Power Electronics

Power Factor Correction in Today's Electrical Networks
Hany Boulos Sales Manager, Power Quality Correction Group Schneider Electric
What is Power Factor?

Definitions: Active (Working) Power: Normally measured in kilowatts (kW). It does the "work" for the system-providing the motion, heat, or whatever else is required. Reactive Power: Normally measured in kilovoltamperes-reactive (kVAR), doesn't do useful "work." It simply sustains the electromagnetic field. Apparent Power: Normally measured in kilovoltamperes (kVA). Active Power and Reactive Power together make up apparent power (in vector sum).
Schneider Electric - Energy Management Seminar- 5.7.09
What is Power Factor?

Power Factor : A measure of efficiency. The ratio of Active Power (output) to Apparant Power (input)
Active Power (kW)
Power Factor =
Reactive Power
Apparant Power (kVA)
= =
Active (Real) Power Apparant Power kW kVA Cosine ()
A power factor reading close to 1.0 means that electrical power is being utilized effectively, while a low power factor indicates poor utilization of electrical power.
Power Factor:The Beer Analogy

kVAR
Reactive Power
Mug Capacity = Apparent Power (KVA) Foam = Reactive Power (KVAR) Beer = Real Power (kW) kVA
Apparent Power
Power Factor =
Beer (kW) Mug Capacity (KVA)
kW
Active Power
Capacitors provide the Foam (KVAR), freeing up Mug Capacity so you dont have to buy a bigger mug and/or so you can pay less for your beer !
Power Factor Example

If you had a load in a paper mill that was operating at 100 kW and the Apparent Power consumed was 125 kVA, what is the Power Factor?
Active Power (kW)
Power Factor
= =
Apparant Power (kVA)
Reactive Power
Active (Real) Power Total Power 100kW 125kVA Cosine () = .80
If we add capacitance to this system and raise the power factor to 95% or 0.95, it would only require 105kVA to supply the same load. That is a reduction of 20%! .95 pf = 100kW Total Power (kVA) Total Power = 100kW .95 = 105kVA
Schneider Electric - Energy Management Seminar- 5.7.09 5
Should we be concerned about harmonics ?

We dont have harmonics in our facility Our devices dont cause harmonics Harmonics have never been a problem before
Who cares about harmonics ?

Utilities care
Distortion inside customers facility can cause distortion to other customers nearby
Customers with sensitive loads care

Most problems occur inside the users facility not at PCC w/utility Occurs where nonlinear loads are concentrated
We need to apply solution for customers benefit and utilities demands
What equipment produces Nonlinear Current?

Computers
Variable Frequency Drives Electronic Ballasts Almost anything electronic
Fax Machines
Copiers
Distortion: what is it ?
A linear waveform is a sinusoidal and periodic waveform (current or voltage) A non-linear (or distorted) waveform is any periodic waveform (current or voltage) which is non-sinusoidal
Distortion and Harmonics

Fundamental
A distorted waveform can be represented as the sum of its Harmonics
3 Harmonic 7 Harmonic
th
rd
t1h
Harmonic
Fundamental
3 Harmonic 7 Harmonic
th
rd
t1h
Harmonic
10
Composition of a Non-linear Waveform

The Cause of Harmonic Currents:
The Choppy, non-linear current drawn by electronic loads is actually a fundamental (60hz) component plus many integer multiples of that fundamental frequency: These integer multiples of the fundamental frequency are just high frequency currents & they cause the problem
F undamental & all harmo nics
11
Time vs Frequency
Time Domain Frequency Domain
1 0.5 0 1 3 5 7 9 1 1
60 Hz
f1 + f3 f5 f7
f1 = 60 Hz
180 Hz
f3 = 3 x 60hz = 180 hz
1 0.5 0 1 3 5 7 9 1 1
+
300 Hz
f5 = 5 x 60 hz = 300 hz
1 0.5 0 1 3 5 7 9 1 1
+
420 Hz
f7 = 7 x 60 hz = 420 hz
1 0.5 0 1 3 5 7 9 1 1
As an experiment, you could add the currents from several power supplies delivering power to a load at different, discrete frequencies & recreate the distorted waveforms.
Distorted Wave = f1 + f3 + f5 + f7
1 0.5 0 1 3 5 7 9 1 1
12
What are Harmonics?

