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GE Industrial Systems
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11/20/2003 10:26:46 PM
wmea-harmonic-1.ppt
Slide 1
GE Industrial Systems
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Harmonic Topics
What are harmonics? Where do they come from? Why worry? Standards. Solutions.
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wmea-harmonic-1.ppt
Slide 2
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Harmonics are voltages and currents at frequencies that are multiples of utility power frequency.
Fundamental
1
0.5
5th
Sum
7th
-1
-1.5
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wmea-harmonic-1.ppt
Slide 3
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11/20/2003 10:26:46 PM
wmea-harmonic-1.ppt
Slide 4
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wmea-harmonic-1.ppt
Slide 5
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Plating Rectifiers Computers, switching power supplies DC Drives AC drives Switching Cap banks
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wmea-harmonic-1.ppt
Slide 6
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Why Worry?
Capacitors can blow from overvoltage Drives can trip offline Transformers can overheat possibly to destruction Motors will heat more Ballasts can pop Electronics can malfunction
11/20/2003 10:26:46 PM wmea-harmonic-1.ppt Slide 7
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IF THIS HAPPENS TO CORRESPOND TO A HARMONIC CURRENT PRESENT IN THE SYSTEM, THE RESONANCE WILL PRODUCE BIG VOLTAGES ON THE CAP BANK!
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6.86 !
5 MVAR
CAP BANK AND SYSTEM Z RESONATE NEAR 7th HARMONIC! ANY DRIVE OR RECTIFIERS ON THE SYSTEM COULD CAUSE HUGE OVERVOLTAGES!
11/20/2003 10:26:46 PM wmea-harmonic-1.ppt Slide 9
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Remove proven offending cap banks OR, Change size of bank OR, Tune the bank with inductors
wmea-harmonic-1.ppt Slide 11
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A
MV DISTRIB
F
CONVEYOR
C
PLANT
EXCAVATORS
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wmea-harmonic-1.ppt
Slide 12
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wmea-harmonic-1.ppt
Slide 13
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Slide 14
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wmea-harmonic-1.ppt
Slide 15
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Harmonic Filters
Medium voltage or low voltage Tune to below desired trap frequency [example, 4.7th] Rising temps move up resonance Filter LC is in parallel with system z causing ANOTHER resonant point New parallel resonant point is hopefully not on critical frequencies
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g
Vprim
GE Industrial Systems
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LOAD
LOAD
6-PULSE RECTIFIER 5th, 7th, 11th, 13th, 17th, 19th, 23rd, 25th Etc.
12-PULSE RECTIFIER 5th, 7th 90% cancelled still have 11th, 13th, 17th, 19th, 23rd, 25th Etc.
wmea-harmonic-1.ppt
18-PULSE RECTIFIER 5th, 7th 11th, 13th 90% cancelled still have 17th, 19th 23rd, 25th Etc.
Slide 17
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Plating Rectifiers
Power range 1-10 MVA Thyristor [SCR] phase controlled Frequently 12 pulse configuration to cancel 5th and 7th harmonics Filters are on transformer primary side. Small 5th and 7th plus 11th and 13th filters.
11/20/2003 10:26:46 PM wmea-harmonic-1.ppt Slide 18
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DC Drives
Phase controlled SCR drives, phase amps in square wave blocks Usually have PF comp and Filters onboard. Typical 5th, 7th etc at 1/N magnitude. HF ringing harmonics due to switching. Switched caps on P&H individually tuned. LAG PF at stall very poor w/o caps.
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Slide 19
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OR
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Slide 20
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Power Conversion
AC Inverter
TRANSFORMATION
AC TO DC DC TO AC
UTILIZATION
LOAD
AC IND MOTOR
UTILITY SUPPLY
RECTIFICATION
SWITCHING
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wmea-harmonic-1.ppt
Slide 21
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Inverter System
3 Ph. Input
Rectifier
DC Bus
Inverter
Motor
Reference
Regulator
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Slide 22
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MOTOR FILTER
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Slide 23
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g
AC Input
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Load Commutated Inverter
Synchronous Motor
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wmea-harmonic-1.ppt
Slide 25
g
AC Input
GE Industrial Systems
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Current Source PWM GTO Inverter
Induction Motor
Advantages
Full regen and DB possible Low parts count Low motor THD Low motor insulation stress
Drawbacks
Requires a controlled front end Poor input power factor Low switching frequency Slow transient response Narrow motor frequency range Poor multi-motor operation
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wmea-harmonic-1.ppt
Slide 26
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Often 12 pulse AC front end is used to reduce 5th and 7th harmonic currents Poor PF at low speeds requires caps to correct Banks must be tuned. Small 5th & 7th still needed, plus 11th.
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LOAD
12-PULSE RECTIFIER 5th, 7th 90% cancelled still have 11th, 13th, 17th, 19th, 23rd, 25th Etc.
Slide 27
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AC PWM Drives
The most frequent AC drives in use today. LV or MV drives - usually use diode front ends. Create unique PF and harmonic problems.
