ENGINEERING REPORT. XYZ Corporation 100 Anyplace Drive Chicago, Illinois 60613

Transcription

1 ENGINEERING REPORT XYZ Corporation 100 Anyplace Drive Chicago, Illinois PERFORMED BY: MIDWEST ELECTRICAL CONSULTANTS, INC UPLAND DRIVE TINLEY PARK, ILLINOIS (708) fax: POWER QUALITY TESTING & INSPECTIONS OF TRANE AIR CONDITIONING COMPRESSOR(S) ELECTRICAL SERVICE PROJECT: C822 1

2 D.J. Sweeney Electric May 5, Hopson Valley Drive Woodridge, Illinois Re: Power quality testing & inspections of Trane compressor(s) electrical service Attention: Mr. Timothy Sweeney, Enclosed is the engineering report detailing the project that we recently completed at the XYZ Corporation 100 Anyplace Drive Chicago, Illinois MEC is a full service independent testing company and appreciates the opportunity to provide your system review, inspection, power quality testing and engineering support services. Our mission is to provide an independent technical service to enhance the safety, reliability and efficiency of electrical systems. Thank you for the opportunity to provide this service. Please contact us if you have any questions or wish to know more about our services. Respectfully Submitted, Douglas Christianson Electrical Engineer Cc: Mr. William W. Baird - XYZ Corporation Cc: Mr. Robert Rogers - Advantage Electric Cc: Mr. Timothy Fashing - Roberts Mechanical 2

3 ENGINEERING REPORT XYZ Corporation 100 Anyplace Drive Chicago, Illinois Power Quality Testing & Inspections of Trane Compressor(s) Electrical Service SECTION 1 SECTION 2 SECTION 3 SCOPE; PURPOSE; PROCEDURE; APPRAISAL AND RECOMMENDATIONS POWER QUALITY MONITORING DATA (separate file) ADDITIONAL TESTING SUPPORT DATA (separate file) 3

4 ENGINEERING REPORT XYZ Corporation Chicago, IL Power Quality Testing & Inspections of Trane Compressor(s) Electrical Service SECTION I SCOPE: On April 29, 2008, Midwest Electrical Consultants, Inc. (MEC) provided power quality testing and inspections at the XYZ Corporation 100 Anyplace Drive Chicago, Illinois twin Trane Heli Rotor RTWA070AY001C3DOWN air conditioning compressor(s) electrical service. All testing and inspections were performed according to the manufacturer and International Electrical Testing Association (NETA) recommendations. Detailed inspection notes and observations documented during the execution of this project are contained in the additional support test data (separate file) test data section (separate file) and recommendation section of this engineering report. This summary contains data for the completed inspections. PURPOSE: The purpose of this inspection and subsequent report is to provide information relative to the operation of the Trane air conditioning compressor(s) electrical service and equipment located in the XYZ Corporation building. This report is intended to assist you in planning for upgrades or changes to the electrical system, increase the safety of the electrical system through inspections and provide recommendations for future equipment usage at the facility. It is not intended to imply that other equipment issues or recommendations not covered in this scope may or may not exist at the time of the inspection. PROCEDURE: All inspections and recommendations are performed in accordance with MEC s standard procedures including, but not limited to, selected specifications from the following: International Electrical Testing Association (NETA), National Electrical Code (NEC), National Fire Protection Association 70B-Electrical Equipment Maintenance (NFPA 70B), Institute of Electrical and Electronic Engineers (IEEE), American Society for Testing and Materials (ASTM), National Electrical Manufacturer's Association (NEMA), Occupational Safety and Health Administration (OSHA), unless otherwise noted. INSPECTIONS: The electrical distribution equipment associated with the Trane air conditioning compressor(s) electrical service was inspected for installation according to standard NEC practices, appropriate sizing and cleanliness. Equipment inspections included the grounding system and ground system bonding. 4

