power quality systems and power factor correction presentation

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CAABB-LPCP, 2015

ABB LV Power Quality CanadaSeminar

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Today‘s PresentationWhat will we see?

1. What is LV Power Quality (PQS) all about?

2. Technical relevance to an end user

3. Business relevance to an end-user

4. Value-add … what’s special about ABB?

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Power QualityWhat is it all about?

Today’s discussion about low voltage power quality products is largely related to two core concepts:

1. Power factor improvement

2. Harmonics mitigation

… on Low Voltage networks (<690V)

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Today‘s PresentationPQS – a little background

1. Large installed base in Canada

2. Mostly industrial applications

3. Business responsibility with Low Voltage Products Canada

4. Sales responsibility for Canada

5. Engineering and production for Canada and USA

6. Best blend of global knowledge base with local competence and production

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R L C

Toaster, oven … Motor, anythingwith a coil

Capacitor, cap bank,…

P

W or kW

Q

var or kvar

Q

var or kvar

Power Factor ImprovementWhat are all the load types?

IR ωVAC IL

ω90°

VAC

VAC

IC ω90°

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Power Factor ImprovementMotor Example

Typical motor = linear inductive load

Active power (kW) does the real work of running the motor

Reactive power (kvar) is the power used for magnetization, etc.

(kVA) is geometrical or vector sum of kW and kvar

kWkvar

kVA

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Power Factor ImprovementRelationship between kW, KVA and kvar

Power factor = cos ϕ = P(kW) / S(kVA)

« Weight of useful power P against the consumed power S »

kVA

Active power PkW

Reactive power

Q

kvar

ϕϕcos×= SP

ϕsin×= SQ22 QPS +=

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Power Factor ImprovementWhat is good power factor?

When angle ϕ 0°, cos ϕ = P(kW) / S(kVA) 1

Source of leading reactive power = capacitors and cap banks

kVA

Active power PkW

Reactive power

Q

kvar

ϕ

kVA

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Power Factor ImprovementBeer analogy

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Power Factor ImprovementFrom beer back to power factor!!

When angle ϕ 0°

cos ϕ = P(kW) / S(kVA) 1

Compensation = capacitors & banks

More beer!!

Presenter

Presentation Notes

Improving power factor simply means reducing the angle phi, which means a smaller reactive power component, so the dark blue line got shorter. Therefore the pink line just got shorter and is now almost the same length as the light blue line. What this means is that when the angle phi tends towards zero, the ratio of real power to apparent power tends towards one. In practical terms it means that you are actually using all or most of the power that you draw from the utility. In other words … you find a way to have a little less froth and a little more beer in the SAME glass.

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Power Factor ImprovementCalculating correction in kvar

kVA

Active power PkW

Reactive power

Q

kvar

ϕ

Method of calculation… Crude estimation = 40% of motor KW

rating Cap amps < 90% of motor amps Power factor (p.f.) = cos ϕ Existing p.f. = x = cos ϕ1 Target p.f. = y = cos ϕ2 Inverse cosine of x & y gives you the

angles ϕ1 and ϕ2 Calculate tangents of ϕ1 and ϕ2 Multiply the difference between tan ϕ1

and tan ϕ2 with the real power (KW) Result gives you required

compensation value in kvar)tan(tanPQ 21comp ϕϕ −×=

Qco

mp

Presenter

Presentation Notes

How do you calculate the amount of correction or compensation required? 40% of the motor kilowatts will give you a rough ball-park figure. It is important to ensure the capacitor current never exceeds 90% of the motor current. There are tables in our capacitor catalog and there’s lots of info on the internet as well. The general principle though, is as follows … If cos phi 1 is the existing power factor and cos phi 2 is the target power factor of where you want to be, you start by taking the inverse cosines of both, which basically gives you the angles phi 1 and phi 2. You then calculate the tan of phi 1 and phi 2 and take the difference of the two, which is basically tan phi 1 minus tan phi 2. Multiply that number with the real power in KW and you get the required compensation value in kvars.

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Power Factor ImprovementWhere do these things go?

Various locations on the electrical n/w

1. Plant feeder (MV)

2. Main LV bus

3. Branch/auxiliary bus

4. Individual load point

Capacitor location1 2 & 3 4

Technical approach BestFlexibility Least Less BestSavings Least Less Max

Cost per kvar Least Lower Highest

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Power Factor ImprovementWhat are the benefits?

