tuesday eaton medium voltage power factor correction...
TRANSCRIPT
© 2016 Eaton. All Rights Reserved.
Eaton Medium Voltage Power Factor Correction Solutions
Tom McCaughn Dave States
Sales Manager Senior Application Engineer
Andy Angrick
Power Quality Specialist
Tuesday
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Power Factor Basics
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Why consider PFC?
PF correction provides many benefits:
• Primary Benefit:
• Reduced electric utility bill if there is a penalty
• Other Benefits:
• Increased system capacity (generators, cables, transformers)
• Reduced losses (heat) in transformers and cables
• Improved voltage regulation
• Greening the power system
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Power Factor Opportunities by Application
Source: IEEE
Std 141-1993
(IEEE Red Book)
Industry Percent Uncorrected PF
Brewery 76-80
Cement 80-85
Chemical 65-75
Coal Mine 65-80
Clothing 35-60
Electroplating 65-70
Foundry 75-80
Forge 70-80
Hospital 75-80
Machine manufacturing 60-65
Metal working 65-70
Office building 80-90
Oil-field pumping 40-60
Paint manufacturing 55-65
Plastic 75-80
Stamping 60-70
Steelworks 65-80
Textile 65-75
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Design and Application Considerations
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Low vs. Medium Voltage PFC
• Low Voltage PFC
• Typically connected at the 480 V level
• Improves kVA loading of LV substation
transformers (assuming inductive loads)
• Automatically switched units are very common
• Typical application is one per LV substation
• Generally more cost effective than installing multiple
fixed units
• Improves no-load to full-load voltage regulation
• Fixed units can also be used at electrical panels or
individual loads
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Low vs. Medium Voltage PFC
• Medium Voltage PFC
• Typically connected at the service entrance or
customer’s MV substations
• Generally used in the following situations:
• Customer has MV loads (e.g., 4160 V induction motors)
• PFC is needed only for the purpose of reducing or
eliminating utility penalties
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Primary Design Decisions for PFC
• Fixed versus Switched Operation
• Filtered/Anti-resonant versus Unfiltered
• Need to consider electrical system and load
characteristics
• Nominal Operating Voltage
• Total kVAR required
• Step Size (Switched/Automatic Units Only)
• Response Time (Automatic Units Only)
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Detuned Filter Design Considerations
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Tuning Selection Basics
• Harmonic Resonance
• The condition when the inductive impedance (X of
L) equals the capacitive impedance (=X of C, say
by adding PFC capacitors to an existing facility
where the transformer, motors generators and
cable mutual inductance acts as the inductor)
• Resonance can amplify existing harmonic voltages
(Parallel Resonance) and currents (Series
Resonance).
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Resonance Basics
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Harmonic Resonance
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Series Resonance
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Parallel Resonance
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How to avoid resonance
• Change the capacitor size. Many times multiple
resonant points so not practical
• OR
• Fix the capacitors resonance point to an impossible
value = make it Anti resonant
• Impossible value = Frequencies that do not exist for
example 4.2 or 4.08 or 4.7 or 3.8 or 3.67 etc.
• Determined mostly by practicality of calculation of
inductor values (for ex. 4.2 = 5%, 4.08 = 6% etc.)
• Done by converting the capacitor into a tuned LC circuit
(add the “L”= inductor)
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Selecting Proper Tuning
• Most facilities have harmonic spectrum with characteristic
harmonic order beginning with 5th harmonic.
• Selecting the tuning below 5th makes the most economical
sense.
• Too close to 5th = lower impedance to the 5th order and
higher current absorbed.
• Too close to 4th = can cause parallel resonance.
• Too far from 5th (3.8, 2.67 etc. much bigger inductor = too
much losses). But situations can exist to select these
tuning orders too.
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4.7 vs 4.2 Tuning
• Both avoid resonance. Avoiding resonance is the key
criteria in selecting an anti resonant bank (detuned
filter).
• 4.7 tuned capacitor can absorb up to 50% more
harmonic currents into itself compared to 4.2 tuned
capacitor. (Size of transformer, impedance and size
and tuning of capacitor dependent).
• Harmonic currents can cause excessive heating (not
just I2R losses) but dielectric losses increase
exponentially with higher harmonic orders = higher
heat = lower life expectancy)
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4.7 vs 4.2 Tuning
• In worst case scenario, purely due to harmonics (both
V and I), the design life expectancy of capacitors used
in a 4.7 tuned filter is 27,000 hours vs. 34,000 hours
in 4.2 detuned filter. Compare this to the design life of
100,000 hours at rated conditions.
