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IET Power Electronics

Research Article

ISSN 1755-4535
Design and application of a thyristor Received on 19th April 2016
Revised on 17th August 2016
switched capacitor bank for a high harmonic Accepted on 11th September 2016
doi: 10.1049/iet-pel.2016.0310
distortion and fast changing single-phase www.ietdl.org

electric welding machine

Wei-Hsiang Ko ✉, Jyh-Cherng Gu
Department of Electrical Engineering, National Taiwan University of Science and Technology, No. 43, Keelung Road, Sec. 4,
Da’an District, Taipei City 10607, Taiwan
✉ E-mail: d10107101@mail.ntust.edu.tw

Abstract: A single-phase electric machine invokes a great reactive power demand in operation, resulting in a large voltage
fluctuation in the supply system. Furthermore, the frequent and rapid operating characteristics of an electric welding
machine cause a serious voltage flicker problem. The operation of welding equipment also generates significant
harmonic current distortion, and distorts the voltage waveform of the supply system. Hence, this study focused on
designing and applying a thyristor switched capacitor (TSC) bank for voltage flicker improvement. However, the single-
phase TSC should also satisfy the reactive power demand and compensation speed, considering proper ratings of TSC
to bear high harmonic distortion. This study shows the calculation results and discusses the impact of different
capacities and different step numbers on TSC design. In addition, thyristor switches and a single-phase power factor
controller were designed and implemented. The experimental results are also presented.

1 Introduction
A load that has rapid and significant changes causes voltage
fluctuation in the power system. Loads such as electric arc
furnaces and steel plant rolling mills produce significant load
current changes, resulting in serious voltage flicker, which is an
important threat to power quality [1]. In fact, static var
compensator (SVC) or static synchronous compensator
(STATCOM) systems are usually employed for power quality
improvement in steel plants [2–7]; these systems not only
compensate voltage flicker and harmonic distortion, but also
compensate the imbalance voltage problem [8–10]. However, this
study focused on a single-phase electric welding machine, which
has periodic and rapid changes, large reactive power demand, and
high harmonic current distortion characteristics, which result in a
serious voltage flicker and harmonic distortion problem while the
welding machine is operated. It is also difficult to apply an SVC
or STATCOM system to improve power quality in a single-phase
low-voltage distribution system.
Rapidly advancing power electronics technology and mature
semiconductor technology have proved beneficial for the
development of power electronics-based equipment that is
indispensable in industrial applications. Many studies have
investigated the application of shunt active harmonic filters for the
harmonic filtering of power systems [11, 12]. Shunt active
harmonic filters can implement instantaneous dynamic
compensation, which can improve the system harmonic distortion
and compensate the reactive power demand [13, 14], and balance
the asymmetrical load currents [15–17]. An active filter is suitable
for compensating the rapid changing characteristics of electric
welding machines. However, the actual industrial applications of
commercial active filters are mainly three-phase active filters,
although there are some special single-phase active filter
applications and researches [18–20]. However, there is no
commercialised single-phase active filter for the time being.
The passive harmonic filter is also a common solution for
harmonic filtering, and there are many studies on passive filter
design [21–24]. The actual applications are presented in [25, 26].
The series resonance frequency of the filter provides an extremely
low impedance path, which shunts harmonic currents out of the
system and thereby further reduces losses and improves power
quality. Because the operation of a welding machine produces
high harmonic current and significant reactive power demand, if a
passive filter is used for improving power quality, then the
required capacity and quantity will become considerable in order
to fulfil the reactive power demand and harmonic current
requirement. Thyristor switched capacitor banks (TSC) can be
applied for compensating the fast changing characteristics of
electric welding machines, provide a maximum response of
one-cycle of system frequency [27–29]. Furthermore, common
automatic power factor controllers, typically used in three-phase
systems, regulate the power factor with an assumption of a
well-balanced three-phase system, and calculate power from one
phase voltage and current as the reference. However, currently there
are no commercial power factor controllers for single-phase systems.
For the reasons above, this study focused on the design and
implementation of a TSC for a single-phase electric welding
machine. The proposed TSC can mitigate the voltage flicker
problem and compensate the power factor; at the same time, the use
of thyristor switches can implement rapid compensation to meet the
fast changing characteristics of the welding machine. Furthermore,
the designed TSC also considers the background harmonic voltage
and harmonic currents from the welding machine. This study not
only designed a reactive power compensation device for the
electric welding machine, but also developed and implemented a
single-phase power factor controller and thyristor switches.
The main contributions of this research are as follows: (i) Design
of a low-voltage TSC for voltage flicker improvement; (ii)
development of a power factor controller for single-phase systems;
(iii) development of transient-free thyristor switches for capacitors;
(iv) implementation of the proposed TSC; and (v) the
implementation results, as shown in the experimental result section.
2 Study of the existing system
The simplified system configuration and measurement point are
depicted in Fig. 1. A V-connected transformer transforms a