Transformers and distribution cables see lower currents

Reduced I²R losses in cables, transformers, protection devices

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Power Factor ImprovementWhat are the benefits?

Frees up system capacity by a value directly proportional to power factor improvement

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Power Factor ImprovementWhat is the business relevance?

Benefits to end-users …1. Utility billing = smaller electricity bills due to lower kvars2. Utilization efficiency = Possible to partially offset capital

expenditure on additional capacity. How?• Installed loads (kW) are fixed• Service capacity (kVA) is fixed• If kvar reduces opens up system capacity

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Power Factor ImprovementCapacitor Element – IPE (Internal Protected Element)

Dry type design

Self-healing, internally protected element

Long lasting and rugged

Proven design and build quality

Manufactured in Belgium

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© ABB GroupSeptember 3, 2015 | Slide 18

Power Factor ImprovementCapacitor Element – IPE self healing

Step 1: Dielectric breakdown takes place

Step 2: Vaporization of the thin electrodes which ends up with breakdown elimination

Principle

Diameter of the hole: 1 µm

Capacitance loss: < 1ppm (part per million)

Presenter

Presentation Notes

Self healing is one unique feature of the capacitors with metalized dielectric. When a dielectric breakdown occurs, which could be caused by moisture or dust trapped inside the element, or other types of defects, a short circuit between two electrodes will create a small plasma which will vaporise the dielectric and leave a void hole. And finally it isolates the breakdown. Hence the faulty point is self healed. Self healing has three effects: -- It isolates the breakdown, prevents it from becoming a bigger breakdown; -- It releases gases; -- It loses a small part of the capacitance, 1ppm.

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Power Factor ImprovementCapacitor Unit – CLMD

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Power Factor ImprovementCapacitor Unit – CLMD

Engineered and built in Canada

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Power Factor ImprovementCapacitor Bank

Auto Cap Bank

208V to 690V

CSA and UL approved

Rugged construction

Proven design

Local expertise

Long operating life

Indoor or outdoor

Standard or custom

Engineered and built in Canada

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Power Factor ImprovementA word on resonance – what is it?

Inductive reactance XL = 2𝜋𝜋𝜋𝜋𝜋𝜋

Varies proportionally with frequency

Capacitive reactance XC = 1

2𝜋𝜋𝜋𝜋𝜋𝜋

Varies inversely with frequency

When XL = XC

Impedances (ZL & ZC) cancel out

Band-pass filter

Creates uncontrolled oscillations

L and C feed off each other

Usually capacitors burn out

Wineglass (YouTube)

https://www.youtube.com/watch?v=17tqXgvCN0E

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Power Factor ImprovementA word on resonance – what is the solution?

Shift the resonance point away from the most likely frequency

Most likely frequency = 5th

harmonic = 60Hz * 5 = 300 Hz

How? With a reactor

Hence we select from a choice of frequency points …

3.78 = 227 Hz (ABB)

4.2 = 252 Hz and so on

This is called a detuned bank, only meant to protect the capacitors

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Power Factor ImprovementA word on resonance – which reactor?

% Vrise = 𝜋𝜋𝑓𝑓𝜋𝜋𝑓𝑓

2× 100

To be safe, capacitor needs to be rated 10% over network voltage

“Pulls” harmonic current away from the capacitor

Largest source of heat loss in a cap bank, 5W per kvar

Depends on loading

We offer option of standard and reinforced reactors

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Power Factor ImprovementCapacitor Bank – CLMM without reactors

Main protection can be added to the bank on request.

Maximum step (1xCLMD encl.) size is 100 kvar @ 480V / 600V.

Maximum bank size 1.20 Mvar @ 480V / 600V

4 steps (90‘‘H x 38‘‘W x 20‘‘D)

5 steps (90‘‘H x 50‘‘W x 20‘‘D)

6 steps (90‘‘H x 62‘‘W x 20‘‘D)

7/8 steps (90‘‘H x 74‘‘W x 20‘‘D)

Cable entry: top, bottom or side

Up 12 steps configuration with slave unit

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Power Factor ImprovementCapacitor Bank – CLMR with reactors

Main protection can be added to the bank on request.

