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ISBN: 978-1-119-23800-3
Dedicated to the memory of Professor Joseph Peter Skala Adjunct Professor at USF and St. Petersburg Junior College for your support and encouragement to your many students.
LIST OF FIGURES
1.1 Appendix A-1 – Application of 1910.269 and 1910 Subpart S to Electrical Installations.
1.2 Appendix A-2 – Application of 1910.269 and 1910 Subpart S to Electrical Safety-Related Work Practices.
1.3 Safety clearance to electric supply station fences.
1.4 Photo of load termination compartment in typical medium voltage switchgear.
1.5 Photo of typical shock protection PPE.
1.6 Photo of typical arc flash protection PPE.
1.7 Typical insulated tools.
1.8 Decision matrix if a task requires arc flash PPE.
1.9 NFPA 497 Table 5.9.2 (a) – Leakage located outdoors, at grade. The material being handled could be a flammable liquid, a liquefied or compressed flammable gas, or a flammable cryogenic liquid.
1.10 Figure 4.8(a) from NFPA 499 – Group F or Group G Dust – Indoor, Unrestricted Area; Open or Semi-Enclosed Operating Equipment.
2.1 T-s diagram for water.
2.2 Basic flow diagram for equipment thermodynamic performance evaluation.
2.3 Basic thermodynamic cycle.
2.4 Basic Carnot cycle.
2.5 Basic Rankine cycle showing operation in subcooled region for pumps.
2.6 Feedwater regenerative cycle.
2.7 Feedwater regenerative T-s diagram.
2.8 Superheat design.
2.9 Feedwater regenerative cycle with reheat.
2.10 Feedwater regenerative cycle with reheat T-s diagram.
16.6 Typical lamination section with ventilation channels.
16.7 Generator stator with rotor removed.
16.8 Flux probe mounted in generator stator.
16.9 Flux probe waveform.
16.10 RTD mounted in generator stator between top and bottom coils.
16.11 Cylindrical rotor (GE) with diagonal flow air gap pickup (DFAGPU) hydrogen cooling system.
16.12 Simplified one-line diagram of power flow.
16.13 Typical capability curve for a hydrogen-intercooled machine.
16.14 Definition of leading and lagging operation for motors and generators and direction of reactive power flow.
16.15 Typical “V-curve” for a hydrogen-intercooled machine.
16.15a “V-curve” solution for Example 16.6.
16.15b “V-curve” solution for Example 16.7.
16.16 Three-phase short circuit decrement curve.
16.17 DC generator commutator exciter
16.18 Alternator rectifier: brushless exciter.
16.19 Potential source rectifier exciter.
16.20 Radial stud configuration.
16.21 Synchronizing relay (25).
16.22 Synchronizing meter.
16.23 Differential relay (87).
16.24 Exciter field ground monitor brush assembly.
17.1 Torque speed curves for various NEMA and IEC design motors.
17.2 Torque speed curves for NEMA design B motor.
17.3 Power triangle for motor absorbing reactive power from the system.
17.4 Power factor location for motor starter.
17.5 Power triangle for motor delivering reactive power to the system.
17.6 Induction motor kVA, kvar, kW and power factor in relation to load.
17.7 Synchronous motor kvar capability in relation to load.
17.8 Induction motor simplified equivalent model.
17.9 Induction motor Eg voltage or electromagnetic force versus speed curve.
17.10 Induction motor current versus speed curve.
17.11 Induction motor total power versus speed curve.
17.12 Induction motor real power versus speed curve.
17.13 Induction power factor versus speed curve.
17.14 Induction motor which is started across the line – torque versus speed (gray area) curve compared with variable torque load versus speed (black area) curve.
17.15 Induction motor which is started across the line – torque versus speed (gray area) curve compared with constant torque load versus speed (black area) curve.
17.16 Induction motor which is started with current limit reduced voltage starter – torque versus speed (gray area) curve compared with variable torque load versus speed (black area) curve.
17.17 Induction motor which is started with current limit reduced voltage starter – torque versus speed (gray area) curve compared with constant torque load versus speed (black area) curve.
