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cover story
2 Commissioning
electrical systems in
mission critical facilities
Engineers should follow best practices to
overcome the inherent challenges of electrical
system functional performance testing.
Anticipating
the Smart Grid
18
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Comparing generator
sizing software
24
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ON THE COVER:
Commissioning is a programmed series of
design and construction documentation
and testing activities that are performed
specifically to ensure that the finished facility
operates as intended. This requires testing
several systems, such as generators as
seen at the top of the cover, and generator
paralleling switchgear at the bottom. The
results, shown on the dashboard in the center,
will determine the overall performance. As
represented with arrows, commissioning
should be an ongoing and routine process
to ensure facilities and their systems are
operating as intended.
Courtesy: Environmental Systems Design Inc.
www.csemag.com/purepower
FEATURES
Cover Story
By Joshua J. Gepner, PE, QCxP, LEED AP O+M,
Environmental Systems Design Inc., Chicago
Commissioning
electrical systems in
mission critical facilities
Engineers should follow best practices to overcome the inherent challenges of
electrical system functional performance testing.
GENERATOR
Including the generators in the commissioning scope for
a critical facility is imperative because they are the only
source of long-term standby power when the utility becomes unavailable (see Figure 1).
When testing a generator, it is best practice to ensure that
the load for step loading and endurance testing has a power
www.csemag.com/purepower
The ATS is an important component of the critical facility because it is used commonly in critical facility designs
to transfer power from a primary source to a secondary
source after the loss of the primary source.
Open transition ATSs are designed to allow for an interruption to the load using a break-before-make transfer.
Because of this, loading the ATS during open transition
transfers during functional performance testing is not
required. Load is also not required when testing an ATSs
ability to perform closed transition transfers. During closed
transition transfers, the ATS will parallel the primary and
secondary sources prior to transferring. It is important to
ensure that the ATS can properly conduct closed transition transfers and will handle the transition in the same
manner, regardless of whether it is carrying load or not. A
power quality meter must be connected to the output of the
ATS to confirm that the transfer is completed within the
Cover Story
UPS
The UPS is probably the most important
piece of equipment in the critical facility
because of its ability to maintain power to
critical loads, regardless of the operation
of all of the other supporting systems (see
Figure 2).
Monitoring the inputs to the rectifier of
the UPS, the static bypass within the UPS,
and the UPS output bus is considered best
practice during functional performance testing. After each transient, step load, or battery discharge test, the waveforms recorded
by the power quality meters set up on the
system should be reviewed to confirm
that no events were triggered and that the
output waveforms stayed within tolerance
and recovered within the specified time
frame. UPS systems are often placed into
service quickly after functional performance
testing, so it is best to check the power
Figure 3: Generator paralleling switchgear must be tested with resistance/reactive loads to
quality meter resultsincluding waveform
confirm the systems ability to properly share kVAR.
capturesduring on-site testing rather than
waiting
for
a
report
from the meter technician. This way,
can arise in situations where ATSs are added to existing
any problem discovered during UPS testing can be quickly
live facilities. Because of their integral role in the power
rectified as the manufacturer often has to consult the facdistribution system, they often cant be tied into the electritory on problematic internal UPS operation.
cal system without bringing down the loads that they will
Full load endurance tests should be conducted on UPS
serve. In an effort to minimize disruption to the live facilsystems after the system has been installed on-site, even
ity, the ATS testing will likely occur prior to connecting it
if full load testing was conducted in the factory. Many
to the live facility. However, the ATS can be connected to
components need to be disconnected for shipping and are
the secondary source if the secondary source is a generathen reassembled on-site. Electrical equipment can also
tor. When the primary source serving the load is restored,
be affected by problems that develop during shipping and
there is usually limited time for testing the ATS as it will
may not be detected without performing the endurance
immediately be required to provide power to critical loads.
test on-site. Generally, an 8-hr duration for a full load test
ATS commissioning case study: An ATS manufacturer
is considered adequate to confirm that the system will be
was required to start up and test the ATS on a project
capable of functioning at full rated load without problems.