A harmonic is a component of a periodic wave having a frequency that is an integer multiple of the fundamental power line frequency
13
Typical Waveforms
Harmonic Signatures:
Each type of load draws current in a unique way which produces a signature which determines the frequency of the harmonics present:
14
Typical Waveforms
Harmonic Current Signatures:
Predominant harmonic currents by load type: A symmetrical current will produce only odd harmonics Different loads draw specific predominant harmonics:
Most 3 phase Delta networks contain 5th harmonic current

Predominant Harmonics 5th 7th 9th 11th
Device 1Ph Computer Power Supplies 3Ph Computer Power Supplies 3Ph UPS Electronic Ballasts 6 Pulse Drive 12 Pulse Drive
3rd
13th
15
Measuring the presence of current harmonics
16
Why are Harmonics a Problem?

Heating Effect: Harmonics create heat in units proportional to the square of the harmonic order.
60Hz = 1heating unit (amp) 5th order = 25 heating units (amps)
17
Total Power Factor

TPF (DPF) (Distortion factor) = x KW DPF = = Cos KVAf Distortion Factor = 1 1 + THD(I)2
= Cos
TPF = Total or true power factor DPF = Displacement power factor Distortion Factor = Harmonic power factor
18
Total Power Factor Example

Variable frequency drive (PWM type)
DPF = .95 THD(I) = 90% (no DC choke & no input line reactor) Distortion Factor =
1 1 + .92
= .7433
TPF = .95 x .7433 = .7061
19
Harmonics have a negative impact on a Facility by. . .

Increasing operating costs Increasing process downtime Making traditional power factor correction difficult Lowering system efficiency This impact is primarily due to the heating effect and produce many recognizable symptoms
20
How Harmonics Affect Capacitors

Capacitors are naturally a low impedance to high frequencies:
Caps absorb harmonics
As capacitor absorbs harmonics, the capacitor heats up

Reduced life expectancy
Voltage harmonics stress the capacitor dielectric

Reduced life expectancy
Parallel combination of capacitors with motor or transformer can cause resonance.......
21
How Harmonics Affect Capacitors (cont.)

You use the principle of resonance every day!
A Radio uses Resonance to Capture a Station: Antenna AMP

f3
Spkr
f2
Variable Capacitor
f1
How Harmonics Affect Capacitors:

Resonance:
XL XC
fr = f 1
Resonance XL
( XL-Xc )
X L = 2 fl
XC =
1 2fc
fr
XC
23
How Harmonics Affect Capacitors:

How Capacitors Tune a circuit: Standard Network: Equivalent circuit:
Ih
M M M
XL
Ih
fr = 60
kVA 100 kVAR Iz
e.g...1500 kVA fr = 60
225 kVAR 5.5% Iz
1500 100 = 660 hz = h11 225 5. 5
24
Capacitor Resonance
Resonant Point likely to amplify dominant harmonic (typically 5th)
Magnification of Harmonic Current when Standard Capacitor are Added to the Network
Power Factor Correction With Harmonics:

De-tuning a network:
Force the resonant point away from naturally occurring harmonics
4.2 Harmonic (252 Hz)
I<h5>
Z
Ih5
f
A
f1
f3
f5
f7
f9
We control the impedance of these two elements

