Power Quality and Harmonic Mitigation 1

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Power Quality and Harmonic
Mitigation
AccuSine
Schneider Electric
2
- Power Quality Correction Group May 2009
Agenda
Overview
Harmonic Basics
IEEE 519
Conventional Harmonic Mitigation Methods
AccuSine
PCS
Applications & Installation Notes
Specification Recommendations
Summary
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Schneider Power Quality Correction Group
Power Factor Correction and
Harmonic Filtering:
Capacitor Systems
LV & MV up to 15 kV
Fixed, Standard and
Detuned Auto Banks
AccuSine PCS
Voltage Regulation:
Hybrid VAR Compensator
Electronic Sag Fighter
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Fundamental
3
rd
Harmonic
Harmonic Basics
What are harmonics?
Proliferated by power semiconductor devices
Converts power (AC to DC)
A harmonic is a component of a periodic wave
having a frequency that is an integer multiple of
the fundamental power line frequency
Characteristic harmonics are the
predominate harmonics seen by the power
distribution system
Predicted by the following equation:
Hc = np +/- 1
h
C
= characteristic harmonics to be expected
n = an integer from 1,2,3,4,5, etc.
p = number of pulses or rectifiers in circuit
Harmonic Frequency Sequence
1 60Hz +
2 120Hz 0
3 180Hz 0
4 240Hz 0
5 300Hz -
6 360Hz 0
7 420Hz +
: : :
19 1140Hz +
5
th
Harmonic
7
th
Harmonic
Resultant
Waveform
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Multi-pulse Converters
Hn
1 phase
4-pulse
2 phase
4-pulse
3 phase
6-pulse
3 phase
12-pulse
3 phase
18-pulse
3 x x
5 x x x
7 x x x
9 x x
11 x x x x
13 x x x x
15 x x
17 x x x x
19 x x x x
21 x x
23 x x x x
25 x x x x
27 x x
29 x x x
31 x x x
33 x x
35 x x x x x
37 x x x x x
39 x x
41 x x x
43 x x x
45 x x
47 x x x x
49 x x x x
Harmonics present by rectifier design
Type of rectifier
H
c
= np +/- 1
H
c
= characteristic
harmonic order present
n = an integer
p = number of pulses
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Harmonic Basics
Nonlinear loads draw it
Example: 6-Pulse VFD
I nver t er Conver t er
DC bus
M
A
B
C
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Harmonic Basics
Why a concern?
Current distortion
Added heating, reduced capacity in :
Transformers
Conductors and cables
Heating effect proportional to harmonic order
squared
Nuisance tripping of electronic circuit
breakers (thermal overload)
Blown fuses
Detrimental to generators
Heating of windings
Detrimental to UPS
UPS cant supply the current
Loads
I
h
V
h
= I
h
x Z
h
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Harmonic Basics
Voltage distortion
Interference with other electronic loads
Faulting to destruction
Creates harmonic currents in linear loads
Generator regulators cant function
Shut downs
Not compatible with standard PF caps
Potential resonance condition
Excessive voltage
Overheating of PF correction capacitors
Tripping of PF protection equipment
Shutdown / damage to electronic equipment
Loads
I
h
V
h
= I
h
x Z
h
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Total Power Factor
TPF = (DPF) x
(Distortion factor)
DPF =
KW
KVA
f
= Cos
Distortion Factor =
1
1 + THD(I)
2
TPF = Total or true power factor
DPF = Displacement power factor
Distortion Factor = Harmonic power factor
= Cos
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Total Power Factor Example
Variable frequency drive (PWM type)
DPF = .95
THD(I) = 90%
(no DC choke & no input line reactor)
Distortion Factor =
TPF = .95 x .7433 = .7061
1
1 + .9
2
= .7433
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How are harmonics handled today?
Mixed bag of objectives
Basis of compliance is mixed
THDi, THDv, TDD?
IEEE 519-1992?
Where is PCC?
What level of harmonics is to be attained?
How to obtain compliance?