before it was tied into the electrical system. To do this, the
In some cases, it can be difficult to monitor the logic
ATS vendor required both the primary and the secondused by the UPS to handle various operations because the
ary sources to be available for the start-up. The electrical
actions are carried out by microprocessors installed on
contractor added a jumper between the two sources and
circuit boards. This emphasizes the importance of propconnected the secondary source of the ATS to the generaerly setting up power quality monitoring equipment prior
tor. When the generator was started, the ATS saw both
to testing the UPS. If a problem is detected during testing,
the primary and secondary sources as available. A major
the manufacturer will have a much easier time solving it if
drawback was that there was no way to disconnect only
it is provided with significant data generated both by the
the primary source during start-up without also simulatUPSs internal monitoring system and the external power
ing the loss of the secondary source, so it was not possible
monitoring equipment used during testing. When a failure
to verify automatic transfer operations without simulation
occurs, it can be very difficult to understand what is haptechniques. The ATS also had a much easier time performpening inside the equipment. Captured test data almost
ing closed transition transfers because the two sources
always improves the issue resolution process.
were perfectly synchronized, as they both came from the
UPS commissioning case study: While setting up the
same generation point. All of the functionality was retested
system configuration for a battery discharge test, both batafter the final tie-in during functional performance testing
tery string breakers opened when load was applied to the
to ensure the system was operating properly in the actual
batteries. The event that caused this response was retested
design configuration.
www.csemag.com/purepower
GENERATOR PARALLELING
SWITCHGEAR
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PLANNED
EVENT
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EVENT
ONE NAME YOU CAN COUNT ON
Whether youre powering a sporting event, or supporting recovery efforts following an ice storm or flooding, your Cat
dealer has the equipment to help you solve the challenge. As part of the Caterpillar dealer network, your local Cat dealer
has access to a vast rental fleet of power generation and temperature control equipment specifically designed to meet the
requirements of commercial, industrial, institutional and manufacturing applications, capable of supporting even the most
critical operating systems.
Whether youre dealing with an emergency, or planning ahead for scheduled downtime, Cat Standby Power equipment
can be on its way in minutes. Visit us online today at www.NECatDealers.com/power
input #401 at www.csemag.com/information
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Alban CAT
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Milton CAT
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800-492-6994
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888-232-5948
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866-385-8538
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877-RANSOME
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used without permission. www.cat.com www.caterpillar.com
Cover Story
Smart Grid
By Sunondo Roy, PE, LEED BD+C, Joshua Polasky,
and Blake Shanahan, CCJM Engineers Ltd., Chicago
Anticipating
the Smart Grid
Designers, building owners, and operators should understand how the emerging
Smart Grid will impact individual buildings.
Figure 1: High-voltage
ac power lines transmit
electrical power from
power generation
stations to the local
utility distribution grid.
Courtesy: Sunondo Roy
www.csemag.com/purepower
Lighting
HVAC
Emergency
IT plug loads
Non-egress lighting
Egress lighting
Non-essential HVAC
Essential HVAC
Corridor receptacles
Workstation
receptacles
Storage rooms
Ventilation fans
Ventilation fans
Security
Office non-IT
receptacles
Toilets
(50% design FC)
Hydronic heating
Hydronic heating
Access control
Critical copiers/
printers
Open offices
(50% design FC)
Emergency heating
Freeze protection
Emergency lighting
IT plug loads
Offices
(50% design FC)
General elevators
(50%)
Support
(50% design FC)
Egress lighting
Egress elevators
10
Smart Grid
Rack Power
Distribution
Manage power consumption.
Power Management
Software
Optimized for virtual environments.
12
Smart Grid
for building owners, managers, and designers, those technologies are not addressed in this article. Rather, the focus
is on those emerging technologies that will be implemented
at the micro-level of individual buildings up to a campus
of related buildings. The common thread at this end of the
power spectrum is targeted metering of power usage, disciplined and orderly power distribution within the facility,
communication device can communicate with other smart controllers further down the distribution, either directly or indirectly
through customer-initiated and directed BAS curtailment actions.
www.csemag.com/purepower
www.mtuonsiteenergy.com
ENSURES A CONSTANT
FLOW OF POWER.
