caso estudio armonicos y correccion fp - fabrica
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Harmonic Analysis and Power FactorHarmonic Analysis and Power Factor
Correction Evaluation Correction Evaluation
Plastic Creations Line 13Plastic Creations Line 13
Prepared by:
Electrotek Concepts, Inc.Knoxville, TNwww.electrotek.com
Wade EcklerPower Systems Engineer
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
ElectrotekConcepts, Inc. ii
- Table of Contents -
Executive Summary ______________________________________________________1
1.0 I ntroduction _________________________________________________________2
One Line Diagram ___________________________________________________________ 2
2.0 Field Measur ements at Newtown ________________________________________3
2.1 AC Drive Characteristics Roll 1 _________________________________________3
AC Drive Characteristics Roll 2 ______________________________________________ 4
2.2 AC Drive Characteristics Kneader B_____________________________________6
Overall Load Characteristics Line 13 __________________________________________ 7
2.3 Voltage Distortion Evaluations ___________________________________________ 9
3.0 Recommended Power Factor Correction _________________________________13
3.1 Summary of Reactive Power Requirements ________________________________ 13
4.0 Proposed F il ter Design _______________________________________________14
Appendix A: Low Vol tage Power Factor Correction Equipment Manuf acturers ____16
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
ElectrotekConcepts, Inc. 1
Executive Summary
The Plastic Creations in Newtown has a new Line 13 with ac variable frequency drives for
the calender line. The drives have high harmonic current levels but do not require the
level of power factor correction that dc drives require.
This evaluation characterizes the loads on Line 13. Power factor correction needs are
calculated and the impact of the existing capacitor bank (provides about 600 kvar of
compensation) is illustrated. The capacitor increases distortion levels at the 7th
and 11th
harmonics, resulting in overall voltage distortion levels exceeding 5% on the 480 volt
system. Although this should not cause problems for now, the distortion levels are likely
to be unacceptable with additional loading from Line 14. Also, the capacitor creates the
potential for magnified transient voltages if the utility switches capacitor banks on the
transmission system.
The capacitor should be converted into a tuned filter and it should be able to provide
power factor correction for the existing Line 13 (correction to a power factor of aboutunity) and should also be sufficient even after the addition of Line 14 (power factor
around 0.97). Specifications for the reactor to tune this bank are provided here.
480 Volt Bus
Tuned
Capacitor
Bank
Capacitor Bank:937.5 kvar600 volts
Inductors:0.046 mH per phaserms current rating = 15th harmonic current r775 amps
Circuit Brea480 Volt, 20
Proposed Filter Configuration for Line 13 and Line 14
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
ElectrotekConcepts, Inc. 2
1.0 Introduction
The Plastic Creations plant in Newtown has a new Line 13 with a dedicated transformer.
Line 13 includes ac variable frequency drives instead of the dc drives that are used onother Plastic Creations lines. This has a dramatic impact on the power factor
characteristics of the load. The ac drives have much better displacement power factor
(not as much compensation needed) but have significant harmonic distortion levels. The
measurements and recommendations presented in this report deal with the power factor
correction and filtering requirements for this line, including the impact of a future Line 14
with similar characteristics to Line 13.
One Line Diagram
Utility 13.8 kV Feeder
138 kV substation
3750 kVA, 7.0 %13.8 kV/480 volts
937.5 kvar600 volts
H110 Kneader13-2
Calender Controls(Protected by 24
UPS)
MCC7H22
H111Kneader
13-1
H112
Mixer
Grinders
CalenderHeaters
H113
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
ElectrotekConcepts, Inc. 3
2.0 Field Measurements at Newtown
Measurements were taken to characterize the ac drive loads and the overall load
characteristics for Line 13. The measurements also evaluated the impact of the existing
capacitor bank on distortion levels on the 480 volt system supplying Line 13.
2.1 AC Drive Characteristics Roll 1
The following waveforms and harmonic spectrums are typical for Roll 1. This is also
typical for Roll 3.
Event waveform/detail
Pre/Post-trigger at 02/25/98 11:32:34.312
CHA Amps
11:32:34.31 11:32:34.32 11:32:34.33 11:32:34.34 11:32:34.35 11:32:34.36 11:32:34.37 11:32:34.38
Amps
-150
-100
-50
0
50
100
150
Event waveform/detail
Total RMS: 61.27 Amps
Total harmonic distortion: 32.52 Amps
Even contribution (H02-H50): 1.31 Amps
Odd contribution (H03-H49): 32.50 Amps
Pre/Post-trigger at 02/25/98 11:32:34.362
CHA Amps
THDabs H05 H10 H15 H20 H25 H30
Amps
0
10
20
30
40
50
60
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
ElectrotekConcepts, Inc. 4
AC Drive Characteristics Roll 2
The following waveforms and harmonic spectrums are typical for Roll 2. This is also
typical for Roll 4.
