Basic Electrical Terminology

AC Fundamentals
Voltage : V
Current : I
Resistance: R
Power : KW
Energy : KWH
Frequency - Hz
Power factor Lead or Lag
AC / DC

A.C.Fundamentals
An alternating current (A.C.) is the current which
changes periodically both in magnitude & direction.
Voltages in a.c.system can be raised or lowered with
transformers. Raising of voltages in d.c.system is not
easy.
It is possible to build up high a.c.voltage, high speed
a.c.generators of large capacities. The construction
& cost of such generators are low.
A.C.motors are simple in cosntruction & requires less
maintenance.

Sine Waveform
Mathematically it is very easy to write the
equations for purely sinusoidal waveform.

Any other type of waveform can be resolved
into a series of sine & cosine waves of
fundamental & higher frequencies. Sum of all
these waves gives original waveform. Hence
sinusoidal waveform is considered as
standard waveform.
Sine Waveform
The sine & cosine waves can pass
through linear circuits containing R,L & C
without distortion.
Integration & derivative of sinusoidal
function is again a sinusoidal function.
This makes analysis of electrical circuits
easy.
Sine Waveform




Single Phase & Three Phase
System
Three Phase System Advantages
The output of three phase machine is always greater
than single phase machine of same size by 1.5
times.
Occupies less space & less cost.
Less copper for transmission & distribution
Three phase motors self starting
Gives steady output
Power factor is more compare to single phase
Economical

Analogy to help understand
Electrical terms
Voltage is equiv. to the water pressure
Current is equiv. to the Flow rate
Resistance is like the pipe size
I = V/r
Pressure(V) Increases, Flow (I) Increases
Pipe Size Increases,r decreases & Flow(I)
increases.

Voltage
Voltage : V Voltage is potential difference between
two points,
What it governs is the insulation thickness , material
to be used for particular line.
Different voltage used at different levels are generally
Residence voltage is 230 VAC,
Industrial voltage is 415 VAC / 3.3 KV, 6.6 KV, 11KV
Generation voltage is normally 11 KV
Transmission voltage is 400KV, 220 KV, 132KV
Distribution voltage varies from, 11 KV, 22 KV, 33 KV,
66 KV, 110 KV, to 220 KV,

Voltage levels
Voltage Levels For Motors:
LT Motors -- < 1000V
HT Motors -- > 1000V

Generally Available Voltages in India
LT 220V,240V,415V,440V
HT 3.3KV,6.6KV,11KV

Generally Available Voltages Outside India
LT 380V,660V
HT 3.0KV,6.0KV



Current
Current : I Current flows through the line.
It governs
Conductor size higher conductor size to handle high
current
Conductor material Aluminum or copper conductors are
commonly used, copper handles more current,
Thumb rule is current density for aluminum is 0.8 A/ mm2
and for copper it is 1.6 A/ mm2
Type of conductor stranded or solid.
Number of runs Single run / double run / triple run etc
Higher the voltage lower is the current handling if power
remains constant. (Hence Transmission of Power is done
by Higher Voltage)

Voltage and current parameters

R
Y
B
N
415VAC
415VAC
230VAC
Ir
Iy
Ib
In
What is Power Factor?

To understand power factor, we will first start with the definition
of some basic terms:
KW is Working Power (also called Actual Power or Active
Power or Real Power). It is the power that actually powers the
equipment and performs useful work.
KVAR is Reactive Power. It is the power that magnetic
equipment (transformer, motor and relay) needs to produce the
magnetizing flux.
KVA is Apparent Power. It is the vectorial summation of KVAR
and KW.


Power Factor

Other way to define to Power Factor
Power factor: cos of phase angle difference between
voltage and current is called the power factor
Unity power factor When there is no phase angle
difference between current and voltage
Lagging power factor- If current is lagging behind
voltage
Leading power factor - If current is leading before
voltage

Unit p.f p.f. =cos (Lag) p.f. =cos (lead)

V I V
V
I


I
Power Factor
Unity power factor is better.
Inductance makes p.f. lagging, Inductance
means any coil design
Capacitance make p.f. leading
Industrial loads are normally inductive type,
hence p.f. is normally lagging-
Capacitors are used to improve p.f. These are
connected to the power system through
automatic cut in/ cutoff circuit.
Power
Power : Single phase P = V x I x cos

Three phase power P= 3 x V
L
x I
L
x cos

Where
P = Power consumption.
V
L
= Line voltage
I
L
= Line current.
cos = Power factor