26
Evaluating Severity of Harmonics

Total Harmonic Distortion: Current
A measure of the amount by which a composite current waveform deviates from an ideal sine wave Caused by the manner in which electronic loads draw current for only a part of a complete sine wave Measured as THD:
Causes additional heating in conductors and transformers, and leads to Voltage Distortion
Expressed as a %, THD is of little value Total Demand Distortion is becoming accepted
I THD
2 2
+ I
+ I
1
2 4
+L
100 % =
h = 2
Ih 2 100 %
1
27
TDD and THD (I) are not the same
THD (I) is the amplitude of the harmonic current (rms value) divided by the amplitude of the fundamental current (rms) for each monitored load. TDD is the amplitude of the harmonic current (rms value) divided by the amplitude of the full load fundamental current. Example: System with nonlinear load current readings
Total I, rms 936.68 836.70 767.68 592.63 424.53 246.58 111.80 Measured Fund I, Harm I, rms rms THD(I) 936.00 35.57 3.8% 836.00 34.28 4.1% 767.00 32.21 4.2% 592.00 27.23 4.6% 424.00 21.20 5.0% 246.00 16.97 6.9% 111.00 13.32 12.0%
Full load
Max level of harmonic current occurs at full load level
TDD 3.8% 3.7% 3.4% 2.9% 2.3% 1.8% 1.4%
As load decreases, TDD decreases while THD(I) increases.
28
Evaluating Severity of Harmonics

Limits for THD (V):
IEEE 519-1992 is considered the standard across North America for acceptable levels of voltage THD at the point of common coupling Maximum 5% THD in voltage (systems below 69kV) Maximum 3% THD for critical systems: Hospital Equipment Air Traffic Control Systems Mainframe Computers Data Processing Centers
29
Anti-Resonant - AV6000
Similar to AV5000 c/w a reactor in series Reactor tuned to 4.2 or 4.4 Up to 300kVAR per section Expandable up to 1200kVAR without split incoming Larger systems available with split incoming Additional cubicles can be field installed if required
30
Harmonic Filter - AV7000

Similar to AV6000 except different reactor tuning Selection of reactor tuning is 4.7 and 4.9. Up to 300kVAR per section Expandable up to 1200kVAR without split incoming Larger systems available with split incoming Additional cubicles can be field installed if required
31
AT6000/AT7000 Transient Free

z z
z z z z
For sensitive networks Similar to AV6000 except solid state switching Reactor tuned to 4.2 or 4.4 Response time of less than 5 sec Up to 450kVAR per section Expandable up to 1350kVAR without split incoming Larger systems available with split incoming Additional cubicles can be field installed if required
32
AT6000 Electronic Switch

L1
Fuses SCR-Diode Capacitor
L2
L3
De-tuned Inductor
Introducing Accusine PCS Active Harmonic Filter

New breed of power quality product
Harmonics cancellation Power factor correction VAR compensation Resonance elimination
Independent or simultaneous modes of operation
34
ReactiVar AccuSine Power Correction System is the complete solution...

Active Harmonic Filtering
AccuSine PCS monitors the line current, determines the frequency and magnitude of the harmonic content in it and then injects harmonic current canceling the harmonics for the electrical system.
Resonance Elimination
AccuSine PCS dynamically removes harmonics from the network meaning no energy is present at the resonant frequency
More than just a harmonic filter: Instantaneous Power Factor Correction

AccuSine PCS injects leading or lagging current as required at the fundamental frequency.
Dynamic VAR compensation

AccuSine PCS is able to inject peak current at two and a quarter times its rms current rating for up to 3 cycles. For many high current in-rush applications this level of compensation eliminates visible flicker and voltage sags.
35
AccuSine PCS is Leading Edge Technology

IGBTs, 20 kHz modulation, to synthesize the output current for injection Real time control algorithms
Responds instantly to inrush situations (40 micro-sec) Full response in 8 msec for steady state situations
AccuSine Output Wave Form pure harmonics
36
AccuSine PCS Fundamentals

AccuSine PCS generates the harmonic currents required by non-linear loads. These currents are opposite in phase with respect to the current supplied by the source. The AccuSine PCS Active Harmonic Filter (AHF) is sized only for the harmonic currents The current consumed by the load is then: I (load) = I (source) + I (conditioner)
37
Application of AccuSine PCS

I. source
2 1,5 1 0,5 0 -0,5 -1 -1,5 -2 2 1,5 1 0,5 0 -0,5 -1 -1,5 -2
I. Harmonics
I. Active Conditioner
I. resultant
2 1,5 1 0,5 0 -0,5 -1 -1,5 -2
I.s
Source
I.ac
active conditioner
-2 -1,5 1,5 -1 1 0,5 0 -0,5
I.h
non linear load
38
What does it take to get SYSTEM SOLUTION?