Sometimes defined
Sometimes open ended
Validation
Poorly defined
By each equipment vendor
No Total Responsibility for harmonics
Has the User been protected where it matters inside the facility
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Typical Present Situation
Specifications direct manufacturers of nonlinear loads to comply within
equipment specifications
Manufacturers of nonlinear loads have other concerns
Sell standard equipment at competitive prices
Leads to minimized harmonic solutions
Leads to misleading information about harmonic performance
Leads to operational difficulties
e.g. Cant operate on backup generators/UPS
Force the IEEE 519 discussion to the utility PCC
Many types of solutions are not compatible
Each manufacturer does his own thing without regard to other solutions
Approaches are for my equipment only
My simulation is for my equipment only I cant include the others
Total solution not achieved
User has system that exceeds specification objectives
Consulting engineers cant get overall compliance
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ANSI Standard IEEE 519-1992
Issues addressed:
THD(V) delivered by utility to user (Chapter 11)
THD(V) must be < 5% [< 69 KV systems]
Defines the amount of TDD a user can cause (Chapter 10)
Based upon size of user in relation to power source
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)
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IEEE 519-1992
Defines current distortion as TDD
Total Demand Distortion
Largest amplitude of harmonic current occurs at maximum
load of nonlinear device if electrical system can handle
this it can handle all lower amplitudes
Always referenced to full load current
Effective meaning of current distortion
Defines voltage distortion as THD
Total harmonic voltage distortion
Does not use THD(I)
Total harmonic current distortion
Instrument measurement (instantaneous values)
Uses measured load current to calculate THD(I)
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IEEE 519-1992
Total I,
rms
Fund I,
rms
Harm I,
rms THD(I) TDD
Full load 936.68 936.00 35.57 3.8% 3.8%
836.70 836.00 34.28 4.1% 3.7%
767.68 767.00 32.21 4.2% 3.4%
592.63 592.00 27.23 4.6% 2.9%
424.53 424.00 21.20 5.0% 2.3%
246.58 246.00 16.97 6.9% 1.8%
111.80 111.00 13.32 12.0% 1.4%
Measured
TDD and THD(I) are not the same except at 100% load
As load decreases, TDD decreases while THD(I) increases.
Example:
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IEEE 519-1992 Table 10.3
Current Distortion Limits for General Distribution
Systems (<69 kV)
Isc / Iload
<11 11<=h<17 17<=h<23 23<=h<35 h>=35 TDD
<20 4.0% 2.0% 1.5% 0.6% 0.3% 5.0%
20<50 7.0% 3.5% 2.5% 1.0% 0.5% 8.0%
50<100 10.0% 4.5% 4.0% 1.5% 0.7% 12.0%
100<1000 12.0% 5.5% 5.0% 0.2% 1.0% 15.0%
>1000 15.0% 7.0% 6.0% 2.5% 1.4% 20.0%
Isc = short circuit current capacity of source
Iload = demand load current (fundamental)
(TDD = Total harmonic current distortion measured against
fundamental current at demand load.)
TDD = Total Demand Distortion
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Harmonic Standards
Most harmonic problems are not at the PCC with utility.