AND PEACE OF MIND.
Continuous power is essential to factories, data centers and hospitalswherever
revenue or lives are at risk. MTU Onsite Energy offers reliable emergency power
solutions. Backed by more than 60 years of experience, our diesel generator
sets provide an industry-leading 85 percent average load factor, plus reliability
and availability. Choose from a complete power portfolio including the 3,250 kW
Series 4000, the largest diesel generator set to receive IBC certification.
MTU Onsite Energy Corporation / 100 Power Drive / Mankato, Minnesota 56001 / USA / Phone 800 325 5450 / www.mtuonsiteenergy.com
14
Smart Grid
15
Arc-flash sensor
4/18/13 4:35 PM
16
Smart Grid
www.csemag.com/purepower
No matter what industry youre in, our unrivaled portfolio offers a solution thats
guaranteed to suit your specific business needs and keep your power on.
Thanks to Schneider Electric power and energy management capabilities,
in-house expertise, broad investments in R&D, and global presence, you have
a trusted resource for reliable power, anywhere in the world.
2013 Schneider Electric. All Rights Reserved. All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies.
All other trademarks are property of their respective owners. www.schneider-electric.com 998-4982_GMA-US_Nexus
SM
18
Ia = (EAB - Va)/2Z
Figure 2: This diagram shows bus differential protection of medium-voltage switchgear. Courtesy: CDM Smith
Bus differential
protection of
medium-voltage
switchgear
20
21
side fault would be cleared without delay and the HRC can
be brought down considerably (see Figure 3B).
Current limiting fuses: Current limiting fuses have
the capability to clear faults within a half cycle (less than
0.0083 sec) in addition to limiting the let-through current. Current limiting action of the fuse results from the
melting of the silver filaments inside a sand filling inside
the fuse, thus creating multiple arcs inside. Great reduction in the available incident energy is possible because of
the fast clearing of the fault. However, this is possible only
when the fault current lies in the current-limiting range
of the fuse characteristic. For example, in a 15 kV 300 A
current limiting fuse, the current limiting action takes
place for fault current in excess of 6,000 A. The benefit of
current limiting fuses can be realized only if the available
short-circuit current is in excess of 6,000 A. One must also
recognize that it is difficult to coordinate current limiting
fuses with downstream protective devices.
Maintenance mode on solid state protective relays: A
maintenance switch is now available in most mediumvoltage circuit breakers as a means of temporarily adjusting the settings of the solid state protective device during
scheduled maintenance such that arcing faults are cleared
without delay, while still maintaining the desired settings
for coordination with downstream protective devices.
Figure 4 shows the application and the benefit of a maintenance switch in 4.16 kV switchgear. Figure 4A shows the
single-line diagram of the switchgear. Figure 4B shows the
www.csemag.com/purepower
22
Typical protective
equipment
25
40
1.2
4
25 (1.5)
50 (3.0)
83.3 (5)
133.3 (8)
Figure 5: This diagram shows a typical high-speed grounding switch application. Courtesy: CDM Smith
23
The following equations are used in calculating the arcing fault current:
For system voltage under 1 kV:
lg(Ia) = K + 0.662 lg(Ibf) + 0.0966 V + 0.000526 G + 0.5588 V (lg Ibf) 0.00304 G (lg Ibf)
Where:
lg = the log10 (logarithm to the base 10)
Ia = arcing current, kA
K = -0.153 or open air arcs; -0.097 for arcs-in-a-box
Ibf = bolted three-phase available short-circuit current (symmetrical rms), kA
V = system voltage, kV
G = conductor gap, mm
For system voltage greater than or equal to 1 kV:
lg (Ia) = 0.00402 + 0.983 lg (Ibf)
Figure 6: The photo shows a typical remote operator
panel for a 4,160 V switchgear unit. Courtesy: CDM
Smith
24
Comparing generator
sizing software
Generator sizing software can help engineers optimize emergency system designs for various load types.
factors, such as altitude, temperature, fuel type, and application, that influence generator sizing. In todays mission
critical facilities, there are also number of different types
of loads, such as fire pumps, chillers, and UPS systems
connected to an emergency/standby power system, that
can impact the generator size. Each of these load types has
a different characteristic during start-up and run time, and
reacts differently under various electrical anomalies. Some
load types, such as fire pumps, have specific voltage drop
(less than 15%) or frequency dip requirements that must be
met during start-up. These factors must be considered and
analyzed when sizing a generator.