Nonlinear products made compatible with solution
Uniform harmonic approach 3% input line reactors on most non-linear devices, 5% DC bus choke okay for PWM VFD
Limits rms current at load for diode rectifiers Avoids interaction with snubber circuit for SCR rectifiers A product compatible with all nonlinear products
When applied to above yields results desired Compliance with harmonic specifications Protection for users in his the plant
Vendor willing to assume total responsibility Vendor willing to guarantee solution

AccuSine PCS Installation Flexibility

Load(s) Source XFMR Typical CT Placement
Alternate CT Placement
Can easily add more capacity when required to meet facility expansion needs Multiple units operate in parallel so additional units can be installed using the same CTs
40
Example of AccuSine PCS Performance

Load Side Wave Form
+
AccuSine Output Wave Form
=
Line Side Wave Form
41
AccuSine PCS Performance Example (cont.)
VFD Only
AF off AF on Order % I fund% I fund Fund 100.000% 100.000% 3 0.038% 0.478% 5 31.660% 0.674% 7 11.480% 0.679% 9 0.435% 0.297% 11 7.068% 0.710% 13 4.267% 0.521% 15 0.367% 0.052% 17 3.438% 0.464% 19 2.904% 0.639% 21 0.284% 0.263% 23 2.042% 0.409% 25 2.177% 0.489% 27 0.293% 0.170% 29 1.238% 0.397% 31 1.740% 0.243% 33 0.261% 0.325% 35 0.800% 0.279% 37 1.420% 0.815% 39 0.282% 0.240% 41 0.588% 0.120% 43 1.281% 0.337% 45 0.259% 0.347% 47 0.427% 0.769% 49 1.348% 0.590% %THD(I) 35.28% 2.67%
Harmonic Spectrum
VFD + Active Filter

Dual Mode Operation

Ias =
Ih2 + Ir2
Ias = rms output current of AccuSine Ih = rms harmonic current Ir = rms reactive current
Ias 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 Examples Ih 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 95.0 Ir 99.5 98.0 95.4 91.7 86.6 80.0 71.4 60.0 43.6 31.2
43
AccuSine Sizing Examples

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 = 113.5 amps
Six 125 HP VT VFD w/3% LR

Required AHF size = 157.6 amps (not 6 x 47.5 = 285 amps)
44
Real Time Example - Automotive

Square D Power Quality Correction - Ford Monroe Stamping
FILTER 0 %
L1mains
Voltage [V]
Sub-Station D2- 99021901.RT1 Contents

