Power Quality Clean power, Efficient business. Immediate Energy Efficiency with Power Factor Correction

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1 Power Quality Clean power, Efficient business Immediate Energy Efficiency with Power Factor Correction

2 Outline Power Factor: Definition & Examples Cost Savings Power Factor Correction Equipment Harmonics: Introduction Harmonics and Power Factor Correction Capacitors IEEE 519 Standard Traditional Harmonic Mitigation Methods Active Filter Technology & Applications Schneider Electric Global PQ June

3 Definitions: What is Power Factor? kw = Active Power: It does the "work" for the system - providing the motion, heat, or whatever else is required. kvar = Reactive Power: It doesn't do useful "work." It simply sustains the electromagnetic field. kva = Apparent Power: It is the vector addition of Working Power and Reactive Power. Power Factor : The ratio of Active Power (output) to Total Power (input). It is a measure of efficiency. Total Power (kva) θ Active Power (kw) Reactive Power (kvar) Power Factor = Active (Real) Power Total Power = kw kva = Cosine (θ) Schneider Electric Global PQ June

4 Power Factor:The Beer Analogy kvar Reactive Power kw Active Power kva Apparent Power Mug Capacity = Apparent Power (kva) Foam = Reactive Power (kvar) Beer = Real Power (kw) Power Factor = Beer (kw) Mug Capacity (kva) Capacitors provide the Foam (kvar), freeing up Mug Capacity so you don t have to buy a bigger mug and/or so you can pay less for your beer! Schneider Electric Global PQ June

5 Why is Power Factor Important? Low power factor results in: Poor electrical efficiency Lower system capacity Higher utility bills Most utilities have power factor penalties to encourage power factor correction. Otherwise the utility may have to: Build more power plants Purchase new transformers Use larger cables Power factor correction Reduces power cost Releases system capacity Reduces power losses Improves voltage Schneider Electric Global PQ June

6 Power Factor Correction The easiest solution to improve power factor is to add power factor correction capacitors to your electrical distribution system. The Capacitor Supplies Reactive Current M Current that is drawn from the voltage source is then only used to do real work (kw) and not to create a magnetic field (kvar). The source current is then minimized» The customer only pays for the capacitor» Since the utility doesn t supply the kvar, the customer doesn t pay for it» In short, capacitors save money Schneider Electric Global PQ June 2013 A2 6

7 Power Factor Correction In this example, demand is reduced from 100 kva to 80 kva by installing a 60 kvar capacitor. Before: PF = kw/kva = 80% After: PF = kw/kva = 100% Transformer loading is reduced Schneider Electric Global PQ June

8 Benefits of Power Factor Correction Reduced Power Costs: lower utility bills since utility no longer supplies the reactive current. Released System Capacity Capacitors off-load transformers and cables Improved Voltage Reduced losses kw 100 kvar 100 kva = 141 PF = 70% kw 100 kvar 75 kva = 125 PF = 80% kw 10 0 kva = 100 PF = 100% Schneider Electric Global PQ June

9 How do utilities charge for Power Factor? Example with $5.50 per demand kw Billing Actual Actual Possible Required Required % Reduction Service Demand Power Demand Demand Cost Capacitor kvar Capacitor kvar of Transformer Month kw Factor kva kw Savings for 0.92 pf for 1.0 pf kva Load 05/14/ , $ % 06/14/ $ % 07/16/ $ % 08/15/ $ % 09/16/ , $ % 10/16/ $ % 11/16/ $ % 12/16/ $ % 01/16/ $ % 02/16/ $ % 03/16/ $ % 04/16/ $ % Savings 2012 $7, Approximate cost of standard power factor correction equipment $12 to $15K === Payback about 2 years. Approximate cost of filtered power factor correction equipment $18 to $21K === Payback about 3 years. Schneider Electric Global PQ June