17.18 Wound rotor motor three-line diagram.
17.19 Electronic soft-start three-line diagram.
17.20 One variable frequency drive controlling multiple motors.
17.21 Synchronous motor with eight poles and brushless exciter – main field.
17.22 Synchronous motor with eight poles and brushless exciter – main field and armature of brushless exciter.
17.23 Synchronous motor with eight poles and brushless exciter – stator core and windings.
17.24 Synchronous motor with eight poles and brushless exciter – armature of brushless exciter.
17.25 Synchronous motor with eight poles and brushless exciter – external of diode wheel.
17.26 Synchronous motor with eight poles and brushless exciter – internal of diode wheel.
17.27 Schematic of internal of diode wheel.
17.28 Motor torque and load torque application.
18.1 Motor torque-speed curve for different applied frequencies.
18.2 PWM VSD configuration.
18.3 PWM VSD voltage and current outputs.
18.4 LCI configuration.
18.5 LCI VSD SCR stack assembly.
18.6 Efficiency curves for flow control of fan or pump.
18.7 Torque-speed curve of standard motor showing high speed derate area (a) and low speed derate area (b).
18.8 Torque-speed curve of constant-power load.
18.9 Torque-speed curve of constant-torque load.
18.10 Torque-speed curve of variable (square)-torque load.
18.11 Torque-speed curve of variable (cube)-torque load.
18.12 Voltage vectors for 18-pulse rectifiers: second rectifier.
18.13 Voltage vectors for 18-pulse rectifiers: third rectifier.
18.14 Arrangement of 18-pulse drive isolation transformer for ±20 degree phase shift.
19.1 13.8 kV switchgear lineup.
19.2 Manual close and trip buttons and charge and position flags on circuit breaker.
19.3 Operating mechanism for medium voltage circuit breaker.
19.4 Vacuum bottle assembly of medium voltage circuit breaker.
19.5 13.8 kV switchgear breaker compartment.
