Harmonic Solutions A Side-by-Side Comparison

Presented by: Dan Carnovale; P.E. danieljcarnovale@eaton.com Eaton Corporation

2008 Eaton Corporation. All rights reserved.

Overview
Harmonic Overview Lab Introduction Alternate Source/Generator Issues Harmonic Solutions Lab Simulations Energy Savings and Harmonic Solutions Harmonic Resonance Wrap Up

Which came first?..

Voltage Distortion Current Distortion In this casethe Egg!

Current distortion causes Voltage distortion Voltage distortion is created by pulling distorted current through an impedance Amount of voltage distortion depends on:
System impedance Amount of distorted current pulled through the impedance If either increases, VTHD will increase
3

Internal vs. External Sources

Some harmonic sources are internal
VFDs, switch mode power supplies, etc.

Other harmonic sources are external

Customers sharing the same line

Is the voltage distortion caused by you or your neighbor?

Establish a baseline (your neighbors load) Determine the incremental change (your load)

Harmonic Limits IEEE Std. 519-1992

Utility is responsible for providing clean voltage Customer is responsible for not causing excessive current harmonics Utility can only be fairly judged if customer is within its current limits

Harmonic Limits - System Issues

Actual measurements at 480 V main breaker system with large variable-frequency drives

Voltage distortion at no load is 4%!

Sources of Harmonics
General sources of harmonics
Power electronic equipment (drives, rectifiers, computers, etc.) Arcing devices (welders, arc furnaces, florescent lights, etc.) Iron saturating devices (transformers) Rotating machines (generators)

Most prevalent and growing harmonic sources:

Adjustable frequency drives (AFD) Switch-mode power supplies (computers) Fluorescent lightning

Single loads or groups of loads

Harmonic Producing Loads

Xs

XT 480 V

Electronic Ballast

M M M
8

Welder

+ -

UPS

Harmonic Symptoms/Concerns
Equipment Failure and Misoperation
Notching (electronic control malfunctioning, regulator misoperation) Overheating/Failure (transformers, motors, cables/neutral) Nuisance Operation (fuses, breakers) Insulation deterioration Audible noise in electrical equipment

Economic Considerations
Oversizing (equipment is sized larger to accommodate harmonics) Losses/Inefficiencies/PF Penalties Inconsistent meter reading

Application of Power Factor Correction Capacitors

Harmonics and Heating

Load 100% Harmonics

Std Transformer Max Temp 176 F

10

HMT Max Temp 105 F

Power Quality Lab Harmonic Capabilities

Overview of Lab and Capabilities
Purpose
To demonstrate and Test PQ Problems and Solutions Power Quality solutions, especially harmonic solutions, are difficult to understand Demystify solutions mis-information and confusion regarding PQ and energy savings

Equipment (Harmonic Related)

18 Pulse Drives HMTs Active Filters Broadband Filters Passive (Fixed) Filters 3rd Harmonic Filter Passive (Switched) Filters Drive Transformers Active Rectifier (UPS) K-Rated Transformers Reactors Load Banks/Drives
11

Power Quality Experience Center and Lab

Full Scale Power System for Demonstrating and Testing PQ Problems and Solutions

12

General Layout
Main Power System Commercial Power System Industrial Power System Residential Room Data Center Room Medium Voltage Room

13

Drives

14

Harmonic Loads Commercial System

15

Harmonic Loads Industrial System

16

Examples of Testing
Active Filters (5 tested) Harmonic (Direction) Meter 20 Scenarios Harmonic Mitigating Transformers (40 tested) Black Box Solutions for Energy Savings

17

Alternate Sources
Normal Alternate (18% impedance to simulate a generator) EPRI Sag Generator (200 A)

18

Harmonics and Generators

Generator Concerns
Generator impedance (16-18%) is generally 3-4 times the equivalent source transformer (5-6%)

Utility Souce 4.4% Vthd

Generator Source 13% Vthd Same Load

19

Harmonics and Generators Case #1

Example Generator Sync Failure
Generator 1 (Loaded) Generator 2 (Unloaded)

20

Harmonics and Generators Case #1

Example Generator Sync Failure
Blue (top) = Generator 1 Bus Voltage Red (bottom) = Sync Check Voltage Generator #1 (Loaded) vs. Generator #2 (Unloaded) Blue (top) = 120 V Filtered Sync Check Input from Generator 1 Red (bottom) = 480 V Generator Bus Voltage

Solution: Series-rated surge protector/ring-wave filter

21

Harmonics and Generators Case 2

Generator Filter UPS Filter On/Off Utility Source
Harmonic Filter ON

Generator Source
Harmonic Filter ON Harmonic Filter OFF

22

Harmonic Solutions
Oversized Generator
Xs

480 V

Low Distortion Electronic Ballast

HMT

Broadband Filter Active Rectifier or 18 Pulse

Active Filter

XT

12 Pulse

HMT

Filter

Active Rectifier, Filter or 12 Pulse UPS

+ -

PF Corrected

23

Harmonic Solutions - Commercial

Commercial/Data Center Systems
UPS Filter UPS Active Front End (Rectifier) Harmonic Mitigating Transformers K-Rated Transformers 3rd Harmonic Blocking Filter
Low Distortion Lighting Ballasts PF Corrected Power Supplies

Low Distortion Loads

24

PF Corrected Power Supplies

Data Centers/Servers
Switch Mode Power Supplies (SMPS) have changed over to PF Corrected Power Supplies

Industry driven toward component (load) solutions

25

Rectifier Solutions
Drives, UPS, Battery Chargers
Active front end on UPS and some drives

Industry driven toward component (load) solutions

26

Harmonics and Cancellation

More load/less harmonics cancellation or higher source impedance?

