Harmonic Analysis and Power Factor Harmonic Analysis and Power Factor
Correction Evaluation Correction Evaluation
Plastic Creations Line 13 Plastic Creations Line 13 Prepared by: Electrotek Concepts, Inc. Knoxville, TN www.electrotek.com Wade Eckler Power Systems Engineer Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. ii - Table of Contents - Executive Summary______________________________________________________1 1.0 I ntroduction_________________________________________________________2 One Line Diagram___________________________________________________________ 2 2.0 Field Measurements at Newtown ________________________________________3 2.1 AC Drive Characteristics Roll 1 _________________________________________ 3 AC Drive Characteristics Roll 2 ______________________________________________ 4 2.2 AC Drive Characteristics Kneader B_____________________________________ 6 Overall Load Characteristics Line 13 __________________________________________ 7 2.3 Voltage Distortion Evaluations ___________________________________________ 9 3.0 Recommended Power Factor Correction _________________________________13 3.1 Summary of Reactive Power Requirements ________________________________ 13 4.0 Proposed Filter Design _______________________________________________14 Appendix A: Low Voltage Power Factor Correction Equipment Manufacturers ____16 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 1 Executive Summary The Plastic Creations in Newtown has a new Line 13 with ac variable frequency drives for the calender line. The drives have high harmonic current levels but do not require the level of power factor correction that dc drives require. This evaluation characterizes the loads on Line 13. Power factor correction needs are calculated and the impact of the existing capacitor bank (provides about 600 kvar of compensation) is illustrated. The capacitor increases distortion levels at the 7 th and 11 th harmonics, resulting in overall voltage distortion levels exceeding 5% on the 480 volt system. Although this should not cause problems for now, the distortion levels are likely to be unacceptable with additional loading from Line 14. Also, the capacitor creates the potential for magnified transient voltages if the utility switches capacitor banks on the transmission system. The capacitor should be converted into a tuned filter and it should be able to provide power factor correction for the existing Line 13 (correction to a power factor of about unity) and should also be sufficient even after the addition of Line 14 (power factor around 0.97). Specifications for the reactor to tune this bank are provided here. 480 Volt Bus Tuned Capacitor Bank Capacitor Bank: 937.5 kvar 600 volts Inductors: 0.046 mH per phase rms current rating = 1100 amps 5th harmonic current rating = 775 amps Circuit Breaker: 480 Volt, 2000 A Proposed Filter Configuration for Line 13 and Line 14 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 2 1.0 Introduction The Plastic Creations plant in Newtown has a new Line 13 with a dedicated transformer. Line 13 includes ac variable frequency drives instead of the dc drives that are used on other Plastic Creations lines. This has a dramatic impact on the power factor characteristics of the load. The ac drives have much better displacement power factor (not as much compensation needed) but have significant harmonic distortion levels. The measurements and recommendations presented in this report deal with the power factor correction and filtering requirements for this line, including the impact of a future Line 14 with similar characteristics to Line 13. One Line Diagram Utility 13.8 kV Feeder from138 kV substation 3750 kVA, 7.0 % 13.8 kV/480 volts 937.5 kvar 600 volts H110 Kneader 13-2 Calender Controls (Protected by 24 kVA UPS) MCC7 H22 H111 Kneader 13-1 H112 Mixer Grinders Calender Heaters H113 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 3 2.0 Field Measurements at Newtown Measurements were taken to characterize the ac drive loads and the overall load characteristics for Line 13. The measurements also evaluated the impact of the existing capacitor bank on distortion levels on the 480 volt system supplying Line 13. 