A detailed analysis of the load and sizing parameters to
manually size a generator can be a daunting task. However,
sophisticated software is available to assist the designer in
sizing and selecting the correct engine. Generator sizing
software programs in todays marketplace are intricately
developed to allow for a precise selection that is specifically catered to each application.
To take an in-depth look at their characteristics, this
article presents a hypothetical project using four popular
sizing software programs. The case study includes predefined load parameters and includes tips and techniques
to optimize the generator size.
EXAMPLE PROJECT
For this example, consider a facility that requires a standby
diesel genset to support various loads (see Figure 1). For
these loads, assume that the system can tolerate a maximum of 35% voltage dip and 10% frequency dip. The loads
that the genset must support are listed in Table 1.
Figure 1: This one-line diagram represents an example facility that requires a genset to support various loads. All graphics/data courtesy: ccrd
www.csemag.com/purepower
25
Type of load
Fire pump
Fluorescent lighting
UPS system
Transformer
Medical imaging
Chiller
Elevator
HVAC pump
HVAC fan
HVAC air handling unit fan
Quantity
1
1
1
1
1
1
2
1
1
1
2
Characteristics
100 hp motor, across-the-line starting (15% voltage drop as required by NEC)
100 kW connected load
12 pulse, 150 kVA, 90% loaded
200 kW connected load
MRI, 115 kVA momentary power, 20 kW running power
200 tons, 170 minimum circuit ampacity
60 hp motor (each elevator), variable voltage, variable frequency starting controllers
50 hp motor, across-the-line starting, 0.85 power factor, 90% full load efficiency
40 hp motor, across-the-line starting, 0.85 power factor, 90% full load efficiency
40 hp motor, across-the-line starting, 0.85 power factor, 90% full load efficiency
60 hp motor (each fan), across-the-line starting, 0.85 power factor, 90% full load efficiency
26
GENERAC POWER
DESIGN PRO
Power Design Pro is a software program developed by Generac Power
Systems Inc. The software can be
Cummins Power Suite 5.0 GenSize reduced the required generator from 1,500 kW to 1,000 kWa
reduction of 33% and two full engine sizes.
downloaded from the Generac web Caterpillar Electric Power SpecSizer reduced the required generators from 2,000 kW to 1,500 kW
site to an individual computer. After
a reduction of 25% and one full engine size.
the registration process, program
Kohler QuickSize did not change the result and still required a single 1,500 kW engine. However,
operation begins with the project
some of the parameters, such as voltage dip, were more favorable.
setup. This software includes very
Generac Power Design Pro autoselect function reduced the required generators from six 500 kW to
thorough data preset options, such
four 400 kW generatorsa reduction of 47% and two full engines.
as NEC application, enclosure types,
fuel tank options, and run time.
A
user
settings
tab
offers
overall parameter data input
quantity of motors. Other features expected in the online
for future project use if desired. The software also offers
version include a specific chiller load parameter, which will
downloadable material from the start-up page including
help system designers model chiller loads more accurately
specifications, spec sheets, installation instructions, and an
than the currently available ac load feature.
engine emissions certificate for the recommended genset.
The load data from the example project was entered into
After the project setup is complete, the user adds loads
the program based on the available predetermined loads (see
from the predetermined load menu. This software offers
Table 1). As the loads are added, the software displays an
the largest selection of load options compared to the other
up-to-date report of the connected load on the load scenario
programs (see Table 2). After the load data are entered, the
screen. The loads are assigned a step when the load is enloads are assigned to either a group (non-concurrent load)
tered. After the data are entered and the loads are assigned,
or a step (concurrent load). The load summary page is
the program generates a selection based on the smallest
continually updated with the recommended generators as
generator that will meet the performance requirements.
loads and steps are added.
