -3B1 describes biological conditions. Organisms or animals are not accepted in the 3B1 class. -3C1 A demand that covers chemically active substances. This defines the permissible concentrations of corrosive gases in the space. -3S1 Mechanically active substances. Defines the permissible concentration of particle contaminants e.g. dust, sand etc in the space. 1.2 Typical environments of electrical equipment located in ventilated indoor facilities Table provides a general idea of the "environmental tolerance" of equipment in different spaces. A nomenclature of electrical equipment rooms has not yet been 5

6 determined; Rooms of similar names in different industrial plants can contain very diverse equipment. Therefore, the environmental requirements for each room have to be checked individually during the various project stages. 1.3 Application scope The environmental classification for electrical equipment and the design basis for ventilation represented here, consider all indoor spaces where electrical equipment is located. Chapters 3 (System Performance) and 2.3 (Building Layout and Structures) emphasize ventilation of electrical equipment rooms (computer-, tele-, automation and current supply rooms). 6

7 Table Operating Environments of Electrical and Electronic Equipment, Ventilated Indoor Spaces TYPICAL ENVIRONMENT A Control- and automation rooms a1) workspaces separated from the process a2) automation rooms a3) cross-connection rooms (measuring equipment, monitors and connections) Computer rooms B Electrical equipment rooms -rooms that are separated from outdoor spaces and the process b1) tele cross-connection and device rooms: b2) electrical equipment rooms of the production: (motor use, MCC) b3) electrical exchange rooms:(main distribution centres, sub-main distribution centers) b4) transformer rooms (internal) C Assembling halls in the electronics industry -circuit card production, assembling of micro electronic components testing and adjustments, assembling of fine mechanisms and fibre optics D Production spaces in the metal industry -engineering workshops, light metal industry, bulk assembling: (motors, robots, control devices) -cable spaces E Production spaces in the process industry -spaces where contaminants and corrosive gases are typical:(instrumentation with protective cover, motors, control device) F An open, dirty industrial space -dusty spaces in direct contact with outdoor air, foundries, ore mills, waste treatment plants:(equipment with protective cover, suitable for outdoor use) -outdoor transformers G Movable containers -control cabinets and electrical rooms that are movable during use (for example military purposes) THE ENVIRONMENT CLASS OF THE EQUIPMENT ROOM according to the standard EN See 1.1 for explanation of classification 3K2 / 3Z2 / 3Z4 / 3B1 / 3C1 / 3S1 / (As above, except 3K1) 3K3 / 3Z2 / 3Z4 / 3B1 / 3C1 / 3S1 / 3K2 / 3B1 / 3C1 / 3S1 / 3M1 / 3K4 / 3Z2 / 3Z4 / 3Z7 / 3B2 / 3C2 / 3S2 / 3K5 / 3Z2 / 3Z4 / 3Z7 / 3B2 / 3C2+C3 when necessary/3s2 / 3K6 / 3Z2 / 3Z4 / 3Z7 3B2 / 3C2 / 3S2 / 3K2 / 3Z2 / 3B1 / 3C1 3S1 / 7

8 2 DESIGN CRITERIA 2.1 Given data Meteorological data Consideration of external temperature, humidity, wind forces and solar radiation are necessary in order to determine the cooling, heating and moisture loads. The design criteria shown in 2.5 have been compiled to meet the requirements of the standard EN If the maximum temperature 99% value is used i.e. (the temperature for 99% of the time below the design value). However, if a customer wishes to use higher design temperature for operational reliability the design parameters have to be agreed with the customer Air contaminants Chemically active substances (corrosive gases). In certain areas of the process industry (such as the pulp, chemical and petrochemical industries) and in cities, the concentrations of corrosive gases may be higher than the permissible concentrations for electrical equipment. In a corrosive environment, electrical equipment is easily damaged shortening the operating life. It is difficult to obtain information on the exact environmental air purity since: Outdoor air purity is a complex matter: the concentrations measured in the same place can vary within 1:100. This variation depends on wind direction air pressure and on process malfunctions In recent years air purity is constantly improving due to various environmental protection acts. For these reasons, details that could easily be used in defining the outside air on a design basis cannot be developed. The following approaches can be used to define the contaminant concentration of the intake air 1. Accurate concentration measurements. This however is not often practical, as: The measurements have to be carried out over a long time period (minimum 6 months) if exact initial values are required. To obtain accurate information measurements have to be obtained close to the area of concern. Attention has to be paid to the fact that a new building will create changes in airflows, which can influence standard design requirements. 2. Estimating the concentration beforehand. This can be done by the copper-strip method. 8