Typically harmonic problem occur:
Within a facility
With generator & UPS operation
Where nonlinear loads are concentrated
Need to protect the user from self by moving the harmonic
mitigation requirements to where harmonic loads are located
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Agenda
I. Harmonic Basics
II. Conventional Harmonic Mitigation Methods
III. AccuSine
PCS
IV. Applications
V. Specification Recommendations
VI. Summary
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Harmonic Mitigation Methods
Typically applied per device
Line reactors/DC bus chokes/isolation transformers
5
th
harmonic filters (trap filters)
Broadband filters
Multi-pulse transformers/converters
Active front end (AFE) converter
System solution
Active harmonic filter
Harmonic mitigation methods - (Applied per VFD)
Solution Advantage Disadvantage
Typical %
TDD
Typical Price
Multiplier*
Increase short
circuit capacity Reduces THD(V)
Increases TDD
Not likely to occur**
Dependent
upon SCR***
Cost of transformer and
installation change out
C-Less Technology
Lower TDD
Simplified design
Less cost
Compliance is limited
Application limited
Size limited 30 - 50% TDD 0.90 - 0.95
Impedance (3% LR
or 3% DC choke)
Low cost adder
Simple Compliance difficult 30 - 40% TDD 1.05 - 1.15
5th Harmonic filter
Reduces 5th & total
TDD
Does not meet harmonic
levels at higher orders^ 18 - 22% TDD 1.20 - 1.45
Broadband filter
Reduces TDD (thru
13th)
Large heat losses
Application limited 8 - 15% TDD 1.25 - 1.50
12-pulse rectifiers
Reduces TDD
Reliable
Large footprint/heavy
Good for >100 HP 8 - 15 % TDD 1.65 - 1.85
18-pulse rectifiers
Reduces TDD
Reliable
Good for >100 HP 5 - 8% TDD 1.65 - 1.85
Active front end
converter
Very good TDD
Regeneration
possible
Very high cost per unit
High heat losses < 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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Harmonic mitigation methods
Solution Advantage Disadvantage
Typical %
TDD
Typical Price
Multiplier*
Increase short
circuit capacity Reduces THD(V)
Increases TDD
Not likely to occur**
Dependent
upon SCR***
Cost of transformer and
installation change out
C-Less Technology
Lower TDD
Simplified design
Less cost
Compliance is limited
Application limited
Size limited 30 - 50% TDD 0.90 - 0.95
Impedance (3% LR
or 3% DC choke)
Low cost adder
Simple Compliance difficult 30 - 40% TDD 1.05 - 1.15
5th Harmonic filter
Reduces 5th & total
TDD
Does not meet harmonic
levels at higher orders^ 18 - 22% TDD 1.20 - 1.45
Broadband filter
Reduces TDD (thru
13th)
Large heat losses
Application limited 8 - 15% TDD
12-pulse rectifiers
Reduces TDD
Reliable
Good for >100 HP 8 - 15 % TDD 1.65 - 1.85
18-pulse rectifiers
Reduces TDD
Reliable
Good for >100 HP 5 - 8% TDD 1.65 - 1.85
Active front end
converter
Very good TDD
Regeneration
possible
Very high cost per unit
High heat losses < 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.
AccuSine
AccuSine
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Inductors/Transformers/DC Bus Chokes
Description:
Converter-applied inductors or isolation transformers.
Pros:
Inexpensive & reliable
Transient protection for loads
1st Z yields big TDD reduction (90% to 35% w/3% Z)
Complimentary to active harmonic control
Cons:
Limited reduction of TDD at equipment terminals after 1st Z
Reduction dependent on source Z
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5th Harmonic Filter (Trap
Filter)
Inductor (L
p
) and Capacitor (C) provide low
impedance source for a single frequency
(5
th
)
Must add more tuned filters to filter more
frequencies
Inductor L
s
required to detune filter from
electrical system and other filters
If L
s
not present, filter is sink for all 5
th
harmonics in system
If L
s
not present, resonance with other
tuned filters possible
Injects leading reactive current (KVAR) at
all times may not need
Load
V
s
Z
s
L
p
C
L
s
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Mitigates up to 13
th
order or higher
Each inductor (L) > 8% impedance
V drops ~ 16% at load
Trapezoidal voltage to load
Can only be used on diode converters
Prevents fast current changes (only good for centrifugal loads)
