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Models for Design
Electrical Calculations for
Industrial Plants
Models for Design
Electrical Calculations for
Industrial Plants
Robert E. Henry, PE
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
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List of Figures..........................................................................................................xi
List of Tables......................................................................................................... xiii
Acknowledgments.................................................................................................xv
Author................................................................................................................... xvii
1. Introduction......................................................................................................1
Fun Test..............................................................................................................4
Questions.......................................................................................................4
Answers.........................................................................................................5
3. Storage Batteries.............................................................................................33
The DC System................................................................................................33
Valve-Regulated Lead–Acid Battery............................................................36
Battery Selection..............................................................................................37
vii
viii Contents
xi
List of Tables
xiii
Acknowledgments
xv
Author
xvii
1
Introduction
1
2 Models for Design: Electrical Calculations for Industrial Plants
who don’t know much about these topics. Also, few electrical engineers
know how a power cable’s ampacity is arrived at, and very, very few know
how a power cable responds to kiloampere current spikes lasting several
minutes.
Engineering schools have not taught variable frequency effects in motors
until recently. Nor did they teach the big energy savings that can be realized
by not including traditional valves that control flow in industrial applica-
tions. Decades ago, I was taught analog audio circuits and their response
to variable voice frequencies. This did not give me much preparation for
variable frequency effects in motors. These effects are within the scopes of
both electrical and mechanical engineering. Few universities teach electrical
power and its applications anyway. And the development of power tran-
sistors, which made variable-speed motors practical, is only about three
decades old.
I also thought I might include other topics in industrial power, such as
uninterruptable power supplies. Other related topics are storage batteries
and switchgear at 13.8 kV in a main-tie-main arrangement, the maximum
demand that medium-voltage switchgear can supply. Three-winding trans-
formers used as step-ups in generating plants is another favorite topic. Also,
not all of the calculations are electrical. Some analyze the heat flow in a
battery, cable, or motor. Here, the physics of heat flow is drawn upon. My
models are usually crude. Thereby, the calculation results are approximate.
However, they offer insight and are suitable for verifying computer calcula-
tions based on detailed models.
Motors are fundamental to industrial plants. They are among the few old-
est electrical products. Their complication isn’t widely familiar. Where their
operation is required for short periods at loads beyond their rated horse-
power, is covered in two chapters and Appendix B.
This book is in units of feet, pounds of force, seconds, degrees Celsius,
watts, hertz, amperes, and volts. These are electrical engineering units found
in most texts that were published during the last half of the last century. Also,
for heat, watts and watt-hours, not Btu per hour and Btu’s. Watts and watt-
hours are easier and more direct with electrical heat dissipation, and to heat
flow in power cables and motors. Motor units are horsepower and lb-ft of
torque. The focus is also on 60 Hz and American circular mils. Most product
data on the Internet is in these units. Not that the methods cannot be applied
to 50 Hz and square millimeters. I leave that to the reader. Also, my circuit
calculations use impedance values, not per-unit values. I believe the number
crunching is the same either way. In seeing the results, I believe impedance
values are closer to Ohm’s law and better show the sense of the calculation.
Use what is easier for you.
I have designed European industrial plants and generating stations. Once
one starts working on a European project, thinking in European units is easy.
Introduction 3
Robert E. Henry, PE
Fun Test
Questions
Answers
1. Given a function, y = f(x), for the value of delta y = f(delta x), as the
value of delta x approaches zero, delta y approaches dy.
2. Zero output. The secondary terminals are shorted together with shunts
(or using CTs) in the shorting bars to measure phase currents.
3. With the transformer so connected, the primary voltages are raised from
zero to the value where secondary currents are at their rated value. The
percent of measured primary voltage, at rated shorted secondary cur-
rent, is the percent impedance. (It results from, of all the flux generated
by the windings, not all is being induced into the core, and losses.)
4. One. It represents each of the balanced phases. Its applied voltage is the
single-phase value, the rated primary voltage divided by the square
root of three.
5. Nine.
6. The residual flux in the core. If the transformer is somehow turned off
at the exact instant when the core is at zero flux, and if turned back on at
the same voltage when turned off, there will be no inrush. This is pos-
sible with three phases, each shifted 120° from the other, if each phase
has the same current–voltage relationship.
