Wednesday, December 2, 2009

History Of Power Frequency

Many different power frequencies were used in the 19th century. Very early isolated AC generating schemes used arbitrary frequencies based on convenience for steam engine, water turbine and electrical generator design. Frequencies between 16⅔ Hz and 133⅓ Hz were used on different systems. For example, the city of Coventry, England, in 1895 had a unique 87 Hz single-phase distribution system that was in use until 1906. The proliferation of frequencies grew out of the rapid development of electrical machines in the period 1880 through 1900. In the early incandescent lighting period, single-phase AC was common and typical generators were 8-pole machines operated at 2000 RPM, giving a frequency of 133 cycles per second.

Though many theories exist, and quite a few entertaining urban legends, there is little certitude in the details of the history of 60 Hz vs 50 Hz.



The German company AEG (descended from a company founded by Edison in Germany) built the first German generating facility to run at 50 Hz, allegedly because 60 was not a preferred number. AEG's choice of 50 Hz is thought by some to relate to a more "metric-friendly" number than 60. At the time, AEG had a virtual monopoly and their standard spread to the rest of Europe. After observing flicker of lamps operated by the 40 Hz power transmitted by the Lauffen-Frankfurt link in 1891, AEG raised their standard frequency to 50 Hz in 1891.

Westinghouse Electric decided to standardize on a lower frequency to permit operation of both electric lighting and induction motors on the same generating system. Although 50 Hz was suitable for both, in 1890 Westinghouse considered that existing arc-lighting equipment operated slightly better on 60 Hz, and so that frequency was chosen.[5] Frequencies much below 50 Hz gave noticeable flicker of arc or incandescent lighting. The operation of Tesla's induction motor required a lower frequency than the 133 Hz common for lighting systems in 1890. In 1893 General Electric Corporation, which was affiliated with AEG in Germany, built a generating project at Mill Creek, California using 50 Hz, but changed to 60 Hz a year later to maintain market share with the Westinghouse standard.



25 Hz origins

The first generators at the Niagara Falls project, built by Westinghouse in 1895, were 25 Hz because the turbine speed had already been set before alternating current power transmission had been definitively selected. Westinghouse would have selected a low frequency of 30 Hz to drive motor loads, but the turbines for the project had already been specified at 250 RPM. The machines could have been made to deliver 16⅔ Hz power suitable for heavy commutator-type motors but the Westinghouse company objected that this would be undesirable for lighting, and suggested 33⅓ Hz. Eventually a compromise of 25 Hz, with 12 pole 250 RPM generators, was chosen. Because the Niagara project was so influential on electric power systems design, 25 Hz prevailed as the North American standard for low-frequency AC.

40 Hz origins

A General Electric study concluded that 40 Hz would have been a good compromise between lighting, motor, and transmission needs, given the materials and equipment available in the first quarter of the 20th Century. Several 40 Hz systems were built. The Lauffen-Frankfurt demonstration used 40 Hz to transmit power 175 km in 1891. A large interconnected 40 Hz network existed in north-east England (the Newcastle-upon-Tyne Electric Supply Company, NESCO) until the advent of the National Grid (UK) in the late 1920s, and projects in Italy used 42 Hz. The oldest continuously-operating commercial hydroelectric power plant in the United States, at Mechanicville, New York, still produces electric power at 40 Hz and supplies power to the local 60 Hz transmission system through frequency changers. Industrial plants and mines in North America and Australia sometimes were built with 40 Hz electrical systems which were maintained until too uneconomic to continue. Although frequencies near 40 Hz found much commercial use, these were bypassed by standardized frequencies of 25, 50 and 60 Hz preferred by higher volume equipment manufacturers.

Standardization

In the early days of electrification, so many frequencies were used that no one value prevailed (London in 1918 had 10 different frequencies). As the 20th century continued, more power was produced at 60 Hz (North America) or 50 Hz (Europe and most of Asia). Standardization allowed international trade in electrical equipment. Much later, the use of standard frequencies allowed interconection of power grids. It wasn't until after World War II with the advent of affordable electrical consumer goods that more uniform standards were enacted.

In Britain, implementation of the National Grid starting in 1926 compelled the standardization of frequencies among the many interconnected electrical service providers. The 50 Hz standard was completely established only after World War II.