Maximum step (1xCLMD encl.) size is 100 kvar @ 480V / 600V.

Maximum bank size 1.20 Mvar @ 480V / 600V

3 steps (90‘‘H x 38‘‘W x 20‘‘D)

4 steps (90‘‘H x 50‘‘W x 20‘‘D)

5 steps (90‘‘H x 62‘‘W x 20‘‘D)

6 steps (90‘‘H x 74‘‘W x 20‘‘D)

Cable entry: top, bottom or side

Up 12 steps configuration with slave unit

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Power Factor ImprovementCapacitor Bank – Series, CLMM & CLMR

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Power Factor ImprovementRVT Controller

Smart controller

Color touchscreen

Communication option

cULus approved

Full data readout

6 or 12 steps

Preset power factor

User settable


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Intuitive touch-screen interface

Individual phase p.f. correction for unbalanced loads

Individual phase measurements (V, A, PF, kVA and kWh…)

Graphical display of voltage & current and harmonics spectrum

Communications: Modbus, Ethernet, USB and Can bus (for future use)

Real time clock

One alarm relay (NO/NC) and one FAN relay

Up to 8 temperature probes

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Communication locked


Active output

Inactive output are not highlighted

Temperature alarm

Temperature normal

Unlock (software)

Locked (software)

Communication unlocked

Locked (hardware)

Unlock (hardware)

Alarm active

Alarm inactive

Setting mode

Warning

Mode change

Online help

On demand

Off demand

Manual mode

Auto mode

Close window

Validation

Next page

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Power Factor ImprovementRVT Controller – quickstart guide in brochure

Start here:

Finish here.

1. Start screen, Click “Settings”: 2. Click commissioning: 3. Click automatic: 4. Click OK: 5. Click OK: 6. Select type of connection

7. Click OK: 9. Click OK: 10. Click OK: 8. Lock or unlock the “Bank settings - OK:

11. Click OK: 12.Input CT scaling: 50:

13. Click OK: 15. Click OK: 16. Click OK: 14. Click OK: 17. Click OK: 18. Click OK:

19. Click OK: 21. Automatic commissioning completed:20. Click OK:

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Power Factor ImprovementRVT Controller – intuitive and simple interface

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RVT versatile features Highly efficient switching strategy

t (s)

Q (kvar)

C1 ON C2 ONC1 OFF

Target cos ϕ

C2 ONC1 ON

C3 ONC1 OFFC2 OFF

t (s)

Q (kvar)

C3 ON

Target cos ϕ

Direct: switches the biggest steps first to reach the target cos ϕ fasterProgressive: switches the steps sequentially, one by one

5 switching 1 switching

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Power Factor ImprovementRVT Controller – efficient switching

Linear: first in, last out Circular: first in, first out

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Power Factor ImprovementRVT Controller – 3-ph or 1-ph

RVT three phase model: RVT12

Up to 3 ph voltage and current measurements

Five different CT connection types

RVT base model: RVT6 and RVT12

1 ph voltage and current measurements

Three different CT connection types

Note: set connection type manually

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Individual phase power factor control are necessary for:

Single phase loads industrial, PH-PH

Single phase loads residential and commercial, PH-N

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For unbalanced networks

Typical outputs setting for 6 steps of 3-phase caps and 2 steps of 1-phase caps

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Power Factor ImprovementRVT Controller – harmonic spectrum and values

Select measurement

to display

zoom in / out the chart

Select measurement to display

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Power Factor ImprovementRVT Controller – upto 8 temp probe i/p

T1 T2 T8

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Power Factor ImprovementRVT Controller – real time clock

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Power Factor ImprovementRVT Controller – Modbus, Ethernet, USB, Software

Ethernet

Note: check with ABB about version compatibility for Modbus adapter

USB

To put RVT on USB or Ethernet and OPC server for Modbus

Software

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Power Factor ImprovementDynacomp – for fast varying loads with low p.f.