7. From 15 to 75 thousands of an inch, depending on the engine require-
ments and the spark plug.
8. Two themes (songs) are in a movement. Each is introduced, then devel-
oped in the middle of the movement and mixed, then restated at the
end.
9. It is impossible to store all of the available transformed energy because
losses are inherent. Also, losses are inherent if discharging the storage
device.
10. The First Law of Thermodynamics: Energy cannot be created or
destroyed but can only be transformed.
We beat on, with our models, against the stronger wind of skeptics,
back into the past. Were they skeptics? Or were they just green shackled,
unable to grasp change? Unable to spend the grueling labor of the mind
to gain the visions that the models radiated?
Section I
Plant Equipment
2
Using an Uninterruptible Power Supply
to Feed a Variable-Speed Drive
Introduction
This chapter presents the application of a variable-frequency drive connected
to a motor driving a fan. The fan is ventilating a building with airflow that is
essential to a process within the building. With loss of normal building power,
the process is interrupted, but airflow must be maintained for 20 min longer dur-
ing the power outage. This flow purges the process of gases that could otherwise
accumulate and become explosive. However, 40% flow, reduced from full nor-
mal, is required. Because there is no backup generator, the variable-frequency
drive is switched to an uninterruptible power supply having a 20 min battery.
It may be uncommon to find an uninterruptible power supply feeding a
drive that supplies a fan.
However, this application is necessary
Sometimes, critical loads must operate after loss of normal power and during
the interval when the backup source is being started, especially when start-
ing attempts are prolonged.
The combination of an uninterruptible power supply (UPS) supplying a
variable-frequency drive first begs the question: why isn’t a front end of a
UPS, with its rectifier, battery, and DC bus, married to a variable-frequency
drive’s back end? The drive’s part would have a controller, with its inverter
and motor control. The answers are that the demand for such a combina-
tion is uncommon, and UPS design requirements and variable-frequency
drive requirements are different. The analysis presented herein is useful in
other separate applications of drives and UPSs. The examples are usable for
matching UPSs to other loads besides drives. An example of a drive sup-
plying a motor with a fast transient load is given in Chapter 10.
9
10 Models for Design: Electrical Calculations for Industrial Plants
140 80
Rated 1500 CFM @ 78 in WTR COL
107 F inlet temp 11.6 psia inlet press
0.932 SP GR1.382 K value 2145
1995 rpm –78 in WC inlet
0 in WC outlet Horsepower
120 60
1995
Differential pressure in WC
100 40
em
2145
st
Sy
Surge limit
80 20
Press
ure
1995
60 0
1000 1500 2000 2500 3000 3500
Inlet CFM
FIGURE 2.1
Turbocompressor performance.
Another random document with
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fatty degen.
vessels. Sclerosis
ant. columns.
Atrophy ant. roots.
Foci of softening
in ant. cornua.
Roger and Fatty degen.
29 1871 2 2½ Variola. Both legs. Ibid.
Damaschino. blood-vessels,
circumscribed
myelitis.
Roger and Foci of softening,
30 1871 2 3 Fever. Ibid. Ibid.
Damaschino. as above.
Focus myelitis on
both sides.
Disappearance Virch. Arch.,
31 1873 Roth. 1 2 Ibid. Ibid. ganglion-cells, 1873, Bd.
abundant lviii.
exudation
corpuscles.
Extensive myelitis
ant. and central Med.-Chir.
After
32 1868 L. Clarke. 1 32 Both arms. part gray matter. Trans., li. p.
inoculation.
Disappearance 219.
ganglion-cells.
Atrophy lumbar
cord ant. lat.
columns. Atrophy
Virch.
Acute ganglion-cells.
33 1876 Schultze. 3 22 Both legs. Archiv, Bd.
disease. Abundant exud.
lxviii., 1876.
corpuscles.
Proliferation
neuroglia.
34 1876 Leyden. 2 60 Fall from L. leg. Circumscribed Archiv f.
table. cicatrix with Psych.,
complete 1876, Bd. vi.
destruction gray
substance.
Amyloid
degeneration.
