Harmonics AccuSineSolutions
Content
Power System Harmonic Mitigation for Water/Wastewater Applications
Power Quality Correction
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Make the most of your energy Ben Banerjee Sept. 30 & Oct. 2, 2008
Make the most of SM your energy
Power Quality Correction
Benefits For Harmonics Mitigation For Water & Waste Water Applications
•
Improved Bottom Line:
* System Cost Reduction * Maximize System Reliability * Improve Energy Efficiency * System Capacity Release
Power Quality Correction
Agenda
* * * * * * * * Characteristic of a Typical W/WW Facility Impact of Non-Linear Loads Harmonics Fundamental Effects of Harmonics Harmonics Standard IEEE 519-1992 Cost-Effective Harmonics Mitigations AccuSine Solutions Application Considerations
Power Quality Correction
Distribution System/ Load Characteristics Of
A Typical W/WW Facility
Typical W/WW Applications / Loads
Wastewater Plants
Many pumps for fluid movement (VFD) – VT – Centrifugal pumps – CT – Progressive cavity pumps (semi-solids) Solids handling (VFD) – Conveyors Aeration blowers (VFD) – CT & VT types Disinfectant – UV systems (ultraviolet) – Electronic ballasts – 3Φ – Ozone generators (SCR power supplies) HVAC
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Typical W/WW Applications / Loads
Water Purification
Many pumps (VFD) UV systems (electronic ballasts) Reverse osmosis – Centrifugal pumps (VFD) Ozone generators (SCR power supplies)
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Power Quality Correction
Elect. Loads& System Characteristics For Typical W/WW Facility
Mostly Motor Loads * Typically 40% to 50% FVNR (Linear Loads) * Typically 30% to 40% VFDs (Non-Linear Loads) * Typically 5% to 10% RVSS MCC / SWGR/ SWBR Fed Either From Utility Or Generator VFDS may be within MCC or remote located > Generator Normally Sized for Critical Loads > For Water/ Waste Water Facility: * Sometime UV System (Non-Linear Loads) * Sometime Ozone Generator ( Non-Linear Loads)
>
Power Quality Correction
Harmonics Fundamentals
Power Quality Correction
Linear vs Non-Linear
Until recently, most electrical equipment drew current in a “linear” fashion:
v i
• Current (i) & Voltage (v) are both “Sinusoidal”
Today, many electrical loads draw current in a “non-linear” fashion:
v
• Current (i) is periodic, but not “sinusoidal”
i
Power Quality Correction
Examples
What produces “Non-linear” Current?
• Computers M • Variable Frequency Drives • Electronic Ballasts
• Fax Machines
• Copiers
• Almost Anything Power Electronics
Power Quality Correction All Periodic Waves Are Generated With Sine Waves Of Various Frequencies
Time Domain
f1 = 60 H z
Frequency Domain
1 0.5 0 1 3 5 7 9 1 1
60 Hz
f1
f 3 = 3 x 6 0 hz = 18 0 hz
+
180 Hz
1 0.5 0 1 3 5 7 9 1 1
f3
f 5 = 5 x 6 0 hz = 3 0 0 hz
+
300 Hz
1 0.5 0 1 3 5 7 9 1 1
f5
f 7 = 7 x 6 0 hz = 4 2 0 hz
+
420 Hz
1 0.5 0 1 3 5 7 9 1 1
f7
D is t o rt e d Wa v e = f1 + f3 + f5 + f7
1 0.5
=
0 1 3 5 7 9 1 1
Now We Can Define Harmonics:
Fundamental
3 Harmonic 7 Harmonic
th
rd
– A harmonic is a component of a periodic wave having a frequency that is an integer multiple of the fundamental power line frequency [ In USA , 60Hz]
• Characteristic harmonics are the predominate harmonics seen by the power distribution system
5
t1h
Harmonic
– Predicted by the following equation:
For Six Pulse Drive: Harmonic 1 5 7 11 13 Frequency Sequence 60Hz 300Hz 420Hz 660Hz 780Hz
• hC = characteristic harmonics to be expected • n = an integer from 1,2,3,4,5, etc. • p = number of pulses or rectifiers in circuit
Hc = np +/- 1
Multi-pulse Converters
Harmonic Orders Present Hn = NP +/- 1
Hn 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 Harmonics present by rectifier design Type of rectifier 1 phase 2 phase 3 phase 3 phase 4-pulse 4-pulse 6-pulse 12-pulse 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 3 phase 18-pulse
Hn = harmonic order present N,n = an integer P = number of pulses
x x
x x
Power Quality Correction
Issues With High System Harmonics
• • •
System Reliability Energy Efficiency System Capacity
Power Quality Correction
Power Quality Correction
Power Quality Correction
“K” Factor Rated Transformer
For Dry Type Transformer, To Determine What Amount Of Harmonic Current Can Be Tolerated, “K” Factor Calculation Is Made Instead Of Using The THD(I) Formula
Power Quality Correction
How do you know if Harmonics are present in your system?
Building
a New Electric World
Other Common symptoms of harmonics include:
Random
logic faults: CNC, PLCs, drives, UPSs, computers Random Breaker Thermal Trips Clocks Running Faster
Corporate Presentation 12-Apr-2004 EN
Common Symptoms of Harmonics (cont.)
Building
a New Electric World
Potential Power
Resonance Condition
> Over Voltage
Factor Capacitor
> Harmonic heating effect > Trips on over-current
Limits
on capacity of UPSs faulting-Unable to do frequency
Generator
regulation
Corporate Presentation 12-Apr-2004 EN
SYSTEM CAPACITY ISSUE
Building
a New Electric World
Displacement True
Power Factor
or Total Power Factor
Corporate Presentation 12-Apr-2004 EN
Power Quality Correction
The Power Triangle:
Power Factor is the ratio of Active Power to Total Power:
Power Factor =
Active Power (kW)
φ
Total Power (kVA)
Active (Real) Power Total Power = kW Reactive kVA Power = Cosine (θ) = Displacement Power Factor (DPF)
Power Factor is a measure of efficiency (Output/Input)
Total Power Factor
TPF = (DPF) x (Harm coefficient) KW DPF = KVAf = Cos φ 1 1 + THD(I)2
TPF = Total or true power factor DPF = Displacement power factor Harm coefficient = Harmonic power factor
Harm coefficient =
= Cos δ
Total Power Factor Example
• Variable frequency drive (PWM type) • DPF = .95 • TDD = 90%
– (no DC choke & no input line reactor) 1 1 + .92
• Harm coefficient =
= .7433
• TPF = .95 x .7433 = .7061
Power Quality Correction
How are Harmonic measured ?