2.1 AC Drive Characteristics Roll 1 The following waveforms and harmonic spectrums are typical for Roll 1. This is also typical for Roll 3. Event waveform/detail Pre/Post-trigger at 02/25/98 11:32:34.312 CHA Amps 11:32:34.31 11:32:34.32 11:32:34.33 11:32:34.34 11:32:34.35 11:32:34.36 11:32:34.37 11:32:34.38 Amps -150 -100 -50 0 50 100 150 Event waveform/detail Total RMS: 61.27 Amps Total harmonic distortion: 32.52 Amps Even contribution (H02-H50): 1.31 Amps Odd contribution (H03-H49): 32.50 Amps Pre/Post-trigger at 02/25/98 11:32:34.362 CHA Amps THDabs H05 H10 H15 H20 H25 H30 Amps 0 10 20 30 40 50 60 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 4 AC Drive Characteristics Roll 2 The following waveforms and harmonic spectrums are typical for Roll 2. This is also typical for Roll 4. Event waveform/detail Timed event at 02/25/98 12:48:18.000 CHA Amps 12:48:18.000 12:48:18.005 12:48:18.010 12:48:18.015 12:48:18.020 Amps -300 -200 -100 0 100 200 300 Event waveform/detail Total RMS: 123.67 Amps Total harmonic distortion: 56.36 Amps Even contribution (H02-H50): 0.45 Amps Odd contribution (H03-H49): 56.37 Amps Timed event at 02/25/98 12:48:18.000 CHA Amps THDabs H05 H10 H15 H20 H25 H30 Amps 0 25 50 75 100 125 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 5 Example waveform and spectrum from BMI 3030 Roll 2 Current Waveform 0 10 20 30 40 -200 -100 0 100 200 Time (mS) Roll 2 Harmonic Characteristics 0 10 20 30 40 0 20 40 60 80 100 Frequency (H pu) Freq : Fund : THD : TID : TD : RMSh : RMSi : RMSfh: RMS : ASUM : TIF : IT : 1 89.5784 52.7698 0 52.7698 47.2703 0 101.286 101.286 179.963 454.674 46051.9 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 6 2.2 AC Drive Characteristics Kneader B The following waveforms and harmonic spectrums are typical for Kneader B. This is also typical for Kneader A. Event waveform/detail Snapshot event at 02/25/98 14:53:43.000 CHA Amps 14:53:43.000 14:53:43.005 14:53:43.010 14:53:43.015 14:53:43.020 Amps -750 -500 -250 0 250 500 750 Event waveform/detail Total RMS: 224.85 Amps Total harmonic distortion: 98.85 Amps Even contribution (H02-H50): 9.78 Amps Odd contribution (H03-H49): 98.38 Amps Snapshot event at 02/25/98 14:53:43.000 CHA Amps THDabs H05 H10 H15 H20 H25 H30 Amps 0 50 100 150 200 250 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 7 Overall Load Characteristics Line 13 The following summarizes the overall load characteristics for Line 13. This includes the ac drives characterized in the previous sections along with the calender heaters and other loads that are part of the Line. This information can be used for evaluating harmonic filter and power factor correction requirements. The table also illustrates the effect of the existing capacitor bank on the distortion levels and the power factor. Note that the 7 th harmonic is significantly increased when the capacitor bank is in service and the voltage distortion often exceeds 5%. The current distortion increases to more than 30% with 20% at the 7 th harmonic. This is an indication of the magnification at the 7 th harmonic component. Current 1300-1800 amps 1300-1600 amps Power 1.1-1.3 MVA 1.0-1.1 MVA kvar 480-500 kvar 150-180 kvar lead PF .88-.90 0.95 dPF .88-.91 0.99 lead THDv 2.9-3.2 % 4.5-5.9 % THDi 15-17 % 25-32 % V5 1.9-2.0 % 2.5 % I5 12-13 % 19 % V7 1.8 % 3.2 % I7 8-9 % 20 % No Cap Bank with Cap Bank Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 8 The following waveform and harmonic spectrum represent typical load characteristics for Line 13 (without the capacitor bank). Line 13 Current Waveform 0 10 20 30 40 -3000 -2000 -1000 0 1000 2000 3000 Time (mS) Line 13 Current Harmonic Spectrum 0 3 6 9 12 15 0 250 500 750 1000 1250 1500 1750 Frequency (H pu) Freq : Fund : THD : TID : TD : RMSh : RMSi : RMSfh: RMS : ASUM : TIF : IT : 1 1529.89 14.4941 0 14.4941 221.744 0 1545.87 1545.87 1939.89 85.7982 132633 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 9 2.3 Voltage Distortion Evaluations The following measurement results summarize the voltage distortion concerns at the 480 volt bus supplying Line 13. Voltage Characteristics without Capacitor Bank Typical voltage waveforms and spectrums are provided below without the capacitor bank in service. The distortion is dominated by the 5 th harmonic component since that is the highest current injection from the drive loads. Event