Professional Documents
Culture Documents
Caso Estudio Armonicos y Correccion FP - Fabrica PDF
Caso Estudio Armonicos y Correccion FP - Fabrica PDF
Correction Evaluation
Plastic Creations Line 13
Prepared by:
Electrotek Concepts, Inc.
Knoxville, TN
www.electrotek.com
Wade Eckler
Power Systems Engineer
ii
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 7th and 11th
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.
Circuit Breaker:
480 Volt, 2000 A
Inductors:
0.046 mH per phase
rms current rating = 1100 amps
5th harmonic current rating =
775 amps
Capacitor Bank:
937.5 kvar
600 volts
Tuned
Capacitor
Bank
Proposed Filter Configuration for Line 13 and Line 14
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
H110
H22
H111
MCC7
Kneader
13-2
Kneader
13-1
H113
H112
937.5 kvar
600 volts
Grinders
Calender Controls
(Protected by 24
kVA
UPS)
Mixer
Calender
Heaters
100
50
-50
-100
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
-150
11:32:34.38
CHA Amps
Event waveform/detail
Amps
60
50
40
30
20
10
0
THDabs
H05
H10
H15
H20
H25
H30
CHA Amps
32.52 Amps
1.31 Amps
32.50 Amps
Event waveform/detail
Amps
300
200
100
-100
-200
-300
12:48:18.000
12:48:18.005
12:48:18.010
12:48:18.015
12:48:18.020
CHA Amps
Event waveform/detail
Amps
125
100
75
50
25
0
THDabs
H05
H10
H15
H20
H25
H30
CHA Amps
56.36 Amps
0.45 Amps
56.37 Amps
100
-100
-200
0
10
20
30
40
Time (mS)
Freq : 1
Fund : 89.5784
THD : 52.7698
TID : 0
TD : 52.7698
RMSh : 47.2703
RMSi : 0
RMSfh: 101.286
RMS : 101.286
ASUM : 179.963
TIF : 454.674
IT : 46051.9
80
60
40
20
0
0
10
20
30
40
Frequency (H pu)
500
250
-250
-500
-750
14:53:43.000
14:53:43.005
14:53:43.010
14:53:43.015
14:53:43.020
CHA Amps
Event waveform/detail
Amps
250
200
150
100
50
0
THDabs
H05
H10
H15
H20
H25
H30
CHA Amps
98.85 Amps
9.78 Amps
98.38 Amps
Current
Power
kvar
PF
dPF
No Cap
1300-1800
1.1-1.3
480-500
.88-.90
.88-.91
Bank
amps
MVA
kvar
THDv
THDi
2.9-3.2
15-17
%
%
4.5-5.9
25-32
%
%
V5
I5
1.9-2.0
12-13
%
%
2.5
19
%
%
V7
I7
1.8
8-9
%
%
3.2
20
%
%
2000
1000
-1000
-2000
-3000
0
10
20
30
40
Time (mS)
Freq : 1
Fund : 1529.89
THD : 14.4941
TID : 0
TD : 14.4941
RMSh : 221.744
RMSi : 0
RMSfh: 1545.87
RMS : 1545.87
ASUM : 1939.89
TIF : 85.7982
IT : 132633
1500
1250
1000
750
500
250
0
0
12
15
Frequency (H pu)
500
250
-250
-500
-750
15:48:40.01
15:48:40.00
15:48:40.03
15:48:40.02
15:48:40.05
15:48:40.04
15:48:40.07
15:48:40.06
CHA Volts
Event waveform/detail
Volts
500
400
300
200
100
0
THDabs
H05
H10
H15
H20
H25
H30
CHA Volts
15.76 Volts
2.68 Volts
15.54 Volts
500
250
-250
-500
-750
16:20:59.000
16:20:59.005
16:20:59.010
16:20:59.015
16:20:59.020
CHA Volts
Event waveform/detail
Volts
500
400
300
200
100
0
THDabs
H05
H10
H15
H20
H25
H30
CHA Volts
24.32 Volts
0.59 Volts
24.33 Volts
10
3.00
With Caps
2.00
1.00
0.00
THDv
5th
7th
11th
13th
Harmonic
11
0.4
0.3
0.2
0.1
0.0
0.00
3.00
6.00
9.00
12.00
15.00
18.00
21.00
24.00
27.00
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 (5th and 7th).
Frequency Scan Showing Effect of Filter
0.4
0.3
0.2
0.1
0.0
0.00
3.00
6.00
9.00
12.00
15.00
18.00
21.00
24.00
27.00
Frequency (H pu)
12
Transformer Size
Transformer Impedance
Peak Load (kVA)
Displacement Power Factor
Reactive Power (kvar)
Real Power (kW)
3750
7%
1300
0.9
567
1170
3750
7.00%
2600
0.9
1133
2340
Compensation (kvar)
Total Reactive Power with Compensation (kvar)
Power Factor with Compensation
600
-33
1.00
600
533
0.97
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.
13
Circuit Breaker:
480 Volt, 2000 A
Inductors:
0.046 mH per phase
rms current rating = 1100 amps
5th harmonic current rating =
775 amps
Capacitor Bank:
937.5 kvar
600 volts
Tuned
Capacitor
Bank
Proposed Filter Configuration for Lines 13 and 14
14
5 th
937.5 kVAr
902 Amps
480 Volts
Derated Capacitor:
721.7 Amps
60 Hz
Capacitor Rating:
4.7 th
600 Volts
60 Hz
600 kVAr
2500 kVA
282 Hz
0.3840
6907.8 uF
Reactor Impedance:
0.0174
Reactor Rating:
0.0461 mH
755.9
944.9
3750
7.00
Amps
Amps
kVA
%
Supplied Compensation:
628 kVAr
2.00 % THD
20.00 % Fund
601.4 Amps
175.5 Amps
776.9 Amps
1084.0 Amps
502.8 Volts
103.3 Volts
606.1 Volts
513.3 Volts
1532.8 Amps
FILTER CONFIGURATION:
4 8 0 Volt Bus
Peak Voltage:
Current:
KVAr:
RMS Voltage:
Limit
120%
180%
135%
110%
Actual
101%
120%
103%
86%
Xl =
0.0272
6 0 0 kVAr @
6 0 0 V o lts
0.0174
755.9 Amps
Reactor Rating:
Harmonic Current:
0.0461 mH
776.9 Amps
15
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
16
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
17