Harmonic Solutions –

A Side-by-Side Comparison

Presented by:
Dan Carnovale; P.E.
danieljcarnovale@eaton.com
Eaton Corporation

1 © 2008 Eaton Corporation. All rights reserved.

Overview
• Harmonic Overview
• Lab Introduction
• Alternate Source/Generator Issues
• Harmonic Solutions
• Lab Simulations
• Energy Savings and Harmonic Solutions
• Harmonic Resonance
• Wrap Up

2
Which came first?…..

Voltage Distortion Current Distortion

• In this case…the Egg!
• Current distortion causes Voltage distortion
• Voltage distortion is created by pulling distorted current
through an impedance
• Amount of voltage distortion depends on:
• System impedance
• Amount of distorted current pulled through the impedance
• If either increases, VTHD will increase

3
Internal vs. External Sources
• Some harmonic sources are internal
• VFDs, switch mode power supplies, etc.
• Other harmonic sources are external
• Customers sharing the same line
• Is the voltage distortion caused by you or your
neighbor?
• Establish a baseline (your neighbor’s load)
• Determine the incremental change (your load)

4
Harmonic Limits IEEE Std. 519-1992
• Utility is responsible for providing “clean” voltage
• Customer is responsible for not causing
excessive current harmonics
• Utility can only be fairly judged if customer is
within its current limits

5
Harmonic Limits - System Issues
Actual measurements at
480 V main breaker -
system with large
variable-frequency drives

Voltage distortion
at no load is 4%!

6
Sources of Harmonics
• General sources of harmonics
• Power electronic equipment (drives, rectifiers, computers, etc.)
• Arcing devices (welders, arc furnaces, florescent lights, etc.)
• Iron saturating devices (transformers)
• Rotating machines (generators)
• Most prevalent and growing harmonic sources:
• Adjustable frequency drives (AFD)
• Switch-mode power supplies (computers)
• Fluorescent lightning
• Single loads or groups of loads

7
 Harmonic Producing Loads

Xs

G XT

480 V

Electronic Ballast M
Welder
M
UPS
M + -

8
Harmonic Symptoms/Concerns
• Equipment Failure and Misoperation
• Notching (electronic control malfunctioning, regulator misoperation)
• Overheating/Failure (transformers, motors, cables/neutral)
• Nuisance Operation (fuses, breakers)
• Insulation deterioration
• Audible noise in electrical equipment
• Economic Considerations
• Oversizing (equipment is sized larger to accommodate harmonics)
• Losses/Inefficiencies/PF Penalties
• Inconsistent meter reading
• Application of Power Factor Correction Capacitors

9
 Harmonics and Heating

Load 100%
Harmonics

Std Transformer – Max Temp – 176 F HMT – Max Temp – 105 F

10
 Power Quality Lab – Harmonic Capabilities
• Overview of Lab and Capabilities
• Purpose
• To demonstrate and Test PQ
Problems and Solutions
• Power Quality solutions, especially
harmonic solutions, are difficult to
understand
• Demystify solutions – mis-information and confusion regarding PQ
and energy savings
• Equipment (Harmonic Related)
• 18 Pulse Drives • Passive (Fixed) Filters • 3rd Harmonic Filter
• HMT’s • Passive (Switched) Filters • Drive Transformers
• Active Filters • Active Rectifier (UPS) • K-Rated Transformers
• Broadband Filters • Reactors • Load Banks/Drives

11
 Power Quality Experience
Center and Lab

Full Scale Power System for

Demonstrating and Testing
PQ Problems and Solutions

12
General Layout
• Main Power System
• Commercial Power System
• Industrial Power System
• Residential Room
• Data Center Room
• Medium Voltage Room

13
Drives 14
Harmonic Loads – Commercial System

15
Harmonic Loads – Industrial System

16
Examples of Testing
• Active Filters (5 tested)
• Harmonic (Direction) Meter – 20 Scenarios
• Harmonic Mitigating Transformers (40 tested)
• “Black Box” Solutions for Energy Savings