Because of the cost of conversion, some parts of the distribution system may continue to operate on original frequencies even after a new frequency is chosen. 25 Hz power was used in Ontario, Quebec, the northern USA, and for railway electrification. In the 1950s, many 25 Hz systems, from the generators right through to household appliances, were converted and standardized. Some 25 Hz generators still exist at the Beck 1 and Rankine generating stations near Niagara Falls to provide power for large industrial customers who did not want to replace existing equipment; and some 25 Hz motors and a 25 Hz electrical generator power station exist in New Orleans for floodwater pumps. Some of the metre gauge railway lines in Switzerland operate at 16⅔ Hz, which can obtained from the local 50 Hz 3 phase power grid through frequency converters.

In some cases, where most load was to be railway or motor loads, it was considered economic to generate power at 25 Hz and install rotary converters for 60 Hz distribution.Converters for production of DC from alternating current were larger and more efficient at 25 Hz compared with 60 Hz. Remnant fragments of older systems may be tied to the standard frequency system via a rotary converter or static inverter frequency changer. These allow energy to be interchanged between two power networks at different frequencies, but the systems are large, costly, and consume some energy in operation.

Rotating-machine frequency changers used to convert between 25 Hz and 60 Hz systems were awkward to design; a 60 Hz machine with 24 poles would turn at the same speed as a 25 Hz machine with 10 poles, making the machines large, slow-speed and expensive. A ratio of 60/30 would have simplified these designs, but the installed base at 25 Hz was too large to be economically opposed.

In the United States, the Southern California Edison company had standardized on 50 Hz. Much of Southern California operated on 50 Hz and did not completely change frequency of their generators and customer equipment to 60 Hz until around 1948. Some projects by the Au Sable Electric Company used 30 Hz at transmission voltages up to 110,000 volts in 1914.

In Mexico, areas operating on 50 Hz grid were converted during the 1970s, uniting the country under 60 Hz.

In Japan, the western part of the country (Kyoto and west) uses 60 Hz and the eastern part (Tokyo and east) uses 50 Hz. This originates in the first purchases of generators from AEG in 1895, installed for Tokyo, and General Electric in 1896, installed in Osaka.

Utility Frequencies in Use in 1897 in North America
Cycles Description
140 Wood arc-lighting dynamo
133 Stanley-Kelly Company
125 General Electric single-phase
66.7 Stanley-Kelly company
62.5 General Electric "monocyclic"
60 Many manufacturers, becoming "increasing common" in 1897
58.3 General Electric Lachine Rapids
40 General Electric
33 General Electric at Portland Oregon for rotary converters
27 Crocker-Wheeler for calcium carbide furnaces
25 Westinghouse Niagara Falls 2-phase - for operating motors

Even by the middle of the 20th century, utility frequencies were still not entirely standardized at the now-common 50 Hz or 60 Hz. In 1946, a reference manual for designers of radio equipment listed the following now obsolete frequencies as in use. Many of these regions also had 50 cycle, 60 cycle or direct current supplies.

Frequencies in Use in 1946 (As well as 50 Hz and 60 Hz)
Cycles Region
25 Canada (Southern Ontario), Panama Canal Zone(*), France, Germany, Sweden, UK, China, Hawaii,India, Manchuria,
40 Jamaica, Belgium, Switzerland, UK, Federated Malay States, Egypt, West Australia(*)
42 Czechoslovakia, Hungary, Italy, Monaco(*), Portugal, Romania, Yugoslavia, Libya (Tripoli)
43 Argentina
45 Italy, Libya (Tripoli)
76 Gibraltar(*)
100 Malta(*), British East Africa

Where regions are marked (*), this is the only utility frequency shown for that region.

Harmonics Resonance

Harmonics Resonance is a phenomenon which can occur in a power system. It can cause system instability or damage to electrical components such as capacitors and transformers. Harmonic resonance occurs when the inductive reactance and the capacitive reactance of the power system become equal.

However, as the order of the harmonics (frequency) increases, the inductive reactance increases while the capacitive reactance decreases.

At a particular frequency of harmonics, the inductive and capacitive reactances become equal and resonance sets in. Resonance can cause erratic conditions in the power systems such as transient high or low voltages, unexplained breakdown of equipment such as failure of transformer windings or failure of capacitor. Transient voltages generated by such harmonics resonance can also result in unexpected operation of relays and breakers.



The phenomenon of Harmonic Resonance should be borne in mind when modifying the system to add capacitors to improve the power factor or when adding new inductive loads such as motors, reactors, or transformers to existing systems containing capacitors.