• When there is no Power Quality study 4.2 tuning will
avoid resonance and protect the capacitor bank while
providing the needed kVAR’s
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4.7 vs 4.2 Impedance Scan
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PFC Detuned Filter Recommendations
• PFC banks react to “VAR” demand and so
cannot truly control how much harmonic is
absorbed which can sometimes lead to too
much harmonic current and failures.
• For PFC and resonance concerns begin by
recommending Anti Resonant “Detuned PFC”
• 4.2 detuned.
• Avoids resonance, provides PF correction.
• 50% less harmonic current than 4.7th resulting in
longer life
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Considerations for Selecting PFC/ Anti-Resonant PFC
• Type of system (weak or strong – high or low
source impedance)
• Possibility of resonance
• Current Divider phenomenon
• Primary purpose of the capacitor bank
• Ratio of largest block of kVAR required to
capacitor step sizes
• Voltage rise / Lead PF penalties for fixed
stages/steps
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MV PFC Minimum Specification Requirements
• Nominal Operating Voltage
• Operation Type (Fixed or Switched)
• Filtered/Anti-resonant or Unfiltered
• Please specify tuning point, such as 4.2H, if a
filtered unit is required
• Total kVAR required
• Step Size (Switched/Automatic Units Only)
• Response Time (If Standard 200 second
response time is not sufficient)
© 2016 Eaton. All Rights Reserved.
Eaton’s MV Metal-Enclosed Power Factor Correction Solutions
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Eaton Power Factor Correction
• Eaton LV & MV PFC
solutions are
engineered and
manufactured in our
plant in the
Asheville, NC area.
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MV Capacitor Banks
• AUTOVAR MV (2.4kV to 14.4kV
SWITCHED CAPACITOR)
Medium Voltage Metal Enclosed
Capacitor Bank.
Capacitor banks enclosed in a steel
enclosure for indoor or outdoor locations.
• UNIVAR-XV (FIXED CAPACITOR)
Capacitor cells with Terminal Box for
Indoor or Outdoor Installation.
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Univar-XV Fixed Capacitors
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Univar – XV Features
• NEMA 1/3R/12 Indoor/Outdoor
• Viewing Window – A viewing window has been added to
the front cover to allow routine inspection of fuse status
without opening the enclosure.
• Removable Front Cover – A removable front cover and
top cover.
• Typical Application: Full Voltage across the line start
induction motor, connected to motor terminals
• Fuses: Each phase is fused, 50kAIC rating.
• Capacitor: 3-phase internally delta connected with
internal discharge resistors.
• Voltage Range: 2,400V to 4,800V
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Univar-XV Available Sizes
• The following sizes are available, in
increments of 25kVAR.
• 2400V 25kVAR – 825kVAR
• 4160V 25kVAR – 900kVAR
• 4800V 25kVAR – 900kVAR
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Univar – XV Advantages
• Viewing window allows easy and safe
indication of fuse status
• Removable front and top panel allows easy
access to terminals for wiring – others are top
only
• More wiring space allows room for bends and
stress cones.
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MV Autovar Engineered Metal Enclosed Banks
• Voltages from 2.3kV
to14.4kV
• 50 kVAR to 10,000 kVAR
• Heavy Duty NEMA 3R
Outdoor enclosure
• Custom Engineered and
Standard Designs available
• Fixed or Switched capacitor bank
• Automatic capacitor bank
• De-Tuned Anti-resonant Capacitor bank
with standard 4.2H tuning, other tunings
available (e.g., 4.4H, 4.6H, 4.7H, 6.7H)
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Typical One-Line
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MV PFC Sample Dimensional View
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Shipping & Handling Information
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Main-Tie-Main Bank Configuration
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MV PFC Front View
Removable lifting eyes
Isolated Controls
Compartment
Capacitor compartment
Key interlocks
Main
Incoming
Section
Base
channel
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MV Autovar Example: 13.2kV 1,200kVAR
13.2kV, 4.2H, (300 + 900 = 1200kVAR)
DETUNED FILTER CAPACITOR BANK
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MV Autovar Example: 13.8kV 9000kVAR
13.8kV, 4.2H, (3000 + 3000 + 3000 = 9000kVAR)
DETUNED FILTER CAPACITOR BANK
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MV Capacitor Bank Options
• Incoming section with NEMA 2 or 4 hole pads
• Main Disconnect
• Grounding Switch
• Surge arrestors
• Main fuses
• Control Power Transformer
• 1 to 10 stages
• Flexible stage sizes
• Non-Filtered or Detuned anti-resonant Filter
• Stages can be fixed or automatic or combination
• Thermostatically controlled space heater in each section
• Thermostatically controlled cooling fans in each section
• Eaton PowerXpert Communications Gateway
• And many more options
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Capacitor Bank Control Features
• H-O-A Selector switch to manually force any stage
ON or OFF when not in automatic.