17
Alternate Sources
• Normal
• Alternate (18% impedance to simulate a
generator)
• EPRI Sag Generator (200 A)

18
Harmonics and Generators
• Generator Concerns
• Generator impedance (16-18%) is generally 3-4
times the equivalent source transformer (5-6%)

Utility Souce Generator Source

4.4% Vthd 13% Vthd
Same Load
19
Harmonics and Generators – Case #1
Example – Generator Sync Failure

Generator 1 (Loaded) Generator 2 (Unloaded)

20
 Harmonics and Generators – Case #1
Example – Generator Sync Failure
Blue (top) = Generator 1 Bus Voltage Blue (top) = 120 V Filtered Sync Check
Input from Generator 1
Red (bottom) = Sync Check Voltage
Generator #1 (Loaded) vs. Generator #2 Red (bottom) = 480 V Generator Bus
(Unloaded) Voltage

Solution: Series-rated surge protector/ring-wave filter

21
Harmonics and Generators – Case 2
• Generator Filter – UPS Filter On/Off

Utility Source Generator Source

Harmonic Filter ON Harmonic Filter ON Harmonic Filter OFF

22
Harmonic Solutions
Oversized
Xs
Generator

G XT

Active
Filter
480 V

HMT Broadband
12 HMT
Low Distortion Filter
Electronic Ballast M Active Pulse
Rectifier or
18 Pulse Active
Rectifier,
Filter or 12
M Pulse UPS
Filter M + - PF Corrected

23
Harmonic Solutions - Commercial
Commercial/Data Center Systems
• UPS Filter
• UPS Active Front End (Rectifier)
• Harmonic Mitigating Transformers
• K-Rated Transformers
• 3rd Harmonic Blocking Filter
• Low Distortion Loads
• Low Distortion Lighting Ballasts
• PF Corrected Power Supplies

24
 PF Corrected Power Supplies
• Data Centers/Servers
• Switch Mode Power Supplies (SMPS) have changed over to
PF Corrected Power Supplies

Industry driven toward component (load) solutions

25
 Rectifier Solutions
• Drives, UPS, Battery Chargers
• Active front end on UPS and some drives

Industry driven toward component (load) solutions

26
 Harmonics and Cancellation
• More load/less harmonics – cancellation or higher source impedance?

Two SMPS – 75 kVA transformer Two SMPS – high impedance source

• Like adding a large line reactor in front of a drive (changes current waveshape)
• High impedance (low resistance) is helpful in most cases to reduce harmonic
currents (although voltage may “flat top”)

27
Neutral Heating – Oversize Equipment
10A at 180 Hz
10A at 60 Hz
A 10A at 180 Hz
10A at 60 Hz
B 10A at 180 Hz
10A at 60 Hz
C
N
0A at 60 Hz
30A at 180 Hz

28
3rd Harmonic Summation in Neutral

29
3rd Harmonic Summation in Neutral

30
 3rd Harmonic Blocking Filter
• Application of 3rd Harmonic 60

Blocking Filter addresses the 40

most dominant harmonic in the 20

distribution system.

Amps
0
• Makes the current waveshape
significantly more linear -20

• K-rating the transformer is no -40

longer necessary. -60

Time

• Most appropriate for retrofit Linear Load

Non-Linear Load
Non-Linear Load with HSS

31
3rd Harmonic Blocking Filter

32
3rd Harmonics and Delta/Wye Transformers

• Third harmonic current flowing

in the phases adds up in the
neutral.
• On the primary, the third
harmonic current is trapped in
the delta if it is balanced.
Otherwise, the difference flows
in the phases.
WYE CONNECTION
• Balanced third harmonic
currents are called “triplen”
harmonic currents (3rd, 9th, etc.).
• Delta-wye transformers are said
3rd Harmonic Currents Couple to “trap” triplen harmonic
current in the delta. They do
not eliminate other harmonics.