The formula to determine the order of harmonic which may cause resonance is



where MVAsc is the impedance of the source and MVARcap is the reactive power drawn by the capacitors.Thus when a 20 MVAr capacitance is connected across a source of 1000 MVA, there will be a condition of resonance at the 7th Harmonic.

The possibility of harmonic resonance should be explored and eliminated during any modification/addition of loads in the power system.

AC Motor Construction

Three-phase AC induction motors are commonly used in industrial applications. This type of motor has three main parts, rotor, stator, and enclosure. The stator and rotor do the work, and the enclosure protects the stator and rotor.



Stator Core
The stator is the stationary part of the motor’s electromagnetic circuit. The stator core is made up of many thin metal sheets, called laminations. Laminations are used to reduce energy loses that would result if a solid core were used.



Stator Windings Stator laminations are stacked together forming a hollow cylinder. Coils of insulated wire are inserted into slots of the stator core.



When the assembled motor is in operation, the stator windings are connected directly to the power source. Each grouping of coils, together with the steel core it surrounds, becomes an electromagnet when current is applied. Electromagnetism is the basic principle behind motor operation.



Rotor Construction
The rotor is the rotating part of the motor’s electromagnetic circuit. The most common type of rotor used in a three-phase induction motor is a squirrel cage rotor. Other types of rotor construction is discussed later in the course. The squirrel cage rotor is so called because its construction is reminiscent of the rotating exercise wheels found in some pet cages.



A squirrel cage rotor core is made by stacking thin steel laminations to form a cylinder.



Rather than using coils of wire as conductors, conductor bars are die cast into the slots evenly spaced around the cylinder. Most squirrel cage rotors are made by die casting aluminum to form the conductor bars. Siemens also makes motors with die cast copper rotor conductors. These motor exceed NEMA Premium efficiency standards.

After die casting, rotor conductor bars are mechanically and electrically connected with end rings. The rotor is then pressed onto a steel shaft to form a rotor assembly.


Enclosure
The enclosure consists of a frame (or yoke) and two end brackets (or bearing housings). The stator is mounted inside the frame. The rotor fits inside the stator with a slight air gap separating it from the stator. There is no direct physical connection between the rotor and the stator.



The enclosure protects the internal parts of the motor from water and other environmental elements. The degree of protection depends upon the type of enclosure. Enclosure types are discussed later in this course.

Bearings, mounted on the shaft, support the rotor and allow it to turn. Some motors, like the one shown in the following illustration, use a fan, also mounted on the rotor shaft, to cool the motor when the shaft is rotating.

AC Motor

AC motors are used worldwide in many applications to transform electrical energy into mechanical energy. There are many types of AC motors, but this course focuses on threephase AC induction motors, the most common type of motor used in industrial applications. An AC motor of this type may be part of a pump or fan or connected to some other form of mechanical equipment such as a winder, conveyor, or mixer. Siemens manufactures a wide variety of AC motors. In addition to providing basic information about AC motors in general, this course also includes an overview of Siemens AC motors.



NEMA Motors
Throughout this course, reference is made to the National Electrical Manufacturers Association (NEMA). NEMA develops standards for a wide range of electrical products,
including AC motors. For example, NEMA Standard Publication MG 1 covers NEMA frame size AC motors, commonly referred to as NEMA motors.

Above NEMA Motors
In addition to manufacturing NEMA motors, Siemens also manufactures motors larger than the largest NEMA frame size. These motors are built to meet specific application requirements and are commonly referred to as above NEMA motors.

IEC Motors
Siemens also manufactures motors to International Electrotechnical Commission (IEC) standards. IEC is another organization responsible for electrical standards. IEC standards perform the same function as NEMA standards, but differ in many respects. In many countries, electrical equipment is commonly designed to comply with IEC standards. In the United States, although IEC motors are sometimes used, NEMA motors are more common. Keep in mind, however, that many U.S.-based companies build products for export to countries that follow IEC standards.

Force and Motion

Before discussing AC motors it is necessary to understand some of the basic terminology associated with motor operation. Many of these terms are familiar to us in some other context. Later in the course we will see how these terms apply to AC motors.

Force In simple terms, a force is a push or a pull. Force may be caused by electromagnetism, gravity, or a combination of physical means. Net Force is the vector sum of all forces that act on an object, including friction and gravity. When forces are applied in the same direction, they are added. For example, if two 10 pound forces are applied in the same direction the net force would be 20 pounds

If 10 pounds of force is applied in one direction and 5 pounds of force is applied in the opposite direction, the net force would be 5 pounds and the object would move in the direction of the greater force.