Two SMPS 75 kVA transformer Two SMPS high impedance source Like adding a large line reactor in front of a drive (changes current waveshape) High impedance (low resistance) is helpful in most cases to reduce harmonic currents (although voltage may flat top)

27

Neutral Heating Oversize Equipment

10A at 180 Hz 10A at 60 Hz

A B C N

10A at 180 Hz 10A at 60 Hz 10A at 180 Hz 10A at 60 Hz

0A at 60 Hz 30A at 180 Hz

28

3rd Harmonic Summation in Neutral

29

3rd Harmonic Summation in Neutral

30

3rd Harmonic Blocking Filter

Application of 3rd Harmonic Blocking Filter addresses the most dominant harmonic in the distribution system. Makes the current waveshape significantly more linear K-rating the transformer is no longer necessary. Most appropriate for retrofit
60 40

20 Amps

-20

-40

-60 Time

Linear Load Non-Linear Load Non-Linear Load with HSS

31

3rd Harmonic Blocking Filter

32

3rd Harmonics and Delta/Wye Transformers

Third harmonic current flowing in the phases adds up in the neutral. On the primary, the third harmonic current is trapped in the delta if it is balanced. Otherwise, the difference flows in the phases. Balanced third harmonic currents are called triplen harmonic currents (3rd, 9th, etc.). Delta-wye transformers are said to trap triplen harmonic current in the delta. They do not eliminate other harmonics.

WYE CONNECTION

3rd Harmonic Currents Couple

33

Transformers and Harmonics (HMTs)

5th & 7th harmonics Use different secondary winding to treat these Use PhaseShifting to treat these

Triplen Harmonics
34

Transformers and Harmonics (HMTs)

5th & 7th harmonics Use different secondary winding to treat these Use PhaseShifting to treat these

Triplen Harmonics
35

Secondary Treatment of Triplens (HMTs)

Harmonic Mitigating Transformer (HMT)
HMT Secondary

ZIG-ZAG CONNECTION

Currents Couple

Opposing magnetic fields triplens arent magnetically coupled to primary Loads continue to operate as designed Minimizing impact on electrical infrastructure
36

Transformer Testing Affect of Harmonic Load

Load Banks 480 In

Meter Box (Wall)

Input Output

Meter Cart

120 Out 480 In

Transformer

37

Transformer Family Testing Affect of Harmonic Load on Efficiency

Efficiency Testing for 75 kVA Family with 100% Harmonic Load
99.000% 98.000%

97.000%

% Efficiency

96.000%

95.000%

94.000%

93.000%

92.000%

91.000% K-13 HMT Standard TP-1

15 94.74% 97.85% 95.58% 97.83%

25 96.29% 98.41% 96.95% 98.13%

35 96.81% 98.51% 97.39% 98.18%

50 97.09% 98.40% 97.45% 98.01%

75 96.98% 98.08% 97.15% 97.63%

100 96.64% 97.70% 96.63% 97.00%

Nominal % of Full Load

38

Transformer Testing Affect of Harmonic Load vs. Resistive Load

Transformer Efficiency - 75 kVA Example
0.99

0.985

0.98

0.975

0.97

0.965

0.96 Resistive Load 100% Harmonic Load 0.955 15 25 35 % Load 50 75 100

39

Harmonic Solutions Industrial

Industrial System (Drives and Rectifiers)
Line Reactors Drive Isolation/Harmonic Mitigating Transformers Tuned Filters LV/MV Fixed/Switched De-Tuned Filters Static Switched (Transient Free) Filters Harmonically Hardened Capacitors Active Filters Clean Power (18 Pulse) Drives Broadband Drive Filters Active Rectifier Drives
40

Drive and Rectifier Solutions

Drive without line reactor

41

Drive with line reactor

Effect of Drive Line Reactors

Effect of Line Reactors
100% 0.5% 3.0% 5.0%

Current - % of Fundamental

80%

60%

40%

20%

0% 1 3 5 7 9 11 13 15 17 19

Harmonic Order
42

Reactor/Isolation Transformer
w/ isola trans
Order 1 3 5 7 11 13 17 19 Magnitude 33.41 0.90 9.92 2.00 1.87 1.10 0.67 0.67 Angle -16 -186 101 -182 -154 -127 -70 -50

w/o isola trans

Order 1 3 5 7 11 13 17 19 Magnitude 33.41 0.60 15.97 7.48 1.77 1.40 0.87 0.57 Angle -14 -160 114 -110 -89 -1 60 122