5 ENGINEERING REPORT XYZ Corporation 100 Anyplace Drive Chicago, Illinois Power Quality Testing & Inspections of Trane Compressor(s) Electrical service APPRAISAL AND RECOMMENDATIONS: The Trane Heli Rotor air conditioning compressor(s) system was found to be installed according to manufacture and electrical standard practices. A digital power recorder was installed at the local compressor(s) disconnect and allowed to monitor during multiple starts of the unit. Compressor(s) disconnect location (240 volt compressor) 1) Utility/system voltage levels were found to be imbalanced during the monitoring period (approximately 4.7%). Average voltage levels were found to be 236 volts on A-B, 247 volts on B-C, 245 volts on C-A. Voltage magnitudes were consistent during compressor(s) starts, indicating the system is not overloaded. MEC recommends review of the electrical service voltage levels with the utility to determine if the voltage imbalance is caused by service entrance equipment (transformer(s), cabling, connectors, etc.) or utility distribution (grid) system voltage deviation caused perhaps by loading or other issues. 2) Compressor(s) motor currents (amps) were found to be severely imbalanced at the main disconnect panel. Average current for each phase was 28.6 amps- Phase A, 46.3 amps - Phase B, and 54.7 amps - Phase C per motor. Load imbalances greater than 4% (91% during the monitoring period) would typically indicate an internal motor problem. Further investigation indicates a different problem exists at this location. Motor leads were moved to accommodate proper rotation at the compressor(s) control board. Upon restart of the compressor(s) with exchanged phasing, the voltage and current imbalances followed the same phases to different motor windings (See two attached files, section 2 power quality monitoring data, and section 3 additional testing support data). Investigation of the electrical service voltage levels is recommended. 3) Overhead transformers providing service for the facility were inspected for proper installation and operation. Inspection of the transformers indicate that transformer bank A (East) is currently or was previously overloaded. Localized discoloration and corrosion of transformer tank components (secondary bushings) generally indicates an overloaded condition. MEC recommends investigation of the electrical transformers by utility personnel. 5

6 4) Voltage magnitudes at the utility transformer secondary locations were found to be identical to the voltage levels measured at the compressor(s) disconnect location. Due to similar voltage readings, we recommend a review of the utility distribution system. 5) We recommend that an adequately sized dedicated power source (e.g. diesel or natural gas generator) be used to support the compressor(s) load to confirm the existing utility source issue, and run the equipment until the problem is corrected. APPRAISAL AND RECOMMENDATIONS: General 1) MEC recommends REGULAR ELECTRICAL INSPECTIONS, CLEANING AND TESTING of electrical equipment to assist in identifying deteriorated insulation, abnormal operating temperatures and malfunctioning protective devices prior to equipment failure. 2) All electrical protective equipment including ground fault relays, circuit breakers and fused disconnects should be tested, exercised and lubricated on a regular basis. Mechanical equipment may not operate properly when called upon if regular maintenance is neglected. 3) New OSHA requirements have been issued regarding Arc Flash recommendations and personnel safety. New Arc Flash requirements will require all facilities (industrial, commercial, institutional) to display information about the arc flash availability at each panel, switch or breaker where the equipment is accessible by maintenance/site personnel. The arc flash information on the panel fronts will indicate the level of clothing and level of training required to open and maintain the equipment within the panel or switchboard. See note #2 above; protective equipment which does not operate within specified tolerances (tripping time or magnitudes) will invalidate any Arc flash study results. 4) Transient voltage surge suppressor (tvss) units were not evident on any of the electrical distribution equipment we inspected or tested at. We recommend the installation of a properly sized high quality tvss unit on the main electrical switchboard. The main tvss unit will mitigate or remove any and all transient voltage spike and surge disturbances caused externally to the building (lightning, electrical storms, downed power lines, utility company switching, high winds, tree branches, ice/snow on utility lines and distribution equipment, other utility customers in close proximity, etc.) Also secondary sub panel or final point of protection tvss units should be installed on or at ALL critical equipment especially electronic loads (fire alarm, security, telephone, roof hvac, elevators, etc.) to address or clamp internally generated switching transient/surge events created by all electrical and electronic equipment being turned off and on or duty cycled within the building. The secondary level of protection would also act as back up protection should the primary tvss unit become damaged or sacrificial. 6

7 All plug in or corded electronic equipment (pc s, monitors, printers, modems, Fax, etc.) should be plugged into a quality corded power strip tvss unit. I would direct your attention to the documentation I left with you for a more detailed explanation on this subject. We would be happy to provide any engineering assistance in the selection or installation of any of the transient voltage surge suppressors outlined in this report. 7

