The quest for a bigger breaker box!

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The quest for a bigger breaker box! N9WOS 12-21-2007
Posted by N9WOS on December 21, 2007, 9:56 pm
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Once in a while, the urge to type my ideas down in one big post and post
them for the world to see, hits me. And this is one of those times.

(....Brain dump commencing...)

While we are talking about predictions...

The earlier post about micro nukes and related stuff got me thinking. What
would happen if cheep fission power and cheep fusion power (Pray for ITER)
ever took hold? Or even where cheep solar power brings down electric prices
to new lows.

As time goes by fossil fuels will get more expensive. Stationary equipment
that use to run on natural gas, propane, gasoline, or diesel, will slowly be
changed over to electric power. That, in addition to natural growth of
electric usage will mean that house electrical services in the next fifty
years will become enormous!!

Just look at history. When electricity first come along houses had two or so
circuits. About 15A to 30A total service capacity. Then comes along electric
ranges and the like. Pretty soon, the 60A fuse box became standard with four
lighting and plug circuits, and one range circuit. As went buy, it needed to
run an electric water heater, and more and more lighting , plug, and range
circuits. It soon grew into a 100A fuse box, and then a 150 amp fuse box.

About then, breaker usage was coming into full stride. The 100A breaker box
pretty much become a base installation. They had 10 to 20 some spaces, or
more. But it didn't stop there.

As house electrical usage grew, breaker boxes grew to 150A and then they
finally grew to 200A There was also several manufactures offering 200A fuse
boxes at the end of the fuse box rain many years back.

It is now pretty much considered that a 200A breaker box is the minimum
required for the primary service for a house. And it is the largest size
that is normally offered at home improvement stores.

But the pattern of expansion hasn't come to a stop. Many new homes are being
built with 400A service. That consist of two 200A breaker boxes. Two breaker
boxes are used only because a 400A breaker box isn't readily available right
now. But that is only a temporary situation. Breaker box manufactures are
starting to produce 400A service boxes for the residential market. It will
only be time until they are offered in most electrical supply houses, and
home improvement stores.

There is even some homes that have went to 600A service.

Do you think the expansion trend will stop with 600A services?

What will happen when those houses stop using propane and natural gas when
it starts getting more expensive and switch those appliances over to
electricity when electricity gets cheaper?

What will happen when the owners buy electric cars because of high gasoline
prices, and they have to have the power on tap to rapidly charge two or
three vehicles?

How come I get the odd feeling that 1000A services will become standard?

The grid will also expand with time.

If fusion comes to reality, you will see terawatt level generation stations
dot the landscape. And superconductor transmission lines may be the only way
to disperse that level of power.

Once it gets to the local level, expect to see local distribution systems
slowly push up system voltages as loads increase.

Normal system voltages for light urban is normally 2.4KV. For rural
distribution systems an REMC's it is normally 7.2KV. For heavier areas it
normally is 14.4 to 28.8KV A lot of heavy city areas spread out the power at
60+KV throughout the city to small substations which drop it down to 7.2 or
2.4KVfor the lines running through the back yard.

The problem with those voltages is they won't handle the type of residential
loads that will come about in the future. The utilities will either have to
go with superconductor distribution lines, or push up the voltages to
sustain the loads. Most likely, they will push residential distribution
voltages to 28.8KV or even higher. Local substations feeding that 28.8KV
grid will probably feed by 100KV+ feeders. Or they may use super conducting
28.8KV transmission lines to feed the conventional grid segments. With the
28.8KV being derived at a central substation using a new compact
superconductor transformer that is being directly feed by a transmission
line coming from a fusion power station.

Micro nukes, and in the future, micro fusion plants, will also allow the
large sums of power to be generated closer to the point of use. That will
reduce the need for super conducting transmission systems.

The main big change I think is going to happen is... The standard service
voltage (to the house) is going to increase. Because when you get into 1000A
levels at 120V/240V you start getting into huge conductors. Most residential
wiring is already rated to 600VAC. I think we are going to start using more
of that 600V headroom The way you get around large current levels at high
power levels is push up the voltage. Most large factories and buildings have
already left 480V in the past for the primary service voltage coming from
the utility, at the meter point. They have either went to 600V, 1.2Kv or
higher for the on premises distribution system. I expect to see people shift
away from 120/240V as the primary service voltage to the house. I have seen
some farms that use 480V single phase or three service to feed single phase
step down transformers in buildings throughout the property that feed
conventional 120/240V boxes. That allows them to get around high copper cost
and achieve a more solid voltage supply. The savings in copper paid for the
cost of the transformers. If houses shift over to 480V three phase for the
primary service then the person designing the house can be free to decide if
he wants 120V/240V single phase 120/208V three phase, 240V wye or delta or
even the original 480V to drive something depending on what step down
transformer they use in that part of the house.