10 Power Factor Correction Capacitors: Low Voltage Power Factor Correction Capacitor Banks Fixed Standard Automatic Detuned Transient Free Medium Voltage Power Factor Correction Capacitor Banks Fixed Standard Automatic Detuned Active Filters LV and MV Hybrid VAR Compensation Products Schneider Electric Global PQ June

11 Schneider Electric Global PQ June

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13 Outline Power Factor: Definition & Examples Cost Savings Power Factor Correction Equipment Harmonics: Introduction Harmonics and Power Factor Correction Capacitors IEEE 519 Standard Traditional Harmonic Mitigation Methods Active Filter Technology & Applications Schneider Electric Global PQ June

14 Waveform seen with oscilloscope 3 rd Harmonic Fundamental 5 t1h Harmonic 7 th Harmonic Harmonic Frequency Sequence 1 60Hz Hz Hz Hz Hz Hz Hz + : : Hz + Harmonic Basics What are harmonics? A harmonic is a component of a periodic wave with a frequency that is an integer multiple of the fundamental frequency Created by power semiconductor devices Converts power (AC to DC) Characteristic harmonics are the predominate harmonics seen by the power distribution system Predicted by the following equation: = 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 Schneider Electric Global PQ June Hc

15 Harmonic Filtering Schneider Electric Global PQ June

16 Multi-pulse Converters H n = np +/- 1 H n = characteristic harmonic order present n = an integer p = number of pulses Elimination of lower orders removes largest amplitude harmonics Harmonic Orders Present Harmonics present by rectifier design Type of rectifier 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 AccuSine SWP AccuSine PCS Schneider Electric Global PQ June

17 Harmonic Basics Nonlinear loads draw harmonic current from source Does no work Voltage: flat topping of waveform Current: high TDD between % Converter Basic PWM VFD Inverter DC bus M A B C Schneider Electric Global PQ June

18 Harmonic Basics Why the concern? Current distortion Added heating = reduced capacity Equipment failures Transformers Conductors and cables Nuisance tripping of electronic circuit breakers (thermal overloads) Heating proportional to harmonic order in cables & bus bars Squared effect on transformers & AC motors I h Loads V h = Ih Z h Schneider Electric Global PQ June

19 Harmonic Basics Voltage distortion Created as current harmonics flow through the system Interference with other electronic loads Malfunctions to failure Induces harmonic currents in linear loads AC motor winding over heating & bearing failures I h Loads V h = Ih Z h Schneider Electric Global PQ June

20 Harmonics and Standard Capacitors Utility M M M VFD Capacitors absorb harmonics Overheating of PFC capacitors Tripping of PF protection devices Reduced life expectancy Magnification of harmonics by resonance Amplification of current between capacitor and transformer Current distortion rises Voltage distortion rises Main transformer &/or capacitor fuses blow Equipment damage Schneider Electric Global PQ June

21 Capacitor Resonance Schneider Electric Global PQ June

22 Detuned Capacitors Schneider Electric Global PQ June

23 Conventional Switch Structure HRC Fuses Contactors Optional De-tuned Inductor L1 L2 L3 Electromechanical switching elements (contactors) are used to connect a capacitor group. Schneider Electric Global PQ June

24 IEEE 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 levels of amplitudes Always referenced to full load current Effective meaning for 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) THDv = Vf V 2 h TDD = I If ( FLA) 2 h THDi = If I 2 h Schneider Electric Global PQ June

25 IEEE 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) Schneider Electric Global PQ June

26 IEEE TDD and THD(I) are not the same except at 100% load As load decreases, TDD decreases while THD(I) increases. Example: Total I, rms Measured Fund I, rms Harm I, rms THD(I) TDD Full load % 3.8% % 3.7% % 3.4% % 2.9% % 2.3% % 1.8% % 1.4% Schneider Electric Global PQ June