If 10 pounds of force is applied equally in both directions, the net force would be zero and the object would not move.


Torque is a twisting or turning force that causes an object to rotate. For example, a force applied to the end of a lever causes a turning effect or torque at the pivot point. Torque (τ) is the product of force and radius (lever distance).

τ = Force x Radius

In the English system of measurements, torque is measured in pound-feet (lb-ft) or pound-inches (lb-in). For example, if 10 lbs of force is applied to a lever 1 foot long, the resulting torque is 10 lb-ft.

An increase in force or radius results in a corresponding increase in torque. Increasing the radius to two feet, for example, results in 20 lb-ft of torque.

An object in motion takes time to travel any distance. Speed is the ratio of the distance traveled and the time it takes to travel the distance.

Speed = Distance/Time

Linear speed is the rate at which an object travels a specified distance. Linear speed is expressed in units of distance divided by units of time, for example, miles per hour or meters per second (m/s). Therefore, if it take 2 seconds to travel 40 meters, the speed is 20 m/s.


The angular speed of a rotating object determines how long it takes for an object to rotate a specified angular distance. Angular speed is often expressed in revolutions per minute (RPM). For example, an object that makes ten complete revolutions in one minute, has a speed of 10 RPM.


An object can change speed. An increase in speed is called acceleration. Acceleration occurs only when there is a change in the force acting upon the object. An object can also change from a higher to a lower speed. This is known as deceleration (negative acceleration). A rotating object, for example, can accelerate from 10 RPM to 20 RPM, or decelerate from 20 RPM to 10 RPM


Mechanical systems are subject to the law of inertia. The law of inertia states that an object will tend to remain in its current state of rest or motion unless acted upon by an external force. This property of resistance to acceleration/deceleration is referred to as the moment of inertia. The English system unit of measurement for inertia is pound-feet squared (lb-ft2). For example, consider a machine that unwinds a large roll of paper. If the roll is not moving, it takes a force to overcome inertia and start the roll in motion. Once moving, it takes a force in the reverse direction to bring the roll to a stop

Any system in motion has losses that drain energy from the system. The law of inertia is still valid, however, because the system will remain in motion at constant speed if energy is added to the system to compensate for the losses. Friction occurs when objects contact one another. As we all know, when we try to move one object across the surface of another object, friction increases the force we must apply. Friction is one of the most significant causes of energy loss in a machine.

Whenever a force causes motion, work is accomplished. Work can be calculated simply by multiplying the force that causes the motion times the distance the force is applied.

Work = Force x Distance

Since work is the product of force times the distance applied, work can be expressed in any compound unit of force times distance. For example, in physics, work is commonly expressed in joules. 1 joule is equal to 1 newton-meter, a force of 1 newton for a distance of 1 meter. In the English system of measurements, work is often expressed in foot-pounds (ft-lb), where 1 ft-lb equals 1 foot times 1 pound.

Another often used quantity is power. Power is the rate of doing work or the amount of work done in a period of time. Power can be expressed in foot-pounds per second, but is often expressed in horsepower. This unit was defined in the 18 th century by James Watt. Watt sold steam engines and was asked how many horses one steam engine would replace. He had horses walk around a wheel that would lift a weight. He found that a horse would average about 550 foot-pounds ofwork per second. Therefore, one horsepower is equal to 550 foot-pounds per second or 33,000 foot-pounds per minute.


When applying the concept of horsepower to motors, it is useful to determine the amount of horsepower for a given amount of torque and speed. When torque is expressed in lb-ft and speed is expressed in RPM, the following formula can be used to calculate horsepower (HP). Note that an increase in torque, speed, or both increases horsepower.

power in HP = Torque in lb-ft x Speed in RPM/5252

Horsepower and Kilowatts AC motors manufactured in the United States are generally rated in horsepower, but motors manufactured in many other countries are generally rated in kilowatts (kW). Fortunately it is easy to convert between these units.

power in kW = 0.746 x power in HP

For example, a a motor rated for 25 HP motor is equivalent to a motor rated for 18
.65 kW.

0.746 x 25 HP = 18 .65 kW

Kilowatts can be converted to horsepower with the following formula.

power in HP = 1.34 x power in kW

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