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system equivalent resistance (Ω), XS is the system equivalent
reactance (Ω).
|ΔV| can be expressed as follows

|DV |  XS × DS, (2)















where ΔS is calculated from DQ2 + DP2 . Therefore, the required
reactive power to meet the expected maximum voltage fluctuation
(ΔVt), that is, the total output reactive power (QC) of the TSC, can
be formulated as

























2

 2  
    DV   DP 
QC = DQ −  t  −   . (3)
XS (1 − DVt )2 

3.2 Component ratings

From the total output reactive power and the total step number (M),
the capacitance (C ) of each step can be expressed as
Fig. 1 Power system configuration of the electric welding machine
(1 − p)QC
C= (4)
vMVS2
three-phase power source to one single-phase power source for
supplying an electric welding machine. The primary and where p is the percentage of series reactor (%), M is the total step
secondary voltage ratings are 11.4 kV and 440 V, respectively. number of the capacitor bank, VS is the system voltage (V ), ω is
Fig. 2a depicts the measured welding machine current and voltage the angular frequency (rad/s).
waveforms of the single-phase 440 V system. The active power and The impedance of the series reactor can be calculated by
power factor are 773 kW and 0.44 lagging, respectively; the total XL = pXC , and the inductance (L) of each step can be expressed as
harmonic voltage distortion is approximately 14%, and the total
harmonic current is approximately 1242 A. The measured system
voltage and reactive power demand statistic result is shown in pMVS2
L= . (5)
Fig. 2b. The reactive power demand of the load is approximately v(1 − p)QC
between 1400 and 1900 kvar. During the operation of the welding
machine, the measured load current and voltage rms value of the From Fig. 4b, the harmonic impedance, seen from the load terminal,
single-phase 440 V system are shown in Figs. 2c and d. can be expressed as
The welding machine has rapid and periodically changing features;
the maximum current fluctuation is approximately 6000 A within V (f ) Z ( f )ZC ( f )
1.8 s. The measured voltage drop is 11.37%, refer to the rated ZTH ( f ) = = S . (6)
voltage 440-V, during load operation. Furthermore, Figs. 2e and f I(f ) ZS ( f ) + ZC ( f )
shows the measured harmonic voltage and current spectrum, where
the third harmonic is the main component. The simulated phase The definition of the current dividing factor into capacitor branch is
voltage rms values in the 11.4 kV side is shown in Fig. 3, the given by
maximum voltage fluctuation is approximately 3.12% while
welding machine operated. ZS ( f ) Z (f)
Fcf ( f ) = = TH (7)
ZS ( f ) + ZC ( f ) ZC ( f )

3 TSC design
From the existing system study result, the electric welding machine
produced high harmonic current, large reactive power demand, and
rapid changes. In this study, the proposed low-voltage TSC can be
incorporated into this rapid changing and high harmonic distortion
system for voltage flicker improvement.
3.1 Reactive power capacity
Then, the harmonic currents from the load into the capacitor branch
can be calculated as
ZTH ( f )
Iload ( f ) = Ih ( f )Fcf ( f ) = Ih ( f ) (8)
ZC ( f )
where Ih is the harmonic current source. The harmonic current that
comes from the upstream side harmonic voltage distortion (Vhv)
and flows into the capacitor branch can be expressed as

The low voltage single-phase equivalent circuit is shown in Fig. 4a, Vhv ( f )
Ihv ( f ) = . (9)
including a system voltage source, a system equivalent impedance, ZS ( f ) + ZC ( f )
and the electric welding machine. When the TSC is incorporated
into the system, the system equivalent circuit can be simplified as If the phase of the harmonics are in phase, the total harmonic current
shown in Fig. 4b, where the welding machine is regarded as a in the capacitor branch is given by
harmonic current source.
The voltage fluctuation can be expressed as follow [30]
IC ( f ) = Ihv ( f ) + Iload ( f ). (10)