Step down transformers have been a cornerstone of the industrial and
commercial electrical systems for decades. They use them to derive 120V
lighting power from high power 480V three phase systems running through the
buildings. I think they will start showing up in residential areas one of
these days.

Think of the savings you could have. Where you would normally have a 1000A
120/240V service, which is 240KW. You could deliver that same power with a
289A three phase service. That would yield much savings in equipment and
copper, and a far easier installation. The heavy loads could run directly
off of three phase power. Like water heating, space heating, range, air
conditioning and electric car charging. The lighting and appliance loads
could run off of a 480V to 120V/240V step down transformer. When you don't
have anything else running off of it, it wouldn't take much just to run
lighting electronics and the appliances around the house. A 100A box being
driven by a 25KVA transformer would do fine. If you needed more plug power
for a new addition then you could put a new transformer and new 120/240V box
in the addition. If you have 3phase shop tools, you can run them. If you
have two phase equipment, you can run it. If you have single phase
equipment, you can run it. It would give the home owner ultimate opportunity
for expansion of his electrical system how ever he sees fit.

Instead of driving a 9.6KW load by 4AGW wire with 80A at 120V or 8AWG wire
with 40A at 240V. You would instead drive it with 12AWG wire at 20A with
480V single phase. Or you could even use 14AWG with 12A at 480V three phase.

If $1 a watt solar ever comes reality then you will also have new needs for
200KW+ residential services It would be required for back feeding the grid
with huge solar installations. At those prices, expect to see people
installing 200KW+ solar farms.

It is all a natural progression.

The 200A and 400A single phase services that are in homes now, was once
reserved for large commercial and small industrial operations.

The 480V three phase services that are in the 1000A+ range in commercial
businesses, was once strictly reserved for large industrial installations.
If you would of told a utility engineer 50 years ago that a single store
would need a 1MW utility supply. They would of looked at you like you lost
your mind.

Industrial and large industrial installations now use 2.4KV distribution in
the plant, and usually buy their power at distribution line, or transmission
line voltage. They step the 7.4KV to 100KV down to 2.4KV by a company owned
substation located on site. That type of setup was once strictly reserved
for utility companies.

So, I fully expect that in the years to come, we will either see the primary
service box in residential homes to grow to the 1000A level at the present
voltages. Or it will grow to the 480V three phase level while the current
stays about the same. One way or the other, the power supply to the home
will grow with time. It's not a mater of opinion, it is a mater of history.

Some may say, "1000 amps!!!!!! Are you crazy??" All I have to say is people
70 years ago would of said the same thing when you would tell them that we
currently have houses with 200A breaker boxes.

I say a basic service of, 400A at 480V 3P for a house seems to be a
reasonable level for homes in the year 2050 to 2070.

400A 480V 3 phase fused disconnects are standard commodity item right now
for industrial and commercial systems. Expect to see them showing up as the
main disconnect at a house near you.

(....end brain dump.....)



Good day...



Posted by N9WOS on December 21, 2007, 10:01 pm
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> The earlier post about micro nukes and related stuff got me thinking. What
> would happen if cheep fission power and cheep fusion power (Pray for ITER)
> ever took hold? Or even where cheep solar power brings down electric
> prices to new lows.

I did it again. Using the word "cheep" several times when I was wanting to
used the word "cheap". Sometimes I want a brain transplant!