North American Standard
ANSI Standard IEEE 519-1992 IEEE Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems
ANSI Standard IEEE 519-1992
• Chapter 11
– Addresses THD(V) delivered by utility to user – THD(V) must be < 5% [< 69 KV systems]
• Chapter 10
– – – – Defines the amount of TDD a user can cause Based upon Demand Load & System Fault Level Table 10.3 for systems < 69 kV Defines limits for voltage notches caused by SCR rectifiers – Table 10.2
• Defines PCC (point of common coupling)
Power Quality Correction
IEEE 519-1992 Table 10.2
Limits on Commutation Notches (Applies to SCR rectifiers – only)
Table 10.2 Low-Voltage System Classification and Distortion Limits
*Special Applications Notch Depth THD (Voltage) Notch Area, µVs 10% 3% 16,400 General System 20% 5% 22,800 **Dedicated System 50% 10% 36,500
Note: Notch area for other than 480 V systems should be multiplied by V / 480.
*Special Applications – Airports, Hospitals ** Dedicated System – Dedicated exclusive to converter loads
IEEE 519 - Harmonic Distortion Limits
• Table 11.1 - Voltage Distortion Limits
Bus voltage at PCC 69kV and below 69.001 kV through 161kV 161.001kV and above Max. individual Voltage distortion (%) 3.0 1.5 1.0 Total Voltage distortion THD (%) 5.0 2.5 1.5
The limits listed above should be used as system design values for the “worst case” for normal operation (conditions lasting longer than one hour). For shorter periods, during start-ups or unusual conditions, the limits may be exceeded by 50%.
THD =
∑V
h=2
50
2 h
*100
V1
Power Quality Correction
Total Harmonic Current Distortion Is Same As
Total Demand Distortion (TDD)
∞
I
TDD
=
I
2 2
+ I
3
2
+ I
1
2 4
+L
∑
× 100 % =
h = 2
Ih
2
× 100
1
%
I
I
IEEE 519-1992 Table 10.3
Current Distortion Limits for General Distribution Systems (<69 kV)
Isc/Iload <20 20<50 50<100 100<1000 >1000 <11 4.0% 7.0% 10.0% 12.0% 15.0% 11<=h<17 17<=h<23 23<=h<35 2.0% 1.5% 0.6% 3.5% 2.5% 1.0% 4.5% 4.0% 1.5% 5.5% 5.0% 0.2% 7.0% 6.0% 2.5% h>=35 0.3% 0.5% 0.7% 1.0% 1.4% TDD 5.0% 8.0% 12.0% 15.0% 20.0%
Isc = short circuit current capacity of source Iload = demand load current (fundamental) TDD = Total Demand Distortion (TDD = Total harmonic current distortion measured against fundamental current at demand load.)
Utility
IEEE 519-1992 Chapter 10 states “…Within an • industrial plant, the PCC is the point between the nonlinear load and other loads.”
Other customers PCC 1 PCC 2
Most harmonic problems are not at PCC with utility >Occurs with generators & UPS >Occurs where nonlinear loads are concentrated >Occurs inside the plant Need to protect the user by moving the harmonic mitigation requirements to where harmonic loads are located
Customer 1
Customer 2
Specification Issues
• Write Separate harmonic spec from nonlinear load spec (Section 16)
– Write standard nonlinear load specification – It is System Standard & NOT Product Standard
• Universal solution is more Cost Effective
– Good for all nonlinear loads – Apply AHF per electrical bus (best economics)
•
5% TDD per load or bus inside the plant ?
– IEEE 519-1992 Chapter 10 states “…Within an industrial plant, the PCC is the point between the nonlinear load and other loads.”
• Write TDD specs not THD(I)
Methods For Harmonics Mitigation
**Individual Device Solution •Embedded Solution **System Solution
Individual Device Solution
Harmonic Mitigation Methods
• Typically applied per device: -Isolating Harmonic Loads --Line reactors
– 5th harmonic filters (Only 5th) – Broadband filters (up to 13th) Embedded Solutions: – Multi-pulsing (6-Pulse,18-Pulse) – Active front end (AFE) converter – C-Less Technology
•
System solution
– Active Harmonic Filter – Harmonics Mitigation Transformer (Up to 19th)
Inductors
•Pros:
– – – – Inexpensive & reliable Transient protection for loads Big TDD reduction (90% to 35% w/3% Z) Complimentary to active harmonic control
•Cons:
– Limited reduction of TDD at equipment terminals after 3% Z – Reduction dependent on source
Impedance
Input Current Distortion as a Function of inductor Size Input Current Distortion (%) 80% 70% 60% 50% 40% 30% 20% 10% 0% 0 1 2 3 4 5 Inductor Size (% on Drive Base)
Power Quality Correction
Current Distortion THD(I) or TDD as a function of Rsce With 6-pulse power converter
Multi-pulse Converters
Harmonic Orders Present Hn = NP +/- 1
Hn 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 Harmonics present by rectifier design Type of rectifier 1 phase 2 phase 3 phase 3 phase 4-pulse 4-pulse 6-pulse 12-pulse 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 3 phase 18-pulse
Hn = harmonic order present N,n = an integer P = number of pulses
x x
x x
Harmonic mitigation methods
VFD mitigation topologies
• 6-Pulse converter
DC Link Reactor
Wye
C
4 7
•
12-Pulse converter
+
DC Bus Load
•
A B
18-Pulse converter
Multipulse Transformer A Line Reactor
9 1 2
Rectifier Assembly DC+
8
3
M
AC Line Delta
C
6
5
B
DC-
Delta
Transformer Tertiary
“C-less” or 3% reactance min (if included); small footprint, simplified cabling
A
100 0
Externally mounted 3 winding transformer; more wire and cabling; complicated
A
100 0
Large footprint, more steel & copper (losses)
A
100 0
6 pulse
12 pulse
0.0s 0.02s
18 pulse
Current waveform distorted TDD 30% to 40% with 3% reactor (depending on network impedance)
Current slightly distorted TDD 8% to 15% (depending on network impedance)
Current wave form good TDD 5% to 7% (depending on network impedance)
Multi-Pulse Drives
Description: Drives/UPS with two (12 pulse) or three (18 pulse) input bridges fed by a transformer with two or three phase shifted output windings.
•Pros:
– Reduces TDD to 10% (12 pulse) & 5% (18 pulse) at loads – Reliable
•Cons:
– – – – – High installation cost with external transformer Large footprint (even w/autotransformer) Series solution with reduction in efficiency One required for each product Cannot retrofit
Active Front End Converter
Products with active power converter and input broadband filter to create sinusoidal current & voltage waveforms on AC lines.