Atrophy ant. roots.
Atrophy ganglion-
cells. Cellular
35 1876 Leyden. ¾ 1¾ Suddenly. L. leg. diffused infilt. Ibid.
(myelitis) gray
subst'ce.
Amyloid infiltration
ant. horns,
atrophy ganglion-
Sudden
36 1876 Leyden. 4 58 L. leg. cells left lumbar Ibid.
over night.
horn. Diffuse
atrophy gray
substance.
Sclerotic focus in
right lumbar and
in left cerv. region.
R. leg, L. Diffuse meningo-
37 1876 Leyden. 3 20 Ibid. Ibid.
arm. myelitis. Atrophy
ant. lat. columns.
Encapsulated
myelitis.
Purulent focus in
Quoted by
ant. cornua
Seeligmüller,
38 1876 Demme. ? 3½ ? — lumbar region.
loc. cit., p.
Atrophy ganglion-
18.
cells.
Diffuse
inflammation
39 1876 Eisenlohr. ? ¾ ? B. legs. Ibid.
anterior horns and
ant. lat. columns.
Myelitic
disorganization Trans. Path.
40 1879 Turner. 2½ 2¾ ? gray substance Soc. Lond.,
ant. cornua 1879.
lumbar cord.
41 1883 Archambault 30 m's 31 m's, Malaise Left leg Focus red Le Union
et or 26 and and right softening ant. médicale,
Damaschino. arm. horns left lumbar; 1883.
d'ys fr. prostration right cervical
début. one day. region. Enormous
enlargement
vascular network,
and distension
blood-vessels;
granular
corpuscles in
lymphatic
sheaths; marked
atrophy cells and
of myeline
sheaths of fibres
in ant. roots;
myeline balls in
sheath; axis-
cylinders
disappeared.
Lesions more or
less marked
throughout cord.
Nerves not
examined.
Red area both
anterior cornua
lumbar region.
Fever and Here distension Trans. Path.
42 1884 Money. 2 yrs. 28 m's. vomiting Paraplegia. and thrombosis Soc. Lond.,
for a week. vessels; infiltration 1884.
leucocytes;
absence
multipolar cells.
1884 Money. Unknown 7 yrs. Unknown. Right leg. Wasting anterior
horn almost
throughout lumbar
region. Atrophy
cells chiefly in
ant., ant.-lat.,
post.-lateral, and
central groups,
replaced by dense
nucleated tissue.
It will be useful to add another table, which will group together the cases
in which the autopsies were made within two years after the occurrence
of the paralysis. Of these, all but the two made by Laborde, in which the
cornua are declared to be healthy and the lesion limited to the white
columns, show traces of destructive morbid processes in the gray
substance of the cord, greatly predominating in the anterior cornua, but
not absolutely limited to them, nor even to the part of the cord which
corresponds to the paralyzed limb:
TABLE VI.
Date of Autopsy Year of
Case No. Name of Author. after Paralysis. Publication.
41 Damaschino. 6 weeks. 1883
40 Turner. 26 days. 1879
28 Roger and Damaschino. 2 mos. 1871
42 Money. 4 mos. 1884
27 Echeverria. 6 mos.
39 Eisenlohr. 6 mos.
29 Roger. 6 mos. 1871
31 Roth. 9 mos. 1873
35 Leyden. 11 mos. 1876
14 Bouvier and Laborde. 12 mos. 1864
30 Roger. 13 mos. 1871
15 Cornil and Laborde. 16 mos. 1864
12 Recklinghausen. 24 mos. 1863
38 Demme. 24 mos. 1876
23 Taylor. 18 mos. 1879
25 Humphrey. 24 mos. 1879
Leucocytes are often disseminated through the diseased area, and in one
case (Demme) were accumulated into a focus of pus. Besides the
leucocytes, the foci are often infiltrated with large round granular cells that
seem to be transformed neuroglia-cells (Leyden). In one case neuroglia
nuclei were accumulated in a ring around the focus, seeming to indicate
the beginning of encapsulation.