9 If the measuring period is long enough, and the concentration is measured at the air intake, provided the copper-strip is in a warm location. The contaminant ratio can be 1:4 within a few meters of the air inlet. 3. General measurements of the air conditions. For example in Finland, these results can be obtained from the following sources: - The Environment Department of the company. - Measurements carried out by the county, city or town authorities. - Meteorological Institute data 4. By rough estimations. For example tables provided by the equipment manufacturers can be used. 5. Experience. This is probably the most important way knowledge is gained; it depends on experience, regarding filters life and equipment corrosion. This is accomplished by comparing practical experiences with similar plants in the organization or in other factories. While dimensioning filters the possible sudden pressure changes caused by malfunctions in the process have to be considered as these changes can cause the gas concentrations to momentarily rise up to times the average concentrations. Measuring preconditions are described in Appendix Mechanically active substances (sand, dust) The outdoor air data, relating to dust will not normally provide a base for selecting particle filters. In consideration is given on how to select a filter for electrical equipment rooms. The surrounding dust concentration can be defined by similar principles as gases. 2.2 Process description Introduction Regardless of the electrical equipment installed, there are usually no other emission sources in electrical equipment rooms. In control- and automation rooms however, employees may occupy the space for long periods of time. Internal loads in electrical equipment rooms are: the heat developed by the equipment the emissions from humans (control cabinets and automation rooms) 9

10 In battery rooms hydrogen is liberated into the air, and care has to be taken regarding explosion hazards. The role of the ventilation in electrical equipment rooms is to: - remove the heat developed by electrical equipment keep the room clean of contaminants from the surroundings Typical electrical equipment room A typical electrical equipment room has equipment cabinets positioned in several rows. Many different-sized cables are fed to and from these cabinets either from below or above. In the process industry the cable space is usually separated in its own compartment. Due to fire safety reasons the cable space is confined by a raised floor forming its own fire cell (compartment). Figures and show two alternative typical cross-sections of electrical equipment rooms. Figure The recommended minimum dimensions of aisles for an equipment room 10

11 Figure A cable space 2.3 Building layout and structures Location of electrical equipment rooms Introduction The room shall be over-pressurised to reduce air infiltration from surrounding areas. The air tightness of electrical equipment rooms has to be sound, and the degree of overpressurization has to be sufficient to neutralize the influence of wind forces, temperature differences and surrounding process spaces, which may be operating under negative pressure Effect of wind forces If an electrical equipment room has external wall it can be greatly influenced by wind forces. These may, over-pressure on the wind-exposed wall resulting in polluted outdoor air entering the room. This effect has to be considered in the design process. The electrical equipment room if possible should be positioned, so that wind forces do not influence it. In spaces which rely on high air flows for cooling, the structural tightness and exhaust air openings sizes should be dimensioned so that the internal overpressure is kept to a reasonable level, e.g. not more than 20 Pa. Figure shows graphically the wind pressure on the outer wall of a building with the wind velocity in the 0, 5 and 10 m.s -1 range against the wall. 11

12 The example results have been calculated by using the formula: - p=k*0.5 *ρ*v 2 (1) where K= a pressure coefficient depending on building shape and the wind direction ρ= air density = 1,2,kg.m -3 v= the wind velocity [m.s -1 ] For air of standard density the above equation becomes p = K 0.6 v 2 Figure The wind pressure on the outer wall of a building with wind velocities of 0, 5 and 10 m/s on the wall Vertical position in building A temperature difference between indoor and outdoor air causes a pressure difference on the outer wall. An internal neutral plane is formed at some height above the building floor. The actual position of the neutral plane changes due to the influence of wind forces and openings (crackage) in the structure. Above the neutral plane the inner parts of the building are over-pressurized with respect to the outdoor air and below this point it has a negative pressure when outdoor air is colder than the indoor air. This causes problems to the resulting pressure ratios, especially when the room is located on the outer wall of a high quality process space. Figure shows graphically the pressure difference on the outer wall created by temperature difference, as a function of the distance from the neutral plane with different temperatures, for a room temperature of 20 o C. 12