A C S o u r c e
VFD
IGBT DC Bus IGBT
Filter
Converter
AC Motor Inverter
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AFE Converters >Pros:
Meets 5% TDD limit of IEEE 519
>Cons:
Mains
Larger and more expensive than 6 pulse drives
Approximately twice the size & price
Mains voltage must be free of imbalance and voltage harmonics
– Generates more harmonics
200 KVA rated AFE VFD PWM VFD DC Drive PF caps
100 KVA rated
Without mains filter THD(V) can reach 40% Requires short circuit ratio > 40 at PCC Switched mode power supplies prohibited Capacitors prohibited on mains IGBT & SCR rectifiers prohibited on same mains
– No other nonlinear loads permitted
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Harmonic mitigation methods (Applied per VFD)
Solution Increase short circuit capacity Advantage Reduces THD(V) Lower TDD Simplified design Less cost Low cost adder Simple Reduces 5th & total TDD Disadvantage Increases TDD Not likely to occur** Compliance is limited Application limited Size limited Compliance difficult Does not meet harmonic levels at higher orders^ Large heat losses Application limited Large footprint/heavy Good for >100 HP Large footprint/heavy Good for >100 HP Large footprint/heavy Very high cost per unit High heat losses Typical % TDD Dependent upon SCR*** Typical Price Multiplier* Cost of transformer and installation change out
C-Less Technology Impedance (3% LR or 5% DC choke) 5th Harmonic filter
30 - 50% TDD 30 - 40% TDD 18 - 22% TDD
0.90 - 0.95 1.05 - 1.15 1.20 - 1.45
Broadband filter
Reduces TDD (thru 13th) Reduces TDD Reliable Reduces TDD Reliable
8 - 15% TDD
1.25 - 1.50
12-pulse rectifiers
8 - 15 % TDD
1.65 - 1.85
18-pulse rectifiers
5 - 8% TDD
1.65 - 1.85
Active front end converter
Very good TDD Regeneration possible
< 5% TDD
2.0 - 2.5
* Price compared to a standard 6-pulse VFD. ** Utilities and users are not likely to change their distribution systems. *** Increasing short circuit capacity (lower impedance source or larger KVA capacity) raises TDD but lowers THD(V). ^ Can be said for all methods listed.
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System Solution
Applied to one or many nonlinear loads
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When wave shapes with different phase shifts are combined
Application of Harmonic Mitigation Transformers
AccuSine® PCS
**Guarantees elimination of harmonic
problems – both TDD and THD(V) ** 2nd through 50th order
5
System Solution
Active Harmonic Filter • Applied to one or many nonlinear loads – VFD, UPS, UV, DC drives, DC power supplies • Provides DPF correction • More cost effective for multiple loads • Saves space • Lower heat Losses
Active Harmonic Filter: System Solution
~
Source Is Ia CT Il L
Load
AHF
•Is + Ia = Il
AHF
•Parallel connected
•Ia includes 2nd to 50th harmonic current •Is <5% TDD
Active Harmonics Filter
I. source
2 1,5 1 0,5 0 -0,5 -1 -1,5 -2 2 1,5 1 0,5 0 -0,5 -1 -1,5 -2
I. Harmonics
I. Active Conditioner
-0,5 0 0,5 1 -1 1,5 -1,5 -2 2 1,5 1 0,5 0 -0,5 -1 -1,5 -2
I. resultant
+
=
I.s
Source
I.ac
active conditioner
57
2
I.h
non linear load
AHF HarmonicsPerformance
At VFD Terminals
Order Fund 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 % TDD AHF off % I fund 100.000% 0.038% 31.660% 11.480% 0.435% 7.068% 4.267% 0.367% 3.438% 2.904% 0.284% 2.042% 2.177% 0.293% 1.238% 1.740% 0.261% 0.800% 1.420% 0.282% 0.588% 1.281% 0.259% 0.427% 1.348% 35.28% AHF on % I fund 100.000% 0.478% 0.674% 0.679% 0.297% 0.710% 0.521% 0.052% 0.464% 0.639% 0.263% 0.409% 0.489% 0.170% 0.397% 0.243% 0.325% 0.279% 0.815% 0.240% 0.120% 0.337% 0.347% 0.769% 0.590% 2.67%
AHF injection
Source current
AccuSine® PCS Overall Performance
Harmonic compensation
2nd through 50th order Includes inter-harmonics Independent of source impedance – Selection and operation same whether on AC line or backup generator or UPS output
Obtain 5% TDD (current distortion) Reactive current injection ( VAR Correction)
Reactive current injection is secondary to harmonic mitigation
Either or both functions VAR compensation
100 µsecond detect-to-inject ½ cycle to full control for step load changes
Dynamic response
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Dual Mode Operation
Ias =
Ih2 + Ir2
Ias = rms output current of AHF Ih = rms harmonic current Ir = rms reactive current
Ias 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 Examples Ih 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 95.0 Ir 99.5 98.0 95.4 91.7 86.6 80.0 71.4 60.0 43.6 31.2
AccuSine® PCS
Advantages
Disadvantages
Highly effective (2nd to 50th orders cancelled) Scalable – Parallel units as needed Universal solution – Handles many loads – Many types of loads at same time HMI & Modbus Communication Best cost for multiple loads – Lowest heat profile Smallest footprint with std VFD/UPS
Heat from high speed switching of IGBT Cost issues possible for single load
Considerations
Load must have input impedance (3%) – Protects load – Limits size of AHF Need branch circuit protection
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AccuSine® PCS Specifications
Universal Application
208 – 480 VAC – No user action required to set 50 or 60 Hz Use highly customized transformers for higher voltages (to 15 kV)
Fuse protected (200,000 AIC) UL 508 & CSA approved CE (EMC) - 400V Logic ride through – 1 to 10 minutes
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Power Diagram For A Typical AHF
IGBT Module
C C C
Pre-charge Contactor
Fuse
E
E
E
S1
S3
S5
AC Lines
Fuse Fuse
Line Inductor
DC Bus Capacitors
+ C
Inductor
C
C
C
Filter Board
S2
E
E
E
S4
S6
Product Package
Standard (UL/CSA, ABS) Three sizes-50A,100A,300A NEMA 1, 1A, 12, & 3R Enclosed – NEMA 1
50 amp – 52” x 21” x 19” – Weight – 250Lbs 100 amp – 69” x 21” x 19” – Weight – 350 Lbs 300 amp – 75” x 32” x 20” – Weight – 775 Lbs
Chassis – IP00 Wall mount – 50 & 100 amp Free standing – 300 amp with disconnect
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Product Package
International enclosures
NEMA 12, IP30, IP54 – 50 amp – 75” x 31.5” x 23.62” – Weight – 661 Lbs – 100 amp – 75” x 31.5”x 23.62” – Weight – 771 Lbs – 300 amp – 91” x 39.37” x 31.5” – Weight – 1212 Lbs Free standing with door interlocked disconnect CE Certified, ABS, UL, CUL