The most striking lesion, however, and the one which is common to the
most recent as well as to old cases, is the deformation, atrophy, and final
disappearance of the large ganglionic cells of the anterior cornua. The
first change consists in granular pigmentation;98 then the prolongations
disappear, leaving the body of the cell shrunken and deformed; at last the
whole cell disappears. Sometimes all the cells of an anterior horn have
disappeared throughout the entire depth of the focus; quite as often, in
certain sections at least, the atrophy is limited to certain groups, as the
external,99 or the external in one focus, the antero-lateral in another,
situated on the opposite side of the cord.100
98 Case of Echeverria, Tab. V.
99 Case by Schultze (this is a case of ancient lesion), Tab. V. (Virch. Arch., Bd. lviii.).
These focal lesions of the cord explain admirably, as will be seen, the
permanent symptoms of the disease. But of great importance for
understanding its initial period is the fact that structural changes—similar
to, but less severe than, those just described—have beer found diffused
throughout the cord. In several cases hyperæmia, partial atrophy of
ganglionic cells and nerve-fibres, infiltration with exudation corpuscles, in
the anterior cornua and even central gray canal from the lumbar to the
cervical region.101 In Damaschino's case, besides the focal lesions which
corresponded to the paralyses of the right arm and left leg, were others
corresponding to the left arm and right leg where no paralysis existed.
101 See cases by Leyden, Roth, Schultze, Clarke, Damaschino.
This case (1883) is also interesting in bringing out another lesion not
usually noticed. This is the breaking up into balls of the myeline in the
medullated tubes, both of the anterior intraspinal nerve-roots and of such
fibres as traversed the anterior nerves. In balsam preparations these
myeline drops are dissolved; but in osmic acid and glycerin preparations
they appear as black balls all over the field. The lesion is identical with
that already described by Dejerine (1875) in both nerves, roots, and white
columns. The columns of Clarke have always been found intact.
In the recent cases no lesions of the white columns have been observed
—a fact upon which reposes the doctrine that such lesions, when
existing, are secondary to those of the cornua.
The date of these lesions varies from seven to seventy-six years. In two
or three cases, where the autopsy was made on very old people, the
early history of the disease was unknown, but the probable date of the
paralysis was calculated.
In this group of cases patches of atrophy, semi-transparent and grayish in
color, focal or diffused, are clearly perceptible to the naked eye. As a rule,
the atrophy is unilateral, and sensibly affects the entire half of the cord. In
some cases of paraplegia, however, there is a bilateral, symmetrical
shrinkage of the entire lumbar cord, which has been reduced to the size
of a quill.
The atrophy involves, first and most markedly, one or both anterior
cornua; second, the anterior nerve-roots arising from them; third, the
antero-lateral columns.
In both the latter localities the microscope will often find individual nerve-
tubes wasted and deprived of their myeline. The atrophied patches are
generally sclerosed as the seat of a proliferated neuroglia, coloring deeply
with carmine. In Laborde's cases, published at the very beginning of what
may be called the anatomical period, the atrophy and sclerosis were said
to be limited to the antero-lateral columns and the nerve-roots, while the
cornua remained intact. In all more recent observations, however, the
lesion of the white columns and roots has been found strictly proportioned
to that of the gray horns. The sclerosis extended into the latter,
constituted by a reticulum of connective-tissue fibres, sometimes fine,
sometimes so matted together as to form a dense felt-like substance,
sometimes offering the ordinary aspect of sclerosis.
103 Seguin (loc. cit.) observes that the opinion is gaining ground which ascribes these to a
transformation of the neuroglia corpuscles.
As in the relatively fresh cases, the circumstance which has attracted the
most attention is the atrophy of the ganglionic cells from the sclerosed
patches of the anterior cornua. The completeness with which these have
disappeared in any focus seems to be proportioned to the completeness
of the paralysis in the corresponding limb. Partial atrophy or
disappearance of spinal groups of cells from the cornua may sometimes
be correlated with paralysis of special muscles.105
105 Thus in Schultze's case, already quoted, the external group of cells had disappeared
from the focus in one gray horn, and the extensors of the foot were alone paralyzed. This
seems to confirm the opinion advanced by Spitzka, that this external group of motor-cells
corresponds to the extensor, the internal groups to the flexor muscles.