8 Power Analysis Collected Data Summary Section 2 Introduction This is a summary of the power conditions at the XYZ Coporation 100 Anyplace Drive Chicago, Illinois as recorded at location delta setup#2 Trane Heli Rotor air conditioning compressor(s) service disconnect. Data at this location was collected from 04/29/08 11:16:18 through 04/29/08 11:31:18. This summary is composed of: The Voltage Current and Frequency, (VIF), section. This section contains summaries for each of these parameters during the monitor interval. The Harmonics section. This contains the voltage and current harmonic, and harmonic distortion summaries acquired during the monitor interval. The Power section. This contains the VA, VARS., Watts, and Power factor acquired during the monitor interval. For multiphase locations, voltage and current imbalance are also included. Site and Location Information Site Information Name XYZ Coporation Account Number Date and Time 04/29/08 09:24:20 Phone Number Contact Memo Problem Description Date First noticed 04/29/08 Problem Frequency Unknown How problem exhibits itself Unknown Problem Cost Location Information Name delta setup #2 Trane compressor(s) service disconnect Power Type Three phase delta Feed Phase Unknown Phone Date and Time 04/29/08 11:06:38 Nominal Voltage 240 Volts Nominal Frequency 60 Hz 1

9 Report Parameters This report was prepared on 4/29/2008 by Midwest Electrical Consultants, Inc Upland Drive Tinley Park, Illinois (708) fax: The following limits were used in analyzing the results. Maximum Phase Voltage. 254 volts Minimum Phase Voltage. 208 volts Maximum Impulse Voltage. 500 volts Maximum. Waveshape Voltage. 10 volts Maximum Frequency Deviation..02 Hz Minimum Power Factor..85 Maximum Voltage T.H.D. 5 % Maximum Current T.H.D 20 % Maximum Voltage Imbalance. 2 % Maximum Current Imbalance. 5 % Any values outside these limits are noted in the report. Values within the limits are considered to be within a safe operating range. These limits have been programmed by Midwest Electrical Consultants, Inc. 2

10 Voltage, Current and Frequency Summaries Voltage, Current and Frequency measurements for XYZ Coporation:delta setup#2 from 04/29/08 11:16:18 through 04/29/08 11:31:18. RMS. Voltages Value Date and Time Phase A minimum 229.2V Apr :21:22 Phase A average 235.8V Phase A maximum 240.4V Apr :21:22 Phase B minimum 240.3V Apr :21:22 Phase B average 247.2V Phase B maximum 255.3V Apr :21:22 Phase C minimum 239.5V Apr :19:48 Phase C average 245.1V Phase C maximum 252.2V Apr :21:22 RMS. Currents Value Date and Time Phase A minimum 549.3mA Apr :21:41 Phase A average 11.93A Phase A maximum 380.3A Apr :19:49 Phase B minimum 3.662A Apr :21:52 Phase B average 20.53A Phase B maximum 487.2A Apr :22:18 Phase C minimum 1.098A Apr :18:23 Phase C average 23.14A Phase C maximum 343.5A Apr :22:18 Frequency Value Date and Time Phase A minimum 42.12Hz Apr :21:22 Phase A average 43.61Hz Phase A maximum 44.69Hz Apr :16:42 Phase B minimum 42.12Hz Apr :21:22 Phase B average 43.61Hz Phase B maximum 44.69Hz Apr :16:42 Phase C minimum 42.12Hz Apr :21:22 Phase C average 43.61Hz Phase C maximum 44.69Hz Apr :16:42 3

11 RMS. Voltage Summaries for XYZ Coporation:delta setup#2. Phase A Voltage Summary. Min. Avg V 235.8V Apr :21:22 Max V Apr :21:22 4

12 Phase B Voltage Summary. Min. Avg V 247.2V Apr :21:22 Max V Apr :21:22 5

13 Phase C Voltage Summary. Min. Avg V 245.1V Apr :19:48 Max V Apr :21:22 6

14 RMS. Current Summaries for XYZ Coporation:delta setup#2. Phase A Current Summary. Min. Avg mA 11.93A Apr :21:41 Max A Apr :19:49 7