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Product Re-packaging
Maximum ambient into air inlet – 400C Must meet air flow at inlet of AccuSine
50 amp – 300 CFM 100 amp – 500 CFM 300 amp - 1250 CFM 50 amp – 1800 watts 100 amp – 3000 watts 300 amp – 9000 watts On chassis Remote with cable
Heat released
HMI considerations required
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Product Re-packaging
MCC Packaging
50 & 100 amp models only Requires one vertical 20” x 20” section Includes circuit breaker in section
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Comparison of 18-P VFD To AccuSine + 6-P VFD+3%LR
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System Solution
AccuSine® PCS Sizing Example A 125 HP variable torque 6-pulse VFD with 3% LR
Required AHF filtering capability = 47.5 amperes Required AHF size = 84.4 amps Required AHF size = 113.5 amps Required AHF size = 157.6 amps – (not 6 x 47.5 = 285 amps)
Two 125 HP VT 6-pulse VFD w/3% LR
Three 125 HP VT 6-pulse VFD w/3% LR
Six 125 HP VT VFD w/3% LR
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System solution
Comparison of 18-P VFD to AccuSine + 6-P VFD+3%LR Footprint required
AccuSine PCS+ Std VFD less than 18-P VFD (w/autotransformer) for all conditions AccuSine PCS+ Std VFD less than 18-P VFD – Exception at single units of 50-75 HP, advantage 18-P VFD Less site cooling required with AccuSine PCS + Std VFD When more than one VFD, AccuSine PCS + 6-P VFD always beats 18-P VFD If only one VFD involved, 300-500 HP sizes favor 18-P VFD
Heat losses
Less Operating Cost AccuSine PCS+ 6-P VFD
Price ( Installed Cost)
SQ D Software Tool
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AccuSine to18-pulse Comparisons
IR: 10.00% Years: 10
System:
kWH rate: $.10 Days/week: 7 Hours/day: 24
1x 125 HP AccuSine 18-pulse System 35,914.49 31,342.92 9.03 5.02 4,228.22 3,960.89 Advantage: AccuSine 6,257.33 System 2x 125 HP AccuSine 18-pulse System 72,909.11 56,776.63 18.06 7.37 8,456.45 6,885.12 Advantage: AccuSine 26,041.16 System 3x 125 HP AccuSine 18-pulse System 109,363.67 88,590.87 27.09 12.39 12,684.67 10,504.07 Advantage: AccuSine 34,523.50 System 3x 150 HP AccuSine 18-pulse System 116,681.51 96,415.47 27.09 12.39 15,253.06 12,198.66 Advantage: AccuSine 39,526.83 system 2x 150 HP AccuSine 18-pulse System 77,787.68 78,288.60 18.06 10.03 10,168.70 8,598.35 Advantage: AccuSine 9,401.64 system 3x 200 HP AccuSine 18-pulse System 151,521.89 117,574.82 27.09 12.39 19,603.58 14,125.78 Advantage: AccuSine 68,489.71 System 1x 150 HP AccuSine 18-pulse System 38,893.84 43,866.16 9.03 5.02 5,084.35 4,342.66 Advantage: -295.25 18-pulse 2x 200 HP AccuSine 18-pulse System 101,014.59 86,099.03 18.06 10.03 13,069.06 10,132.22 Advantage: AccuSine 33,435.03 System 3x 300 HP AccuSine 18-pulse System 186,321.52 139,746.79 54.17 20.84 27,859.10 23,563.31 Advantage: AccuSine 73,663.68 system 1x 200 HP AccuSine 18-pulse System 50,507.30 47,771.37 9.03 5.02 6,534.53 5,102.25 Advantage: AccuSine 11,767.77 System 2x 300 HP AccuSine 18-pulse System 124,214.34 110,330.12 36.11 15.34 18,572.74 16,664.58 Advantage: AccuSine 25,916.93 system 3x 400 HP AccuSine 18-pulse System 212,625.00 190,969.18 54.17 23.49 36,350.50 29,184.76 Advantage: AccuSine 66,842.42 system 1x 300 HP AccuSine 18-pulse System 62,107.17 71,451.53 18.06 10.81 9,286.37 8,428.81 Advantage: -4,277.20 18-pulse 2x 400 HP AccuSine 18-pulse System 141,750.00 127,318.85 36.11 15.34 24,233.66 20,373.23 Advantage: AccuSine 38,774.77 system 3x 500 HP AccuSine 18-pulse System 233,887.50 247,668.92 54.17 25.20 45,995.04 35,958.34 Advantage: AccuSine 49,509.34 system 1x 400 HP AccuSine 18-pulse System 70,875.00 89,389.61 18.06 10.81 12,116.83 10,178.29 Advantage: -6,290.32 18-pulse 2x 500 HP AccuSine 18-pulse System 155,925.00 173,686.31 36.11 18.00 30,663.36 24,273.86 Advantage: AccuSine 22,540.43 system 1x 500 HP AccuSine 18-pulse System 77,962.50 99,703.69 18.06 10.81 15,331.68 11,968.30 Advantage: -531.93 18-pulse
User Price Sq Ft Annual operating costs
NPV Cash Flow System:
User Price Sq Ft Annual operating costs
NPV Cash Flow System:
User Price Sq Ft Annual operating costs
NPV Cash Flow
AccuSine® PCS Installation Considerations
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AHFInstallation Considerations
Main – Left
Main-tie-main
Tie
Main – Right
CBml CTml CTtl CTtr CTmr CBar
CBmr
CBal
AHF- L
AHF-R
This configuration provides individual AHF operation per side regardless of breaker positions.
AHF Installation Considerations
Utility Main Power CB CTm CBa CTg Generator
~
Generator CB
Regardless of Main Power CB and Generator CB positions, AHF limits harmonics for both sources.
AHF
AccuSine PCS Limitations
• 3-Phase / 3-Wire design only
– Does not help neutral harmonics
• “Sine-Wave” Product for
3-Phase / 4-Wire System
AccuSine Selection
• Use Spreadsheet—SQ D Software • No Harmonics Analysis required • Information Required for Sizing: * One Line * All VFDs Details—HP & CT or VT * All Linear Loads Details-HP/KW * Other Non-Linear Loads—UV / OG * If DPF Correction is required. * Both LV & MV Bus * Add 3% LR for all Non-Linear Loads
Generator & Harmonics Load
Generator Feeding Nonlinear Loads
• • • • • •
Soft Source High Impedance with limited over load capacities High Impedance produces excessive THDv High THDv directly affects Voltage Regulation Many existing Generators with old Regulator Design can fail High THDv affects Electronics Loads & can fail
Power Quality Correction
Voltage distortion THD(V) as a function of RSCE with 6-pulse power converter
Generator Feeding Nonlinear Loads
*Harmonics Current Generates Excessive Heating
in the Windings *Derating of Generator needed with Nonlinear Loads
Generator Feeding Nonlinear Loads: AccuSine Advantages
*Helps Generator runs “Cooler” *Helps Voltage Regulation *Helps Older Existing Generators in the Field *Helps Retrofits– Space & Generator Rating *Helps Environment
Solution Approach
Measure
Supply & Commission
Solution Cycle
Simulate
Specify & Propose
Analyze & Report
Power Quality Correction
Thank You ! Questions?