13 Figure Pressure difference created by the temperature difference between the indoor and outdoor air, on the outer wall of the building with different outdoor air temperatures. The interaction of the wind and temperature differences on the pressure difference of the outer wall is shown in figure Problems of resulting pressure ratios will be created when the electrical equipment rooms are connected to both indoor and outdoor areas. If the room outlet is at a high position, the airflow will be outward from the space and if the outlet is at low level the flow will be reversed. Figure The interaction of wind and temperature on the outer wall of a building when θ = -20 C Surrounding rooms The external heat loads on electrical equipment rooms vary considerably. The external heat loads are due to open cable spaces, and adjacent process areas. The positioning of electrical equipment rooms close to hot process should be avoided. The pressure ratios in surrounding rooms will influence the design pressure conditions. A typical example is that a strongly negative-pressurized cable space will reduce the overpressure in an electrical equipment room. Cable spaces should be designed to have evenpressures. If located beside, under or over an electrical equipment room. Process spaces may be held at positive and negative pressure. 13

14 2.3.2 Tightness of the structure Introduction The air tightness of the structure is a critical factor when considering the influence the contaminant loads have on electrical equipment. It also influences the design of the ventilation system, as well as investment and operating costs. The design of the ventilation supply is related to the structural air tightness. The required over-pressure necessary to avoid infiltration will not be achieved if air leakage through the room structure is greater than that calculated. The tighter the structure, the less outdoor air flow is needed to provide the desired room over-pressure, the operating costs will also be reduced. The worst leakage areas are service holes and crackage in the structure, and it is essential that these be kept to a minimum. The structure of an electrical equipment room is usually brick, concrete or sheet metalmineral wool-sheet metal elements. Untreated tile and concrete surfaces and porous, and air flows through them. The structural leakage paths can be reduced by the use of special paints. If the electrical equipment room is built of sheet metal-mineral wool-sheet metal elements, the joints between the elements and connections to other structures have to be sealed to reduce external and internal air transfer. Partition walls also require sealing Estimation of the room tightness The general formula (Olander 1982) that describes the leakage air flow through walls, is following: Q VL = C * (dp) 0,65 [m 3 s -1 m -2, Pa 0,65 ] (2) Factor C varies according to the tightness of the wall, typical values being A tight wall An average wall A leaky wall 0,0003 0,0005 0,0007 With the above formula (2) the air tightness of electrical equipment rooms can be determined. The required air volume flow for the room pressurization depends not only on the room volume but also on the room shape and size. Therefore the correct design criteria must be based on room wall area. In normal cases the floor and ceiling can be considered as being airtight due to the coatings on them. Measurement of the make-up airflow according to new design criteria can be made using the diagram shown in Figure In properly sealed rooms the required make-up airflow, to maintain a 20 Pa overpressure in the room, is 2,1 l.s 1, per m 2 of wall. 14

15 Figure Dimensioning diagram for pressurization airflow in electrical equipment rooms After the electrical equipment room has been completed, it should be tested to ensure that the required over-pressure in the room is achieved with the designed outdoor airflow. In normal cases it is aimed to reach the over-pressure of 20 Pa with an outdoor airflow of 2,1 l/(s m 2 ) of wall. For checking the actual over-pressure, a pressure difference meter should be installed outside the door. The measurements recorded should logged and used for all future service checks. If the required over-pressure is not reached, or if it reduces during use, leakages may be the cause, and extra sealing is required. Fan problems also cause a pressure drop and fan airflow should be checked for design conditions. If the over-pressure is greater than the required design energy costs will increase Effect of openings on the room tightness DOORS: The number of doors must be kept to a minimum. Doors not in everyday use, like hauling and trap doors, should be securely sealed. It is recommended to use only one door in the room and carefully seal other exits. Doors in everyday use should have air locks to reduce uncontrollable airflow. Doors should be self-closing, essential fire doors must be fitted with tight seals. WINDOWS: These should be avoided in electrical equipment rooms. It is difficult to seal window frames. In addition solar radiation through the windows increases the external heat gain to the room. STRUCTURAL PENETRATIONS FOR CABLES AND PIPES: The holes for cables and pipes in the walls of the room should be sealed carefully with an incombustible airtight material. Gypsum can be used for sealing, but it can break down with movement. 15