15 Phase B Current Summary. Min. Avg A 20.53A Apr :21:52 Max A Apr :22:18 8

16 Phase C Current Summary. Min. Avg A 23.14A Apr :18:23 Max A Apr :22:18 9

17 Voltage and Current Distortion Summaries Voltage and Current harmonic distortion measurements for XYZ Coporation:delta setup#2 from 04/29/08 11:16:18 through 04/29/08 11:31:18. Voltage Distortion Value Date and Time Phase A minimum 2.83% Apr :23:55 Phase A average 3.388% Phase A maximum 5.68% Apr :21:22 Phase B minimum 2.55% Apr :21:00 Phase B average 3.039% Phase B maximum 4.83% Apr :21:22 Phase C minimum 2.95% Apr :19:15 Phase C average 3.523% Phase C maximum 5.38% Apr :21:22 Current Distortion Value Date and Time Phase A minimum 4.81% Apr :19:48 Phase A average 34.15% Phase A maximum 67.92% Apr :17:47 Phase B minimum 4.06% Apr :19:48 Phase B average 121.5% Phase B maximum 308.2% Apr :17:42 Phase C minimum 3.8% Apr :19:48 Phase C average 30.55% Phase C maximum 143.9% Apr :16:43 Voltage Flicker Value Date and Time Phase A minimum Phase A average Phase A maximum Phase B minimum Phase B average Phase B maximum Phase C minimum Phase C average Phase C maximum N/A N/A N/A N/A N/A N/A N/A N/A N/A 10

18 Voltage T.H.D. Summaries for XYZ Coporation:delta setup#2. Phase A Voltage Distortion. Min. Avg. 2.83% 3.388% Apr :23:55 Max. 5.68% Apr :21:22 11

19 Phase B Voltage Distortion. Min. Avg. 2.55% 3.039% Apr :21:00 Max. 4.83% Apr :21:22 12

20 Phase C Voltage Distortion. Min. Avg. 2.95% 3.523% Apr :19:15 Max. 5.38% Apr :21:22 13

21 Current T.H.D. Summaries for XYZ Coporation:delta setup#2. Phase A Current Distortion. Min. Avg. 4.81% 34.15% Apr :19:48 Max % Apr :17:47 14

22 Phase B Current Distortion. Min. Avg. 4.06% 121.5% Apr :19:48 Max % Apr :17:42 15

23 Phase C Current Distortion. Min. Avg. 3.8% 30.55% Apr :19:48 Max % Apr :16:43 16

24 Power Summaries Power measurements for XYZ Coporation:delta setup#2 from 04/29/08 11:16:18 through 04/29/08 11:31:18. Imbalance Value Date and Time Minimum Voltage Imbalance 2.68% Apr :23:30 Average Voltage Imbalance 2.840% Maximum Voltage Imbalance 3.37% Apr :21:22 Minimum Current Imbalance 2.17% Apr :22:17 Average Current Imbalance 48.58% Maximum Current Imbalance 154.8% Apr :16:43 VA Power Value Date and Time Phase A minimum 97.69VA Apr :21:41 Phase A average 1.660kVA Phase A maximum 51.31kVA Apr :19:49 Phase B minimum 512.7VA Apr :21:52 Phase B average 2.868kVA Phase B maximum 65.88kVA Apr :22:18 Phase C minimum 179.5VA Apr :21:48 Phase C average 3.346kVA Phase C maximum 48.39kVA Apr :22:18 Total minimum 925.0VA Apr :21:48 Total average 7.874kVA Total maximum 77.57kVA Apr :19:48 VARS Power Value Date and Time Phase A minimum kVAR Apr :19:49 Phase A average 1.457kVAR Phase A maximum 49.95kVAR Apr :22:18 Phase B minimum kVAR Apr :22:18 Phase B average 1.475kVAR Phase B maximum 26.88kVAR Apr :22:17 Phase C minimum kVAR Apr :16:43 Phase C average 2.845kVAR Phase C maximum 46.66kVAR Apr :22:18 Total minimum kVAR Apr :16:43 Total average 5.777kVAR Total maximum 68.11kVAR Apr :19:48 17