DES = (RS + jXS ) × DI + DV , (1) From the IEEE and IEC shunt capacitor standards [31, 32], when
considering harmonic voltages, the definition of the rated voltage
where ES is the equivalent system voltage source (V), RS is the of the capacitors is the arithmetic sum of the rms values of the

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2753
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& The Institution of Engineering and Technology 2016
Fig. 2 Measured in the existing 440-V system

b Voltage and reactive power demand statistic

a Voltage and current waveforms

e Harmonic voltage spectrum

f Harmonic current spectrum
d Voltage rms value
c Current rms value
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Fig. 3 Simulated 11.4 kV phase voltage rms values in the existing system

harmonic voltage and the fundamental ( f1) voltage, as given by switch configuration consists of a bipolar thyristor module and a
control circuit module. When the thyristor switch receives an

1
external conducting control signal from the power factor
VC = VC (f ). (11) controller, the zero-cross triggering technology of the control
f =f1 circuit module will switch on the capacitor without excessive
inrush current and switch off at the instant when the current is
In addition, the rated current of the capacitors is the square root of the reduced to zero.
sum of the squared values of the currents at the fundamental and
harmonic frequencies, as given by (12). The rated current is also
the rating of the series reactors and the thyristor switches. 3.4 Single-phase power factor controller


1






IC = IC2 (f ). (12)
f =f1
3.3 Thyristor switch
If a magnetic contactor is applied for the capacitor switching, the
mechanical lifetime will be significantly shortened because of the
frequent switching. Furthermore, the contactor is controlled by an
exciting coil, and the switching time is heavily limited by its
mechanical structure; the switching time is generally longer than
several hundred milliseconds. Therefore, the contactor is not
suitable for rapid and frequent switching applications. In order to
meet the fast switching requirement, this study employed thyristor
switches for the capacitor switching. Owing to the firing and
cut-off characteristics of thyristors, the shortest switching time is
one cycle of the power system frequency. The developed thyristor
To control the single-phase reactive power, the power factor
controller must be suitable for a single-phase system and exhibit
fast control performance. Therefore, a single-phase power factor
controller was developed; the signal process diagram of each cycle
is shown in Fig. 5a. The controller calculates the instantaneous
power from the single-phase voltage and current signals every
cycle, and the controller can control the required reactive power on
the basis of the configurable power factor target, as shown in
Fig. 5b. A default one-cycle delay time was used.
4 Simulation and discussion
In this study, an 11.11 and a 14.80% series reactor for the capacitor
bank were calculated as discussed in this section. The voltage
fluctuation before improvement was 11.37%, and the average
reactive power demand was 1440 kvar. The 440-V system
equivalent short-circuit capacity was 12.96 MVA. The calculated
voltage fluctuation with different total reactive power output of

Fig. 4 Equivalent system circuit Fig. 5 Developed single-phase power factor controller
a Single-phase circuit a Signal process diagram of each cycle
b Harmonic impedance circuit b Reactive power control diagram