16 Leaks through penetrations must not unduly impair the air tightness of the wall. This concerns the normal use, as not all of the so-called expanding sealants are suitable for stopping penetrations. When old building stock is being rebuilt, it is essential that an asbestos study be carried out before work commences. Asbestos was in the past frequently used in structural firebreaks. ELEMENT JOINTS: All the element joints have to be carefully sealed airtight before painting the walls. The expansion joints shall not be placed on the roof of an electrical equipment room. If an expansion joint has to be located in the room, it has to be carefully tightened Figures give examples of expansion joint construction Effect of the structural mass on the heat dynamics of the room Over a short time period, say, less than 10 minutes, the structural mass will not have a major influence on the decrement and the resulting thermal transmission. Obviously for a longer time period a heavy structure will balance out the room temperature changes. In the approach used, thermally lightweight structure rooms are formed when the mean surface areas are covered with timber panels or other similar materials. Structures made of light concrete are graded as medium structures. Spaces classed as heavy structures have at least a half of their surfaces of uncovered concrete. Figures show calculated warming curves with the help of two time-constants model for a 1000 m 3 type room during the period of time of eight hours. Figures indicate the effect of different parameters (heat load, initial temperature and weight of structure) to the warming of the room. Temperature of the environment was held at 25 C. 16

17 Figure Tightening the expansion joint, examples. 17

18 Figure Warming curves of a middle-heavy construction room with 4 different heat loads, when the initial temperature is 25 ºC. With heat loads less than 100 W.m 2 the room temperature will not rise above 40 ºC regardless of the nature of the structure when the outdoor temperature is +25º C. With heat loads of 200 W.m 2 the temperature of the room will rapidly rise over +40 ºC when the initial temperature is 35 ºC. With an initial temperature of 30 o C warming up to 40 ºC will take 3-8 hours regardless of the nature of the structure. In rooms of heavy structure, with heat loads over 300 W.m -2 the temperature will rise above 40 ºC regardless of the initial temperature. The temperature of an electrical equipment room cannot be controlled by structural means alone. As in the case of air conditioning plant failure with high heat gains, it is impossible to maintain the design temperature. In order to control the temperature the space must be provided with back up air-conditioning. Figure Warming curves of a light construction room with 4 different heat loads, with initial temperature 25 ºC. 18

19 Figure Warming curves of a medium heavy weight construction room with four different heat loads, with initial temperature at 30ºC Materials Construction materials Untreated tile and concrete surfaces liberate dust, causing electrical equipment problems. For this reason the walls of electrical equipment rooms have to be covered with a dustbinding coat of paint. Precoated sheet metal-mineral wool-sheet metal elements are also used Ceilings should not have mineral wool panels or other dust producing materials included in them. Alternatives for mineral wool are bag wool with a fabric top. Closed suspended ceilings, however, should be avoided in electrical equipment rooms Material emissions Materials that liberate gases due to aging, which are harmful to equipment, should not be used in electrical equipment rooms. After applying a surface coating, adequate time should be allowed for drying before the electrical equipment is installed. A typical drying-time for epoxy paints is 7 days and for acrylate latex 2-4 days, for wall temperatures of +20 C Insulation Moisture insulation and gas tightness The diffusion of moisture and gases through the walls should be avoided. Holes and cracks in the structure have to be filled with an airtight material. Surfaces to be sealed by specially selected paints such as Epoxy and acrylate latex paints. Alloprene and vinyl paints are not recommended, since they emit chlorine and hydrochloric acid during a fire. 19