25 Watts Power Value Date and Time Phase A minimum kW Apr :19:49 Phase A average 737.8W Phase A maximum 15.35kW Apr :22:18 Phase B minimum W Apr :21:22 Phase B average 2.118kW Phase B maximum 19.78kW Apr :22:18 Phase C minimum kW Apr :21:22 Phase C average 1.706kW Phase C maximum 20.38kW Apr :19:49 Total minimum W Apr :21:22 Total average 4.563kW Total maximum 36.85kW Apr :19:48 Demand Power Value Date and Time Phase A minimum 645.8W Apr :16:42 Phase A average 707.4W Phase A maximum 788.7W Apr :21:18 Phase B minimum 1.806kW Apr :16:42 Phase B average 1.982kW Phase B maximum 2.214kW Apr :21:18 Phase C minimum 1.434kW Apr :16:42 Phase C average 1.570kW Phase C maximum 1.750kW Apr :21:18 Total minimum 3.887kW Apr :16:42 Total average 4.260kW Total maximum 4.753kW Apr :21:18 Power Factor Value Date and Time Phase A minimum Lead Apr :19:49 Phase A average Lag Phase A maximum Lag Apr :21:22 Phase B minimum Lead Apr :21:22 Phase B average Lag Phase B maximum Lag Apr :17:46 Phase C minimum Lead Apr :16:43 Phase C average Lag Phase C maximum Lag Apr :16:43 Total minimum Apr :22:18 Total average Total maximum 0 Apr :21:23 18

26 Voltage and Current Imbalance Summaries for XYZ Coporation:delta setup#2. Minimum Voltage Imbalance 2.68% Apr :23:30 Average Voltage Imbalance 2.840% Maximum Voltage Imbalance 3.37% Apr :21:22 19

27 Minimum Current Imbalance 2.17% Apr :22:17 Average Current Imbalance 48.58% Maximum Current Imbalance 154.8% Apr :16:43 20

28 VA Power Summaries for XYZ Coporation:delta setup#2. Phase A VA Summary. Min VA Apr :21:41 Avg kVA Max kVA Apr :19:49 21

29 Phase B VA Summary. Min VA Apr :21:52 Avg kVA Max kVA Apr :22:18 22

30 Phase C VA Summary. Min VA Apr :21:48 Avg kVA Max kVA Apr :22:18 23

31 Total VA Summary. Min VA Apr :21:48 Avg kVA Max kVA Apr :19:48 24

32 VARS Power Summaries for XYZ Coporation:delta setup#2. Phase A VARS Summary. Min kVAR Apr :19:49 Avg kVAR Max kVAR Apr :22:18 25

33 Phase B VARS. Summary. Min kVAR Apr :22:18 Avg kVAR Max kVAR Apr :22:17 26

34 Phase C VARS. Summary. Min kVAR Apr :16:43 Avg kVAR Max kVAR Apr :22:18 27

35 Total VARS Summary. Min kVAR Apr :16:43 Avg kVAR Max kVAR Apr :19:48 28

36 WATTS Power Summaries for XYZ Coporation:delta setup#2. Phase A Watts Summary. Min kW Apr :19:49Avg W Max kW Apr :22:18 29

37 Phase B Watts. Summary. Min W Apr :21:22 Avg kW Max kW Apr :22:18 30

38 Phase C Watts. Summary. Min kW Apr :21:22 Avg kW Max kW Apr :19:49 31

39 Total Watts Summary. Min W Apr :21:22 Avg kW Max kW Apr :19:48 32

40 Power Factor Summaries for XYZ Coporation:delta setup#2. Phase A Power Factor Summary. Min Lead Apr :19:49 Avg Lag Max Lag Apr :21:22 33

41 Phase B Power Factor. Summary. Min Lead Apr :21:22 Avg Lag Max Lag Apr :17:46 34

42 Phase C Power Factor. Summary. Min Lead Apr :16:43 Avg Lag Max Lag Apr :16:43 35

43 Total Power Factor Summary. Min Apr :22:18 Avg Max. 0 Apr :21:23 36

44 SECTION 3 MIDWEST ELECTRICAL CONSULTANTS, INC UPLAND DRIVE TINLEY PARK, ILLINOIS (708) fax: Trane Heli Rotor compressor motor power supply testing : Tests performed during the monitoring period at the XYZ Coporation 100 Anyplace Drive Chicago, Illinois 60613, consisted of rotation of the phases to test the compressor(s) equipment for problems. Amperage readings are taken on each phase, then the phases are rotated and a second set of amperage readings are taken. Comparing the two sets of readings indicates if the problem is located in the motor or power supply system. The following example in figures 1 and 2 illustrates the procedure per motor: Step 1: Measure all three legs A phase amps B phase amps C phase amps Figure 1 Page 2

45 Figure 2 Step 3: Measure amperages again C phase amps A phase amps B phase amps Notice that the amperages rotated with the wires. This indicates the problem lies within the utility electrical supply to the facility, had the amperages remained with the motor windings when the wires were rotated, the problem would have been in the motor windings. Page 2