107 Charcot, Leçons sur les Maladies du Syst. nerveux; Prévost, Soc. Biol., 1864; Joffroy,
Arch. de Physiol., 1870; Petitfils, “De l'Atrophie aigue des Cellules matrices,” Thèse de
Paris, 1873.
108 Schultze, Virch. Arch., Bd. lxviii.; Roth, Ibid., Bd. lviii.; Henoch, loc. cit., p. 208; Ross, loc.
cit., p. 125; Seguin, loc. cit., 1877; Erb, Ziemssen's Handbuch; Seeligmüller, Gerhardt's
Handbuch; Roger and Damaschino, Gaz. méd., 1871; Turner, Path. Trans. Lond., 1879;
Hammond, loc. cit.
111 When this objection is accepted, Barlow's remark falls to the ground, that “the similarity
of lesion found in two such different diseases as infantile paralysis and progressive muscular
atrophy proves the failure of anatomical characters, taken alone, to serve as a basis of
nosology” (Brain, April, 1879, p. 74).
113 It might be said that the fall of the fever as soon as the paralysis is declared and the
motor cells presumably melted down should contradict the idea that their dying substance
acts as an irritant upon surrounding tissues.
A third objection has been brought forward by Leyden, and is really an
enlargement on the second. It is, that various lesions or morbid processes
may underlie the same clinical history. In four autopsies of cases
presenting all the clinical history of acute anterior poliomyelitis this author
has found three different lesions. In one an extensive lepto-meningitis,
together with irregular focal sclerosis of the white columns, evidently
depended upon the latter, and in turn caused sclerosis of the anterior
cornua with consequent destruction of their cells.114 In two other cases an
anterior poliomyelitis was accompanied by diffused lesions of the central
canal. Finally, in a fourth case the lesions were limited to the anterior
cornua, as is most usual.
114 This case of Leyden's throws light on the two autopsies by Laborde with sclerosis of the
white columns and intact cornua. It seems probable that a process originating in the cornua
had then been arrested or had receded, while continuing its evolution in the white columns.
1. Inflammation of motor and trophic nerve-cells: (a) Infantile spinal paralysis; (b) Spinal
paralysis of adults; (c) Pseudo-hypertrophic spinal paralysis.
3. Inflammation of trophic cells: (a) Progressive muscular atrophy; (b) Progressive facial
atrophy (Dis. Nerv. Syst., 6th ed., p. 464).
“There cannot be the slightest doubt,” observes Erb, “that the lesions
described constitute a degenerative atrophy similar to what may be
caused by section or sense traumatism of a peripheric nerve.”
The peripheric nerves have been much less thoroughly studied than the
spinal cord. Leyden first directed special attention to the nerves. He found
the sciatic altered in two cases,118 in the first by an interstitial neuritis; in
the second by partial atrophy. In 1880 the same writer, in an extensive
article on poliomyelitis and neuritis,119 greatly extends his views as earlier
expressed. Not only does he claim the coexistence of neuritis with spinal-
cord disease in atrophic paralysis, but thinks that many cases of this, and
also of other forms of paralysis, “lately supposed to originate in the spinal
cord, may really begin in any part of the motor apparatus,” thence
sometimes generalize throughout the whole apparatus, sometimes
remain limited to the original portion affected. Thus, progressive muscular
atrophy may sometimes begin in the nerves, sometimes in the muscles,
and sometimes in the ganglionic cells of the cord; and this variety of origin
explains the discrepancies of opinion which have been held upon the
nature of this disease. Similarly, all forms of acute or chronic atrophic
paralysis in either children or adults may begin in either the nerves or
cord, thence become generalized to both, or remain limited to one part of
the spinal motor system. Cases of atrophic paralysis which recover are
probably not cases of poliomyelitis at all, but of multiple neuritis,
rheumatic, traumatic, or infectious in nature. The regeneration of
peripheric nerves is a well-demonstrated possibility, but not that of the
cells of the cord. Lead-paralysis is usually confined to the nerves, but
sometimes extends to the cord. In diphtheritic paralysis Buhl has found
injection, thickening, and granular infiltration of nerves at the union of their
anterior and posterior roots;120 and as long ago as 1876, Dejerine, in a
case of atrophic paralysis in a syphilitic woman, found varicose swelling
of the medullary sheath in the nerves of the paralyzed lower extremities,
together with heaping up of the myeline into large drops, colored black in
glycerin and osmic-acid preparations. Coincidently, in the cord, at the
origin of the same nerves, the number of motor-cells was diminished, and
of those that remained the prolongations, and even the body, of the cell
were atrophied.121
118 Cases 34 and 35 of Table V., quoted from Arch. de Psychiatrie, Bd. vi., 1876.
The brain is usually normal, unless indeed the paralysis has affected
children previously rendered idiotic by congenital atrophia cerebri.