20 Vapour barriers should be on the high moisture content side, usually the process side. The electrical equipment room surfaces should be painted to bind any dust. The cavity in the outer walls should be painted from inside Thermal insulation The heat load from the surrounding spaces into electrical equipment rooms might be high in excess of 100 W per-m 2 floors. Normally the main portion of the surrounding loads comes through the roof and/or the floor from the cable spaces. In the case of a wall separating a hot process area, thermal insulating is not normally economical unless other advantages are achieved such as improved reliability of temperature control in the case of ventilation plant failure Fire protection Requirements concerning fire protection are covered in National Building Regulations and in the requirements of insurance companies. During a structural or cable insulation fire toxic gases are emitted to a room (a typical example is PVC -> HCl). Care has to be taken in the design of exits from these areas. The water used for fire fighting these toxic gases forms an aggressive liquid that destroys equipment and primary structures. Typical conditions during a fire are covered in IEC Target level assessment The effect of environmental parameters on electrical equipment High temperature Effects of temperature on electrical equipment must consider: - The air temperature The equipment temperature. The equipment temperature depends on its electrical loading and its ability to liberate this heat to the surroundings. The convection to the surrounding air has a major influence on the rate of heat transfer. When the equipment has a cover, the thermal conductivity of the equipment and the path to the cover is an essential factor to consider. The actual temperatures at which a fault occurs, varies with different equipment. For example semiconductor silicon components can tolerate a range of 125 to 175 C while germanium components can only tolerate 70 to 100 C. The memory in a hard disk is damaged with a temperature in the 70 ºC range. The failure frequency of plant depends on the surrounding conditions, the load and the age of the equipment. A typical failure frequency curve for electronic equipment is shown in figure The service life of equipment can be divided into three stages. 20

21 The early operating period lasting for 0,5 to 2 years, when the failure frequency is 2-10-fold compared to the actual operating period. The actual operating period that in the normal conditions lasts for years after which the equipment is usually replaced with more efficient equipment. The ageing period when the frequency of failure increases rapidly. Figure A typical graph for the fail frequency of an electronic equipment (Z (t)=fail frequency) The temperature rise has a great influence on the failure frequency of electronic equipment. It is said that when the temperature rises by 10 C the frequency of failure doubles. It is assumed that the failure frequency of electronic components follows Arrhenius law: z=z 0 *e -E/(k*T) (3) where z= failure frequency z 0 =failure frequency in the normal conditions k=bolzmann's constant E=the activation energy of the fault mechanism T=the component temperature K The formula shows that temperature increase influences exponentially the failure frequency of components. If the electrical stress rate is high, the temperature effect increases the failure rate. Figure indicates how temperature, affects the failure frequency of components. The figure indicates the mean time between component failures as a function of the temperature. The mean time between failures (MTBF) is the inverse value of the failure frequency. Except for MTBF, the temperature will also influence also component efficiency. 21

22 Figure The predicted mean time between failures of equipment with different component choices (A and B) as a function of the temperature (m (h)= the mean time between failures) Excessive high temperatures ages electrical equipment reducing considerably their working period. It has been claimed that a temperature rise of 14 C reduces the lifetime of electronic components by 50% Cable insulating materials age with temperature increase, the lifetime of rubber insulating materials at different operating temperatures is given in table 2.4.1: Table The rubber insulation service life at different operating temperatures Temperature Insulation service life C years ,5 46 3,7 International research work has been carried out covering the environmental factors and their effects on electrical equipment. This work is published in the IEC (International Electronic Commission) standards, many of which have been adopted as European Standards. In standard EN the principal effects of environmental factors and typical faults caused by them are covered. The effects of high temperatures are shown in table 2.4.2: 22

