THE ELECTRIC PLANT AT WORK Direct-connected generating sets—Belt drive—The switchboard—Governors and voltage regulators—Methods of achieving constant pressure at all loads: Over-compounding the dynamo; A system of resistances; (A home-made electric radiator); Regulating voltage by means of the rheostat—Automatic devices—Putting the plant in operation. Dynamos may be connected to water wheels either by means of a belt, or the armature may spin on the same shaft as the water wheel itself. The latter is by far the more desirable way, as it eliminates the loss of power through shafting and belting, and does away altogether with the belts themselves as a source of trouble. An installation with the water wheel and armature on the same shaft is called a "direct-connected set" and is of almost universal use in large power plants. To be able to use such a direct-connected When it comes to the larger wheels, however, of the impulse type, or to turbines operating under their usual head the question becomes a little more difficult. In such cases, the speed of the water wheel will vary In practice, in large plants, with alternating-current machines it has become usual to mount the field magnets on the shaft, and build the armature as a stationary ring in whose air space the field coils revolve. This simplifies the construction of slow-speed, large-output dynamos. Such a machine, however, is not to be had for the modest isolated plant of the farmer with his small water-power. Dynamos can be designed for almost any waterwheel speed, and, among small manufacturers especially, there is a disposition to furnish these special machines at little advance in price over their stock machines. Frequently it is merely a matter of changing the winding on a stock machine. The farmer himself, in many cases, can re-wind an old dynamo to fit the speed requirements of a direct-connected drive if the difference is not too When direct drive cannot be had, a belt must be used, either from a main shaft, or a countershaft. The belt must be of liberal size, and must be of the "endless" variety—with a scarfed joint. Leather belt lacing, or even the better grades of wire lacing, unless The dynamo is mounted on a wooden base, in a dry location where it is protected from the weather, or dampness from any source. It must be mounted firmly, to prevent vibration when running up to speed; and the switchboard should occupy a place within easy reach. Wires running from the dynamo to the switchboard should be protected from injury, and must be of ample size to carry The Switchboard The switchboard is constructed of some fireproof material, preferably slate or marble. When the cost of this material is an item to consider, build a substantial wooden frame for your switchboard. You can then screw asbestos shingles to this to hold the various Governors and Voltage Regulators A centrifugal governor (Courtesy of the C. P. Bradway Company, West Stafford, Conn.) The necessity for water wheel governors will vary with conditions. As a general rule, it may be said that reaction turbines working under a low head with a large quantity of water do not require as much governing as the impulse wheel, working under high heads with small quantities of water. When governing is necessary at all, it is because the prime mover varies in speed from no load to full load. Planning one's plant with a liberal allowance of power—two water horsepower to one electrical horsepower is liberal—reduces the necessity of governors to a However, a surplus of water-power is not usual. Generally plants are designed within narrow limits; and then the need of a governor becomes immediately apparent. There are many designs of governors on the market, the cheapest being of the centrifugal type, in which a pair of whirling balls are connected to the water wheel gate by means of gears, and open or close the gate as the speed lowers or rises. Constant speed is necessary because voltage is directly dependent on speed. If the speed falls 25 per cent, the voltage falls likewise; and a plant with the voltage varying between such limits would be a constant source of annoyance, as well as expense for burned-out lamps. Since constant voltage is the result aimed at by the use of a governor, the same result can be attained in other ways, several of which will be explained here briefly. Over-Compounding (1) Over-compounding the dynamo. This is simple and cheap, if one buys the right dynamo in the first instance; or if he can do the over-compounding himself, by the method described in the concluding paragraphs of Chapter Seven. If it is found that the speed of the water wheel drops 25 per cent between no load and full load, a dynamo with field coils over-compounded to this extent would give a fairly constant regulation. If you are buying a special dynamo for direct drive, your manufacturer can supply you with a machine that will maintain constant voltage under the normal variations in speed of your wheel. A System of Resistances (2) Constant load systems. This system provides that the dynamo shall be delivering a fixed amount of current at all times, under which circumstances the water wheel would not require regulation, as the demands on it would not vary from minute to minute or hour to hour. This system is very simply arranged. It consists of having a set of "resistances" to throw into the circuit, in proportion to the amount of current used. Let us say, as an example, that a 50-ampere generator is used at a pressure of 110 volts; and that it is desirable to work this plant at 80 per cent load, or 40 amperes current draft. When all the lights or appliances were in use, there would be no outside "resistance" in the circuit. When none of the lights or appliances were in use (as would be the case for many hours during the day) it would be necessary to consume this amount of current in some other way—to waste it. A resistance permitting 40 amperes of current to flow, would be necessary. Of what size should this resistance be? The answer is had by applying Ohm's Law, explained in Chapter Five. The Law in this case, would be read R = E/C. Therefore, in this case R = 110/40 = 2¾ ohms resistance, would be required, switched across the mains, to keep the dynamo delivering its normal load. The cheapest form of this resistance would First figure the number of feet of copper wire suitable for the