Posted by PhattyMo on December 23, 2007, 6:29 am
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N9WOS wrote:
> Once in a while, the urge to type my ideas down in one big post and post
> them for the world to see, hits me. And this is one of those times.
>
> (....Brain dump commencing...)
>
> While we are talking about predictions...
>
> The earlier post about micro nukes and related stuff got me thinking. What
> would happen if cheep fission power and cheep fusion power (Pray for ITER)
> ever took hold? Or even where cheep solar power brings down electric prices
> to new lows.
>
> As time goes by fossil fuels will get more expensive. Stationary equipment
> that use to run on natural gas, propane, gasoline, or diesel, will slowly be
> changed over to electric power. That, in addition to natural growth of
> electric usage will mean that house electrical services in the next fifty
> years will become enormous!!
>
> Just look at history. When electricity first come along houses had two or so
> circuits. About 15A to 30A total service capacity. Then comes along electric
> ranges and the like. Pretty soon, the 60A fuse box became standard with four
> lighting and plug circuits, and one range circuit. As went buy, it needed to
> run an electric water heater, and more and more lighting , plug, and range
> circuits. It soon grew into a 100A fuse box, and then a 150 amp fuse box.
>
> About then, breaker usage was coming into full stride. The 100A breaker box
> pretty much become a base installation. They had 10 to 20 some spaces, or
> more. But it didn't stop there.
>
> As house electrical usage grew, breaker boxes grew to 150A and then they
> finally grew to 200A There was also several manufactures offering 200A fuse
> boxes at the end of the fuse box rain many years back.
>
> It is now pretty much considered that a 200A breaker box is the minimum
> required for the primary service for a house. And it is the largest size
> that is normally offered at home improvement stores.
>
> But the pattern of expansion hasn't come to a stop. Many new homes are being
> built with 400A service. That consist of two 200A breaker boxes. Two breaker
> boxes are used only because a 400A breaker box isn't readily available right
> now. But that is only a temporary situation. Breaker box manufactures are
> starting to produce 400A service boxes for the residential market. It will
> only be time until they are offered in most electrical supply houses, and
> home improvement stores.
>
> There is even some homes that have went to 600A service.
>
> Do you think the expansion trend will stop with 600A services?
>
> What will happen when those houses stop using propane and natural gas when
> it starts getting more expensive and switch those appliances over to
> electricity when electricity gets cheaper?
>
> What will happen when the owners buy electric cars because of high gasoline
> prices, and they have to have the power on tap to rapidly charge two or
> three vehicles?
>
> How come I get the odd feeling that 1000A services will become standard?
>
> The grid will also expand with time.
>
> If fusion comes to reality, you will see terawatt level generation stations
> dot the landscape. And superconductor transmission lines may be the only way
> to disperse that level of power.
>
> Once it gets to the local level, expect to see local distribution systems
> slowly push up system voltages as loads increase.
>
> Normal system voltages for light urban is normally 2.4KV. For rural
> distribution systems an REMC's it is normally 7.2KV. For heavier areas it
> normally is 14.4 to 28.8KV A lot of heavy city areas spread out the power at
> 60+KV throughout the city to small substations which drop it down to 7.2 or
> 2.4KVfor the lines running through the back yard.
>
> The problem with those voltages is they won't handle the type of residential
> loads that will come about in the future. The utilities will either have to
> go with superconductor distribution lines, or push up the voltages to
> sustain the loads. Most likely, they will push residential distribution
> voltages to 28.8KV or even higher. Local substations feeding that 28.8KV
> grid will probably feed by 100KV+ feeders. Or they may use super conducting
> 28.8KV transmission lines to feed the conventional grid segments. With the
> 28.8KV being derived at a central substation using a new compact
> superconductor transformer that is being directly feed by a transmission
> line coming from a fusion power station.
>
> Micro nukes, and in the future, micro fusion plants, will also allow the
> large sums of power to be generated closer to the point of use. That will
> reduce the need for super conducting transmission systems.
>
> The main big change I think is going to happen is... The standard service
> voltage (to the house) is going to increase. Because when you get into 1000A
> levels at 120V/240V you start getting into huge conductors. Most residential
> wiring is already rated to 600VAC. I think we are going to start using more
> of that 600V headroom The way you get around large current levels at high
> power levels is push up the voltage. Most large factories and buildings have
> already left 480V in the past for the primary service voltage coming from
> the utility, at the meter point. They have either went to 600V, 1.2Kv or
> higher for the on premises distribution system. I expect to see people shift
> away from 120/240V as the primary service voltage to the house. I have seen
> some farms that use 480V single phase or three service to feed single phase
> step down transformers in buildings throughout the property that feed
> conventional 120/240V boxes. That allows them to get around high copper cost
> and achieve a more solid voltage supply. The savings in copper paid for the
> cost of the transformers. If houses shift over to 480V three phase for the
> primary service then the person designing the house can be free to decide if
> he wants 120V/240V single phase 120/208V three phase, 240V wye or delta or
> even the original 480V to drive something depending on what step down
> transformer they use in that part of the house.
>
> Step down transformers have been a cornerstone of the industrial and
> commercial electrical systems for decades. They use them to derive 120V
> lighting power from high power 480V three phase systems running through the
> buildings. I think they will start showing up in residential areas one of
> these days.
>
> Think of the savings you could have. Where you would normally have a 1000A
> 120/240V service, which is 240KW. You could deliver that same power with a
> 289A three phase service. That would yield much savings in equipment and
> copper, and a far easier installation. The heavy loads could run directly
> off of three phase power. Like water heating, space heating, range, air
> conditioning and electric car charging. The lighting and appliance loads
> could run off of a 480V to 120V/240V step down transformer. When you don't
> have anything else running off of it, it wouldn't take much just to run
> lighting electronics and the appliances around the house. A 100A box being
> driven by a 25KVA transformer would do fine. If you needed more plug power
> for a new addition then you could put a new transformer and new 120/240V box
> in the addition. If you have 3phase shop tools, you can run them. If you
> have two phase equipment, you can run it. If you have single phase
> equipment, you can run it. It would give the home owner ultimate opportunity
> for expansion of his electrical system how ever he sees fit.
>
> Instead of driving a 9.6KW load by 4AGW wire with 80A at 120V or 8AWG wire
> with 40A at 240V. You would instead drive it with 12AWG wire at 20A with
> 480V single phase. Or you could even use 14AWG with 12A at 480V three phase.
>
> If $1 a watt solar ever comes reality then you will also have new needs for
> 200KW+ residential services It would be required for back feeding the grid
> with huge solar installations. At those prices, expect to see people
> installing 200KW+ solar farms.
>
> It is all a natural progression.
>
> The 200A and 400A single phase services that are in homes now, was once
> reserved for large commercial and small industrial operations.
>
> The 480V three phase services that are in the 1000A+ range in commercial
> businesses, was once strictly reserved for large industrial installations.
> If you would of told a utility engineer 50 years ago that a single store
> would need a 1MW utility supply. They would of looked at you like you lost
> your mind.
>
> Industrial and large industrial installations now use 2.4KV distribution in
> the plant, and usually buy their power at distribution line, or transmission
> line voltage. They step the 7.4KV to 100KV down to 2.4KV by a company owned
> substation located on site. That type of setup was once strictly reserved
> for utility companies.
>
> So, I fully expect that in the years to come, we will either see the primary
> service box in residential homes to grow to the 1000A level at the present
> voltages. Or it will grow to the 480V three phase level while the current
> stays about the same. One way or the other, the power supply to the home
> will grow with time. It's not a mater of opinion, it is a mater of history.
>
> Some may say, "1000 amps!!!!!! Are you crazy??" All I have to say is people
> 70 years ago would of said the same thing when you would tell them that we
> currently have houses with 200A breaker boxes.
>
> I say a basic service of, 400A at 480V 3P for a house seems to be a
> reasonable level for homes in the year 2050 to 2070.
>
> 400A 480V 3 phase fused disconnects are standard commodity item right now
> for industrial and commercial systems. Expect to see them showing up as the
> main disconnect at a house near you.
>
> (....end brain dump.....)
>
>
>
> Good day...
>
>