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Fig. 6 Calculated voltage fluctuation against total installed reactive power
Table 1 Capacitor bank calculation parameters
Reactor, p 11.11% 14.80%
equivalent capacitance 16009.93 µF 15345.52 µF
equivalent inductance 0.049 mH 0.068 mH
tuning frequency 180 Hz 165 Hz
total output capacity 1314.55 kvar 1314.55 kvar
TSC is shown in Fig. 6. When the installed total reactive power
output exceeds 1300 kvar, the voltage fluctuation can be reduced
to 5.42%, mainly from the active power. The total reactive power
output of 1315 kvar was used for the simulation, which showed a
reduction in voltage fluctuation from 11.37% to 5.42%.
The tuning frequency of the capacitor bank is 180 Hz when p =
11.11%; that is, a third-harmonic filter bank. When p = 14.80%,
the tuning frequency is 156 Hz, and the capacitor bank is mainly
for reactive power compensation. Because of the harmonic
impedance characteristic, some part of the third-harmonic current
will flow into the capacitor bank. The parameters for calculation
are listed in Table 1.
The calculated capacitor rated voltage with different installed
reactive power output values is shown in Fig. 7a. When the
capacitor is in series with the 11.11% reactor, which provides a
third-harmonic current with an extremely low impedance, most of
the third-harmonic current flows through the capacitor branch, thus
producing an extremely large voltage drop on the capacitor
terminals. The rated voltage of the capacitor must be at least
2.2 kV when the total reactive power is only 50 kvar; when the
total reactive power is 1315 kvar, the rated voltage can be reduced
to 593 V. Nevertheless, when a 14.80% reactor is in series with
the capacitor, only some part of the third-harmonic current goes
through the capacitor. When 1315 kvar output capacity is installed,
the rated voltage of the capacitors must be at least 597 V. Fig. 7b
shows the calculated total harmonic current into the capacitor bank
vs. total installed output capacity. A total harmonic current of 830
A flows into the capacitor bank with the 14.80% reactor when the
total reactive power of 1315 kvar is installed. When 11.11%
reactors are involved, most of third-harmonic current will flow
through the capacitor bank, regardless of the installed total
capacity. However, when the total reactive power output capacity
of 1315 kvar is installed in the system, the fundamental current of
the capacitor bank is approximately 3137 A. Therefore, the
capacitor bank is mandatorily split into several small steps, in
order to reduce the required ratings of the components. The
calculated total harmonic current into each capacitor with different
total step number is shown in Fig. 7c. When the total step number
is greater than 12, the total harmonic current into each capacitor is
less than 100 A. However, the larger the total step number, the
greater the component cost and required installation space;
the smaller the total step number, the higher the required
component current ratings; the smaller the total installed output
capacity, the higher the required component rated voltage. Thus,
the improvement in voltage flicker is restricted. Therefore, the
capacitor bank design needs to consider the tradeoffs between the
improvement requirement, installation cost, and installation space.
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In this research work, the final implemented TSC had a total of
660 kvar output capacity, owing to the limited budget and
restricted installation space. The capacitor bank was split to 12
steps, with 14.80% reactors. All steps will be switched on
simultaneously by the controller. From the calculated result, the
voltage fluctuation can be improved from 11.27 to 7.28% with a
total installed capacity of 660 kvar. A 0.25% of third-harmonic
voltage and a 0.50% of fifth-harmonic voltage distortion from the
upstream side were considered. The designed fundamental and
harmonic components of each step are listed in Table 2.
Furthermore, the designed capacitor bank took an allowed
overvoltage factor of 1.05 into account; the fundamental voltage
and the total harmonic voltage were 542 and 88 V, respectively.
Hence, the designed rated voltage of the capacitor was required to
be at least 630 V. The designed maximum fundamental current
and the total harmonic currents were 131 and 58 A, respectively.
Hence, the designed rated current values were required to be at
least 143 A for each step.
The actual parameters of the implemented TSC are listed in Table 3,
where the rated capacity of each capacitor unit is 105 kvar, and the
designed quality factor of the series reactors is 37.47. Some
considerations of the TSC design are as follows: (i) The
consideration of harmonic voltage and current followed the
definition of the rated voltage and current of the IEEE and IEC
shunt capacitor standards; (ii) the designed rated voltage of the
capacitor took an allowed system overvoltage factor into account;
(iii) low tolerances of the components were used in order to control
performance and frequency shifts; (iv) the proper capacitor unit
temperature category were chosen for the ambient temperature
on-site [31, 32]; and (v) an individual fuse for each step provided
protection to the components against fault current.
5 Implementation and experimental results
The TSC configuration is shown in Fig. 8. The total installed output
capacity was 660 kvar, each step had approximately 55 kvar;
furthermore, each step included a fuse, single-phase reactor,
thyristor switch, and single-phase capacitor unit. The current
signal of the controller came from the secondary side of the
transformer.
5.1 TSC measurement results
The measured voltage and current rms value at the capacitor terminal
of one step are shown in Figs. 9a and b From the measurement
results in Fig. 9a, the transient voltage exceeded the rated voltage
of the capacitor unit during the switching period; however, the
overvoltage was still in the allowed operating range of capacitor
unit [30, 31]. The experimental measurement results of proposed
TSC are listed in Table 4. Fig. 9c shows the measured transient
current waveform of the TSC. The inrush current of the capacitor
bank was eliminated, and the transient was damped within two
cycles. The measured current waveforms while the TSC was
switched on are illustrated in Fig. 9d. The system current is the
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Fig. 7 Calculated results
a Rated voltage of the capacitor against total installed capacity
b Total harmonic current into the capacitor bank against total installed capacity
c Total harmonic current into each capacitor against total installed step number

measured current at the secondary side of transformer, and the

capacitor current is the measured current of a one-step capacitor.
From the measurement results, the controller sent a switching