For More Information, Please Contact:
B. Ben Banerjee Power Quality Correction Group Schneider Electric San Francisco Field Office Direct: 925-463-7103 Cell: 925-858-2182 E-mail: [email protected]
Power Quality Correction
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Make the most of your energy Ben Banerjee Sept. 30 & Oct. 2, 2008
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Power Quality Correction
Benefits For Harmonics Mitigation For Water & Waste Water Applications
•
Improved Bottom Line:
* System Cost Reduction * Maximize System Reliability * Improve Energy Efficiency * System Capacity Release
Power Quality Correction
Agenda
* * * * * * * * Characteristic of a Typical W/WW Facility Impact of Non-Linear Loads Harmonics Fundamental Effects of Harmonics Harmonics Standard IEEE 519-1992 Cost-Effective Harmonics Mitigations AccuSine Solutions Application Considerations
Power Quality Correction
Distribution System/ Load Characteristics Of
A Typical W/WW Facility
Typical W/WW Applications / Loads
Wastewater Plants
Many pumps for fluid movement (VFD) – VT – Centrifugal pumps – CT – Progressive cavity pumps (semi-solids) Solids handling (VFD) – Conveyors Aeration blowers (VFD) – CT & VT types Disinfectant – UV systems (ultraviolet) – Electronic ballasts – 3Φ – Ozone generators (SCR power supplies) HVAC
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Typical W/WW Applications / Loads
Water Purification
Many pumps (VFD) UV systems (electronic ballasts) Reverse osmosis – Centrifugal pumps (VFD) Ozone generators (SCR power supplies)
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Power Quality Correction
Elect. Loads& System Characteristics For Typical W/WW Facility
Mostly Motor Loads * Typically 40% to 50% FVNR (Linear Loads) * Typically 30% to 40% VFDs (Non-Linear Loads) * Typically 5% to 10% RVSS MCC / SWGR/ SWBR Fed Either From Utility Or Generator VFDS may be within MCC or remote located > Generator Normally Sized for Critical Loads > For Water/ Waste Water Facility: * Sometime UV System (Non-Linear Loads) * Sometime Ozone Generator ( Non-Linear Loads)
>
Power Quality Correction
Harmonics Fundamentals
Power Quality Correction
Linear vs Non-Linear
Until recently, most electrical equipment drew current in a “linear” fashion:
v i
• Current (i) & Voltage (v) are both “Sinusoidal”
Today, many electrical loads draw current in a “non-linear” fashion:
v
• Current (i) is periodic, but not “sinusoidal”
i
Power Quality Correction
Examples
What produces “Non-linear” Current?
• Computers M • Variable Frequency Drives • Electronic Ballasts
• Fax Machines
• Copiers
• Almost Anything Power Electronics
Power Quality Correction All Periodic Waves Are Generated With Sine Waves Of Various Frequencies
Time Domain
f1 = 60 H z
Frequency Domain
1 0.5 0 1 3 5 7 9 1 1
60 Hz
f1
f 3 = 3 x 6 0 hz = 18 0 hz
+
180 Hz
1 0.5 0 1 3 5 7 9 1 1
f3
f 5 = 5 x 6 0 hz = 3 0 0 hz
+
300 Hz
1 0.5 0 1 3 5 7 9 1 1
f5
f 7 = 7 x 6 0 hz = 4 2 0 hz
+
420 Hz
1 0.5 0 1 3 5 7 9 1 1
f7
D is t o rt e d Wa v e = f1 + f3 + f5 + f7
1 0.5
=
0 1 3 5 7 9 1 1
Now We Can Define Harmonics:
Fundamental
3 Harmonic 7 Harmonic
th
rd
– A harmonic is a component of a periodic wave having a frequency that is an integer multiple of the fundamental power line frequency [ In USA , 60Hz]
• Characteristic harmonics are the predominate harmonics seen by the power distribution system
5
t1h
Harmonic
– Predicted by the following equation:
For Six Pulse Drive: Harmonic 1 5 7 11 13 Frequency Sequence 60Hz 300Hz 420Hz 660Hz 780Hz
• hC = characteristic harmonics to be expected • n = an integer from 1,2,3,4,5, etc. • p = number of pulses or rectifiers in circuit
Hc = np +/- 1
Multi-pulse Converters
Harmonic Orders Present Hn = NP +/- 1
Hn 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 Harmonics present by rectifier design Type of rectifier 1 phase 2 phase 3 phase 3 phase 4-pulse 4-pulse 6-pulse 12-pulse 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 3 phase 18-pulse
Hn = harmonic order present N,n = an integer P = number of pulses
x x
x x
Power Quality Correction
Issues With High System Harmonics
• • •
System Reliability Energy Efficiency System Capacity
Power Quality Correction
Power Quality Correction
Power Quality Correction
“K” Factor Rated Transformer
For Dry Type Transformer, To Determine What Amount Of Harmonic Current Can Be Tolerated, “K” Factor Calculation Is Made Instead Of Using The THD(I) Formula
Power Quality Correction
How do you know if Harmonics are present in your system?
Building
a New Electric World
Other Common symptoms of harmonics include:
Random
logic faults: CNC, PLCs, drives, UPSs, computers Random Breaker Thermal Trips Clocks Running Faster
Corporate Presentation 12-Apr-2004 EN
Common Symptoms of Harmonics (cont.)
Building
a New Electric World
Potential Power
Resonance Condition
> Over Voltage
Factor Capacitor
> Harmonic heating effect > Trips on over-current
Limits
on capacity of UPSs faulting-Unable to do frequency
Generator
regulation
Corporate Presentation 12-Apr-2004 EN
SYSTEM CAPACITY ISSUE
Building
a New Electric World
Displacement True
Power Factor
or Total Power Factor
Corporate Presentation 12-Apr-2004 EN
Power Quality Correction
The Power Triangle:
Power Factor is the ratio of Active Power to Total Power:
Power Factor =
Active Power (kW)
φ
Total Power (kVA)
Active (Real) Power Total Power = kW Reactive kVA Power = Cosine (θ) = Displacement Power Factor (DPF)
Power Factor is a measure of efficiency (Output/Input)
Total Power Factor
TPF = (DPF) x (Harm coefficient) KW DPF = KVAf = Cos φ 1 1 + THD(I)2
TPF = Total or true power factor DPF = Displacement power factor Harm coefficient = Harmonic power factor
Harm coefficient =
= Cos δ
Total Power Factor Example
• Variable frequency drive (PWM type) • DPF = .95 • TDD = 90%
– (no DC choke & no input line reactor) 1 1 + .92
• Harm coefficient =
= .7433
• TPF = .95 x .7433 = .7061
Power Quality Correction
How are Harmonic measured ?