When generators are present, re-tuning may be required
Capacitor (C) designed to boost V at load to proper level (injects leading VARs)
Physically large
High heat losses (>5%)
Series device
Broadband Filters
Load
Source
L L
C
~
L
p
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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
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Harmonic mitigation methods
VFD mitigation topologies
6-Pulse converter
C-less or 3% reactance min (if
included); small footprint,
simplified cabling
Current waveform distorted
TDD 30% to 40% with 3% reactor
(depending on network impedance)
Externally mounted 3 winding
transformer; more wire and
cabling; complicated
Current slightly distorted
TDD 8% to 15% (depending on
network impedance)
12-Pulse converter 18-Pulse converter
Large footprint, more steel
& copper (losses)
Current wave form good
TDD 5% to 7% (depending on
network impedance)
0
100
A
6 pulse
0
100
A
12 pulse
0.0s 0.02s
0
100
A
18 pulse
+
-
DC Bus Load
Delta
Delta
Wye
AC Line
A
B
C
DC+
DC-
Line
Reactor
Rectifier Assembly
Transformer
Tertiary
Multipulse
Transformer
A
B C
1
2
3
4
5 6
7
8
9
DC Link
Reactor
M
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Active Front End (AFE) Converters
Used in UPS and VFD
Replaces diode converter with IGBT converter
The hype
Permits current smoothing on AC lines (< 5% TDD)
Permits 4-quadrant operation of VFD
Maintains unity TOTAL PF
Meets all harmonics specs around the world
A
C
S
o
u
r
c
e
Filter
Converter
Inverter
DC Bus
AC
Motor
IGBT IGBT
VFD
Input Filter
Required to
limit THDv to
<5%
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AFE Converters
Significant harmonics above 50
th
order
American Bureau
of Shipping (ABS)
requires
examination to
100
th
order when
AFE applied
Higher frequencies
yield higher heating
of current path &
potential resonance
with capacitors
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AFE Converters
Cons
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
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
200
KVA
rated
PWM
VFD
DC
Drive
PF
caps
100
KVA
rated
AFE
VFD
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Agenda
I. Harmonic Basics
II. Conventional Harmonic Mitigation Methods
III. AccuSine
PCS
IV. Applications
V. Specification Recommendations
VI. Summary
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The System Solution
The System Solution:
Single point of responsibility for the total harmonics
One specification for harmonic definitions
One validation responsibility and guarantee
Standard nonlinear products
3% input line reactors on most non-linear devices, 3% DC bus choke okay for
PWM VFD
Limits rms current at load for diode rectifiers
Avoids interaction with snubber circuit for SCR rectifier
Best cost and performance
Compatible with all nonlinear products
Compliance with harmonic specifications
Controls harmonic levels with facility
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Schneider Electrics Solution
AccuSine Power Correction System (PCS)
Active harmonic filter
Provides 5% TDD per load or system
Cancels everything from 2
nd
to 50
th
harmonic order
Used on any/all nonlinear load
Active reactive current correction
Does not use PF capacitors
Used to correct Displacement PF
In conjunction with or independent of harmonic control (dual mode)
High-speed reactive power
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Active Harmonic Filter System Solution
Applied to one or many nonlinear loads
VFD, UPS, UV, DC drives, DC power supplies
Provides DPF correction
More cost effective for multiple loads
For two or more drives, AccuSine and 6 pulse drive combination
has lower initial and operating costs than 18 pulse drives
For installations with redundant drives, size AccuSine for the
operating drives only
Saves space
Lower heat losses
Not critical to operation
Parallel connected
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Comparison of 18-P VFD to
AccuSine PCS + standard VFD
Footprint required
AccuSine PCS+ Std VFD less than 18-P VFD
(w/autotransformer) for all conditions
Heat losses
AccuSine PCS+ Std VFD less than 18-P VFD
Exception at single units of 50-75 HP, advantage 18-P VFD