23 Table The main effects of a high temperature and typical faults in electrical equipment Main effects Typical faults Thermal aging Insulation faults Oxidation Structural faults Cracking Impairment of greasing properties Chemical reactions Increase in the wearing of moving parts Growth of mechanical stress Softening Melting Sublimation Reduction of viscosity Evaporating Thermal expansion High temperatures also damages equipment indirectly by accelerating chemical reactions, resulting in corrosion by the air contaminants. For example when the temperature rises from 20 C to 30 C the reaction rate doubles. Evaporating of solvents and insulating materials resulting in an acceleration of gaseous contaminants, which further increase contact surfaces fouling Low temperature Low temperatures alone do not increase the failure frequency, provided the temperature stays above 0 C. See figure 2 where, the meantime between failures stay almost as constant between 0 and 20 C. Instability of equipment can cause a change in the parameter values, such temperature reduction, humidity, and air movement. If the intake air temperature is near to the room air dew point, moisture will condense on the surface of electrical equipment, with serious results. When the temperature falls below 0 C, the rate of failures increases rapidly. When the temperature drops to -40 C the failures of different components are about 10-fold compared to normal conditions. When the temperature is below 0 C, moisture condensing on surfaces will freeze in narrow spaces causing joint failure. The main effect of low temperatures and faults caused by them according to EN are shown in table 2.4.3: Table The main effects of low temperatures and typical faults in electrical equipment Main effects Typical faults Increase in viscosity Insulation faults Ice formation Impairment of greasing properties Embrittlement Sealing faults Shrinking Cracking Impairment of mech. strength Failure Structural faults Increase in wearing of moving parts 23

24 Rate of change in temperature Due to different thermal expansion coefficients, component can develop serious stresses if the component temperature varies from its design value. If the temperature changes constantly, the component will experience fatigue" and in time will fail. For example memory protection batteries will be damaged if the temperature increases too often above the permitted value. A single temperature increase above the permitted value will affect the storage capacity. In the EN standard the main effects of the temperature changes are thermal shocks and local temperature differences are covered. Typical faults caused by these are mechanical and insulation faults resulting in cracking and electrical leakage. Temperature changes influence the relative humidity of the surrounding air causing cause moisture to condense locally on components High relative humidity Changes in humidity influence the resistance of electrical insulating materials. These changes result in static electricity, particle formation and corrosion between different materials. It will also cause corrosion by: 1. Directly, by chemical reaction on metals and plastics Corrosive compounds forming with other gases in the air, e.g. sulphuric acid, H 2 SO 4 with sulphur dioxide SO 2 and nitric acid HNO 2 with nitrogen oxides. NOx 3. Electrochemically as an electrolyte on two different metals causing corrosion. For example: - a copper plate coated with gold, if moisture condenses on it electrolysis may result causing hairline cracks. The main problems and typical faults of high relative humidity is given in EN are listed in table Some insulating materials adsorb moisture at high relative humidity. This results in the electrical conductivity of insulating material increasing with electrical leakage causing equipment damage. Dust particles in the air, below a 1 µm (micrometer), can adsorb moisture and gaseous contaminants. This may accelerate equipment corrosion. Corrosion due to gaseous contaminants grows exponentially with an increase in relative humidity If the air relative humidity increases above 80%,the silver used in the circuit cards may develop a "migration phenomenon causing short circuits. The gold used to fasten chips to their beds also suffers from humidity and the chips may loosen and fail. 24

25 Table The main effects of a high relative humidity and typical faults in electrical equipment Main effects Typical faults Absorption of humidity and condensation on the surface of an article Mechanical faults Swelling Breaking Impairment of mechanical Insulation faults Strength Chemical reactions such as: - corrosion and electrolysis Increasing of the conductivity of the insulation When the relative humidity increases to 80 %, a water film forms on the equipment surfaces. High humidity is not an actual a problem in an automation/electrical equipment room with well-designed ventilation systems, as air movement at the correct temperature removes the moisture from the space. However if the intake air temperature is low, local moisture will condense. A failure in room over-pressurization and a poor moisture barrier will cause an increase in the local relative humidity Low relative humidity The main effects due to low relative humidity and the typical faults caused by them according to EN are given in table 2.4.5: Table The main effects of low relative humidity and typical faults in electrical equipment. Main effects Typical faults Drying Mechanical faults of non-metallic parts Embrittlement Cracking Shrinking Electrical faults Impairment of mechanical strength Increase in wearing of contact surfaces Developing of static charge The worst threat to electrical equipment from the above-causes is that low relative humidity increases the incidence of static charges. A static charge is when similar charges build up in a substance and do not immediately become neutralized with opposite charges. A typical electrostatic phenomenon is to have high potential differences, but the appearance of small quantities of electricity. Normally an electrical charge leaks slowly along the surface of a material or through it, without causing any problems. If the potential of a charged area becomes high, a powerful discharge occurs which may cause damages to equipment wiping out memory, cause electrical shocks to employees and create fire hazards. The aim of protection is to keep the leakage rate greater than its rate of generation. By maintaining the relative humidity in the % range will eliminate static electricity problems. As the temperature inside electrical motors is greater than that of the surrounding air, the relative humidity in the surrounding should be 65% or more. The problems of static 25