L2mains L3mains Avg/Tot Mains L1cap L2cap L3cap
True RMS
Avg/Tot Cap
280 270 260 3000 2000 1000 0 2000 1000
Reactive [kVAR]
Current [A]
19-08:25:22 19-08:25:24 19-08:25:26 19-08:25:28 19-08:25:30 19-08:25:32 19-08:25:33 19-08:25:35 19-08:25:37 19-08:25:39 19-08:25:41 19-08:25:43 19-08:25:45 19-08:25:46 19-08:25:48
V-L1 V-L2 V-L3 Im-L1 Im-L2 Im-L3 Qm-L1 Qm-L2 Qm-L3 QmTot Qc-L1 Qc-L2 Qc-L3 QcTot
272.5 278.0 273.5 276.9 279.4 275.9 278.6 273.1 280.6 894.0 606.5 1055.0 534.6 1105.0 736.8 759.3 844.6 584.0 129.5 21.8 97.3 68.9 45.3 116.8 -46.5 151.0 -115.3 152.7 217.7 99.4 261.1 263.6 208.0 268.8 278.4 214.1 271.0 262.5 215.9 800.8 804.4 638.1
278.9 278.9 274.6 179.7 449.3 489.7 15.1 -41.6 92.6 66.1 109.3 109.6 105.8 324.7
278.0 279.9 275.1 188.7 489.7 512.2 17.1 -28.2 101.9 90.8 107.5 108.7 105.7 321.9
278.5 277.4 272.6 323.5 678.4 678.4 46.5 49.0 146.9 242.0 107.2 107.6 104.3 319.1
280.4 278.4 276.1 179.7 431.3 332.5 -50.3 16.5 65.0 30.6 53.2 52.7 51.4 157.4
273.5 277.9 275.6 876.1 521.1 516.7 202.9 135.1 51.6 390.3 0.0 0.0 1.6 1.7
278.9 278.9 279.1 9.0 13.5 13.5 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
271.5 274.0 275.5 266.1 254.2 262.1 271.9 271.4 272.4 268.9 251.9 262.4 269.1 266.1 275.1 269.1 255.7 260.2 763.8 516.7 525.6 1545.0 2951.0 1779.0 799.7 983.9 822.2 1181.0 3216.0 1882.0 992.9 1195.0 494.2 1239.0 2538.0 1882.0 197.2 129.8 88.9 344.3 625.6 408.4 173.8 154.9 202.6 289.2 754.0 428.0 240.5 297.0 134.1 235.5 603.4 438.3 611.4 581.1 425.1 869.4 1982.0 1274.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.1 0.0 0.0 0.0 0.0 0.0 0.1 0.0
Time [DD-HH:MM:SS]
45
Product Package
Standard (UL/CSA, ABS) Three sizes Enclosed NEMA 1
50 amp 52(1321mm) x 21(533mm) x 19(483mm) Weight 250#(114 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)
Chassis IP00 Wall mount 50 & 100 amp Free standing 300 amp with disconnect
46
Product Package
International enclosures
NEMA 12, IP30, IP54 50 amp 75(1905mm) x 31.5(800mm) x 23.62(600mm) Weight 661Ib(300Kg) 100 amp 75(1905mm) x 31.5(800mm) x 23.62(600mm) Weight 771Ib(350 Kg) 300 amp 91(2300mm) x 39.37(1000mm) x 31.5(800mm) Weight 1212Ib(550 Kg) Free standing with door interlocked disconnect CE Certified, C-Tick, ABS, UL, CUL
47
Product in MCC line up
MCC Packaging in Model 6

50 & 100 amp models Requires one vertical 20 x 20 section Includes circuit breaker in section Can compensate multiple VFDs in one line up
48
AccuSine PCS current Transformers

AC lines
Class 1 400 Hz Four sizes 500:5/1000:5/3000:5/5000:5 Stock split core round units
Added to AccuSine PCS (when parallel connected & source sense)

Use solid core at equal ratio as AC lines CT
49
AccuSine: the best choice for harmonic control

Can meet IEEE 519 Eliminates harmonic simulations/studies
Cannot select AccuSine based on studies Use Excel spreadsheet for selection
Packages easily with DE and MC

Bundles with MCC, VFD, & Powerlogic All are MCC packaged to provide clean MCC
Multipurpose one harmonic solution

Not just on VFD Ultraviolet lighting (tertiary treatment)
MW of power
Ozone generators/UPS
50
Accusine Applications
Pumping stations Office building, hospitals & hotels Mills - paper, steel, rubber, textile Semiconductor plants Automated factories Oil drilling & refineries Amusement parks & ski lifts Large industrial facilities
51
AccuSine Around the World
52
Hybrid Filters & HVC