North American Standard
ANSI Standard IEEE 519-1992 IEEE Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems
ANSI Standard IEEE 519-1992
• Chapter 11
– Addresses THD(V) delivered by utility to user – THD(V) must be < 5% [< 69 KV systems]
• Chapter 10
– – – – Defines the amount of TDD a user can cause Based upon Demand Load & System Fault Level Table 10.3 for systems < 69 kV Defines limits for voltage notches caused by SCR rectifiers – Table 10.2
• Defines PCC (point of common coupling)
Power Quality Correction
IEEE 519-1992 Table 10.2
Limits on Commutation Notches (Applies to SCR rectifiers – only)
Table 10.2 Low-Voltage System Classification and Distortion Limits
*Special Applications Notch Depth THD (Voltage) Notch Area, µVs 10% 3% 16,400 General System 20% 5% 22,800 **Dedicated System 50% 10% 36,500
Note: Notch area for other than 480 V systems should be multiplied by V / 480.
*Special Applications – Airports, Hospitals ** Dedicated System – Dedicated exclusive to converter loads
IEEE 519 - Harmonic Distortion Limits
• Table 11.1 - Voltage Distortion Limits
Bus voltage at PCC 69kV and below 69.001 kV through 161kV 161.001kV and above Max. individual Voltage distortion (%) 3.0 1.5 1.0 Total Voltage distortion THD (%) 5.0 2.5 1.5
The limits listed above should be used as system design values for the “worst case” for normal operation (conditions lasting longer than one hour). For shorter periods, during start-ups or unusual conditions, the limits may be exceeded by 50%.
THD =
∑V
h=2
50
2 h
*100
V1
Power Quality Correction
Total Harmonic Current Distortion Is Same As
Total Demand Distortion (TDD)
∞
I
TDD
=
I
2 2
+ I
3
2
+ I
1
2 4
+L
∑
× 100 % =
h = 2
Ih
2
× 100
1
%
I
I
IEEE 519-1992 Table 10.3
Current Distortion Limits for General Distribution Systems (<69 kV)
Isc/Iload <20 20<50 50<100 100<1000 >1000 <11 4.0% 7.0% 10.0% 12.0% 15.0% 11<=h<17 17<=h<23 23<=h<35 2.0% 1.5% 0.6% 3.5% 2.5% 1.0% 4.5% 4.0% 1.5% 5.5% 5.0% 0.2% 7.0% 6.0% 2.5% h>=35 0.3% 0.5% 0.7% 1.0% 1.4% TDD 5.0% 8.0% 12.0% 15.0% 20.0%
Isc = short circuit current capacity of source Iload = demand load current (fundamental) TDD = Total Demand Distortion (TDD = Total harmonic current distortion measured against fundamental current at demand load.)
Utility
IEEE 519-1992 Chapter 10 states “…Within an • industrial plant, the PCC is the point between the nonlinear load and other loads.”
Other customers PCC 1 PCC 2
Most harmonic problems are not at PCC with utility >Occurs with generators & UPS >Occurs where nonlinear loads are concentrated >Occurs inside the plant Need to protect the user by moving the harmonic mitigation requirements to where harmonic loads are located
Customer 1
Customer 2
Specification Issues
• Write Separate harmonic spec from nonlinear load spec (Section 16)
– Write standard nonlinear load specification – It is System Standard & NOT Product Standard
• Universal solution is more Cost Effective
– Good for all nonlinear loads – Apply AHF per electrical bus (best economics)
•
5% TDD per load or bus inside the plant ?
– IEEE 519-1992 Chapter 10 states “…Within an industrial plant, the PCC is the point between the nonlinear load and other loads.”
• Write TDD specs not THD(I)
Methods For Harmonics Mitigation
**Individual Device Solution •Embedded Solution **System Solution
Individual Device Solution
Harmonic Mitigation Methods
• Typically applied per device: -Isolating Harmonic Loads --Line reactors
– 5th harmonic filters (Only 5th) – Broadband filters (up to 13th) Embedded Solutions: – Multi-pulsing (6-Pulse,18-Pulse) – Active front end (AFE) converter – C-Less Technology
•
System solution
– Active Harmonic Filter – Harmonics Mitigation Transformer (Up to 19th)
Inductors
•Pros:
– – – – Inexpensive & reliable Transient protection for loads Big TDD reduction (90% to 35% w/3% Z) Complimentary to active harmonic control
•Cons:
– Limited reduction of TDD at equipment terminals after 3% Z – Reduction dependent on source
Impedance
Input Current Distortion as a Function of inductor Size Input Current Distortion (%) 80% 70% 60% 50% 40% 30% 20% 10% 0% 0 1 2 3 4 5 Inductor Size (% on Drive Base)
Power Quality Correction
Current Distortion THD(I) or TDD as a function of Rsce With 6-pulse power converter
Multi-pulse Converters
Harmonic Orders Present Hn = NP +/- 1
Hn 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 Harmonics present by rectifier design Type of rectifier 1 phase 2 phase 3 phase 3 phase 4-pulse 4-pulse 6-pulse 12-pulse 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 3 phase 18-pulse
Hn = harmonic order present N,n = an integer P = number of pulses
x x
x x
Harmonic mitigation methods
VFD mitigation topologies
• 6-Pulse converter
DC Link Reactor
Wye
C
4 7
•
12-Pulse converter
+
DC Bus Load
•
A B
18-Pulse converter
Multipulse Transformer A Line Reactor
9 1 2
Rectifier Assembly DC+
8
3
M
AC Line Delta
C
6
5
B
DC-
Delta
Transformer Tertiary
“C-less” or 3% reactance min (if included); small footprint, simplified cabling
A
100 0
Externally mounted 3 winding transformer; more wire and cabling; complicated
A
100 0
Large footprint, more steel & copper (losses)
A
100 0
6 pulse
12 pulse
0.0s 0.02s
18 pulse
Current waveform distorted TDD 30% to 40% with 3% reactor (depending on network impedance)
Current slightly distorted TDD 8% to 15% (depending on network impedance)
Current wave form good TDD 5% to 7% (depending on network impedance)
Multi-Pulse Drives
Description: Drives/UPS with two (12 pulse) or three (18 pulse) input bridges fed by a transformer with two or three phase shifted output windings.
•Pros:
– Reduces TDD to 10% (12 pulse) & 5% (18 pulse) at loads – Reliable
•Cons:
– – – – – High installation cost with external transformer Large footprint (even w/autotransformer) Series solution with reduction in efficiency One required for each product Cannot retrofit
Active Front End Converter
Products with active power converter and input broadband filter to create sinusoidal current & voltage waveforms on AC lines.