Automotive welding

Cranes & hoists

Presses, etc

Problems:

Decreased power transmission efficiency

Voltage fluctuations and/or collapse, Flicker

Other issues:

Tend to be large loads

Can be weak networks

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Power Factor ImprovementDynacomp – heart of the beast

Measure fast and react fast

Thyristors = SCR = Silicon Controlled Rectifiers

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Power Factor ImprovementDynacomp – Dynaswitch

Thyristors

RC snubbers

Fixings

Terminals for power cables

Heatsinks Thermal protection

ControllerFan

2 pairs of antiparallel HV thyristor modules

Aluminium heat sinks

Thermal protection

Firing control circuit

Only full alternations of current allowed (hence, no harmonics or transients)

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Power Factor ImprovementDynacomp – why is it better for fast varying loads?

SCR switched banks

Near instantaneous response

No disturbances at caps switching

No maintenance = fit & forget

Low losses

Theoretically unlimited operations

Contactor switched banks

Time delay to discharge capacitors

High inrush current

Limited life of the contactors

Fixed step size

Can create disturbances

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Response time

Less than 1 cycle in open loop

Max 3 cycles in closed loop

Instantaneous in external trigger (after first firing)

Transient free switching (no inrush current)

Harmonic absorption (reactors allowed)

Infinite number of switching

400 kvar max. step size (at 600V)

Single-phase or three-phase

50Hz or 60Hz

Power Factor ImprovementDynacomp – key features

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Power Factor ImprovementDynacomp – RVT-D

User-friendly

Monochrome alphanumeric + graphic display with menus & help

Keyboard

Intuitive parameter settings

Measurements

V, I, P, cos-phi, distortion p.f.

Harmonics (bar graph and values)

Temperature (2 sensor inputs)

Logging function (peak and duration)

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Power Factor ImprovementDynacomp – control types

Closed loop

CT on line side

CT on line side with additional CT in Dynacomp

Open loop

Normal open loop (CT on the load side)


External trigger

Without CT

CT in open loop


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Power Factor ImprovementDynacomp – SCR driven

Month DD, YYYY

Dynamic compensation

Instantaneous compensation to real-time demand

Specifically for rapid and intermittent demand

Built in Canada

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Power Factor ImprovementWhat‘s new? Qcap – key features

Cylindrical design

Compact

Unique design

cULus approved


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Power Factor ImprovementQcap – mechanical protection

SNAP on guard SNAP actuated

Rigid connections

Locked by groove Internal pressure OK Internal pressure NOK

Presenter

Presentation Notes

In addition to the fixed elements by the groove and the “LOCK”, it is also important to have the three wires very rigidly connected: the connections to the lids and the connections to the elements. As shown in the slides, when the pressure rise up to the breaking point, the wires snap perfectly.

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Power Factor ImprovementQcap – dimensions

Presenter

Presentation Notes

With QCap dimensions, it will be very easy to mount the caps into most common electrical switchgears. It is also convenient to fit the QCap into typical enclosures.

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Power Factor ImprovementQcap – spec

Voltages available: from 380 to 600 V

Frequency: 50 or 60 Hz

Connection: 3-phase

Net output power: from 12.5 to 30 kvar

Tolerance on capacitance: 0%, +10%

Typical losses:

< 0.2W/kvar (dielectric only)

< 0.5W/kvar (including discharge resistors)

Discharge resistor: discharge from Un to 50V in 1 minute

Max permissible current: 1.3 x In for continuous operation

Tolerance on voltage: 30% for maximum 1 min.

Presenter

Presentation Notes

Specifications highlights: tolerance

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Power Factor ImprovementQcap – spec

Case material: recyclable aluminum

Color: raw aluminum

Fixing: single stud (M12)

Weight: approx. 3kg

Terminals: Cage screws

Minimum clearance above unit: 20mm

Earth: earth connection on the fixing bolt Installation: indoor use only (inside enclosure) Temperature : -25°C to +55°C (class D per IEC 60831) Altitude: up to 2000m Protection degree: IP20 Cable section: up to 16mm²

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Power Factor ImprovementQcap – range

Presenter

Presentation Notes

With QCap dimensions, it will be very easy to mount the caps into most common electrical switchgears. It is also convenient to fit the QCap into typical enclosures.

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Power Factor ImprovementWhat‘s new? Qcap – strategy

Commercial applications

Malls

Towers

Warehouses

Small industrial sheds

Price-sensitive market

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Harmonic DistortionWhat is it? Some key words …

Definition: integer multiples of the fundamental frequency of any periodical waveform are called Harmonics

Waveform = oscillations (e.g., waves in the ocean, guitar string, pendulum, electricity, sound, light, etc.