Less costly to operate AccuSine PCS+ Std VFD
Less site cooling required with AccuSine PCS + Std VFD
Price (first cost)
When more than one VFD, AccuSine PCS + Std VFD always
beats 18-P VFD
If only one VFD involved, 300-500 HP sizes favor 18-P VFD
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AccuSine Active Harmonic Filter
AHF
Load
CT
Source
L
I
s
I
a
I
l
~
AHF
Parallel connected
I
s
+ I
a
= I
l
Ia includes 2
nd
to 25/50
th
harmonic current
I
s
<5% TDD
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AccuSine PCS
Power Diagram
+
C
E
C
E
C
E
C
E
C
E
C
E
C
Line
Inductor
Filter
Board
Pre-charge
Contactor
Inductor
Fuse
Fuse
Fuse
AC
Lines
DC Bus
Capacitors
S4
S5
S6
S1
S2
S3
IGBT Module
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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
Two 125 HP VT 6-pulse VFD w/3% LR
Required AHF size = 84.4 amps
Three 125 HP VT 6-pulse VFD w/3% LR
Six 125 HP VT VFD w/3% LR
(not 6 x 47.5 = 285 amps)
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AS off AS on
Order % I fund % I fund
Fund 100.000%100.000%
3 0.038% 0.478%
5 31.660% 0.674%
7 11.480% 0.679%
9 0.435% 0.297%
11 7.068% 0.710%
13 4.267% 0.521%
15 0.367% 0.052%
17 3.438% 0.464%
19 2.904% 0.639%
21 0.284% 0.263%
23 2.042% 0.409%
25 2.177% 0.489%
27 0.293% 0.170%
29 1.238% 0.397%
31 1.740% 0.243%
33 0.261% 0.325%
35 0.800% 0.279%
37 1.420% 0.815%
39 0.282% 0.240%
41 0.588% 0.120%
43 1.281% 0.337%
45 0.259% 0.347%
47 0.427% 0.769%
49 1.348% 0.590%
TDD 35.28% 2.67%
AccuSine Performance
AccuSine injection
Source current
At VFD Terminals
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700 HP Drive AccuSine ON OFF
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Applications
Most common VFD sites
Centrifugal pumps and fans
Pumping Stations
Potable
Wastewater
Wastewater Plants
Water Purification (potable)
Disinfectant Systems
UV systems (ultraviolet)
Electronic ballasts 3
Ozone generators (SCR power supplies)
Industrial in-rush support
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AccuSine PCS Specifications
Universal Application
208 480 VAC
No user action required to set
Highly customized transformers for higher voltages (to 15 kV)
50 or 60 Hz
Fuse protected (200,000 AIC)
UL 508 & CSA approved
CE EMC - 400V
Logic ride through 1 to 10 minutes
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Specification Discussion
Write a specification in Section 16 for an active harmonic filter
Specify any points of concern for insertion of AHF
Size of AHF
Located per electrical bus
Specify total responsibility for all harmonics in facility
Specify TDD levels desired at each location
5% TDD guarantees 5% THDv (caused by the loads) with any source
Specify compliance tests for each location
Write standard nonlinear load specification
Reduces harmonic incompatibilities and product interactions
Need 3% impedance on each nonlinear load
Universal solution
Good for all nonlinear loads
Apply AccuSine per electrical bus (best economics)
Can attain 5% TDD per load or bus inside the plant
Avoids harmonic problems both TDD and THD(V)
Write TDD specs not THD(I) at 5%
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AccuSine Tools
Internet Tools
Active Filter Guide Spec (www.reactivar.com)
Stand alone spec section (Section 16)
Includes harmonic and PF correction requirements
Selection Program (www.squaredleantools.com)
Easy selection based upon loads not source (same
selection for utility or generator)
Simple tool to use
We guarantee results if used properly during
design/layout stage
Brochure
Application Notes
Water/wastewater and other applications
Installation Bulletin
Best/total information for consultant
MCC Selector
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Product Package
Standard (UL only)
Enclosed NEMA 1
50 amp 48H x 21W x 19D, 250 lbs
100 amp 65H x 21W x 19D, 350 lbs
Wall mounted
300 amp 75H x 32W x 20D, 775 lbs
Free standing
Chassis & NEMA12 Also Available
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Product Package
International enclosures
NEMA 12, IP30, IP54
50 amp 75(1905mm) x 31.5(800mm)
x 23.62(600mm)
Weight 661Ib(300Kg)
100 amp 75(1905mm) x
