ENGINEERING REPORT
ENGINEERING REPORT XYZ Corporation 100 Anyplace Drive Chicago, Illinois 60613 PERFORMED BY: MIDWEST ELECTRICAL CONSULTANTS, INC 18055 UPLAND DRIVE TINLEY PARK, ILLINOIS 60487 (708) 444-0001 fax: 444-0003 www.midwestelectrical.com. POWER QUALITY TESTING & INSPECTIONS OF TRANE AIR CONDITIONING COMPRESSOR(S) ELECTRICAL SERVICE PROJECT: C822 1 D.J. Sweeney Electric 6813 Hopson Valley Drive Woodridge, Illinois 60517 May 5, 2008 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 60613. 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 ENGINEERING REPORT XYZ Corporation 100 Anyplace Drive Chicago, Illinois 60613 Power Quality Testing & Inspections of Trane Compressor(s) Electrical Service SECTION 1 SCOPE; PURPOSE; PROCEDURE; APPRAISAL AND RECOMMENDATIONS SECTION 2 POWER QUALITY MONITORING DATA (separate file) SECTION 3 ADDITIONAL TESTING SUPPORT DATA (separate file) 3 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 60613 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 ENGINEERING REPORT XYZ Corporation 100 Anyplace Drive Chicago, Illinois 60613 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 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 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 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 60613 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 Account Number Date and Time Phone Number Contact Memo Problem Description Date First noticed Problem Frequency How problem exhibits itself Problem Cost Location Information Name Power Type Feed Phase Phone Date and Time Nominal Voltage Nominal Frequency XYZ Coporation 04/29/08 09:24:20 04/29/08 Unknown Unknown delta setup #2 Trane compressor(s) service disconnect Three phase delta Unknown 04/29/08 11:06:38 240 Volts 60 Hz 1 Report Parameters This report was prepared on 4/29/2008 by Midwest Electrical Consultants, Inc. 18055 Upland Drive Tinley Park, Illinois 60487 (708) 444-0001 fax: 444-0003 www.midwestelectrical.com The following limits were used in analyzing the results. Maximum Phase Voltage. Minimum Phase Voltage. Maximum Impulse Voltage. Maximum. Waveshape Voltage. Maximum Frequency Deviation. Minimum Power Factor. Maximum Voltage T.H.D. Maximum Current T.H.D Maximum Voltage Imbalance. Maximum Current Imbalance. 254 volts 208 volts 500 volts 10 volts .02 Hz .85 5% 20 % 2% 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 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 Phase A average Phase A maximum Phase B minimum Phase B average Phase B maximum Phase C minimum Phase C average Phase C maximum 229.2V 235.8V 240.4V 240.3V 247.2V 255.3V 239.5V 245.1V 252.2V Apr 29 2008 11:21:22 RMS. Currents Value Date and Time Phase A minimum Phase A average Phase A maximum Phase B minimum Phase B average Phase B maximum 549.3mA 11.93A 380.3A 3.662A 20.53A 487.2A Apr 29 2008 11:21:41 Phase C minimum Phase C average Phase C maximum 1.098A 23.14A 343.5A Apr 29 2008 11:18:23 Frequency 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 42.12Hz 43.61Hz 44.69Hz 42.12Hz 43.61Hz 44.69Hz 42.12Hz 43.61Hz 44.69Hz Apr 29 2008 11:21:22 Apr 29 2008 11:21:22 Apr 29 2008 11:21:22 Apr 29 2008 11:21:22 Apr 29 2008 11:19:48 Apr 29 2008 11:21:22 Apr 29 2008 11:19:49 Apr 29 2008 11:21:52 Apr 29 2008 11:22:18 Apr 29 2008 11:22:18 Apr 29 2008 11:16:42 Apr 29 2008 11:21:22 Apr 29 2008 11:16:42 Apr 29 2008 11:21:22 Apr 29 2008 11:16:42 3 RMS. Voltage Summaries for XYZ Coporation:delta setup#2. Phase A Voltage Summary. Min. Avg. Max. 229.2V 235.8V 240.4V Apr 29 2008 11:21:22 Apr 29 2008 11:21:22 4 Phase B Voltage Summary. Min. Avg. Max. 