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wmea-harmonic-1.ppt
Slide 28
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Utility Considerations
Stiffness of supply Utility power level variations Quality of power as received Restrictions on power quality effects by new installation [power factor, harmonics] Impact of new loads on existing system.
UTILITY
Drive
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Slide 29
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Drive AC Drive
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Slide 30
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Power Distribution
Harmonic effects on equipment True meaning of power factor Feeder sizing Mixture of drive and non drive loading. Transformer rating factors
UTILITY
Drive AC Drive
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Slide 31
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Economic tradeoffs.
Drive AC Drive
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Slide 32
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LOGIC
Motor
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Slide 33
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wmea-harmonic-1.ppt
Slide 34
GE Industrial Systems
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3 -P h a s e
0 .8
0 .6
0 .4
0 .2
[+]
AC Incoming Line
T hree P h ase In p u t
1.2
Cap Bank
DBR
a
c
0.7
-0.8
-1.3
[- ]
Motor Amps
11/20/2003 10:26:46 PM wmea-harmonic-1.ppt Slide 35
GE Industrial Systems
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0 .4
0 .2
A Cap Bank
IGBTs M
General Rule: 5% Z needed in System Z + Line Reactor OR include DC Link reactor to Prevent Fuse Blowing. Some drives have SCR in rectifier to control charging. Line reactor &/or DC reactor Improve average power factor & reduce Harmonics
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GE Industrial Systems
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A Cap Bank
IGBTs M
LINE AMPS
Rectified 3-Phase
1.2
CAPACITOR CAN FILL ONLY WHEN PEAK LINE VOLTS AT A ARE ABOVE CAPACITOR VOLTS: * LINE AMPS CHARGE CAPS IN VERY UNEVEN BUMPS [NOT SINE WAVE!] * NON SINE WAVE CURRENT IS FULL OF HARMONICS.
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0.8
0.6
0.4
0.2
Slide 37
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wmea-harmonic-1.ppt
Slide 38
GE Industrial Systems
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DC Link Reactor
5.9
469
5.0
467
5.0
471
5.0
468
7.2
5.0%
6.2
3.2%
6.1
2.8%
6.2
2.6%
AC Line Reactors
69.1%
0.1% 4.8%
31.8%
0.1% 2.4%
34.2%
0.1% 5.5%
27.8%
0.2% 0.8%
0.81
3.5%
0.94
3.0%
0.91
3.0%
0.93
3.3%
Ref Page 12-9 & 12-10 GEZ-7984E 11/20/2003 10:26:46 PM wmea-harmonic-1.ppt Slide 39
GE Industrial Systems
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5.2
469
3.8
467
3.2
470
3
469
DC Link Reactor
Avg Inp Volts Avg Ph Amps Input VoItageThd.. Input Current Thd Input Volts Imb Input Amps Imb
6.2
1.70%
4.7
1.40%
4
1.20%
3.7
1.30%
AC Line Reactors
39.4%
0.30% 4.8%
0.61
4.2%
0.85
3.3%
0.83
4.4%
0.9
4.1%
Ref Page 12-9 & 12-10 GEZ-7984E 11/20/2003 10:26:46 PM wmea-harmonic-1.ppt Slide 40
GE Industrial Systems
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M
6-PULSE BASIC PWM DRIVE
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Slide 42
g
Vprim
GE Industrial Systems
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INVERT.
INVERT.
M M
6-PULSE BASIC PWM DRIVE 12-PULSE BASIC PWM DRIVE
M
18-PULSE BASIC PWM DRIVE
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Slide 43
GE Industrial Systems
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6- PULSE WAVEFORM
R e c t if ie d 3 - P h a s e
1 .2 1 0 .8
0 .6
0 .4
0 .2
IGBTs M
Cap Bank
Fuses
0 .6
0 .4
Fuses
0 .2
Vprim
Fuses
0 .6
0 .4
0 .2
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Slide 44
350 400
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None, or Transformer Simple [Can Share] Harmonics [drive only] Complexity / Parts Count Potential Reliability
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Large TDD
Simplest Most
wmea-harmonic-1.ppt
Slide 45
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Advantages
Low motor current THD Low motor insulation stress Partial N+1 redundancy available Easy repair Fast transient response Wide motor frequency range High power factor Low power system harmonics
Drawbacks
No regen or DB possible Large parts count Reduced efficiency (many series IGBTs and diodes) Special transformer required Larger footprint in high HP
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wmea-harmonic-1.ppt
Slide 46
g
AC Input
GE Industrial Systems
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Inverter Topology
Three or Five Level Voltage Source IGBT PWM Inverter
Advantages
Minimum parts count for voltage rating Full regen and DB available High efficiency Low motor current THD Low motor insulation stress Easy repair Fast transient response Wide motor frequency range Smooth low speed operation
Drawbacks
Motor termination impedance matching [3 level only] Not N+1 redundant
Inverter duty motor not necessary due to 3 or 5 level switching Laminated bus which has lower parasitic inductance that allows for a snubberless design Fault current tolerance no longer an issue due to the use of IGBTs and optimized gate control. No inductor needed (di/dt limit) and no fuses (current magnitude protection) Smaller footprint due to the use of heat pipe technology that improves power density
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Slide 47
GE Industrial Systems
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Utility Considerations
Stiffness of supply Utility power level variations Quality of power as received Restrictions on power quality effects by new installation [power factor, harmonics] Impact of new loads on existing system.