Sandie, however, examined one brain with an interesting positive
result.124 The brain was taken from a boy of fifteen paralyzed since the
age of three in almost all his muscles, with even paresis of the muscles of
the trunk and neck. The paralysis was more marked upon the right than
on the left side. At the autopsy, in addition to atrophy of the muscles and
of the motor nerves, with exquisite atrophy of the anterior columns and
anterior cornua, was found a decided atrophy of the left central
convolution, and, less marked, of the paracentral lobule. This was shown
by comparative measurements with the opposite side of the same brain,
and also with the corresponding convolution and lobule in two other
brains. The child's intelligence had not been affected.
124 Centralblatt f. d. Med. Wissensch., No. 15, 1875.
FIG. 55.
c, trophic cell for nerve; a, cerebral fibre; b, trophic cell for muscle; d,
ganglionic cell; s, sensory fibre; f, trophic path to muscle; m, muscle. (From
Ziemssen's Handbuch der Speciellen Pathol., Bd. xi. Zweite H., Zweite Abtheil,
p. 313.)
Duchenne and Joffroy128 also argue the existence of special trophic
nerve-cells. The absence129 of the nutritive lesions of the skin and cellular
tissue which are so conspicuous when the gray matter around the central
canal or posterior to it is involved,130 the dependence of the nutrition of the
motor apparatus, nerves, muscles, bones on the integrity of the anterior
horns, are facts which, taken together, seem to indicate that the
maintenance of nutrition depends on the unbroken continuity of the motor
or sensory apparatus from the periphery to the ultimate central element,
rather than on any special central cells endowed with trophic functions.131
Erb's hypothesis, as his own scheme moreover denotes, demands not
only trophic cells distinct from motor cells, but separate trophic cells for
the muscles, for the motor, and for the sensory nerves.
128 “De l'Atrophie aigue et chronique des Cellules nerveuses,” Arch. de Phys., No. 4, 1870.
129 Money, and also Gowers, have signalized a condition of the skin resembling myxœdema
(Tr. Path. Soc. London, 1884, and Brit. Med. Journ., 1879).
130 Mayer (Herman's Handbuch Physiol.) sums up the great mass of evidence now
accumulated, which demonstrates the trophic influence of the central gray mass of the cord
upon the tissue.
131 Nepveu (La France médicale, 1879) mentions some cases of infantile paralysis
complicated with trophic lesions of the skin. The facts, if accepted, could only indicate an
extension of the myelitis to the central and posterior regions of the gray columns. The
relations between non-atrophic paralysis caused by interruptions of the motor tracts and
muscular atrophy dependent on lesion of the anterior cornua are exquisitely shown in a case
reported by Sander. An adult suffered from chronic motor paralysis, gradually increasing, in
the right arm, with paresis of the lower extremities. In the hand, arm, and shoulder the
paralysis was followed by gradual atrophy and diminution of the faradic contractility; in the
lower extremities no atrophy occurred. At the autopsy was found a gliomatous tumor seated
in the anterior cornua predominating on the right side, extending from the level of the sixth
dorsal to that of the eighth cervical vertebra. The ganglion-cells were pigmented and
compressed, not altogether destroyed. The lumbar cord was intact, and the non-atrophic
paresis of the lower extremities evidently resulted from the interruption of the motor tract
above.
Money133 points out that for the gray matter of the cord, as of the brain,
the centre or maximum force of the circulation is on the periphery, and the
nutritive supply of the centre is thus easily cut off. Moreover, while the
blood-vessels of the cervical and dorsal regions of the cord pass to it