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RESOLVING TRANSFORMER NOISE AND ELECTRICAL HARMONICS PROBLEMS ASSOCIATED WITH DEEP WELL PUMPING SYSTEMS
Craig Patterson, Project Engineer, Meurer & Associates
Paul D. Goldfain, Associate Principal, Meurer & Associates
Robert Anderson, Electrical Engineer, The RMH GroupDavid Kaunisto, District Manager, East Cherry Creek
Valley Water & Sanitation District
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East Cherry Creek Valley Water & Sanitation District
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East Cherry Creek Valley Water & Sanitation District
Approximately 50,000 population 10-15 MGD yearly range
Water Supply– Arapahoe aquifer (1,500’ - 1,800’ deep)
– Laramie-Fox Hills aquifer (1,800’ – 2,300’ deep)
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Deep Well Installation Diagram
480 Volts 480 Volts 2300 Volts
SUBMERSIBLE WELL PUMP AND MOTOR
UTILITYTRANSFORMER
(XFMR)
VARIABLE FREQUENCY
DRIVE(VFD)
STEP-UP TRANSFORMER
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Deep Well Installation Diagram
480 Volts 480 Volts 2300 Volts
1-YEAR
10-YEAR
PUMPING WATER LEVEL (PWL)
PUMPING WATER LEVEL (PWL)
VFD
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Variable Speed Pumps
70 Hz
60 Hz
50 Hz
Head
3000
2000
0 Gallons Per Minute
0 200 400 600
10 Year PWL
1 Year PWL
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Discussion of Problem – Power Factor
Power Factor is the percentage difference between apparent and actual power.
The Electric utility requires at least 95%.
P.S. SA-8 was 84%.
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Discussion of Problem – Power Factor The current lags the voltage
because of motor load.
Vol
tage
Cur
rent
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Discussion of Problem – Transformer Noise
Complaints from neighbors about transformer noise.
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Transformers
Step-up
Utility
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Physical Muffling of Transformer Noise by Fence
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Goal
Equipment combination that will:
Provide adequate power factorReduce noise to acceptable levelProvide operating flexibility to meet varying demands.
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Electrical Analysis
RMH Group analyzed the power systems at several pump stations.
They determined that problem was caused by voltage and current harmonics generated in the VFDs.
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Variable-Frequency Drive
VFDs
AccusineActive Filter
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Variable Frequency Drive
6-step VFD voltage source output
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Electrical Harmonics
Graph of harmonics
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Electrical Harmonics
Graph of harmonics
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Harmonic Current Distortion
Well SL-10 VFD operating without Accusine
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Transformer Vibration
Core
Base connected to box
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How Noisy Is It?
decibels (dB)Whisper 30Light Traffic 40-50Vacuum Cleaner 70Garbage Disposal 80Circular Saw 100Rock Concert 110-130Threshold of Pain 108-130Jet Takeoff 140
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Decibels vs. Audible Noise
Au
dib
le
Nois
e
Decibels (dB)
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Equipment Tested
12-step or Pulse-Width Modulated VFD– More frequent pulsing reduces distortion.
Southwest Electric “Quiet” Transformers– Larger core, rubber supports, sound proofing
MTE load filter (for PWM drive)– Converts VFD output to sinusoidal wave
Accusine “Active” filter– Senses current, then gates just the right amount of power through the filter to correct distortion.
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Transformer Vibration
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Harmonic Current Distortion
Well SL-10 VFD operating without Accusine
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Harmonic Current Distortion
Well SL-10 VFD operating with Accusine
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Accusine Installation Diagram
480 Volts 480 Volts 2300 Volts
SUBMERSIBLE WELL PUMP AND MOTOR
UTILITYTRANSFORMER
(XFMR)
6-STEPVFD
STEP-UP TRANSFORMER
ACCUSINEACTIVEFILTER
480 Volts
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MTE Load Filter Installation Diagram
480 Volts 480 Volts 2300 Volts
SUBMERSIBLE WELL PUMP AND MOTOR
UTILITYTRANSFORMER
(XFMR)
PWM(VFD)
STEP-UP TRANSFORMER
MTE LOAD
FILTER
480 Volts
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Equipment Tests – P.S. SA-8/SL-8
6-Pulse VFDUtility Transformer 72 dBStep-up Transformer 68 dB
SWE “Quiet” Step-up Transformer 60 dB
12-Pulse VFD with Phase-Shift Transformer
Utility Transformer 68 dBSWE “Quiet” Step-up Transformer 60 dB
TAPS Phasor Step-up Transformer 63 dB
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Equipment Tests – P.S. SA-8/SL-8
Before: Utility Transformer 72 dB
After adding Accusine Active Filter and Quiet Xfmrs:
Step-up Transformer 68 dB
Utility Power Factor 84%
Utility Transformer 66 dB
SWE Quiet Step-up Transformer 60 dB
Utility Power Factor 97%
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Equipment Tests – P.S. A-19/L-19
Installed MTE Output (Load) Filters
A-19 Step-up Transformer 64 dB
L-19 Step-up Transformer 69 dB
Utility Transformer 62 dB, Power Factor 99%
Well A-19 equipped with Toshiba PWM 12-pulse VFD
Well L-19 equipped with Toshiba PWM 6-pulse VFD
A-19 Step-up Transformer 81 dB
L-19 Step-up Transformer 82 dB
Utility Transformer 69 dB
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Equipment Tests – P.S. SA-1/SL-1
Both wells equipped with Centrilift 6-step VFDs and SWE Quiet transformers.Without Accusine operating:
SA-1 Step-up Transformer 57 dBSL-1 Step-up Transformer 50 dBUtility Transformer 66 dB, Power Factor 25%
With Accusine operating:SA-1 Step-up Transformer 55 dBSL-1 Step-up Transformer <50 dBUtility Transformer 59 dB, Power Factor 95%
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$ Equipment Costs $
6-pulse drive $18,000 - $22,000 12-pulse drive $22,000 – $24,000 “Regular” Step-Up Xfmr SWE “Quiet” Xfmr
130 KVA $7,600 130 KVA $13,000260 KVA $11,300 260 KVA $17,600
PCS300 Accusine Active Filter $36,900 MTE Load Filter $4,500 Transportation and Installation – Add 20 - 30%
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Results
Installation of “Quiet” transformers generally reduced transformer noise by 1/2.
Installation of Accusine “Active Filter” corrected power factor to better than 95%, and reduced utility transformer noise.
Installation of MTE load filter on PWM drives reduced transformer noise by almost 1/2.
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Questions?
Craig Patterson, Project Engineer, Meurer & AssociatesPaul D. Goldfain, Associate Principal, Meurer & Associates
Robert Anderson, Electrical Engineer, The RMH GroupDavid Kaunisto, District Manager, East Cherry Creek
Valley Water & Sanitation District
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PWM Output Wave Forms