A C S o u r c e
VFD
IGBT DC Bus IGBT
Filter
Converter
AC Motor Inverter
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AFE Converters >Pros:
Meets 5% TDD limit of IEEE 519
>Cons:
Mains
Larger and more expensive than 6 pulse drives
Approximately twice the size & price
Mains voltage must be free of imbalance and voltage harmonics
– Generates more harmonics
200 KVA rated AFE VFD PWM VFD DC Drive PF caps
100 KVA rated
Without mains filter THD(V) can reach 40% Requires short circuit ratio > 40 at PCC Switched mode power supplies prohibited Capacitors prohibited on mains IGBT & SCR rectifiers prohibited on same mains
– No other nonlinear loads permitted
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Harmonic mitigation methods (Applied per VFD)
Solution Increase short circuit capacity Advantage Reduces THD(V) Lower TDD Simplified design Less cost Low cost adder Simple Reduces 5th & total TDD Disadvantage Increases TDD Not likely to occur** Compliance is limited Application limited Size limited Compliance difficult Does not meet harmonic levels at higher orders^ Large heat losses Application limited Large footprint/heavy Good for >100 HP Large footprint/heavy Good for >100 HP Large footprint/heavy Very high cost per unit High heat losses Typical % TDD Dependent upon SCR*** Typical Price Multiplier* Cost of transformer and installation change out
C-Less Technology Impedance (3% LR or 5% DC choke) 5th Harmonic filter
30 - 50% TDD 30 - 40% TDD 18 - 22% TDD
0.90 - 0.95 1.05 - 1.15 1.20 - 1.45
Broadband filter
Reduces TDD (thru 13th) Reduces TDD Reliable Reduces TDD Reliable
8 - 15% TDD
1.25 - 1.50
12-pulse rectifiers
8 - 15 % TDD
1.65 - 1.85
18-pulse rectifiers
5 - 8% TDD
1.65 - 1.85
Active front end converter
Very good TDD Regeneration possible
< 5% TDD
2.0 - 2.5
* Price compared to a standard 6-pulse VFD. ** Utilities and users are not likely to change their distribution systems. *** Increasing short circuit capacity (lower impedance source or larger KVA capacity) raises TDD but lowers THD(V). ^ Can be said for all methods listed.
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System Solution
Applied to one or many nonlinear loads
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When wave shapes with different phase shifts are combined
Application of Harmonic Mitigation Transformers
AccuSine® PCS
**Guarantees elimination of harmonic
problems – both TDD and THD(V) ** 2nd through 50th order
5
System Solution
Active Harmonic Filter • Applied to one or many nonlinear loads – VFD, UPS, UV, DC drives, DC power supplies • Provides DPF correction • More cost effective for multiple loads • Saves space • Lower heat Losses
Active Harmonic Filter: System Solution
~
Source Is Ia CT Il L
Load
AHF
•Is + Ia = Il
AHF
•Parallel connected
•Ia includes 2nd to 50th harmonic current •Is <5% TDD
Active Harmonics Filter
I. source
2 1,5 1 0,5 0 -0,5 -1 -1,5 -2 2 1,5 1 0,5 0 -0,5 -1 -1,5 -2
I. Harmonics
I. Active Conditioner
-0,5 0 0,5 1 -1 1,5 -1,5 -2 2 1,5 1 0,5 0 -0,5 -1 -1,5 -2
I. resultant
+
=
I.s
Source
I.ac
active conditioner
57
2
I.h
non linear load
AHF HarmonicsPerformance
At VFD Terminals
Order Fund 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 % TDD AHF off % I fund 100.000% 0.038% 31.660% 11.480% 0.435% 7.068% 4.267% 0.367% 3.438% 2.904% 0.284% 2.042% 2.177% 0.293% 1.238% 1.740% 0.261% 0.800% 1.420% 0.282% 0.588% 1.281% 0.259% 0.427% 1.348% 35.28% AHF on % I fund 100.000% 0.478% 0.674% 0.679% 0.297% 0.710% 0.521% 0.052% 0.464% 0.639% 0.263% 0.409% 0.489% 0.170% 0.397% 0.243% 0.325% 0.279% 0.815% 0.240% 0.120% 0.337% 0.347% 0.769% 0.590% 2.67%
AHF injection
Source current
AccuSine® PCS Overall Performance
Harmonic compensation
2nd through 50th order Includes inter-harmonics Independent of source impedance – Selection and operation same whether on AC line or backup generator or UPS output
Obtain 5% TDD (current distortion) Reactive current injection ( VAR Correction)
Reactive current injection is secondary to harmonic mitigation
Either or both functions VAR compensation
100 µsecond detect-to-inject ½ cycle to full control for step load changes
Dynamic response
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Dual Mode Operation
Ias =
Ih2 + Ir2
Ias = rms output current of AHF Ih = rms harmonic current Ir = rms reactive current
Ias 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 Examples Ih 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 95.0 Ir 99.5 98.0 95.4 91.7 86.6 80.0 71.4 60.0 43.6 31.2
AccuSine® PCS
Advantages
Disadvantages
Highly effective (2nd to 50th orders cancelled) Scalable – Parallel units as needed Universal solution – Handles many loads – Many types of loads at same time HMI & Modbus Communication Best cost for multiple loads – Lowest heat profile Smallest footprint with std VFD/UPS
Heat from high speed switching of IGBT Cost issues possible for single load
Considerations
Load must have input impedance (3%) – Protects load – Limits size of AHF Need branch circuit protection
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AccuSine® PCS Specifications
Universal Application
208 – 480 VAC – No user action required to set 50 or 60 Hz Use highly customized transformers for higher voltages (to 15 kV)
Fuse protected (200,000 AIC) UL 508 & CSA approved CE (EMC) - 400V Logic ride through – 1 to 10 minutes
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Power Diagram For A Typical AHF
IGBT Module
C C C
Pre-charge Contactor
Fuse
E
E
E
S1
S3
S5
AC Lines
Fuse Fuse
Line Inductor
DC Bus Capacitors
+ C
Inductor
C
C
C
Filter Board
S2
E
E
E
S4
S6
Product Package
Standard (UL/CSA, ABS) Three sizes-50A,100A,300A NEMA 1, 1A, 12, & 3R Enclosed – NEMA 1
50 amp – 52” x 21” x 19” – Weight – 250Lbs 100 amp – 69” x 21” x 19” – Weight – 350 Lbs 300 amp – 75” x 32” x 20” – Weight – 775 Lbs
Chassis – IP00 Wall mount – 50 & 100 amp Free standing – 300 amp with disconnect
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Product Package
International enclosures
NEMA 12, IP30, IP54 – 50 amp – 75” x 31.5” x 23.62” – Weight – 661 Lbs – 100 amp – 75” x 31.5”x 23.62” – Weight – 771 Lbs – 300 amp – 91” x 39.37” x 31.5” – Weight – 1212 Lbs Free standing with door interlocked disconnect CE Certified, ABS, UL, CUL