Three Phase circuit
Star connection


V
L
V
ph
N

R

Y

B

V
L
=3 x V
ph
I
L
= I
ph
I
L
I
ph
Three Phase circuit
Delta connection


V
L
V
ph
R

Y

B

V
L
= V
ph
I
L
= 3 x I
ph
I
L
I
ph
Motor Terminals Star connection
R Y B
U1 V1 W1
W2 U2 V2
Motor
T.B.
Supply Voltage
V2

W2

U2

V1

W1

U1

R

B

Y

Motor Terminals Delta connection
R Y B
U1 V1 W1
W2 U2 V2
Motor
T.B.
Supply Voltage
Selection of cable size
Current flowing through the cable
Cable length
Cable type copper or aluminum
Voltage drop during motor running
shall be less than or equal to 3%
Voltage drop during motor starting
shall be less than or equal to 10%
MOTOR INTERLOCK LOGIC
STARTING INTERLOCK
Discharge Damper Closed (Fan Motors)
Discharge Valve Closed (Pump Motors)
RUNNING INTERLOCK
Deaerator Level Very Low (Pump I/L)
Drum Level Very low (Process I/L)









(This circuit is made in MCC)
Phase Future Interlock
(Running interlock)
Stop PB
Start PB
KM
Neutral
Motor contactor
coil
Basic circuit diagram of motor starter
Future Interlock
(Starting interlock or
Permissive)
KM









These NO contacts
are used for interlocks
in MCC
Phase
Deaerator level
very low switch
This circuit is made in control Panel /PLC/DCS/SCADA
Neutral
Auxiliary
contactor
KA
MOTOR INTERLOCK
MULTIPLE INTERLOCK SYSTEM

ID Fan
running
FD
Fan
run
ning
SA
Fan
run
ning
Drum
level
not
very
low
KA1
KA5
KA2
KA3
KA4
N
KA5 KA3 KA2 KA1
P
KA4
Case : Cable selection for 200
KW motor
Motor parameters are- 200 KW, 3ph,
339A,
Cable conductor- Aluminum
Length of cable is 200 meters
Starter is option : DOL
Standard cable size chart
Motor - Selection
Following are major parameters
Load GD2
Load RPM
Load MCR power consumption
Test block power consumption
Margin on Test block power for considering the motor
rating 15% for power up to 55 KW and10% for more
Standard motor rating available
Look at minimum temperature power consumption
Any special accessories like VPI insulation, winding
RTD, bearing RTD, vibration sensors etc



Motor - Selection
A) DRIVEN EQUIPMENT DETAILS FOR DRIVE MOTOR SELECTION (EMS 2)

1. EQUIPMENT / APPLICATION --- FD FAN
2. MODEL --- 14144B / 1106 (TLT Engg. make)
3. METHOD OF COUPLING --- Flexible
4. RATED SPEED OF FAN --- 1480 RPM
5. GD2 AT RATED/MOTOR SPEED --- 840 kgf-m2
6. STARTING TORQUE VS. SPEED --- As enclosed
CURVE (Motor to be selected for starting with Inlet damper
closed position)
7. INSTALLATION --- Outdoor
B) DRIVE (MOTOR) DETAILS
1. MOTOR MOUNTING REQD. --- Foot (B3)
2 TYPE OF BEARINGS OF DRIVEN --- Anti friction grease lubricated
EQUIPMENT.
3. MOTOR BEARINGS --- Ball / Roller
4. DUTY CYCLE --- S1
5. SHAFT POWER AT
1) 100% MCR --- 265 kW
2) TEST BLOCK --- 334 kW @ 50 C, 374 KW @ 5 C

6. MOTOR RATING AT OPERATING --- 415 KW.
CONDITION
7. CABLE SIZES FOR SIZING TERM. --- Customer to specify
BOX OF MOTORS
8. DIRECTION OF ROTATION --- Bi-directional motor
9. QUANTITY --- One
NOTE : 1) MOTOR SHALL CONFORM TO EMS1 D14-FM-CS-29480 REV. 1.
2) VENDOR SHALL SUBMIT THE MOTOR DATA SHEET & PERFORMANCE CURVES AS
MENTIONED IN EMS-1.
Motors selection Other common
electrical parameters

Based on phases - Single phase & three phase
motors
Based on voltages Low voltage (LT) / high
voltage (HT)
Based on working principle Squirrel cage
Induction motor, Slip ring Induction motor
In Industry majority motors are Induction
motor.
Voltage, frequency, Insulation class

Motors Important parameters
Enclosure /Cooling
Frame size
Duty
Fan torque speed curve
Number of starts per hour

MOTOR PERFORMANCE
CURVES
Speed Vs Torque Curve
Thermal withstand curve
Efficiency Vs Output curve
Power factor Vs Output curve
Current Vs Starting Time / speed curve