Combination of passive & active technologies
53
Hybrid Var Compensators HVC

4 High speed response 4 infinite variability 4 Full duration 4 Unity Power Factor maintained
54
Hybrid Approach
Use fix caps for inrush support
Always on line Instant response
Use AccuSine for fine tuning

Injects leading or lagging VARs Cancels fix caps leading VARs at no load Adds leading VARs as loads increase One half cycle response
55
HVC Performance
HVC
2000 Vars Leading/Lagging 1500 1000 500 0 -500 -1000 Time in cycles
4 0 2 6 8 12 14 10 16 18
Fixed Kvar Load Accusine Result Kvar
56
The Challenge
To compensate reactive power required by rapid and frequent load variations
increased productivity elimination of voltage flicker and sags increased system capacity and energy efficiency gas tight tubular fabrication essential weld quality Economical
57
Welding deformation
58
Thank you!
59

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Power Factor Correction in Today's Electrical Networks

What is Power Factor?

Schneider Electric - Energy Management Seminar- 5.7.09

What is Power Factor?

Active Power (kW)

Apparant Power (kVA)

Active (Real) Power Apparant Power kW kVA Cosine ()

Schneider Electric - Energy Management Seminar- 5.7.09

Power Factor:The Beer Analogy

Beer (kW) Mug Capacity (KVA)

Schneider Electric - Energy Management Seminar- 5.7.09

Power Factor Example

Apparant Power (kVA)

Active (Real) Power Total Power 100kW 125kVA Cosine () = .80

Should we be concerned about harmonics ?

Schneider Electric - Energy Management Seminar- 5.7.09

Who cares about harmonics ?

Customers with sensitive loads care

We need to apply solution for customers benefit and utilities demands

Schneider Electric - Energy Management Seminar- 5.7.09

What equipment produces Nonlinear Current?

Variable Frequency Drives Electronic Ballasts Almost anything electronic

Schneider Electric - Energy Management Seminar- 5.7.09

Schneider Electric - Energy Management Seminar- 5.7.09

Distortion and Harmonics

A distorted waveform can be represented as the sum of its Harmonics

Schneider Electric - Energy Management Seminar- 5.7.09

Composition of a Non-linear Waveform

Schneider Electric - Energy Management Seminar- 5.7.09

Schneider Electric - Energy Management Seminar- 5.7.09

What are Harmonics?

Schneider Electric - Energy Management Seminar- 5.7.09

Schneider Electric - Energy Management Seminar- 5.7.09

Most 3 phase Delta networks contain 5th harmonic current

Schneider Electric - Energy Management Seminar- 5.7.09

Measuring the presence of current harmonics

Schneider Electric - Energy Management Seminar- 5.7.09

Why are Harmonics a Problem?

Schneider Electric - Energy Management Seminar- 5.7.09

Total Power Factor

Schneider Electric - Energy Management Seminar- 5.7.09

Total Power Factor Example

TPF = .95 x .7433 = .7061

Schneider Electric - Energy Management Seminar- 5.7.09

Harmonics have a negative impact on a Facility by. . .

Schneider Electric - Energy Management Seminar- 5.7.09

How Harmonics Affect Capacitors

As capacitor absorbs harmonics, the capacitor heats up

Voltage harmonics stress the capacitor dielectric

Parallel combination of capacitors with motor or transformer can cause resonance.......

Schneider Electric - Energy Management Seminar- 5.7.09

How Harmonics Affect Capacitors (cont.)

A Radio uses Resonance to Capture a Station: Antenna AMP

How Harmonics Affect Capacitors:

Schneider Electric - Energy Management Seminar- 5.7.09

How Harmonics Affect Capacitors:

kVA 100 kVAR Iz

225 kVAR 5.5% Iz

1500 100 = 660 hz = h11 225 5. 5

Schneider Electric - Energy Management Seminar- 5.7.09

Power Factor Correction With Harmonics:

4.2 Harmonic (252 Hz)

We control the impedance of these two elements