I hope solar/wind/hydro/micronuke/whatever takes off a bit.
I'm not sure that the grid can keep up with such high demands without
some serious upgrades,and we're already having problems now in some areas.
Localized generation would go a long way to lowering the load on the
grid,one would think.

Posted by nick hull on December 24, 2007, 7:46 am
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> How come I get the odd feeling that 1000A services will become standard?

Because you fail to understand money. Electricity is expensive. The
trend will be to use LESS electricity to save money. Even now the 400
amp boxes don't draw 400 amps, the homeowner uses a lot less.

Free men own guns - www(dot)geocities(dot)com/CapitolHill/5357/

Posted by Mark F on December 25, 2007, 6:43 pm
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>
> > How come I get the odd feeling that 1000A services will become standard?
>
> Because you fail to understand money. Electricity is expensive. The
> trend will be to use LESS electricity to save money. Even now the 400
> amp boxes don't draw 400 amps, the homeowner uses a lot less.
1000A seems high, but:
1. Of course the load on a 400 amp service is less than 400 amperes -
how can it be higher.
2. If you want lots of breakers you are required to have a larger
service

Possibly:
3. If you want more complicated breakers, such as arc arrest/GFCI
you need more breaker spaces. This forces a larger box. I'm
not sure if having a larger breaker box can force a larger service.

Many of the things done to lower electricity use turn out to
require more circuit breakers. Needing to go from 100Amp by 2 phase
load to 300Amp by 2 phase would easily happen in a single family
home.

>
> Free men own guns - www(dot)geocities(dot)com/CapitolHill/5357/

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