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Product Re-packaging
Maximum ambient into air inlet – 400C Must meet air flow at inlet of AccuSine
50 amp – 300 CFM 100 amp – 500 CFM 300 amp - 1250 CFM 50 amp – 1800 watts 100 amp – 3000 watts 300 amp – 9000 watts On chassis Remote with cable
Heat released
HMI considerations required
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Product Re-packaging
MCC Packaging
50 & 100 amp models only Requires one vertical 20” x 20” section Includes circuit breaker in section
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Comparison of 18-P VFD To AccuSine + 6-P VFD+3%LR
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System Solution
AccuSine® PCS Sizing Example A 125 HP variable torque 6-pulse VFD with 3% LR
Required AHF filtering capability = 47.5 amperes Required AHF size = 84.4 amps Required AHF size = 113.5 amps Required AHF size = 157.6 amps – (not 6 x 47.5 = 285 amps)
Two 125 HP VT 6-pulse VFD w/3% LR
Three 125 HP VT 6-pulse VFD w/3% LR
Six 125 HP VT VFD w/3% LR
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System solution
Comparison of 18-P VFD to AccuSine + 6-P VFD+3%LR Footprint required
AccuSine PCS+ Std VFD less than 18-P VFD (w/autotransformer) for all conditions AccuSine PCS+ Std VFD less than 18-P VFD – Exception at single units of 50-75 HP, advantage 18-P VFD Less site cooling required with AccuSine PCS + Std VFD When more than one VFD, AccuSine PCS + 6-P VFD always beats 18-P VFD If only one VFD involved, 300-500 HP sizes favor 18-P VFD
Heat losses
Less Operating Cost AccuSine PCS+ 6-P VFD
Price ( Installed Cost)
SQ D Software Tool
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AccuSine to18-pulse Comparisons
IR: 10.00% Years: 10
System:
kWH rate: $.10 Days/week: 7 Hours/day: 24
1x 125 HP AccuSine 18-pulse System 35,914.49 31,342.92 9.03 5.02 4,228.22 3,960.89 Advantage: AccuSine 6,257.33 System 2x 125 HP AccuSine 18-pulse System 72,909.11 56,776.63 18.06 7.37 8,456.45 6,885.12 Advantage: AccuSine 26,041.16 System 3x 125 HP AccuSine 18-pulse System 109,363.67 88,590.87 27.09 12.39 12,684.67 10,504.07 Advantage: AccuSine 34,523.50 System 3x 150 HP AccuSine 18-pulse System 116,681.51 96,415.47 27.09 12.39 15,253.06 12,198.66 Advantage: AccuSine 39,526.83 system 2x 150 HP AccuSine 18-pulse System 77,787.68 78,288.60 18.06 10.03 10,168.70 8,598.35 Advantage: AccuSine 9,401.64 system 3x 200 HP AccuSine 18-pulse System 151,521.89 117,574.82 27.09 12.39 19,603.58 14,125.78 Advantage: AccuSine 68,489.71 System 1x 150 HP AccuSine 18-pulse System 38,893.84 43,866.16 9.03 5.02 5,084.35 4,342.66 Advantage: -295.25 18-pulse 2x 200 HP AccuSine 18-pulse System 101,014.59 86,099.03 18.06 10.03 13,069.06 10,132.22 Advantage: AccuSine 33,435.03 System 3x 300 HP AccuSine 18-pulse System 186,321.52 139,746.79 54.17 20.84 27,859.10 23,563.31 Advantage: AccuSine 73,663.68 system 1x 200 HP AccuSine 18-pulse System 50,507.30 47,771.37 9.03 5.02 6,534.53 5,102.25 Advantage: AccuSine 11,767.77 System 2x 300 HP AccuSine 18-pulse System 124,214.34 110,330.12 36.11 15.34 18,572.74 16,664.58 Advantage: AccuSine 25,916.93 system 3x 400 HP AccuSine 18-pulse System 212,625.00 190,969.18 54.17 23.49 36,350.50 29,184.76 Advantage: AccuSine 66,842.42 system 1x 300 HP AccuSine 18-pulse System 62,107.17 71,451.53 18.06 10.81 9,286.37 8,428.81 Advantage: -4,277.20 18-pulse 2x 400 HP AccuSine 18-pulse System 141,750.00 127,318.85 36.11 15.34 24,233.66 20,373.23 Advantage: AccuSine 38,774.77 system 3x 500 HP AccuSine 18-pulse System 233,887.50 247,668.92 54.17 25.20 45,995.04 35,958.34 Advantage: AccuSine 49,509.34 system 1x 400 HP AccuSine 18-pulse System 70,875.00 89,389.61 18.06 10.81 12,116.83 10,178.29 Advantage: -6,290.32 18-pulse 2x 500 HP AccuSine 18-pulse System 155,925.00 173,686.31 36.11 18.00 30,663.36 24,273.86 Advantage: AccuSine 22,540.43 system 1x 500 HP AccuSine 18-pulse System 77,962.50 99,703.69 18.06 10.81 15,331.68 11,968.30 Advantage: -531.93 18-pulse
User Price Sq Ft Annual operating costs
NPV Cash Flow System:
User Price Sq Ft Annual operating costs
NPV Cash Flow System:
User Price Sq Ft Annual operating costs
NPV Cash Flow
AccuSine® PCS Installation Considerations
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AHFInstallation Considerations
Main – Left
Main-tie-main
Tie
Main – Right
CBml CTml CTtl CTtr CTmr CBar
CBmr
CBal
AHF- L
AHF-R
This configuration provides individual AHF operation per side regardless of breaker positions.
AHF Installation Considerations
Utility Main Power CB CTm CBa CTg Generator
~
Generator CB
Regardless of Main Power CB and Generator CB positions, AHF limits harmonics for both sources.
AHF
AccuSine PCS Limitations
• 3-Phase / 3-Wire design only
– Does not help neutral harmonics
• “Sine-Wave” Product for
3-Phase / 4-Wire System
AccuSine Selection
• Use Spreadsheet—SQ D Software • No Harmonics Analysis required • Information Required for Sizing: * One Line * All VFDs Details—HP & CT or VT * All Linear Loads Details-HP/KW * Other Non-Linear Loads—UV / OG * If DPF Correction is required. * Both LV & MV Bus * Add 3% LR for all Non-Linear Loads
Generator & Harmonics Load
Generator Feeding Nonlinear Loads
• • • • • •
Soft Source High Impedance with limited over load capacities High Impedance produces excessive THDv High THDv directly affects Voltage Regulation Many existing Generators with old Regulator Design can fail High THDv affects Electronics Loads & can fail
Power Quality Correction
Voltage distortion THD(V) as a function of RSCE with 6-pulse power converter
Generator Feeding Nonlinear Loads
*Harmonics Current Generates Excessive Heating
in the Windings *Derating of Generator needed with Nonlinear Loads
Generator Feeding Nonlinear Loads: AccuSine Advantages
*Helps Generator runs “Cooler” *Helps Voltage Regulation *Helps Older Existing Generators in the Field *Helps Retrofits– Space & Generator Rating *Helps Environment
Solution Approach
Measure
Supply & Commission
Solution Cycle
Simulate
Specify & Propose
Analyze & Report
Power Quality Correction
Thank You ! Questions?
For More Information, Please Contact:
B. Ben Banerjee Power Quality Correction Group Schneider Electric San Francisco Field Office Direct: 925-463-7103 Cell: 925-858-2182 E-mail: [email protected]