UTILITY
Drive
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Slide 48
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Drive AC Drive
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wmea-harmonic-1.ppt
Slide 49
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Power Distribution
Harmonic effects on equipment True meaning of power factor Feeder sizing Mixture of drive and non drive loading. Transformer rating factors
UTILITY
Drive AC Drive
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wmea-harmonic-1.ppt
Slide 50
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Economic tradeoffs.
Drive AC Drive
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Slide 51
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Vpcc
Notes: Even Harmonics limited to 25% of the harmonic level TDD = Total Demand Disortion %, based on maximum demand current at the point of common coupling [PCC]. Isc = Maximum Short Circuit current or kVA at the PCC I-load = Fundamental freqency load current or kVA at the PCC
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D M
Slide 52
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Vpcc
I-Load [fund]
I-harm
D M
Slide 53
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% OF FUNDAMENTAL AMPS
200 Total Effective Current
200
% OF FUNDAMENTAL AMPS
100
100
% OF FUNDAMENTAL AMPS
% OF FUNDAMENTAL AMPS
11th
23rd 25th
25th
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Slide 54
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Harmonic Calculations
Consider both drives and linear loads. TDD per IEEE is a % of total kva, including PCC Isc Available Vpcc non-VFD motors Demand distortion is not instantaneous number, but based on meter kva-hours. I-harm I-Load Must define a Point of Common Coupling: [fund] where currents sum. Computer programs are available [see www.transcoil.com]. D If you ignore harmonics, then breakers, M transformers and feeders may be under-sized.
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Slide 55
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wmea-harmonic-1.ppt
Slide 56
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wmea-harmonic-1.ppt
Slide 57
GE Industrial Systems
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Breakers Disconnect switches, fused or unfused Vacuum switches Thermal protection for reactors (CT's & relays) Unbalance/Blown Fuse detection (CT's & relays) Automatic banks (controllers, switches & reactors for each step) Ground switches Ventilation/heaters Provisions for Kirk key interlocks
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Slide 59
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wmea-harmonic-1.ppt
Slide 60
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Incoming MV Feed
PER DRIVE FILTER 6-PULSE PWM DRIVE 6-DIODE RECT. INVERT. MOTOR & LOAD
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Slide 61
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Harmonic Correction:
Rational Approaches
Correct known problems, use consultation if needed. Local filters - at the source. System level filters. Minimize injection of currents by equipment selection & application. Maintain standards to prevent future problems.
11/20/2003 10:26:46 PM wmea-harmonic-1.ppt Slide 62
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Incoming MV Feed
M
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M
wmea-harmonic-1.ppt
M
Slide 63
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LV BUS
Incoming MV Feed
M
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M
wmea-harmonic-1.ppt
M
Slide 64
GE Industrial Systems
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MV BUS
Incoming HV Feed
11 13
M
11/20/2003 10:26:46 PM wmea-harmonic-1.ppt Slide 65
GE Industrial Systems
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GE Industrial Systems
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IEEE 519-1992
awg 8 awg 1
99
98
CURVES ARE BASED ON FOLLOWING HARMONIC CURRENT DISTRIBUTION h 5 7 11 13 17 19 23 25 Ih[(pu) 0.175 0.110 0.045 0.029 0.015 0.010 0.009 0.008
98
1/0 AWG 2/0 AWG 3/0 AWG
97
97 250 kcmil 350 kcmil 500 kcmil 750 kcmil 1000 kcmil 94 80 90 100 95 96
4/0 AWG
96
95
SIMPLIFIED CONCLUSION: REDUCE VFD HARMONICS TO THESE LEVELS OR LESS AND CABLE IMPACT WILL BE MINIMAL.
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Slide 67
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Harmonic Solutions
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Slide 68
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Harmonic Surveys
What are they? When are they needed?
Serious & widespread symptoms Starting fresh To fix utility complaints
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Slide 69
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Harmonic Surveys
Do-it-yourself Approach
Measurement locations Instrument availability, setup, calibration. Data interpretation
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Slide 70
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A
MV DISTRIB
F
CONVEYOR
C
PLANT
EXCAVATORS
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Slide 71
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Slide 72
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Summary
Use common sense approach - dont be pushed into excessive action. Recognize symptoms of harmonic problems. Use design tools to do simple calcs and planning Consult reliable systems analysis sources when help is needed.
11/20/2003 10:26:46 PM wmea-harmonic-1.ppt Slide 73
GE Industrial Systems
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Summary
Use common sense approach - dont be pushed into excessive action. Recognize symptoms of harmonic problems. Use design tools to do simple calcs and planning Consult reliable systems analysis sources when help is needed.
11/20/2003 10:26:46 PM wmea-harmonic-1.ppt Slide 74