• Timers blocking re-closing of stage within 200
seconds. Allows time to discharge the cells.
• Digital Meter/Relay to display capacitor bank
current and phase current unbalance detection.
• Digital Power Factor Controller Eaton BLR-CM.
• 120V Circuit Breaker for control power
• Full Voltage LED Indicating Lights
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15 kV MV PFC Interior View
Fuses
15KV
Vacuum
switches
Capacitors
Main
Incoming
Disconnect
Ground
Switch
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5kV MV PFC Interior View Capacitor Fuses
Capacitor
Reactor
Arrestors Main Switch
Ground Switch
PT’s Main Fuses
Vacuum Contactor
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Typical Control Panel Shatter Proof Glass Multifunction Digital Meter
Alarms & Control
Stage Counter
Future Stages
Kirk Key Interlock
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Capacitor Fusing
Fault Current: Fuses rated
50KA, FULL VOLTAGE
Tank-Rupture: Maximum
clearing TCC curve must
coordinate with tank rupture
curve of the capacitor.
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MV Autovar – Additional Advantages
• Shipping splits / Modular design
• Air filter replacement without entering the
enclosure
• Multifunction Relay
• Barriers between sections
• Floor pan in each section
• Anti-condensation heaters
• Control Power Transformer is standard
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MV Autovar – Standard Designs
• Standard Designs are currently available for 4160 V
applications
• Available in the most commonly requested sizes
• Standard design units include the following features
• Main Switch
• Main Fuses
• Ground Switch
• Type CM controller with Modbus RTU RS-485 Com Port
• Integrated Meter/Relay
• Extreme Duty Capacitor Cells (Filtered units only)
• Optional Factory CSA Certification is available
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MV Autovar – Standard Designs
• Unfiltered 4160 V, 60 Hz units
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MV Autovar – Standard Designs
• Filtered 4160 V, 60 Hz units, 4.2H Detuned
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EATON AUTOVAR MV
VS.
COMPETITION
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MV Competitor Comparison – Part 1
EATON N C E A D G
Capacitor cells mounted vertically
with bushings on top so the oil does
not leak at the bushing weld.
Encapsulated Control Power
Transformer
Full Voltage LED Indicating Light
Isolated compartments for each
stage
Smaller Shipping Sections (90"W x
49"D) for easy handling and
installation. Sections shipped on
pallets for fork-lift handling.
Inrush reactors made with copper
windings and manufactured for
better cooling.
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MV Competitor Comparison – Part 2 EATON N C E A D G
Bottom Steel Pan
Capacitor cells are HEAVY DUTY
55 Deg. C Rated, 15kA fault
handling and 125% Overvoltage
Capability
INFO NOT
PUBLISHED
INFO NOT
PUBLISHED
ISO-9001 Certification
Capacitor Fuses are Rated Full
SYSTEM VOLTAGE CLASS
INFO NOT
PUBLISHED
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PUBLISHED
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INFO NOT
PUBLISHED
120V Control Power Surge
Protection
Incoming Section Designed for Both
TOP OR BOTTOM Entry as
Standard
INFO NOT
PUBLISHED
Multi-Ratio Current Transformers for
Capacitor Bank Current Monitoring
and Future Expansion
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MV Competitor Comparison – Part 3
EATON N C E A D G
Only Front Access Clearance
Required
7.2KV Vacuum Contactors for 5kV
Capacitor bank
INFO NOT
PUBLISHED
INFO NOT
PUBLISHED
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PUBLISHED
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PUBLISHED
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PUBLISHED
Air Filters Removable without
opening enclosure door
11-Gauge or equivalent steel
thickness
INFO NOT
PUBLISHED
INFO NOT
PUBLISHED
INFO NOT
PUBLISHED
Redundant Cooling fans with
thermostat control offered as
standard
52 © 2016 Eaton. All Rights Reserved.
Other Eaton PFC Advantages
• Both LV & MV Eaton products built in Asheville, NC
• Eaton has a staff of 5 Application Engineers in the USA to
support pre and post sales questions
• Can be reached via an 800# or e-mail
• Eaton PFC customers are supported by over 300 Eaton field
service engineers in locations throughout North America
• Eaton PFC products are sold through local electrical distributors
who understand the area and provide local support
• Eaton has well qualified regional Manufactures Representatives
that can provide PFC application guidance and local support
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