43

Total Current
Fundamental = 100% Fundamental = 100% Harmonic = 20%
Total = 102

Harmonic = 100%

To

ta l

14

1%

44

Phase Shifting/Cancellation
12 Pulse, 18 Pulse or 24 Pulse Cancellation by Design

#1

#2

45

Video Demonstrations
www1.eatonelectrical.com/pqlab/pqvideos 4 drives without phase shifting 4 drives with phase shifting (24 pulse system) Active Fitler 18 pulse (clean power) drive Tacoma Narrows Bridge

46

Phase Shifting/Cancellation
Without Cancellation

With Cancellation

47

18 Pulse Rectifier
18 Pulse Design
Voltage

Current

48

Drive/UPS Dedicated Filter

Standard Drive Drive with Dedicated Filter

49

Harmonics and Motor Heating

Xs

XT

M
Linear Load (Motor) Draws Non-60Hz (Harmonic) Current
50

Distorted Current Causes Distorted Voltage

Motor Heating and Vibrations

Motor Heating Vibrations System Losses

51

Reducing Harmonics Saving Money

How can reducing harmonics save you money?
Physical damage from overheating and misoperation Energy savings HVAC savings Oversizing equipment / Release Capacity Motor failure or overheating Low PF

52

Harmonics and Energy Efficiency

EPRI Presentation You can only save energy that is wasted Infrastructure (system) losses are generally 1-4%
Saving 25% of your losses is not equal to saving 25% of your energy bill (ex: 25% X 2% = 0.5% of your bill)

UPS losses may be 2-10% or more PQ solutions are often sold as energy-saving New (2007) Federal Requirements for Transformer Efficiency

53

Cost of Harmonic Correction

Description
Reactor Capacitors (LV) Filter (MV) Filter (MV) Switched K-Rated Transformer Capacitors (LV) Switched Filter (LV) Filter (LV) Switched Harmonic Mitigating Transformer Blocking Filter (3rd's) Broadband Filter (Drives) Active Filter

Cost $/kVA
3 12 12 15 20 25 35 45 50 100 100 150

Cost p.u.
1 4 4 5 7 8 12 15 17 33 33 50

Per unit costs compared to reactor pricing Note that prices are generalized for comparison only Some equipment must be fully rated for loads - others can be partially rated Capacitors are shown for reference only

54

Harmonic Resonance

On November 7, 1940, at approximately 11:00 AM, the Tacoma Narrows suspension bridge collapsed due to wind-induced vibrationsthe bridge had only been open for traffic a few months.
55

Harmonic Resonance
The Self Correcting Problem
Blown Fuses Failed Capacitors Damaged Transformer

Harmonics = Wind (Excites Resonance)

56

Harmonic Resonance
hR = kVASC kVARCAP
1500 kVA 5.0% 480 V Xs

500 HP

200 HP Drive Source of Harmonics

600 kvar Capacitor

57

Harmonic Resonance - Solutions

1. Change the method of kvar compensation (harmonic filter, active filter, etc.) 2. Change the size of the capacitor bank to over-compensate or under-compensate for the required kvar and live with the ramifications (i.e. overvoltage or PF penalty).

58

Harmonic Resonance Switched Capacitor

Parallel Resonant Frequencies for Various Capacitor Sizes
600 500 400 300 200 100 0 0 0 5 10 15 20 25 Harmonic Order 500 450 Capacitor Size 400 350 300 250 200 150 100 50

59

Harmonic Resonance SKM Output

Plot1 - Distortion Waveform
- - Case 2 - 300 kVAR - Capacitor Fdr - Branch D - - Case 1 - 200 kVAR - Capacitor Fdr - Branch D
Branch Distortion Current Waveform (pu)

- - Case 3 - 5th Filter - Capacitor Fdr - Branch

2 1 0 -1 -2

50

100

150 200 250 Time (1 Cycle) or 0-360 degrees

300

350

Plot1 - Distortion Spectrum

- - Case 2 - 300 kVAR - Capacitor Fdr - Branch D - - Case 1 - 200 kVAR - Capacitor Fdr - Branch D 1.00
Branch Distortion Current Spectrum (pu)

- - Case 3 - 5th Filter - Capacitor Fdr - Branch

0.75

0.50

0.25

0.00 1 2 3 4 5 6 7 8 9 10 Harmonic Order 11 12 13 14 15 16 17

60

Wrap Up
Most people are visual learners the PQ Lab allows for first hand learning of complicated subjects like harmonics. Varied experience and knowledge require varied demonstrations (Residential, Data Center, Industrial, Commercial, Utility) Comparing results from one harmonic solution vs. another reinforces decision making Technical solution Economic solution Alternate source (generator) issues significantly impact the voltage distortion Energy savings has become the buzz with harmonic (and other PQ) solutions be careful

61