19.6 Aftermath of an arc flash in a 13.8 kV breaker.
19.7 Circuit breaker close circuit schematic.
19.8 Circuit breaker trip circuit schematic.
19.9 Application of IEEE Standards to Switchgear.
20.1 Battery ground fault tracer operation.
20.2 Simplified DC distribution system.
21.1 Ground detection relay (59N) for a three-phase ungrounded system.
21.2 Balanced phase-to-ground voltages of an ungrounded system (no phase-to-ground fault).
21.3 Unbalanced phase-to-ground voltages of an ungrounded system (phase A-to-ground fault).
21.4 High impedance system protection relay showing zero sequence CT input.
21.5 Grounding arrangement for ground-fault protection in solidly grounded systems.
21.6 Grounding arrangement for ground-fault protection in resistance grounded systems.
21.7 Grounding arrangement for ground-fault protection in ungrounded systems.
22.1 Device 27, undervoltage relay.
22.2 Device 49, thermal relay.
22.3 Device 50, instantaneous overcurrent relay.
22.4 Device 51, time delay overcurrent relay.
22.5 Time-current curve (TCC) for time delay relay.
22.6 Typical relay time-current characteristics.
22.7 Device 51N, neutral-ground fault time delay overcurrent relay.
22.8 Device 59, overvoltage relay.
22.9 Device 81O and 81U, overfrequency and underfrequency relay.
22.10 Device 87, differential relay.
22.11 Simplified one line diagram of generator (E1), generator reactance (Xd) and system (E2).
14.8 Wiring Methods for Hazardous Classified Locations
14.9 DC Cable Insulation Testing Levels
14.10 Minimum Trained Bend Radius for Non-shielded or Non-armored Cable
14.11 Minimum Trained Bend Radius for Shielded or Armored Cable
14.12 Table of Slope Adjustment Factor (SAF)
14.13 Development of Effective Conduit Length Comparison
14.14 Conduit-Cable Pulling Chart for Control Cable SWBP = 500 lbf/ft and K′ = 0.5
14.15 Summary of Results for Example 14.4
14.16 Summary of Example 14.5
15.1 Classes of Oil-Filled Transformer Cooling System Ratings
15.2 Classes of Dry-Type Transformer Cooling System Ratings
15.3 Standard Insulation System Ratings for Oil-Filled Transformers
15.4 Standard Insulation System Ratings for Dry-Type Transformers
15.5 Standard BIL Levels and Optional BIL Levels for Dry-Type Transformers
15.6 Insulation Classes for Dry-Type Transformers
17.1 Torque Speed Characteristics – Various NEMA and IEC Design Motors
17.2 Chart of Power Factor Correction
17.3 Maximum Capacitor Sizes for Direct Connection to the Terminals of an Induction Motor
17.4 Induction Motor Locked Rotor Currents
17.5 Starting Characteristics of Squirrel Cage Induction Motors
17.6 Insulation Class Definitions
17.7 Motor Enclosure Definitions
17.8 Motor Voltage Selection
18.1 Maximum Safe Operating Speed for Standard Squirrel Cage Motors
18.2 Required Phase Shift for Number of Rectifier Pulses
18.3 Required Voltage Magnitudes and Angles for Number of Rectifier Pulses
19.1 Voltage and Insulation Levels for AC LV Switchgear
19.2 Voltage and Insulation Levels for DC LV Switchgear
19.3 Preferred Voltage and Insulation Levels for Metal-Clad (MC) Switchgear
19.4 Device Descriptions for Figures 19.7 and 19.8
20.1 Expected Life of Battery Cell as Function of Ambient Temperature
20.2 Recommended Cell Temperature
20.3 Sample Load List for Battery Capacity Calculation
20.4 Battery Discharge Rates
20.5A First Period Calculation in Tabular format
20.5B Second Period Calculation in Tabular Format
20.5C All Calculations in Tabular Format
21.1 Step and Touch Potential Limits from IEEE 80
23.1 NFPA 85 Section Applications
23.2 Standard Control System Graphic Color Code System
23.3 Alarm Sequence
24.1 Thermocouple Color Codes and Information According to ISA MC 96.1
24.2 Thermocouple Color Codes and Information
24.3 Common RTD Resistance Reference Values
24.4 Unit Comparison for Pressure Measurements
24.5 Standard Current Transformer Burdens
24.6 Standard Accuracy Class Ratings for Current Transformers in Metal-Clad Switchgear
24.7 Common Classes of Energy Meters
24.8 Metering Requirements for PTs and CTs
24.9 Instrument Identification Letters
24.10 Drawing Types Utilized in the Electric Generation Industry
LIST OF ANNEX
A NEMA Enclosure Types
B IEEE Device Numbers and Functions
C Common System Codes for Power Generation Facilities
D Common Equipment Codes for Power Generation Facilities
E Unit Conversion Factors
F Solutions to Problems
ACKNOWLEDGMENTS
THE AUTHOR wishes to thank the many people who contributed their time, expertise, and encouragement to the development of the course material for the Energy Production Systems Engineering course at the University of South Florida (USF) Master's Degree Power Engineering Program and, subsequently, this textbook. I especially would like to thank Professor Joe Skala and Dr. Ralph Fehr.
Back in 1980, Professor Joe Skala, while still working as a full-time Professional Engineer at Florida Power Corporation, planted the seed that has since grown into the Power Engineering Program at USF. When Professor Skala started at USF as an Adjunct Professor, there were only two power courses offered at the university as electives. By the time Professor Skala retired in 2000, he had started the Power Engineering Program at USF and developed it into an independent master's degree offering. Under Professor Skala's guidance, the power program grew by about eight courses. Even after retirement in 2000, Professor Skala continued to support education by becoming an Adjunct Professor in the Mathematics Department at St. Petersburg Junior College (SPJC). During his time at SPJC, he, along with Professor Warren DiNapoli, donated his entire salary from teaching mathematics at the Clearwater campus of SPJC to the “DiNapoli and Skala Families Scholarship.” This scholarship is awarded to Clearwater campus students who have a demonstrated financial need, a GPA of 3.0 or higher and have completed a minimum of 24 semester hours. He was also an avid supporter to the “Women on the Way” (WOW) program at SPJC, which is a resource and support center developed to help women succeed in college.
Professor Skala touched many people over his lifetime including mine. While he is gone from us now, his influence is within all of his students and will remain with us for a long time to come.