240.3V 247.2V 255.3V Apr 29 2008 11:21:22 Apr 29 2008 11:21:22 5 Phase C Voltage Summary. Min. Avg. Max. 239.5V 245.1V 252.2V Apr 29 2008 11:19:48 Apr 29 2008 11:21:22 6 RMS. Current Summaries for XYZ Coporation:delta setup#2. Phase A Current Summary. Min. Avg. Max. 549.3mA 11.93A 380.3A Apr 29 2008 11:21:41 Apr 29 2008 11:19:49 7 Phase B Current Summary. Min. Avg. Max. 3.662A 20.53A 487.2A Apr 29 2008 11:21:52 Apr 29 2008 11:22:18 8 Phase C Current Summary. Min. Avg. Max. 1.098A 23.14A 343.5A Apr 29 2008 11:18:23 Apr 29 2008 11:22:18 9 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 Phase A average Phase A maximum Phase B minimum Phase B average Phase B maximum Phase C minimum Phase C average Phase C maximum 2.83% 3.388% 5.68% 2.55% 3.039% 4.83% 2.95% 3.523% 5.38% Apr 29 2008 11:23:55 Current Distortion Value Date and Time Phase A minimum Phase A average Phase A maximum 4.81% 34.15% 67.92% Apr 29 2008 11:19:48 Phase B minimum Phase B average Phase B maximum Phase C minimum Phase C average Phase C maximum 4.06% 121.5% 308.2% 3.8% 30.55% 143.9% Apr 29 2008 11:19:48 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 Apr 29 2008 11:21:22 Apr 29 2008 11:21:00 Apr 29 2008 11:21:22 Apr 29 2008 11:19:15 Apr 29 2008 11:21:22 Apr 29 2008 11:17:47 Apr 29 2008 11:17:42 Apr 29 2008 11:19:48 Apr 29 2008 11:16:43 10 Voltage T.H.D. Summaries for XYZ Coporation:delta setup#2 . Phase A Voltage Distortion. Min. Avg. Max. 2.83% 3.388% 5.68% Apr 29 2008 11:23:55 Apr 29 2008 11:21:22 11 Phase B Voltage Distortion. Min. Avg. Max. 2.55% 3.039% 4.83% Apr 29 2008 11:21:00 Apr 29 2008 11:21:22 12 Phase C Voltage Distortion. Min. Avg. Max. 2.95% 3.523% 5.38% Apr 29 2008 11:19:15 Apr 29 2008 11:21:22 13 Current T.H.D. Summaries for XYZ Coporation:delta setup#2. Phase A Current Distortion. Min. Avg. Max. 4.81% 34.15% 67.92% Apr 29 2008 11:19:48 Apr 29 2008 11:17:47 14 Phase B Current Distortion. Min. Avg. Max. 4.06% 121.5% 308.2% Apr 29 2008 11:19:48 Apr 29 2008 11:17:42 15 Phase C Current Distortion. Min. Avg. Max. 3.8% 30.55% 143.9% Apr 29 2008 11:19:48 Apr 29 2008 11:16:43 16 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 Average Voltage Imbalance Maximum Voltage Imbalance Minimum Current Imbalance Average Current Imbalance Maximum Current Imbalance 2.68% 2.840% 3.37% 2.17% 48.58% 154.8% Apr 29 2008 11:23:30 VA Power 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 Total minimum Total average Total maximum 97.69VA 1.660kVA 51.31kVA 512.7VA 2.868kVA 65.88kVA 179.5VA 3.346kVA 48.39kVA 925.0VA 7.874kVA 77.57kVA Apr 29 2008 11:21:41 VARS Power Value Date and Time Phase A minimum Phase A average Phase A maximum -3.482kVAR 1.457kVAR 49.95kVAR Apr 29 2008 11:19:49 Phase B minimum Phase B average Phase B maximum Phase C minimum Phase C average Phase C maximum -4.439kVAR 1.475kVAR 26.88kVAR -13.10kVAR 2.845kVAR 46.66kVAR Apr 29 2008 11:22:18 Total minimum Total average Total maximum -3.962kVAR 5.777kVAR 68.11kVAR Apr 29 2008 11:16:43 Apr 29 2008 11:21:22 Apr 29 2008 11:22:17 Apr 29 2008 11:16:43 Apr 29 2008 11:19:49 Apr 29 2008 11:21:52 Apr 29 2008 11:22:18 Apr 29 2008 11:21:48 Apr 29 2008 11:22:18 Apr 29 2008 11:21:48 Apr 29 2008 11:19:48 Apr 29 2008 11:22:18 Apr 29 2008 11:22:17 Apr 29 2008 11:16:43 Apr 29 2008 11:22:18 Apr 29 2008 11:19:48 17 Watts Power 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 Total minimum Total average Total maximum -11.75kW 737.8W 15.35kW -97.99W 2.118kW 19.78kW -3.091kW 1.706kW 20.38kW -98.06W 4.563kW 36.85kW Apr 29 2008 11:19:49 Demand Power 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 645.8W 707.4W 788.7W 1.806kW 1.982kW 