For the example project, the software indicated that no
A unique feature of Power Design Pro is the ability to
standard SINGLE genset is large enough under the specimanually select the generator. Instead of using an autosefied site conditions. Sizing will continue by paralleling
lect function, the designer may input a specific kW rating
the minimum number of generator sets necessary. The
and configuration. For the example project, after the loads
software recommended four 550 kW/687.5 kVA paralleled
were entered under the autoselect function, the program
units. The initial results were unexpected because Caterrecommended six 500 kW/625 kVA paralleled generators.
pillar offers larger size engines. After further discussion
When switched to the manual function, and 600 kW units
with the software expert, it was discovered that SpecSizer
were selected (the maximum kW rating offered by Genoffers three different input parameters for the genset duty.
erac), the program recommended three 600 kW/750 kVA
If emergency standby is selectedas opposed to standby
units. Although it wasnt recommended by the autoselect
or standby/ESPthe program limits the selection to a very
function, alternate quantities and sizes of generators were
narrow rating category that isnt applicable here. The softallowed to be selected that still met the project parameters.
ware expert indicated that this will not even be an option
If a system that will not meet the parameters is selected,
in the next revision of the software.
the entries are highlighted in red indicating that the
After the correct engine duty was selected, the software
manual selection would not meet the project parameters.
recommended one 2,000 kW/2,500 kVA genset. Under the
This is a very flexible option for the program, allowing the
technical section of the software, the program generates
Figure 3: This graph shows the results of applying the selected optimization strategies shown in Figure 2.
www.csemag.com/purepower
27
KOHLER QUICKSIZE
QuickSize is a software program developed by Kohler Power Systems. It is an
easy-to-use, Web-based application that
requires a login and password from a local
distributor. The login information is the
same for each member of a company for
easy file sharing. All projects developed
using this software are automatically
available to the Kohler representative and
can be viewed if additional help is desired.
Specification sheets and other PDF drawings are available through the site. However, CAD drawings and BIM models must
be requested through a representative.
After running through the sizing software,
a custom specification is available (as a
Word document) for the project based on
the parameters and genset selected. The
specification can be used as a whole, or
copied and pasted into another specification format to suit the users needs.
Similar to the other programs, QuickSize
uses preset pull-down buttons for entering
parameters, which can be revised during
any step of data entry. All of the information is shown on one screen, and all of the
data can be changed at any time.
First, the load steps are entered, and
then specific loads are added. The loads
can be moved up or down between the
steps at any time, and all information is
easily editable throughout the process.
After all data are entered and load steps
are assigned, a click of the search result
button yields a list of applicable gensets,
listed by model number, alternator, and
engine with the smallest recommended
size at the top. Engines that will not meet
the requirements are indicated in red at
Load Options
Air conditioning
Battery charging
Centrifugal pump
Chiller
Elevator
Traction
Hydraulic
Fire pump
Induction furnace
Office equipment
Lighting
Fluorescent
Incandescent
HID
UV
Medical imaging
Motor
Intermittent motor feature
Non-linear
Resistive
UPS
PC
Server
User defined/misc.
Welding
Fuel Options
Diesel
Propane
Natural gas
Dual fuel
Bi fuel
Emissions Options
EPA stationary non-emergency
EPA stationary emergency
EPA non-road (portable)
EU stationary
EU mobile
Access
Online
Available off-line
x
x
x
x
Caterpillar
SpecSizer
x
x
x
x
x
x
x
x
x
x
x
x
x
x*
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Generac Power
Design Pro
Kohler
QuickSize
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x*
x
x**
x
x
x
x
x
x
x
x*
x
x
* Available soon
** Online program to launch 4th quarter 2013
www.csemag.com/purepower
28
RESULTS ANALYSIS
OPTIMIZATION STRATEGIES
After initial project data are entered into the system, there
are several tips and tricks for reducing the required system
size. A partial list of tips includes:
Provide higher quality rectifiers on equipment to
reduce harmonics.