27 IEEE 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< % 4.5% 4.0% 1.5% 0.7% 12.0% 100< % 5.5% 5.0% 0.2% 1.0% 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 Demand Distortion (TDD = Total harmonic current distortion measured against fundamental current at demand load.) Schneider Electric Global PQ June

28 Harmonic Standards Designed to protect utility Most harmonic problems are not at PCC with utility Occur inside the plant Occur where nonlinear loads are concentrated Occur with generators & UPS (high probability of problems) Need to protect the user from self by moving the PCC to where harmonic loads are located. Apply principals of IEEE Table 10.3 inside the plant Assures trouble free operations Assures compliance to standard We have the products to meet 5% TDD inside the plant Schneider Electric Global PQ June

29 Harmonic mitigation methods - (Applied per VFD) Solution Advantage Disadvantage Increase short circuit capacity C-Less Technology Impedance (3% LR or 3% DC choke) 5th Harmonic filter Broadband filter 12-pulse rectifiers 18-pulse rectifiers Reduces THD(V) Lower TDD Simplified design Less cost Increases TDD Not likely to occur** Typical % TDD Dependent upon SCR*** Typical Price Multiplier* Cost of transformer and installation change out Compliance is limited Application limited Size limited 30-50% TDD Low cost adder Simple Compliance difficult 30-40% TDD Reduces 5th & total TDD Reduces TDD (thru 13th) Reduces TDD Reliable Reduces TDD Reliable Does not meet harmonic levels at higher orders^ 18-22% TDD Large heat losses Application limited 8-15% TDD Large footprint/heavy Good for >100 HP 8-15 % TDD Large footprint/heavy Good for >100 HP 5-8% TDD Active front end converter Very good TDD Regeneration possible Large footprint/heavy Very high cost per unit High heat losses < 5% TDD * 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.

30 Active Filter Concept Load(s) Source XFMR SOURCE Sense LOAD Sense I s I l Ia Parallel connected I s + I a = I l Optional CT location I a includes 2 nd to 50 th harmonic current I s <5% TDD Schneider Electric Global PQ June

31 Harmonic Mitigation Solutions System solution Comparison of 18-P VFD to AccuSine PCS + standard VFD Price (first cost) Footprint required Heat losses Cost to operate Site cooling required Net Present Value (NPV) Schneider Electric Global PQ June

32 Solutions by AccuSine Model Schneider Electric Global PQ June

33 Schneider Electric Offer AccuSine SWP Amps 400 VAC Neutral correction AccuSine PCS Amps VAC/600 VAC/690 VAC AccuSine PFV Amps VAC/600 VAC/690 VAC No harmonics Use customized transformers for higher voltages (to 15 kv for harmonics & 35 kv for non-harmonic modes) Schneider Electric Global PQ June

34 AccuSine SWP The Schneider Electric solution for harmonic filtering in buildings. Schneider Electric Global PQ June

35 AccuSine PCS The Schneider Electric solution for active harmonic filtering in industrial installations. Most common VFD sites Centrifugal pumps and fans Pumping Stations Potable Wastewater Wastewater Plants Water Purification (potable) Schneider Electric Global PQ June

36 AccuSine PCS/PFV Power Diagram IGBT Module C C C AC Lines Fuse Fuse Line Inductor Pre-charge Contactor S1 E S3 E S5 E + DC Bus Capacitors C Fuse Inductor C C C Filter Board S2 E S4 E S6 E Schneider Electric Global PQ June

37 AccuSine PCS Performance Summary - Harmonics Discrete Spectrum Logic (DSL) TDD <= 5%, if loads have =>3% Z installed 2 nd to 50 th orders, discrete <2 cycle response Resonance avoidance logic Adjustable trip limits per harmonic order On-board commissioning program Phase rotation (clockwise required) Automatic CT orientation (phase rotation/polarity/calibration) Run lockout if not possible to re-orient Oscilloscope feature built into HMI Load/source bar graphs Load balancing Can parallel up to 99 units of each size and mix sizes Schneider Electric Global PQ June