31.5(800mm) x 23.62(600mm)
Weight 771Ib(350 Kg)
300 amp 91(2300mm) x
39.37(1000mm) x 31.5(800mm)
Weight 1212Ib(550 Kg)
Free standing with door interlocked
disconnect
CE Certified, C-Tick, ABS, UL, CUL
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Product Re-packaging
Maximum ambient into air inlet 40
0
C
Must meet air flow at inlet of AccuSine
50 amp 300 CFM
100 amp 500 CFM
300 amp - 1250 CFM
Heat released
50 amp 1800 watts
100 amp 3000 watts
300 amp 9000 watts
DIM considerations required
On chassis
Remote with cable
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Product Re-packaging
MCC Packaging
50 & 100 amp models only
Requires one vertical 20 x 20 section
Includes circuit breaker
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AccuSine PCS Current Transformers
AC lines
Class 1
400 Hz
Four sizes
500:5/1000:5/3000:5/5000:5
Stock split core round units
Added to AccuSine (when parallel connected & source sense)
Use solid core at equal ratio as AC lines CT
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AccuSine PCS Performance
Source XFMR
Load(s)
I
s
I
as
AccuSine Logic
I
s
+ I
as
= I
l
AccuSine injects the harmonics the loads want
DEFINITIONS
I
s
= source current
I
as
= AccuSine current
I
l
= total load current
(vector representations)
I
l
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AccuSine PCS Performance
Obtain 5% TDD (current distortion)
Overall 10:1 attenuation
Cos = .998
Obtain near unity lagging DPF (Cos )
Optional: Inject to obtain a user set point
Either or both functions
VAR compensation
100 second detect-to-inject
Dynamic response
cycle to full control for step load changes
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AccuSine PCS Overall Performance
Harmonic compensation
2
nd
through 50
th
order
Includes inter-harmonics
Independent of source impedance
Selection and operation same whether on AC line or backup generator or UPS
output
Reactive current injection
Secondary function to harmonic mode
Defaults to unity lagging set point
Injects leading or lagging reactive current
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AccuSine PCS Cos Performance
In dual mode (Cos + Cos )
Reactive current injection is secondary to harmonic mitigation
Activation of Cos in the field via DIM
Default to unity lagging Cos
Can enter a set point (i.e. 0.90 lagging)
Can inject leading (capacitive) or lagging (inductive) reactive current
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Dual Mode Operation
I
as
= rms output current of AccuSine
I
h
= rms harmonic current
I
r
= rms reactive current
I
as
= I
h
2
+ I
r
2
Ias Ih Ir
100.0 10.0 99.5
100.0 20.0 98.0
100.0 30.0 95.4
100.0 40.0 91.7
100.0 50.0 86.6
100.0 60.0 80.0
100.0 70.0 71.4
100.0 80.0 60.0
100.0 90.0 43.6
100.0 95.0 31.2
Examples
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AccuSine PCS
Installation Considerations
(When in harmonic mode does not apply for reactive mode-only)
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AccuSine PCS Installation Considerations
For Optimal Performance:
Impedance 3% input line reactors (minimum) on every nonlinear load
Transformer, 3% DC bus choke for PWM VFD or long power cables (not
encapsulated type) can substitute for line reactors
Standardizes selection of AccuSine
Diode rectifiers: Need to limit rms current at load (limits rise of I
hrms
at load)
Thyristor rectifiers: Need to protect snubbers (capacitors) on thyristor
No capacitors downstream of CT
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AccuSine PCS Installation Considerations
This configuration provides individual AccuSine
operation per side regardless of breaker positions.
Main Left Main Right
CB
m
l CB
mr
Tie
CT
ml
CT
tl
CT
tr
CT
mr
AccuSine R
AccuSine L
CB
al
CB
ar
Main-tie-main
Schneider Electric
61
Summary
Universal solution
Good for all nonlinear loads (3-phase)
Apply AccuSine per electrical bus (best economics)
System Solution
Can attain 5% TDD per load or bus inside the plant
Guarantees 5% THDv
Requires 3% impedance at loads
Selection based upon loads
Easy to use on-line tool
www.squaredleantools.com
Schneider Electric
62
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