Include VFDs or reduced voltage starters on motor
loads to allow soft starting and minimize the starting
impact.
Allow for additional load steps on the project by
adding automatic transfer switches, programmable
logic controllers, or time delays.
Load the system with the largest motor loads first.
Disable capacitors on emergency loads.
Include a UPS upstream of medical imaging or other
sensitive loads to reduce their voltage and frequency
dip requirements.
AD INDEX
Baldor Electric Company - C-2
479-646-4711
RS 400
www.baldor.com
Caterpillar - Northeast - pg 6
RS 401
www.NECatDealers.com/power
Eaton Corp - pg 11
877-423-0065
Kohler - pg C-4
800-544-2444
RS 402
www.switchon.eaton.com/93PM
RS 407
www.KOHLERPOWER.COM/INDUSTRIAL
RS 403
www.mtu-online.com
RS 406
www.russelectric.com
Schneider Electric - pg 17
847-397-2600
RS 405
www.schneider-electric.com
RS 404
www.selinc.com
Abby Lipperman has 8 years of electrical engineering experience with ccrd in Dallas. Her primary project
experience is in the health care industry, but she is also
involved in many different project types including data
centers, technology labs, museums, schools, banks, and
commercial and office spaces. Lipperman was also a Consulting-Specifying Engineer 40 Under 40 winner in 2009.
Danna Jensen is associate principal at ccrd in Dallas.
With 13 years of electrical engineering experience, most
of her work consists of designing electrical distribution
systems for hospitals; however, she also designs electrical
systems for office and retail facilities. Jensen was a 2009
Consulting-Specifying Engineer 40 Under 40 winner and
is a member of the Consulting-Specifying Engineer Editorial Advisory Board.
www.csemag.com/purepower
DE-5
Evaluating software
tools for electrical
system design
Software tools and online resources are available for designing electrical systems.
www.csemag.com/purepower
Figure 1: This diagram shows the site plan of Project X, highlighting the design
requirements and the associated tools that can be used to assist in the design.
DE-6
DESIGN CHALLENGES
Cable pulling: The site electrical infrastructure distribution
for Project X presents existing utility conflicts. The result
is a service and feeder duct bank system with many bends,
elevation changes, and offsets. This presents a challenge in
terms of cable pulling and determining the proper location
for pulling points along the system.
For complex cable pulls or simply to document a cable
pull run, the software tool Cable 3D from SKM System
Analysis models complex three-dimensional cable-pulling
tension and sidewall pressure calculations, allowing rapid
and accurate design decisions. The Cable 3D program
provides both forward and reverse pull results for each
cable profile modeled. For Project X, the Cable 3D program
is used to document sections of the utility service entrance
duct bank, and to adjust bends of cable profiles between
sections of medium-voltage cable runs. It also helps demonstrate that a manhole is not necessary as a pulling point for
the duct bank routing from the central utility building and
the main electrical room, thus informing the designer so
that the proper installation is constructed (see Figure 2).
QUICK TIP
SIMpull Cable Pull Calculator from Southwire is a convenient online tool
for cable pulling calculations and estimating support in a spreadsheet
format. It is an Excel-based calculator specific to Southwire products.
Pull Planner 3000 from American Polywater Corp. is a software tool
for performing cable pulling tension calculations and conduit system
design. The Windows-based software is available online for purchase
and download.
Figure 2: This screen shot shows the Cable 3D program data input screen
with an image of the cable design.
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Figure 4: This partial single-line drawing of Project X indicates associated voltage-drop information as calculated using the PTW program. Voltage-drop
information is automatically added to the single-line diagram in the PTW program by applying a data-block tag.
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QUICK TIP
ETAP is another electrical power systems design and analysis software
tool. It can be used in design, analysis, maintenance, and operation of
electrical power systems. There are both ac and dc databases, and it
can perform calculations for both types of systems.
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Alberto G. Cordero is a senior electrical engineer with Affiliated Engineers Inc., where he specializes in complex higher
education, health care, and research facilities.
Candace Dolan is an electrical engineer with Affiliated Engineers Inc., where she specializes in higher education and
research facilities.
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