26 electricity are minimised when the relative humidity of the surrounding air is greater than 55%. Relative humidity influences occupant s safety. For example cotton clothing is safe due to its good electric conductance. This is true when the relative humidity is high, but below 40% relative humidity, cotton is a good insulating material. The value of clothing electric conductance is important to neutralize the electrical charges between man and electrical equipment. Wrist and foot straps will prevent electrostatic discharge from the people to equipment; this is often a much cheaper solution than humidifying the room. If the relative humidity drops below 40% static charges will attract dust particles and cause undesirable dust forming. The formed dust causes wear of contact surfaces, breaks and corrosion depending on the dust properties. The increase in contact faults with a decrease in relative humidity is covered in figure Figure The effects of relative humidity on the functioning of tele-exchanges Rate of change of the relative humidity Rapid changes in relative humidity may cause local condensation resulting in corrosion. The corrosion rate caused by gases increases considerably when the rate of change of the relative humidity is greater than 6% in an hour Chemically active substances The effect of chemically active corrosive gases on electrical equipment according to EN is given in table

27 Table The main effects of chemically active gases and typical faults in electrical equipment. Main effects Typical faults Chemical reactions Increased wearing Corrosion Mechanical faults Electrolysis Electrical faults Surface decay Increase in conductance Increase in contact resistance Mechanically active substances The effect of mechanically active substances, such as particulate matter, on electrical equipment is given in table Table The main effects of mechanically active gases and typical faults in electrical equipment. Main effects Typical faults Friction, wearing Mechanical faults Clogging Increased wearing Getting stuck Electrical faults Frictional electricity Over heating Increase in thermal insulation Basis for design of electrical equipment rooms Introduction The equipment supplier defines the environmental demands for each room, and the equipment heat loads. Initial information is given by the electrical designer. Table can be used to initially define the room environmental information during the preliminary design. Other heat loads are calculated individually for each case. Condition information/ checklist: Temperature Environment class + the requirements of air conditioning Target value Accuracy (range of variation) Steadiness (rate of change) Maximum and minimum values in the case of disturbance Humidity As temperature Chemical contaminants Environment class Permitted concentration for each gas 27

28 Particle contaminants Environment class Over-pressure/outdoor airflow Electrical equipment rooms are designed in over-pressure against environment. In normal case 20 Pa over-pressure is enough. It is reached in a tight room with makeup airflow of approx. 2,1 l.s 1 per m2 wall see figure The room design criteria will define the choice of the air conditioning system required. In addition to system selection the following have to be considered: - available space (foot print and height) reliability in use, and possible room future extension Pressurization As the requirements for electrical equipment room conditions are usually stricter than those in the surrounding areas, they require pressurising. Normally 20 Pa excess is adequate for rooms that border on outdoor air, see 2.3 and figure for details. When the conditions are extreme such as exposed sites high buildings and spaces having high negative pressures, the over-pressure and the air flow rates required, have to be calculated separately Introduction to the environmental parameter concept When the operating conditions of electronic equipment are defined, all the condition factors have to be determined for several operating parameters. The parameters can be divided into: - Base value i.e. normal conditions Range of variation above and below the base value Minimum and maximum values required when the equipment is in operation Minimum and maximum values required when the equipment is not operating The real limit values necessary to avoid equipment damage. The relationship between the parameters is shown in figure 2.4.4: 28

