Harmonic Analysis and Power Factor

Correction Evaluation –
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

- Table of Contents -
Executive Summary ______________________________________________________1
1.0 Introduction _________________________________________________________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

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

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.

480 Volt Bus

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

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

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

H110 H22 Kneader Kneader

H111 MCC7 13-2 13-1 937.5 kvar
600 volts
H112 H113
Grinders

Calender Controls Mixer Calender

(Protected by 24 Heaters
kVA UPS)

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

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
Amps
150

100

50

-50

-100

-150
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
CHA Amps

Pre/Post-trigger at 02/25/98 11:32:34.312

Event waveform/detail
Amps
60

50

40

30

20

10

0
THDabs H05 H10 H15 H20 H25 H30
CHA Amps

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

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

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
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

Timed event at 02/25/98 12:48:18.000

Event waveform/detail
Amps
125

100

75

50

25

0
THDabs H05 H10 H15 H20 H25 H30
CHA Amps

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

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

Example waveform and spectrum from BMI 3030

Roll 2 Current Waveform

200

100

-100

-200
0 10 20 30 40
Time (mS)

Roll 2 Harmonic Characteristics

100
Freq : 1
Fund : 89.5784
THD : 52.7698
80 TID : 0
TD : 52.7698
RMSh : 47.2703
RMSi : 0
60 RMSfh: 101.286
RMS : 101.286
ASUM : 179.963
TIF : 454.674
40 IT : 46051.9

20

0
0 10 20 30 40
Frequency (H pu)

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

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
Amps
750

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

Snapshot event at 02/25/98 14:53:43.000

Event waveform/detail
Amps
250

200

150

100

50

0
THDabs H05 H10 H15 H20 H25 H30
CHA Amps

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

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

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 7th 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 7th harmonic. This is an indication
of the magnification at the 7th harmonic component.

No Cap Bank with Cap Bank

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 %

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

The following waveform and harmonic spectrum represent typical load characteristics for
Line 13 (without the capacitor bank).

Line 13 Current Waveform

3000

2000

1000

-1000

-2000

-3000
0 10 20 30 40
Time (mS)

Line 13 Current Harmonic Spectrum

1750
Freq : 1
Fund : 1529.89
1500 THD : 14.4941
TID : 0
TD : 14.4941
1250 RMSh : 221.744
RMSi : 0
RMSfh: 1545.87
1000 RMS : 1545.87
ASUM : 1939.89
TIF : 85.7982
750 IT : 132633

500

250

0
0 3 6 9 12 15
Frequency (H pu)

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

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 5th harmonic component since that is the
highest current injection from the drive loads.

Event waveform/detail
Volts
750

500

250

-250

-500

-750
15:48:40.01 15:48:40.03 15:48:40.05 15:48:40.07
15:48:40.00 15:48:40.02 15:48:40.04 15:48:40.06
CHA Volts

Snapshot event at 02/25/98 15:48:40.000

Event waveform/detail
Volts
500

400

300

200

100

0
THDabs H05 H10 H15 H20 H25 H30
CHA Volts

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

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

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 7th and 11th harmonics,
magnifying both of these components. The voltage distortion levels are increased overall
and can exceed 5%. The highest distortion is typically at the 7th harmonic with the
capacitor bank in due to the magnification.

Event waveform/detail
Volts
750

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

Meter mode snapshot at 02/25/98 16:20:59.000

Event waveform/detail
Volts
500

400

300

200

100

0
THDabs H05 H10 H15 H20 H25 H30
CHA Volts

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

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

Comparison of Voltage Characteristics

The figure below shows the THD of the voltage on the Line 13 Main Bus and the values
of the 5th, 7th, 11th, and 13th 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
7th harmonic is virtually non-existent, at 0.02% of the fundamental, with the capacitor
bank off line. The 11th harmonic was measured at 0.75% without the capacitor banks.
After placing the capacitor banks on line, the 7th increases to 3.73% and the 11th increases
to 2.23% of the fundamental.

Line 13 Main Bus

6.00
Voltage Distortion (%)

5.00
4.00
No Caps
3.00
With Caps
2.00
1.00
0.00
THDv 5th 7th 11th 13th
Harmonic

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

Description of the Resonance Problem

The capacitor bank introduces a resonance between the 7th and 11th 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

0.4

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)

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

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.

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

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

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

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

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 Ω Cap Value (wye equivalent): 6907.8 uF

Reactor Impedance: 0.0174 Ω 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:

4 8 0 Volt Bus
Limit Actual
Peak Voltage: 120% ←→ 101% Xl = 0.0272 Ω
Current: 180% ←→ 120%
KVAr: 135% ←→ 103%
RMS Voltage: 110% ←→ 86% 6 0 0 kVAr @
6 0 0 V o lts

FILTER REACTOR DESIGN SPECIFICATIONS:

Reactor Impedance: 0.0174 Ω Reactor Rating: 0.0461 mH

Fundamental Current: 755.9 Amps Harmonic Current: 776.9 Amps

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

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

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 Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation

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

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