2.214kW 1.434kW 1.570kW 1.750kW Apr 29 2008 11:16:42 Total minimum Total average Total maximum 3.887kW 4.260kW 4.753kW Apr 29 2008 11:16:42 Power Factor 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 Total minimum Total average Total maximum 0.968 Lead 0.271 Lag 0.000 Lag 0.000 Lead 0.608 Lag 0.004 Lag 0.003 Lead 0.344 Lag 0.000 Lag 0.861 0.270 0 Apr 29 2008 11:19:49 Apr 29 2008 11:22:18 Apr 29 2008 11:21:22 Apr 29 2008 11:22:18 Apr 29 2008 11:21:22 Apr 29 2008 11:19:49 Apr 29 2008 11:21:22 Apr 29 2008 11:19:48 Apr 29 2008 11:21:18 Apr 29 2008 11:16:42 Apr 29 2008 11:21:18 Apr 29 2008 11:16:42 Apr 29 2008 11:21:18 Apr 29 2008 11:21:18 Apr 29 2008 11:21:22 Apr 29 2008 11:21:22 Apr 29 2008 11:17:46 Apr 29 2008 11:16:43 Apr 29 2008 11:16:43 Apr 29 2008 11:22:18 Apr 29 2008 11:21:23 18 Voltage and Current Imbalance Summaries for XYZ Coporation:delta setup#2. Minimum Voltage Imbalance Average Voltage Imbalance Maximum Voltage Imbalance 2.68% 2.840% 3.37% Apr 29 2008 11:23:30 Apr 29 2008 11:21:22 19 Minimum Current Imbalance Average Current Imbalance Maximum Current Imbalance 2.17% 48.58% 154.8% Apr 29 2008 11:22:17 Apr 29 2008 11:16:43 20 VA Power Summaries for XYZ Coporation:delta setup#2. Phase A VA Summary. Min. Avg. Max. 97.69VA 1.660kVA 51.31kVA Apr 29 2008 11:21:41 Apr 29 2008 11:19:49 21 Phase B VA Summary. Min. Avg. Max. 512.7VA 2.868kVA 65.88kVA Apr 29 2008 11:21:52 Apr 29 2008 11:22:18 22 Phase C VA Summary. Min. Avg. Max. 179.5VA 3.346kVA 48.39kVA Apr 29 2008 11:21:48 Apr 29 2008 11:22:18 23 Total VA Summary. Min. Avg. Max. 925.0VA 7.874kVA 77.57kVA Apr 29 2008 11:21:48 Apr 29 2008 11:19:48 24 VARS Power Summaries for XYZ Coporation:delta setup#2. Phase A VARS Summary. Min. Avg. Max. -3.482kVAR Apr 29 2008 11:19:49 1.457kVAR 49.95kVAR Apr 29 2008 11:22:18 25 Phase B VARS. Summary. Min. Avg. Max. -4.439kVAR Apr 29 2008 11:22:18 1.475kVAR 26.88kVAR Apr 29 2008 11:22:17 26 Phase C VARS. Summary. Min. Avg. Max. -13.10kVAR Apr 29 2008 11:16:43 2.845kVAR 46.66kVAR Apr 29 2008 11:22:18 27 Total VARS Summary. Min. Avg. Max. -3.962kVAR Apr 29 2008 11:16:43 5.777kVAR 68.11kVAR Apr 29 2008 11:19:48 28 WATTS Power Summaries for XYZ Coporation:delta setup#2. Phase A Watts Summary. Min. -11.75kW Max. 15.35kW Apr 29 2008 11:19:49Avg. 737.8W Apr 29 2008 11:22:18 29 Phase B Watts. Summary. Min. Avg. Max. -97.99W 2.118kW 19.78kW Apr 29 2008 11:21:22 Apr 29 2008 11:22:18 30 Phase C Watts. Summary. Min. Avg. Max. -3.091kW 1.706kW 20.38kW Apr 29 2008 11:21:22 Apr 29 2008 11:19:49 31 Total Watts Summary. Min. Avg. Max. -98.06W 4.563kW 36.85kW Apr 29 2008 11:21:22 Apr 29 2008 11:19:48 32 Power Factor Summaries for XYZ Coporation:delta setup#2. Phase A Power Factor Summary. Min. Avg. Max. 0.968 Lead Apr 29 2008 11:19:49 0.271 Lag 0.000 Lag Apr 29 2008 11:21:22 33 Phase B Power Factor. Summary. Min. Avg. Max. 0.000 Lead Apr 29 2008 11:21:22 0.608 Lag 0.004 Lag Apr 29 2008 11:17:46 34 Phase C Power Factor. Summary. Min. Avg. Max. 0.003 Lead Apr 29 2008 11:16:43 0.344 Lag 0.000 Lag Apr 29 2008 11:16:43 35 Total Power Factor Summary. Min. Avg. Max. 0.861 0.270 0 Apr 29 2008 11:22:18 Apr 29 2008 11:21:23 36 MIDWEST ELECTRICAL CONSULTANTS, INC. 18055 UPLAND DRIVE TINLEY PARK, ILLINOIS 60487 (708) 444-0001 fax: 444-0003 www.midwestelectrical.com SECTION 3 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 - 28.6 amps B phase - 46.3 amps C phase - 54.7 amps Figure 1 Page 2 Figure 2 Step 3: Measure amperages again C phase - 54.7 amps A phase - 28.6 amps B phase - 46.3 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
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