38 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 Required AHF size = amps Six 125 HP VT VFD w/3% LR Required AHF size = amps (not 6 x 47.5 = 285 amps) Schneider Electric Global PQ June

39 AccuSine PCS/PFV Product Package Standard (UL/CSA, ABS) Three current ratings Enclosed NEMA 1/IP20 50 amp 52 (1321mm) x 21 (533mm) x 19 (483mm) Weight 250#(114 K\kg) 100 amp 69 (1753mm) x 21 (533mm) x 19 (483mm) Weight 350#(159 kg) 300 amp 75 (1905mm) x 32 (813mm) x 20 (508mm) Weight 775#(352 kg) Wall mount 50 & 100 amp Free standing 300 amp with disconnect Schneider Electric Global PQ June

40 AccuSine PCS/PFV Product Package Other enclosures ( VAC) NEMA 12, IP30, IP54 50 amp 75 (1905mm) x 31.5 (800mm) x (600mm) Weight 661Ib(300 kg) 100 amp 75 (1905mm) x 31.5 (800mm) x (600mm) Weight 771Ib(350 kg) 300 amp 75 (1905mm) x (1000mm) x 31.5 (800mm) Weight 1012Ib(460 kg) Free standing with door interlocked disconnect CE Certified, C-Tick, ABS, UL, CUL Schneider Electric Global PQ June

41 AccuSine PCS 600/690 VAC Includes autotransformer & input fused disconnect Simple installation 600 VAC: UL/cUL/CE 690 VAC: CE Ratings: PCS 600V 690V 50 A 39 A 33 A 100 A 78 A 67 A 300 A 235 A 200 A Height 300A 1000 mm 800 mm Height 1900 mm Depth 800 mm 50/100A 800 mm 600 mm 1972 mm 600 mm Schneider Electric Global PQ June

42 AccuSine Performance AccuSine injection Source current At VFD Terminals AS off AS on Order % I fund % I fund Fund % % % 0.478% % 0.674% % 0.679% % 0.297% % 0.710% % 0.521% % 0.052% % 0.464% % 0.639% % 0.263% % 0.409% % 0.489% % 0.170% % 0.397% % 0.243% % 0.325% % 0.279% % 0.815% % 0.240% % 0.120% % 0.337% % 0.347% % 0.769% % 0.590% TDD 35.28% 2.67% Schneider Electric Global PQ June

43 700 HP Drive AccuSine ON OFF Schneider Electric Global PQ June

44 700 HP Drive AccuSine ON OFF Schneider Electric Global PQ June

45 700 HP Drive AccuSine ON OFF Schneider Electric Global PQ June

46 AccuSine PCS Dual Mode Operation 2 2 I = I + as h I f Assignment of capacity Assign priority to Harmonic or PF/LB (fundamental) modes Use % of harmonic mode to set split 100% means capacity utilized for harmonic correction, then left over can be used for PF/LB 0% assigns fundamental (PF correction/lb) current as primary mode, left over used for harmonic correction Can split to limit harmonic mode capacity, left over to PF correction/lb I as = rms output current of AccuSine PCS I h = rms harmonic current I f = rms fundamental current Examples I as I h I f Schneider Electric Global PQ June

47 AccuSine PFV Power Factor & VAR Compensation HVC (AccuSine PFV + PF caps) Larger systems approach HVC is Hybrid VAR Control Combines AccuSine PFV with PF caps Caps on line all the time AccuSine adjusts fundamental current to attain unity DPF Cycle-by-cycle response Voltages to 33 kv (6.6 kv shredder in France, kv in US automotive, 13.8 kv steel mill in Colombia) Fundamental current balancing (optional since 1 Nov 10)) Sometimes critical i.e. two phase loads Schneider Electric Global PQ June

48 Thank You Questions? Schneider Electric Global PQ June

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