Resonance = oscillations going out of control

At certain frequencies, harmonics result in resonance

Tacoma Bridge Collapse (Youtube)

https://www.youtube.com/watch?v=m79qESegXHE

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Harmonic DistortionWhat is it? Everyday examples of distortion ...

What if you go ON – OFF – ON – OFF continuously on a garden hose? What if you did that with 4 hoses?

What if everyone in a building were to flush their toilets at the same instant?

What if every light, fan and A/C in this building is switched OFF and ON at the same instant?

What if 10 people got on a garden bridge and jumped up and down at the same time?

What if 10 people crowded up the back of a van?

Why do airliners have a speed cap of 850 kmph?

Now imagine something like this on an electrical network …

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Harmonic DistortionH1 + H5 + H7

h = kq ± 1, where k = any integer, q = pulse number on the converter

Hence, for 6-pulse drive h = 5 & 7 and for 12 pulse, h = 11 & 13 …

© ABB| Slide 62

Harmonic DistortionHow is it represented?

0%

5%

10%

15%

20%

25%

5 7 11 13 17 19 23 25Time domain

Frequency domain

1

2

2

C

CTHD k

k∑==

C substituted by V or I THD = Total Harmonic Distortion, based on measured value TDD = Total Demand Distortion, total load demand denominator IEEE 519 defines TDD <5% at PCC, for networks below 69kV

L

kk

II

ITDD

∑== 2

2

Presenter

Presentation Notes

This can be visually represented over a time domain or a frequency domain. THD is called Total Harmonic Distortion represented by a percentage and defined by the formula on your screen where C can be replaced by V for voltage harmonics or I for current harmonics. So it is basically a squareroot of the sigma or sum of squares of values on all the frequencies after the fundamental, which is why k starts from 2. C1 basically stands for the fundamental frequency. So if you are measuring current harmonics you will have I1 in the denominator, which is the measured current of the fundamental frequency. TDD is called Total Demand Distortion, which is slightly different in that the harmonics are measured against the total load demand for that installation, rather than the measured current. This is considered a more real measure, if you like, of prevailing harmonics at a given installation.

© ABB| Slide 63

Harmonic DistortionIEEE 519 – 1992

Presenter

Presentation Notes

This can be visually represented over a time domain or a frequency domain. THD is called Total Harmonic Distortion represented by a percentage and defined by the formula on your screen where C can be replaced by V for voltage harmonics or I for current harmonics. So it is basically a squareroot of the sigma or sum of squares of values on all the frequencies after the fundamental, which is why k starts from 2. C1 basically stands for the fundamental frequency. So if you are measuring current harmonics you will have I1 in the denominator, which is the measured current of the fundamental frequency. TDD is called Total Demand Distortion, which is slightly different in that the harmonics are measured against the total load demand for that installation, rather than the measured current. This is considered a more real measure, if you like, of prevailing harmonics at a given installation.

© ABB| Slide 64

Harmonic DistortionWhere does it come from?

On electrical networks:

Any device with electronic switchingcomponents

Examples include phone chargers, car chargers, power supplies, LED lighting, UPS, transmission equipment, data centres, etc.

Largest source of harmonics today is VFD’s

© ABB| Slide 65

Harmonic DistortionWhat are the effects?

Heats up equipment

Reduces operating life of equipment, cables, motors, etc.

Causes false tripping of circuit breakers, blown fuses, etc.

Affects electronic control circuits (example, ECG in hospitals)

Affects communication circuits (example, telecom)

Can affect power factor

Potential risk of downtime and production losses

Presenter

Presentation Notes

What are the effects of such distortions. Depends on what kind it is. The fundamental frequency is the active power that does the work. Positive sequence harmonics create heating. Negative sequence also creates heating but in addition it has a retarding effect on the motor, which basically means the motor is going to pull more current simply to run the same given load. Eventually it will heat up and perhaps burn itself out. Zero sequence means you have high currents in the neutral.

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Harmonics MitigationWhat is the business relevance?

Somewhat like medical insurance … you don’t know you need it until you really do !!