33
Transformers and Harmonics (HMT’s)

5th & 7th

harmonics

Use different Use Phase-

secondary Shifting to
winding to treat these
treat these

Triplen
Harmonics
34
Transformers and Harmonics (HMT’s)

5th & 7th

harmonics

Use different Use Phase-

secondary Shifting to
winding to treat these
treat these

Triplen
Harmonics
35
Secondary Treatment of Triplens (HMT’s)

HMT Secondary
Harmonic Mitigating
Transformer (HMT)

ZIG-ZAG CONNECTION

• Opposing magnetic fields – triplens

aren’t magnetically coupled to primary
• Loads continue to operate as designed
• Minimizing impact on electrical
Currents Couple
infrastructure

36
Transformer Testing – Affect of Harmonic Load

Load
Meter Box (Wall)
Banks
Input

480 In
Output

120 Out
Transformer
Meter Cart

480 In

37
Transformer Family Testing –
Affect of Harmonic Load on Efficiency
Efficiency Testing for 75 kVA Family
with 100% Harmonic Load
99.000%

98.000%

97.000%

96.000%
% Efficiency

95.000%

94.000%

93.000%

92.000%

91.000%
15 25 35 50 75 100
K-13 94.74% 96.29% 96.81% 97.09% 96.98% 96.64%
HMT 97.85% 98.41% 98.51% 98.40% 98.08% 97.70%
Standard 95.58% 96.95% 97.39% 97.45% 97.15% 96.63%
TP-1 97.83% 98.13% 98.18% 98.01% 97.63% 97.00%

Nominal % of Full Load

38
Transformer Testing –
Affect of Harmonic Load vs. Resistive Load
Transformer Efficiency - 75 kVA Example
0.99

0.985

0.98

0.975

0.97

0.965

0.96
Resistive Load
100% Harmonic Load
0.955
15 25 35 50 75 100
% Load

39
Harmonic Solutions – Industrial
Industrial System (Drives and Rectifiers)
• Line Reactors
• Drive Isolation/Harmonic Mitigating Transformers
• Tuned Filters – LV/MV – Fixed/Switched
• De-Tuned Filters
• Static Switched (Transient Free) Filters
• Harmonically Hardened Capacitors
• Active Filters
• Clean Power (18 Pulse) Drives
• Broadband Drive Filters
• Active Rectifier Drives

40
Drive and Rectifier Solutions

Drive without line reactor Drive with line reactor

41
Effect of Drive Line Reactors
Effect of Line Reactors
100%
0.5%
3.0%
5.0%
80%
Current - % of Fundamental

60%

40%

20%

0%
1 3 5 7 9 11 13 15 17 19
Harmonic Order

42
Reactor/Isolation Transformer
w/ isola trans
Order Magnitude Angle
1 33.41 -16
3 0.90 -186
5 9.92 101
7 2.00 -182
11 1.87 -154
13 1.10 -127
17 0.67 -70
19 0.67 -50

w/o isola trans

Order Magnitude Angle
1 33.41 -14
3 0.60 -160
5 15.97 114
7 7.48 -110
11 1.77 -89
13 1.40 -1
17 0.87 60
19 0.57 122

43
Total Current
Fundamental = 100% Fundamental = 100%

= 20%
Harmonic
Total
= 102
%

Harmonic = 100%
To
ta
l =
14
1%

44
Phase Shifting/Cancellation
12 Pulse, 18 Pulse or 24 Pulse Cancellation by Design

#1 #2

45
 Video Demonstrations
www1.eatonelectrical.com/pqlab/pqvideos

• 4 drives without phase shifting

• 4 drives with phase shifting (24 pulse system)
• Active Fitler
• 18 pulse (clean power) drive
• Tacoma Narrows Bridge

46
Phase Shifting/Cancellation
Without Cancellation

With Cancellation

47
18 Pulse Rectifier

18 Pulse Design
Voltage

Current

48
Drive/UPS Dedicated Filter
Standard Drive Drive with Dedicated Filter

49
Harmonics and Motor Heating

Xs

XT

Distorted Current
Causes Distorted
M Voltage

Linear Load (Motor) M

Draws Non-60Hz
(Harmonic) Current

50
Motor Heating and Vibrations

• Motor Heating
• Vibrations
• System Losses

51
Reducing Harmonics – Saving Money
How can reducing harmonics save you money?
• Physical damage from overheating and misoperation
• Energy savings
• HVAC savings
• Oversizing equipment / Release Capacity
• Motor failure or overheating
• Low PF