purpose. Allowing 500 circular mills for each ampere, the gauge of the wire should be 40 × 500 = 20,000 circular mills, or approximately No. 7 B. & S. gauge. How many feet of No. 7 copper wire would give a resistance of 2¾ ohms? Referring to the copper wire table, we find that it requires 2006.2 of No. 7 wire to make one ohm. Then 2¾ ohms would require 5,517 feet. Since 30 per cent German silver wire is approximately 30 times the resistance of copper, a No. 7 German silver wire, for this purpose, would be 1/30 the length of the copper wire, or 186 feet. If nichrome wire In actual practice, however, the resistance necessary to keep the dynamo up to full load permanently, would not be furnished by one set of resistance coils. Each lamp circuit would have a set of resistance coils of its own. A double-throw switch would turn off the lamps and turn on the resistance coils, or vice versa. Let us say a lamp circuit consisted of 6 carbon lamps, of 16 candlepower each. It would consume 6 × ½ ampere, or 3 amperes of current, and interpose a resistance of 36.6 ohms—say 37 ohms. Three amperes would require a wire of at least 1,500 circular mills in area for safety. This corresponds to a No. 18 It is simple to figure each circuit in this way and to construct resistance units for each switch. Since the resistance units develop considerable heat, they must be enclosed and protected. A Home-made Stove or Radiator While we are on the subject of resistance coils it might be well here to describe how to make stoves for cooking, and radiators for heating the house, at small expense. These stoves consist merely of resistances which turn hot—a dull red—when the current is turned on. Iron wire, German silver wire, or the various trade brands of resistance wire, of which nichrome, calido, and manganin are samples, Let us say we wish to heat a bathroom, a room 6 × 8, and 8 feet high—that is a room containing 384 cubic feet of air space. Allowing 2 watts for each cubic foot, we would require 768 watts of current, or practically 7 amperes at 110 volts. What resistance would be required to limit the current to this amount? Apply Ohm's Law, as before, and we have R equals E divided by C, or R equals 110 divided by 7, which is 15.7 ohms. Forty-two feet of No. 20 German silver wire would emit this amount of heat and limit the current output to 7 amperes. In the Far West, it is quite common, in the outlying district, to find electric radiators made out of iron pipe covered Regulating Voltage at Switchboards The voltage of any given machine may be regulated, within wide limits, by means of the field rheostat on the switchboard. A dynamo with a rated speed of 1,500 revolutions per minute, for 110 volts, will actually attain this voltage at as low as 1,200 r.p.m. if all the regulating resistance be cut out. You can test this fact with your own machine by cutting out the resistance from the shunt field entirely, and starting the If, on the other hand, the speed of such a machine runs up to 2,500 or over—that is, an excess of 67%—the voltage would rise proportionally, unless extra resistance was cut in. By cutting in such resistance—by the simple expedient of turning the rheostat handle on the switchboard,—the field coils are so weakened that the voltage is kept at the desired point in spite of the excessive speed of the machine. Excessive speeds are to be avoided, as a rule, because of mechanical strain. But within a wide range, the switchboard rheostat can be used for voltage regulation. As it would be a source of continual annoyance to have to run to the switchboard every time the load of the machine was varied greatly this plan would not be practical for the isolated plant, unless the rheostat could be installed,—with a voltmeter—in one's Automatic Devices There are several automatic devices for voltage regulation at the switchboard on the market. These consist usually of vibrator magnets or solenoids, in which the strength of the current, varying with different speeds, reacts in such a way as to regulate field resistance. Such voltage regulators can be had for $40 or less, and are thoroughly reliable. To sum up the discussion of governors and voltage regulators: If you can allow a liberal Starting the Dynamo You are now ready to put your plant in operation. Your dynamo has been mounted on a wooden foundation, and belted to the countershaft, by means of an endless belt. See that the oil cups are filled. Then throw off the main switch and the field switch at the switchboard; open the water gate slowly, Having assured yourself that the mechanical details are all right, now look at the voltmeter. It is probably indicating a few volts pressure, from 4 to 8 or 10 perhaps. This pressure is due to the residual magnetism in the field cores, as the field coils are not yet connected. If by any chance, the needle does not register, or is now back of 0, try changing about the connections or the voltmeter on the back of the switchboard. Now snap on the field switch. Instantly the needle will begin to move forward, though slowly; and it will stop. Turn the rheostat handle gradually; as you advance it, the voltmeter needle will advance. Finally you will come to a point where the needle will indicate 110 volts. If you have designed your transmission line for a drop of 5 volts at half-load, advance the rheostat handle still further, until the Your plant is now ready to deliver current up to the capacity of its fuses. See that it does not lack good lubricating oil, and do not let its commutator get dirty. The commutator should assume a glossy chocolate brown color. If it becomes dirty, or the brushes spark badly, hold a piece of fine sandpaper against it. Never use emery paper! If, after years of service, it becomes roughened by wear, have it turned down in a lathe. Occasionally, every few weeks, say, take the brushes out and clean them with a cloth. They will wear out in the course of time and can be replaced for a few cents each. The Otherwise your electric plant will take care of itself. Keep it up to speed, and keep it clean and well oiled. Never shut it down unless you have to. In practice, dynamos run week after week, year after year, without stopping. This one, so long as you keep it running true to form, will deliver light, heat and power to you for nothing, which your city cousin pays for at the rate of 10 cents a kilowatt-hour. |