Table 2 Designed fundamental and harmonic components of each step

Parameters Voltage, V Current, A

fundamental 542.25 130.71

3rd-harmonic 79.50 57.50
5th-harmonic 4.90 5.90
7th-harmonic 2.10 3.60
9th-harmonic 0.81 1.76
11th-harmonic 0.61 1.62
13th-harmonic 0.29 0.89
rms value 630.46 142.99

Table 3 Parameters of the implemented TSC

Parameters Capacitor Reactor Thyristor switch

rated voltage 660 V 135 V 460 V

rated current 124.48 A 143.00 A 143.00 A
capacitance 639.40 µF – –
inductance – 1.629 mH –
quantity 12 12 12
Fig. 8 Implementation of the TSC configuration

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Fig. 9 Measured in the TSC
a Voltage rms value of a one-step capacitor
b Current rms value of a one-step capacitor
c Inrush current waveform of the 660- kvar TSC
d Transient current waveforms while the TSC was switched on

‘ON’ signal after approximately two cycles (t1 + t2) from load t3 is the time for the thyristor switch finding a voltage
operated, where t1 is the sampling and calculation period of zero-crossing timing.
controller, and t2 is the default one-cycle delay time. The period

Table 4 Parameters of the implemented TSC 5.2 System measurement results

Parameters Designed Measured Error The measured voltage fluctuation was reduced from 11.37 to
6.40%, after a 660 kvar TSC was installed in parallel with the
rated current 143.00 A 136.67 A −6.33 A (−4.43%) welding machine; the measured system voltage is shown in
rated voltage 630.00 V 589.65 V −40.35 V (−6.40%)
3rd-harmonic voltage 79.50 V 73.51 V −5.99 V (−7.53%)
Fig. 10a. The measured system voltage and reactive power
5th-harmonic voltage 4.90 V 5.61 V 0.71 V (14.48%) demand statistic with the TSC are illustrated in Fig. 10b. The
7th-harmonic voltage 2.10 V 1.03 V −1.07 V (−50.95%) reactive power from the system side was approximately between
3rd-harmonic current 57.50 A 53.44 A −4.06 A (−7.06%) 900 and 1500 kvar. If an extra 660 kvar TSC can be installed in
5th-harmonic current 5.90 A 6.69 A 0.79 A (13.39%)
7th-harmonic current 3.60 A 1.38 A −2.22 A (−61.66%)
parallel, then the expected reactive power demand from the
system side will shift to between 400 and 900 kvar, hence

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Fig. 10 Measured in the 440-V system

a Voltage rms value with and without the TSC
b Voltage and reactive power demand statistic with the TSC
c Voltage and current waveforms with the TSC
d Harmonic voltage spectrum with the TSC
e Harmonic current spectrum with the TSC

providing a better voltage fluctuation improvement. The measured 6 Conclusion

system voltage and current waveforms with the TSC are shown in
Fig. 10c. The measured system harmonic voltage and current
spectrum with the TSC are shown in Figs. 10d and e,
respectively. The total harmonic voltage distortion was reduced
approximately from 14 to 8%.
This paper presented a unique TSC to compensate voltage flicker in a
single-phase system. The design of the TSC was proposed and
discussed. The designed TSC can provide fast switching
performance, and has sufficient ratings to bear harmonic currents

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2758 & The Institution of Engineering and Technology 2016

from the load and upstream sides. Furthermore, thyristor switches
and a single-phase power factor controller were also developed.
From the practical experimental results, the proposed TSC
performed a fast reactive power compensation, and operating of
the components were within the designed ratings. As a result, this
design improves the voltage fluctuation caused by a high harmonic
distortion and fast changing single-phase electric welding machine.
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