MCC
MCC is a motor control center from
where individual loads can be controlled.
MCC takes one / two incoming power
supply and makes arrangement for
operating number of motors, heaters etc
with a different combination of rating.
Electrical Components used in
MCC
Power contactors
Auxiliary contactors
Switch Fuse Unit
Air circuit Breaker
Current Transformer (CT)
Ammeter
Voltmeter
Power Contactor

Power Contactor
Auxiliary (Control) Contactor

22 32
18 25
12.5 18
42 to 450 Amps
20 33 & 23 - 40
9.0 15, 14 - 23
6.0 10
4.5 7.5
3.0 5
2 3.3
1.4 2.3
0.9 1.5
0.6 1
0.45 0.75
0.3 0.5
0.2 0.33
22 - 32
17 25
12.5- 18
8.5 - 12.5
5.5 - 8.5
4.0 6
3.5 5
2.4 - 3.6
1.8 - 2.7
1.4 - 2.1
1 - 1.5
0.67 - 1
45 - 75
30 50
20 33
66-110
Over Load relays

Accessories
Accessories
Add - on auxiliary contact block 2 & 4 pole


Mechanical interlock (with top add-on provision)


Surge suppressor

Electrical Components used in
MCC contd..
INCOMER
BUS-BAR
OUT PUT FEEDERS
CABLE CHAMBER
KW / Energy meter
MCB (MINIATURE CIRCUIT BREAKER)
Panel space heater and thermostat
Control transformer

Electrical Components used in
MCC contd..
Timer
Overload relays
Push buttons
Indication lamps
Selector switches ( L/R)
Electrical Components used in
MCC contd..
Component selection based on Type 2
chart.
Fuse Protected selection
Fuseless protected selection
Electrical Components used in
MCC contd..

S.C.P.D.: Fuse / MCCB/MPCB
(Isolation & Short Circuit
Protection)
Starter:
contactor - Normal / overload
operations
+
Relay - Overload protection
upto locked rotor current
M
S.C.P.D.
Starter
Electrical Components used in
MCC contd..

S.C.P.D.: Fuse / MCCB/MPCB
(Isolation & Short Circuit
Protection)
Starter:
contactor - Normal / overload
operations
+
Relay - Overload protection
upto locked rotor current
M
S.C.P.D.
Starter
Type 2 Selection chart
Component selection based on Type 2
chart.
Fuse Protected selection
Fuseless protected selection
Discrimination
Contactor should carry, make and break
normal and overload currents
Relay should provide protection against
small overloads and single phasing.
Fuse/MCCB/MPCB should provide short
circuit protection.
Types of Co-ordination
( IS 13947 / IEC 60947 )
TYPE 1
Damage to contactor & overload relay is acceptable.
No discharge beyond the enclosure is permitted.
TYPE 2
No damage to overload relay or other parts is
allowed. Light welding of contacts of the contactor is
permitted if they can be easily separated (e.g. by a
screw driver) without significant deformation
Discrimination
CURRENT
TIME
CONTACTOR BREAKING
CAPACITY
Relay
H.R.C. Fuse
Ico
Type 2 Co-ordination benefits
Safe and reliable performance of products
during normal and overload conditions
Proper and proven co-ordination with short
circuit protective device

IS / IEC / EN now make verification of co-
ordination with S.C.P.D. a mandatory
requirement

Design parameters which
determine MCC
Rating of MCC ( Busbar rating)
Number of incomers
Number of outgoing feeders
Type of feeders DOL / RDOL/ Star Delta/
Switch fuse /ACB etc.
Draw out or non draw out
Ambient temp.

Design parameters which
determine MCC contd
Temp. rise of MCC.
Operational height
Single front or double front , IP
protection
Components of MCC Microprocessor
based relay, heavy duty relays etc



SYMBOLS


HRC FUSE
DOL
STARTER
STARTER
STAR/DELTA
RDOL
STARTER
VOLTMETER
V
SYMBOLS


AMMETER
A
CURRENT
TRANSFORMER
INDICATION LAMP
SELECTOR
SWITCH
ss
AIR CIRCUIT
BREAKER /MCCB
SYMBOLS


NO CONTACT
NEUTRAL LINK
OVER LOAD RELAY
NC CONTACT
CONTACTOR COIL
SYMBOLS


DELAY)
TIMER (ON
DELAY)
TIMER (OFF
MOTOR STARTERS
DOL STARTER (Direct On Line)
STAR-DELTA STARTER
AUTO TRANSFOREMR
RDOL STARTER
STATOR/ ROTOR RESISTANCE
STARTER
SOFT STARTER
ELECTRICAL DRAWING
READING
Single line diagram
sld.pdf