waveform/detail Total RMS: 464.93 Volts Total harmonic distortion: 15.76 Volts Even contribution (H02-H50): 2.68 Volts Odd contribution (H03-H49): 15.54 Volts Snapshot event at 02/25/98 15:48:40.000 CHA Volts THDabs H05 H10 H15 H20 H25 H30 Volts 0 100 200 300 400 500 Event waveform/detail Snapshot event at 02/25/98 15:48:40.000 CHA Volts 15:48:40.00 15:48:40.01 15:48:40.02 15:48:40.03 15:48:40.04 15:48:40.05 15:48:40.06 15:48:40.07 Volts -750 -500 -250 0 250 500 750 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 10 Voltage Characteristics with Capacitor Bank Typical voltage waveforms and spectrums are provided below after the capacitor bank was switched in. The capacitor creates a resonance between the 7 th and 11 th harmonics, magnifying both of these components. The voltage distortion levels are increased overall and can exceed 5%. The highest distortion is typically at the 7 th harmonic with the capacitor bank in due to the magnification. Event waveform/detail Meter mode snapshot at 02/25/98 16:20:59.000 CHA Volts 16:20:59.000 16:20:59.005 16:20:59.010 16:20:59.015 16:20:59.020 Volts -750 -500 -250 0 250 500 750 Event waveform/detail Total RMS: 473.33 Volts Total harmonic distortion: 24.32 Volts Even contribution (H02-H50): 0.59 Volts Odd contribution (H03-H49): 24.33 Volts Meter mode snapshot at 02/25/98 16:20:59.000 CHA Volts THDabs H05 H10 H15 H20 H25 H30 Volts 0 100 200 300 400 500 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 11 Comparison of Voltage Characteristics The figure below shows the THD of the voltage on the Line 13 Main Bus and the values of the 5 th , 7 th , 11 th , and 13 th harmonic as percentages of the fundamental with the capacitor bank on line and with it off line. The chart makes it easier to see how placing the capacitor bank on line at the Line 13 Main Bus magnifies the 7th and 11th harmonics. The 7 th harmonic is virtually non-existent, at 0.02% of the fundamental, with the capacitor bank off line. The 11 th harmonic was measured at 0.75% without the capacitor banks. After placing the capacitor banks on line, the 7 th increases to 3.73% and the 11 th increases to 2.23% of the fundamental. Line 13 Main Bus 0.00 1.00 2.00 3.00 4.00 5.00 6.00 THDv 5th 7th 11th 13th Harmonic V o l t a g e
D i s t o r t i o n
( % ) No Caps With Caps Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 12 Description of the Resonance Problem The capacitor bank introduces a resonance between the 7 th and 11 th harmonics that magnifies both of these components. The frequency scan below illustrates the voltage at the 480 volt bus per amp injected by the drive loads with and without the capacitor bank in service. Frequency Scan with and Without Capacitor Bank 0.00 3.00 6.00 9.00 12.00 15.00 18.00 21.00 24.00 27.00 0.0 0.1 0.2 0.3 0.4 Frequency (H pu) This problem can be avoided by converting the capacitor bank into a tuned filter. The frequency scan plots below show the effect of the tuned filter in preventing resonances close to the characteristic harmonics of the drive loads (5 th and 7 th ). Frequency Scan Showing Effect of Filter 0.00 3.00 6.00 9.00 12.00 15.00 18.00 21.00 24.00 27.00 0.0 0.1 0.2 0.3 0.4 Frequency (H pu) Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 13 3.0 Recommended Power Factor Correction This section summarizes the power factor correction needs for the existing configuration with Line 13 and estimates the impacts of a similar line (Line 14) in the future. 3.1 Summary of Reactive Power Requirements The following table summarizes the load characteristics measured for Line 13 and shows the impact of the 600 kvar of compensation on the power factor of the overall load. The table also shows the effect of this capacitor bank if the load is doubled to include the effect of Line 14 in the future. The power factor with just Line 13 is corrected to unity with the existing capacitor bank. With Line 14, the capacitor bank will correct the power factor to about 0.97 lagging when both lines are running. Line 13 Line 13 and Line 14 Transformer Size 3750 3750 Transformer Impedance 7% 7.00% Peak Load (kVA) 1300 2600 Displacement Power Factor 0.9 0.9 Reactive Power (kvar) 567 1133 Real Power (kW) 1170 2340 Compensation (kvar) 600 600 Total Reactive Power with Compensation (kvar) -33 533 Power Factor with Compensation 1.00 0.97 Fifth Harmonic Current (%) 15% 15% The capacitor should be configured as a tuned bank to prevent excessive distortion and problems with magnification of capacitor switching transients. The next section gives parameters for the tuning reactor. Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 14 4.0 Proposed Filter Design Plastic Creations has already purchased a capacitor bank for power factor correction. The capacitor is rated 600 volts so it can easily be used as part of a tuned filter. The proposed filter design is illustrated in the one line diagram below. The following page gives the specifications for the filter reactor that should be purchased. 480 Volt Bus Tuned Capacitor Bank Capacitor Bank: 937.5 kvar 600 volts Inductors: 0.046 mH per phase rms current rating = 1100 amps 5th harmonic current rating = 775 amps Circuit Breaker: 480 Volt, 2000 A Proposed Filter Configuration for Lines 13 and 14 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 15 Low Voltage Filter Calculations: 600 kvar 480 Volt Filter
SYSTEM INFORMATION: Filter Specification: 5 th Power System Frequency: 60 Hz Capacitor Bank Rating: 937.5 kVAr Capacitor Rating: 600 Volts Rated Bank Current: 902 Amps 60 Hz Nominal Bus Voltage: 480 Volts Derated Capacitor: 600 kVAr Capacitor Current (actual): 721.7 Amps Total Harmonic Load: 2500 kVA Filter Tuning Harmonic: 4.7 th Filter Tuning Frequency: 282 Hz Cap Impedance (wye equivalent): 0.3840 Cap Value (wye equivalent): 6907.8 uF Reactor Impedance: 0.0174 Reactor Rating: 0.0461 mH Filter Full Load Current (actual): 755.9 Amps Supplied Compensation: 628 kVAr Filter Full Load Current (rated): 944.9 Amps Transformer Nameplate: 3750 kVA Utility Side Vh: 2.00 % THD (Rating and Impedance) 7.00 % (Utility Harmonic Voltage Source) Load Harmonic Current: 20.00 % Fund Load Harmonic Current: 601.4 Amps Utility Harmonic Current: 175.5 Amps Max Total Harm. Current: 776.9 Amps CAPACITOR DUTY CALCULATIONS: Filter RMS Current: 1084.0 Amps Fundamental Cap Voltage: 502.8 Volts Harmonic Cap Voltage: 103.3 Volts Maximum Peak Voltage: 606.1 Volts RMS Capacitor Voltage: 513.3 Volts Maximum Peak Current: 1532.8 Amps CAPACITOR LIMITS: (IEEE Std 18-1980) FILTER CONFIGURATION: Limit Actual Peak Voltage: 120% 101% Current: 180% 120% KVAr: 135% 103% RMS Voltage: 110% 86% FILTER REACTOR DESIGN SPECIFICATIONS: Reactor Impedance: 0.0174 Reactor Rating: 0.0461 mH Fundamental Current: 755.9 Amps Harmonic Current: 776.9 Amps 4 8 0 Vol t Bus 6 0 0 kVAr @ 6 0 0 Vo l ts Xl = 0 . 0 2 7 2 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 16 Appendix A: Low Voltage Power Factor Correction Equipment Manufacturers ABB Steve Colvin 1206 Hatton Road Wichita Falls, TX 76302 817-761-3232 / 817-761-3202 Aerovox Group John Childs 740 Belleville Ave. New Bedford, MA 02745-6194 508-994-9661 / 508-990-8696 ASC Industrial Bruce Marzley / Larry Burch / Chuck Gougler 8967 Pleasantwood Ave NW North Canton, OH 44720 216-499-1210 / 216-499-1213 Commonwealth Sprague Frank Smith Brown Street North Adams, MA 01247 413-664-4466 / 413-664-4465 Controllix Paul Griesmer 21415 Alexander Road Walton Hills, OH 44146 216-232-8757 / 216-232-1893 Freeborn Industries Rudy Wodrich / Kevin Simpson 6675 Rexwood Road Mississauga, Ontario L4V 1V1 Canada 905-677-9272 / 905-677-5448 General Electric Peter Baltz 14131 Midway Road, Suite 500 Dallas, TX 75244 214-702-5274 / 214-702-5283 Gilbert/K&M Neal Ciurro / Jess Hancock P.O. Box 1141 Beckly, WV 25802 304-252-6243 / 304-252-6292 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation Electrotek Concepts, Inc. 17 Macroamp Lesat Bob Stuefen / Allan Freebury P.O. 1512 Ukiah, CA 95482 707-462-2222 / 707-462-3068 Myron Zucker Jim Holley 315 East Parent Street Royal Oak, MI 48067 810-543-2277 / 810-543-1529 Robicon Dennis Lorenzi 100 Sagamore Hill Road Pittsburgh, PA 15239-2982 412-325-7260 / 412-733-8093 TCI J. P. Thorpe 7878 North 86th St. Milwaukee, WI 53224 414-357-4480 / 414-357-4480 Tech-Tran Corp Ted Furst / Charles Roney 50 Indel Avenue Rancocas, NJ 08703 800-257-9420 / 609-267-6751 VAR+Controls Bill McConnell Mail Box 585 Whitmore Lake, MI 48189 800-KILOVAR / 313-449-8710 Versatex Industries Ted Noutko P.O. Box 354 Brighton, MI 48116 810-229-5751 / 810-229-7863