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Resolving Transformer Noise and Electrical Harmonics Issues in Deep Well Pump Systems

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In deep well pumping systems serving approximately 50,000 residents, issues of transformer noise and electrical harmonics have been identified. This paper explores the roots of these problems, particularly focusing on voltage and current harmonics generated by Variable Frequency Drives (VFDs). Solutions implemented include the addition of Accusine active filters and quieter transformers, achieving an improved power factor over 95% and significantly reducing noise levels at pump stations. The study demonstrates the effectiveness of these solutions in enhancing system performance while addressing community concerns.

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Resolving Transformer Noise and Electrical Harmonics Issues in Deep Well Pump Systems

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  1. 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 Group David Kaunisto, District Manager, East Cherry Creek Valley Water & Sanitation District

  2. East Cherry Creek Valley Water & Sanitation District

  3. 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)

  4. Deep Well Installation Diagram 480 Volts 480 Volts 2300 Volts UTILITY TRANSFORMER (XFMR) VARIABLE FREQUENCY DRIVE (VFD) STEP-UP TRANSFORMER SUBMERSIBLE WELL PUMP AND MOTOR

  5. Deep Well Installation Diagram 480Volts 480Volts 2300Volts VFD 1-YEAR PUMPING WATER LEVEL (PWL) 10-YEAR PUMPING WATER LEVEL (PWL)

  6. Variable Speed Pumps Head 3000 2000 0 70 Hz 60 Hz 50 Hz 10 Year PWL 1 Year PWL 0 200 400 600 Gallons Per Minute

  7. 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%.

  8. Discussion of Problem – Power Factor • The current lags the voltage because of motor load. Voltage Current

  9. Discussion of Problem – Transformer Noise • Complaints from neighbors about transformer noise.

  10. Transformers Utility Step-up

  11. Physical Muffling of Transformer Noise by Fence

  12. Goal Equipment combination that will: • Provide adequate power factor • Reduce noise to acceptable level • Provide operating flexibility to meet varying demands.

  13. 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.

  14. Variable-Frequency Drive Accusine Active Filter VFDs

  15. Variable Frequency Drive 6-step VFD voltage source output

  16. Electrical Harmonics Graph of harmonics

  17. Electrical Harmonics Graph of harmonics

  18. Harmonic Current Distortion Well SL-10 VFD operating without Accusine

  19. Transformer Vibration Core Base connected to box

  20. How Noisy Is It? decibels (dB) Whisper 30 Light Traffic 40-50 Vacuum Cleaner 70 Garbage Disposal 80 Circular Saw 100 Rock Concert 110-130 Threshold of Pain 108-130 Jet Takeoff 140

  21. Decibels vs. Audible Noise Audible Noise Decibels (dB)

  22. 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.

  23. Transformer Vibration

  24. Harmonic Current Distortion Well SL-10 VFD operating without Accusine

  25. Harmonic Current Distortion Well SL-10 VFD operating with Accusine

  26. Accusine Installation Diagram 480 Volts 480 Volts 480 Volts 2300 Volts UTILITY TRANSFORMER (XFMR) ACCUSINE ACTIVE FILTER 6-STEP VFD STEP-UP TRANSFORMER SUBMERSIBLE WELL PUMP AND MOTOR

  27. MTE Load Filter Installation Diagram 480 Volts 480 Volts 2300 Volts 480 Volts UTILITY TRANSFORMER (XFMR) PWM (VFD) MTE LOAD FILTER STEP-UP TRANSFORMER SUBMERSIBLE WELL PUMP AND MOTOR

  28. Equipment Tests – P.S. SA-8/SL-8 6-Pulse VFD Utility Transformer 72 dB Step-up Transformer 68 dB SWE “Quiet” Step-up Transformer 60 dB 12-Pulse VFD with Phase-Shift Transformer Utility Transformer 68 dB SWE “Quiet” Step-up Transformer 60 dB TAPS Phasor Step-up Transformer 63 dB

  29. Equipment Tests – P.S. SA-8/SL-8 Before: Utility Transformer 72 dB Step-up Transformer 68 dB Utility Power Factor 84% After adding Accusine Active Filter and Quiet Xfmrs: Utility Transformer 66 dB SWE Quiet Step-up Transformer 60 dB Utility Power Factor 97%

  30. Equipment Tests – P.S. A-19/L-19 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 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%

  31. 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 dB SL-1 Step-up Transformer 50 dB Utility Transformer 66 dB, Power Factor 25% With Accusine operating: SA-1 Step-up Transformer 55 dB SL-1 Step-up Transformer <50 dB Utility Transformer 59 dB, Power Factor 95%

  32. $ 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 $13,000 260 KVA $11,300 260 KVA $17,600 • PCS300 Accusine Active Filter $36,900 • MTE Load Filter $4,500 • Transportation and Installation – Add 20 - 30%

  33. 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.

  34. Questions? Craig Patterson, Project Engineer, Meurer & Associates Paul D. Goldfain, Associate Principal, Meurer & Associates Robert Anderson, Electrical Engineer, The RMH Group David Kaunisto, District Manager, East Cherry Creek Valley Water & Sanitation District

  35. PWM Wave

  36. PWM Output Wave Forms

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