52
Harmonics and Energy Efficiency
• EPRI Presentation – “You can only save energy that is
wasted”
• Infrastructure (system) losses are generally 1-4%
• Saving 25% of your “losses” is not equal to saving 25% of your
energy bill (ex: 25% X 2% = 0.5% of your bill)
• UPS losses may be 2-10% or more
• PQ solutions are often sold as ”energy-saving”
• New (2007) Federal Requirements for Transformer
Efficiency

53
Cost of Harmonic Correction
Description Cost $/kVA Cost p.u.
Reactor 3 1
Capacitors (LV) 12 4
Filter (MV) 12 4
Filter (MV) Switched 15 5
K-Rated Transformer 20 7
Capacitors (LV) Switched 25 8
Filter (LV) 35 12
Filter (LV) Switched 45 15
Harmonic Mitigating Transformer 50 17
Blocking Filter (3rd's) 100 33
Broadband Filter (Drives) 100 33
Active Filter 150 50

Per unit costs compared to reactor pricing

Note that prices are generalized for comparison only
Some equipment must be fully rated for loads - others can be partially rated
Capacitors are shown for reference only

54
Harmonic Resonance

On November 7, 1940, at approximately

11:00 AM, the Tacoma Narrows suspension
bridge collapsed due to wind-induced
vibrations…the bridge had only been open
for traffic a few months.

55
 Harmonic Resonance
The “Self Correcting” Problem
• Blown Fuses
• Failed Capacitors
• Damaged Transformer

Harmonics = Wind (Excites Resonance)

56
Harmonic Resonance

kVASC
hR = Xs
kVARCAP

1500 kVA
5.0%
480 V

500 HP 600 kvar

200 HP Drive Capacitor
Source of Harmonics

57
 Harmonic Resonance - Solutions
1. Change the method of kvar compensation (harmonic filter,
active filter, etc.)
2. Change the size of the capacitor bank to over-compensate
or under-compensate for the required kvar and live with the
ramifications (i.e. overvoltage or PF penalty).

58
Harmonic Resonance – Switched Capacitor
Parallel Resonant Frequencies for Various Capacitor Sizes

600

500 500
450
400 400
Capacitor Size

350
300 300
250
200 200
150
100 100
50
0 0
0 5 10 15 20 25
Harmonic Order

59
Harmonic Resonance – SKM Output
Plot1 - Distortion Waveform
- - Case 2 - 300 kVAR - Capacitor Fdr - Branch D - - Case 3 - 5th Filter - Capacitor Fdr - Branch

- - Case 1 - 200 kVAR - Capacitor Fdr - Branch D

2
Branch Distortion Current Waveform (pu)

-1

-2

0 50 100 150 200 250 300 350

Time (1 Cycle) or 0-360 degrees
Plot1 - Distortion Spectrum
- - Case 2 - 300 kVAR - Capacitor Fdr - Branch D - - Case 3 - 5th Filter - Capacitor Fdr - Branch

- - Case 1 - 200 kVAR - Capacitor Fdr - Branch D

1.00
Branch Distortion Current Spectrum (pu)

0.75

0.50

0.25

0.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Harmonic Order

60
Wrap Up
• Most people are visual learners – the PQ Lab allows for first hand
learning of complicated subjects like harmonics.
• Varied experience and knowledge require varied demonstrations
(Residential, Data Center, Industrial, Commercial, Utility)
• Comparing results from one harmonic solution vs. another
reinforces decision making
• Technical solution
• Economic solution
• Alternate source (generator) issues significantly impact the voltage
distortion
• Energy savings has become the buzz with harmonic (and other
PQ) solutions – be careful…

61