29 Figure Operating parameters and reliability of electronic components. The design value relates to the constant operating conditions (temperature, humidity, particulate matter etc.) required in the area where the equipment is in use. It is necessary these parameters be met to ensure operation reliably over its lifetime. When perfect functioning of equipment is required the conditions defined by the base values must be worked to. The variation range design values define the choice of surroundings in which the equipment reliability remains constant. The reliability over this range is obviously influenced by the rate of change of conditions. The design value and its variation range define the design conditions to be selected. Equipment in normal operating situations provides the initial values for the air conditioning designer. Maximum and minimum conditions, when the equipment is operating, define the extreme environmental values surrounding the equipment in a special case. These cover the event of failure of the air conditioning plant. When conditions reach the extreme values, there is a risk of equipment failure the maximum and the equipment manufacturer provides minimum conditions for equipment, these are based on test performance under given conditions. When designing electrical equipment room ventilation systems, it should be considered that the air conditioning system must operate after a malfunction, before extreme environmental conditions are reached and the manufacturing process fails. Environmental tests for electrical equipment have been standardised. The key methods of the testing are given in EN The environmental standards and the tests related to 29

30 them are used for defining the greatest short-term environmental stresses encountered for a product. However, these classes do not provide information regarding long-term stresses that influence the equipment for its lifetime. Even remaining within the tested environmental class does not guarantee a perfect function of the product in these conditions Long-term stresses can slowly influence the product quality and result finally in failure. The classification considers that different environmental parameters (temperature, humidity of air etc.) are symmetrically divided. The extreme values of classes have been chosen so that average equipment can tolerate that the conditions do not exceed the extreme value for no more than 1% of the operating time. Maximum and minimum values for non-operating periods are used for defining the equipment storing conditions. During installation and shutdown periods the air conditioning must operate to ensure the operating conditions are achieved as soon as possible. When conditions reach the equipment critical limit immediate failure may result Climatic conditions (temperature and humidity) As the basis for designing air conditioning systems, a conditions curve of 75% is used. In practice the humidity can be varied over a wider range of this curve because air humidity in a space changes with the seasons, hence the risk of extreme humidity does not continue over the whole of the time. Some classes are more flexible regarding the requirements of air conditioning. Hence certain precautions can be permitted so that the temperature approaches the outdoor extreme design conditions. The extreme conditions of electrical equipment correspond to the 99% values on the conditions curve. Air-conditioning design has to ensure that the room conditions achieve average values in the middle of the permitted area. Hence care has to be taken with selection of the air terminal devices and their actual positioning. Design requirements are compiled by considering the electrical equipment in the room. Extra requirements for each room, such as workplaces, have also to be considered, see Rooms with high heat loads must be prepared for a sudden temperature change due to malfunction or failure of the air conditioning. This is achieved by reducing the room temperature level with backup equipment or by natural ventilation. The conditions that correspond to individual rooms requirements should be maintained during shutdowns, as moisture condensing on electrical equipment may cause damage on plant start up. When the temperature rate of change is calculated during the design, the initial assumption is perfect mixing. The rate of change has to remain in the given range during a period of 5 30

31 minutes. The calculations have considered the structural damping effect on temperature change. This is achieved by the use of two time-constants models. During operation, the room conditions have to stay within given limits of the electrical equipment. This means the volume around the equipment measured from the floor level up to two meters, and at least to the 50 cm from the equipment surface. The measuring should not be carried out near an air conditioning unit (the minimum distance is 1 m) or in its airflow. Hence positioning of control sensing devices must be taken into account. The design basis given is intended for forced ventilation design. Natural ventilation can be applied by applying the design values of electrical equipment (extreme values). Table and climatographs (see Appendix 1) the air conditioning design conditions for different climatic conditions have to be considered Special climatic conditions Most equipment permits air velocities greater than those mentioned above. This is dealt with separately in special climatic conditions categories. The permitted air velocities in the different classes are given in table Table Special climatic conditions; the permitted air velocity in the different condition classes Condition class Permitted air velocity m.s -1 3Z4 3Z5 3Z6 5 m.s m.s m.s Chemically active substances (corrosive gases) The permitted concentrations of chemically active gases in electrical equipment environments are defined in the classes C of the EN , standard as are chemically active substances. In table the maximum values of different gases for air conditioning design are given. Since the concentrations in the strictest classifications are extremely small, comparison at the size range level with classes (G1-G3, G) of standard ISA are used. The copper-strip method in the above standard can be used to estimate the rooms surrounding classification. The following are the two most critical classes, since concentrations of the other classes are so high, that these other classes are irrelevant for electrical equipment rooms. 31

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