Dr. Ralph Fehr's request to develop a course covering equipment and systems utilized in the electrical power generation industry is the reason there is an Energy Production Systems Engineering course at USF and this textbook. Dr. Fehr was instrumental in the further development of the USF Power Engineering Program after Professor Skala retired. Dr. Fehr joined the power program at USF in 1997. During his tenure at USF, Dr. Fehr has added eight more courses to the power program and, in 2005, Dr. Fehr successfully developed the power program into a PhD offering at USF. As part of this expansion of the power program, Dr. Fehr recommended adding the Energy Production Systems Engineering course to the power engineering curriculum to cover topics associated with the generation side of the utility industry. The intention was that this would be one piece to round out the program to cover all aspects of power engineering: generation, transmission, distribution, and utilization. Dr. Fehr invited me to develop the Energy Production Systems Engineering course material at USF and I was glad to take on the task. Dr. Fehr has been a major contributor of materials for both the university course and the textbook and has spent many hours providing valuable feedback to me. The success of the Energy Production Systems Engineering course at USF is in large part due to the efforts of Dr. Fehr.
Additionally, I would like to thank Joe Simpson with Duke Energy for providing valuable information for Chapter 6. I also would like to thank Bob Buerkel with Parker Pneumatic Division, North America, for his review and suggestions for the valve actuator section. Additionally, Ralph Painter with Tampa Electric has been a great mentor and provided me with technical information in the design, installation, operation, and maintenance of an energy production facility that I have incorporated into the course material. I appreciate the many hours of assistance that Paul Yauilla with Tampa Electric put into editing the images and figures in this textbook. Thank you also to Jane Hutt with National Electric Coil for her efforts on the graphics for the generator section. Divya Narayanan along with all the staff at Wiley-IEEE Publishers spent many hours working with me to develop the final version of this textbook and I greatly appreciate all of their efforts.
I also wish to thank Bill Fowler, Tracy McLellan, John Sheppard, Jack White, Fred Wyly, David Kiepke, Tim Pedro, Tim Parsons, Charles (Terry) Kimbrell, James Cooksey, Michael Burch, Jim Mitchell, Jim Johnson, Dave Ford, Peter Teer, Tim Hart, and all the other many engineers, operators, technicians, electricians, and mechanics that I have worked with over the years and who have freely shared their valuable wisdom and experience. Their many hours of guidance and support have provided me with the background which has allowed me to develop this college course and textbook.
Thomas H. Blair
INTRODUCTION
THOMAS EDISON opened the first commercial electric power generation station in the United States on September 4, 1882, in New York City. This station generated “direct current” electrical energy for distribution locally in Manhattan. Soon after, on November 16, 1896, Nicholas Tesla and George Westinghouse opened a generation station in Niagara, NY, that generated “alternating current” energy. Initially, generation was located near the load center and the various load centers operated independently. Over time, it was determined that, to improve the reliability of the electric supply system and reduce costs, the many load centers and generation stations should be interconnected to a common “transmission” system thus leading to the interconnected systems of generation, transmission, distribution, and utilization that we have today.
Over the past century, power generation has undergone dramatic changes and innovation continues to drive changes and improvements in the electric generation industry. Today, sources of energy to generate electrical energy include coal, oil, natural gas, geothermal, wind, solar, biomass, hydro, tidal, and nuclear power.
Society has become very dependent on the availability of energy and electrical energy has become the primary means of distributing this energy.
The function of the generation station electrical engineer is to ensure a safe and reliable generation facility. The order of these two functions is not arbitrary. Safety is of primary concern for the generation utility engineer. Therefore, safety is the first chapter in this book. If a facility is not a safe facility for employees or the public, then it will not be a reliable facility. Unsafe conditions may not only result in personal injury but often involve equipment failure. An unsafe facility will likely have less reliable equipment and be a less reliable plant. While the primary goal of safety is to ensure the personal health and wellbeing of both the employees and the public, it also must be the primary focus for the utility engineer to ensure both safety and reliability.
This textbook is designed to provide a general introduction to the various facilities, systems, and equipment used in the power generation industry. It provides both theoretical and practical information for various utility systems. This text should provide a solid foundation on which a power generation facility engineer can continue to build.
It is my sincerest hope that this text will be useful in assisting utility electrical engineers to ensure safe and reliable operation of their facilities.