How do you know it’s needed? Network analysis

Benefits to end-users …

1. Prevents unexpected shutdowns and downtime

2. Increases operating life of equipment on plant

3. Ensures network is not polluted

4. Prevents harmonics from spreading upstream

© ABB| Slide 68

PWM Inverter (IGBT-based)

Line reactor

PWM reactor

Output filter

Control system

Harmonics MitigationActive Filters – how do they work?

© ABB| Slide 69

Filter up to H13

Filter up to H25

ABB

Filter up to H50

Technical requirements

Regulation requirements

Harmonics MitigationActive Filters – filtering out the entire range

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Harmonics MitigationActive Filters – why closed loop?

Closed loop controlDirectly control & measure THDI and total

load current then compensate

Future extent ion = easy

VFD VFD VFD VFDVFDPQF

Other loads

spare

CT : x/5A

Control point

Open loop operationTHDI = ? unknownTotal loads = ? UnknownPass/fail regulation = ? Unknown

Accuracy drop !Future extent ion =?

VFD VFD VFD VFDVFDAF?

Other loads

spare

Control point

CT CT CT CTCT:x/1A

SCT

© ABB| Slide 71

Harmonics MitigationActive Filters – why closed loop?

Directly measure and control harmonic current flowing to network

No risk of wrong THDI calculation

Can verify harmonic according to regulation directly

Simple CT connection

Normal CT X/5A class 1 is sufficient

Easy for future harmonic load extensions

Better accuracy & safety

Appropriate for local & global compensation

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Waveform event at 22/11/01 10:25:43.533

CHA Volts CHB Volts CHC Volts CHA Amps CHB Amps CHC Amps

Volts

Amps

10:25:43.72 10:25:43.73 10:25:43.74 10:25:43.75 10:25:43.76 10:25:43.77 10:25:43.78

-750

-500

-250

0

250

500

750

-3000

-2000

-1000

0

1000

2000

3000

Voltage: THDV = 12% Current: THDI = 27%

Harmonics MitigationActive Filters – example with VFD in oil field

LINE VOLTAGES & LINE CURRENTS AT PUMPING CLUSTER

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Waveform event at 22/11/01 10:41:55.533

CHA Volts CHB Volts CHC Volts CHA Amps CHB Amps CHC Amps

Volts

Amps

10:41:55.72 10:41:55.73 10:41:55.74 10:41:55.75 10:41:55.76 10:41:55.77 10:41:55.78

-750

-500

-250

0

250

500

750

-3000

-2000

-1000

0

1000

2000

3000

Voltage: THDV = 2% Current: THDI = 3%

Harmonics MitigationActive Filters – example with VFD in oil field

LINE VOLTAGES & LINE CURRENT WITH ACTIVE FILTER

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Max. Filtering &Q Compensation

MaximumFiltering

Filtering toCurve

Filtering toHardware Limits

Load increase

Loaddecrease

Harmonics MitigationPQF Active Filter Controller – mode changing

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Harmonics MitigationKey Features of PQF – why is it the best?

1. Eliminates up to 50th harmonic

2. 20 individual harmonics at a time (spectrum) with individual presets

3. Unsurpassed harmonic attenuation factor (≥ 97% typical)

4. 3-phase, 3-wire, closed loop control for maximum precision

5. 100A, 180A, 320A ++, scalable upto 8 units, any combination

6. Master-slave or master-master with full redundancy

7. cULus approved

8. User settable parameters

9. Stepless load balancing and reactive power compensation (Mode2)

10. Zero risk of overloading due to parallel connection

11. Zero risk of overheating due to auto-derating function

12. Produced in Belgium

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Why ABB?Value-add, ABB-style

1. Our caps & filters work with any make & brand of switchgear or MCC equipment

2. Global presence – valuable for OEM’s, multinationals, etc.

3. Local presence – expertise in design, engineering, assembly, sales and marketing

4. Local support at all stages from selection to commissioning

5. Service support from ABB and service partners

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Why ABB?How are we promoting Power Quality?

1. Starts with awareness at end-user level

2. Our own installed base

3. Reach out to utilities, engineering consultants, EPCs

4. Engineering shows, events …

5. Distribution channels

6. Outside –> in approach, tailored to each region, vertical …