Power and control schematic diagram for
MCC
P _C wiring.pdf


Comparision DOL and star
Delta starter
DOL Star Delta
Starting voltage Full to the motor
phases
1/3 voltage to the motor
phases
Starting current Normally 6 times the
rated current
Normally 2 times the
rated current
Starting torque Normally 2.5 times of
rated torque
Normally (2.5/3) times
the rated current
Application For lower KW rating,
Our practice is for
motor rated motor
than 37 KW.
However this is not
hard and fast rule. It
is all dependant on
power supply
system
For higher KW rating,
Our practice is for
motor rated motor
than 37 KW.
However this is not
hard and fast rule. It
is all dependant on
power supply system
Speed Torque curve
Comparison DOL and star Delta
VARIABLE SPEED DRIVES
Conventional method of control
Needs for drives
Types of drives
DC DRIVES
AC DRIVES

DC DRIVES ADVANTAGES
HIGH STARTING TORQUE
WIDE SPEED RANGE
GOOD AND PREDICTABLE CONTROL
SYSTEM
VARIABLE SPEED DRIVES

DC DRIVES DIS-ADVANTAGES
Higher Maintenance
Standard DC motor not easily available
Bypass arrangement is not possible incase of
DC drive failure
VARIABLE SPEED DRIVES
AC VARIABLE FREQUENCY
DRIVE
ADVANTAGES
SOFT STARTING OF MOTOR
STANDARD AC MOTOR CAN BE USED
BYPASS ARRANGEMENT POSSIBLE
POWER SAVING
CAN BE USED WITH PID CONTROL LOOP
FOR PROCESS CONTROL
INCREASE IN MOTOR LIFE
AC VARIABLE FREQUENCY
DRIVE
ADVANTAGES
DIRECTION OF MOTOR CAN BE CHANGED
NO MAINTENANCE
Things to remember while
selecting the ACVFD drive
Current Rating of motor
Ambient temperature
IP protection of ACVFD (IP 00, IP 20, IP
55)
Constant torque application or Variable
torque application
Additional features like Communication
with DCS (Type of protocol)
Things to remember while
selecting the ACVFD drive
contd.
Number of DI / DO, AI / AO
Required protections
BATTERY
Two different metals in certain chemical
solutions can produce electricity
Metals in cell are called electrodes
Chemical solution is called electrolyte
The electrolyte reacts oppositely with
two different electrodes causing one
electrode to lose electrons & develop
BATTERY
positive charge & other electrode to build
up surplus of electrons & develop
negative charge
The difference in potential between the
two electrode charges is cell voltage
BATTERY
TYPES OF LEAD ACID BATTERY
SEALED MAINTENANCE FREE (SMF)
SMF VRLA
TUBULAR
PLANTE
Nickel Cadmium (Ni-Cd)

BATTERY
Lead Acid Battery consists of two
electrodes both made of lead sulphate
(PbSO4)
Electrolyte distilled water with some
sulphuric acid
Uncharged cells does not meet any
requirements of battery
No dissimilar metals
BATTERY
During charging, water electrolyte breaks
down & start chemical reactions.
PbSO4 changes to spongy lead (Pb),
other lead sulphate changes to lead
peroxide (PbO2)
At this, good part of water becomes
H2SO4 & Battery gets charged

BATTERY
During charging,current throbattery
causes electrolysis of water & electrolyte
changes from water to mixture of water
& sulphuric acid
Water molecules breaks down in two
hydrogen (H+) ions & one oxygen (O-)
ion.
(H+) & SO4(-) produces H2SO4
BATTERY
When battery is fully charged, electrolyte
contains high percentage of sulfuric acid
as compared to water
When lead acid cell supplies current,Pb
changes to PbSO4; PbO2 changes to
lead sulphate; H2SO4 changes to H2O.
BATTERY
During discharging, both electrodes
become lead sulphate & electrolyte
contains very less sulphuric acid.
UPS
UPS ; Uninterrupted Power Supply
Purpose : To keep the voltage constant and to
maintain the output supply voltage even if there
is no input supply voltage
Parameters for designing :
Redundant or Non redundant
Static bypass required or not
Battery back up time
Type of batteries (Sealed maintenance free Lead Acid
etc)
Voltage, KVA rating,
change over time

Rectifier & Inverter
Rectifier : Converts AC to DC
Inverter: Converts DC to AC
Earthing
Why Earthing is important

All electrical equipment shall be double earthed

GI flats, 8 SWG wire, copper or Al. cables are used for
the earthing the equipments

Earthing Ring type
Earth
Pit
Earth
Pit
Earth Mat
Earthing
Earth
Pit
Earth
Pit