Event waveform/detail
Timed event at 02/25/98 12:48:18.000
CHA A mps
12:48:18.000 12:48:18.005 12:48:18.010 12:48:18.015 12:48:18.020
Amps
-300
-200
-100
0
100
200
300
Event waveform/detail
Total RMS: 123.67 Amps
Total harmonic distortion: 56.36 Amps
Even contribution (H02-H50): 0.45 Amps
Odd contribution (H03-H49): 56.37 Amps
Timed event at 02/25/98 12:48:18.000
CHA A mpsTHDabs H05 H10 H15 H20 H25 H30
Amps
0
25
50
75
100
125
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
ElectrotekConcepts, Inc. 5
Example waveform and spectrum from BMI 3030
Roll 2 Current Waveform
0 10 20 30 40-200
-100
0
100
200
Time (mS)
Roll 2 Harmonic Characteristics
0 10 20 30 400
20
40
60
80
100
Frequency (H pu)
Freq :Fund :THD :TID :TD :
RMSh :RMSi :
RMSfh:
RMS :ASUM :TIF :IT :
189.578452.7698052.769847.27030101.286
101.286179.963454.67446051.9
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
ElectrotekConcepts, Inc. 6
2.2 AC Drive Characteristics Kneader B
The following waveforms and harmonic spectrums are typical for Kneader B. This is also
typical for Kneader A.
Event waveform/detail
Snapshot event at 02/25/98 14:53:43.000
CHA A mps
14:53:43.000 14:53:43.005 14:53:43.010 14:53:43.015 14:53:43.020
Amps
-750
-500
-250
0
250
500
750
Event waveform/detail
Total RMS: 224.85 Amps
Total harmonic distortion: 98.85 Amps
Even contribution (H02-H50): 9.78 Amps
Odd contribution (H03-H49): 98.38 Amps
Snapshot event at 02/25/98 14:53:43.000
CHA A mps
THDabs H05 H10 H15 H20 H25 H30
Amps
0
50
100
150
200
250
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
ElectrotekConcepts, Inc. 7
Overall Load Characteristics Line 13
The following summarizes the overall load characteristics for Line 13. This includes the
ac drives characterized in the previous sections along with the calender heaters and other
loads that are part of the Line. This information can be used for evaluating harmonic filterand power factor correction requirements.
The table also illustrates the effect of the existing capacitor bank on the distortion levels
and the power factor. Note that the 7th
harmonic is significantly increased when the
capacitor bank is in service and the voltage distortion often exceeds 5%. The current
distortion increases to more than 30% with 20% at the 7th
harmonic. This is an indication
of the magnification at the 7th
harmonic component.
Current 1300-1800 amps 1300-1600 amps
Power 1.1-1.3 MVA 1.0-1.1 MVA
kvar 480-500 kvar 150-180 kvar lead
PF .88-.90 0.95
dPF .88-.91 0.99 lead
THDv 2.9-3.2 % 4.5-5.9 %
THDi 15-17 % 25-32 %
V5 1.9-2.0 % 2.5 %
I5 12-13 % 19 %
V7 1.8 % 3.2 %
I7 8-9 % 20 %
No Cap Bank with Cap Bank
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
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The following waveform and harmonic spectrum represent typical load characteristics for
Line 13 (without the capacitor bank).
Line 13 Current Waveform
0 10 20 30 40-3000
-2000
-1000
0
1000
2000
3000
Time (mS)
Line 13 Current Harmonic Spectrum
0 3 6 9 12 150
250
500
750
1000
1250
1500
1750
Frequency (H pu)
Freq :Fund :THD :TID :TD :
RMSh :RMSi :
RMSfh:
RMS :ASUM :TIF :IT :
11529.8914.4941014.4941221.74401545.87
1545.871939.8985.7982132633
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
ElectrotekConcepts, Inc. 9
2.3 Voltage Distortion Evaluations
The following measurement results summarize the voltage distortion concerns at the 480
volt bus supplying Line 13.
Voltage Character ist ics withou t Capaci tor Bank
Typical voltage waveforms and spectrums are provided below without the capacitor bank
in service. The distortion is dominated by the 5th
harmonic component since that is the
highest current injection from the drive loads.
Event waveform/detail
Total RMS: 464.93 Volts
Total harmonic distortion: 15.76 Volts
Even contribution (H02-H50): 2.68 Volts
Odd contribution (H03-H49): 15.54 Volts
Snapshot event at 02/25/98 15:48:40.000
CHA V olts
THDabs H05 H10 H15 H20 H25 H30
Volts
0
100
200
300
400
500
Event waveform/detail
Snapshot event at 02/25/98 15:48:40.000
CHA Volts
15:48:40.00
15:48:40.01
15:48:40.02
15:48:40.03
15:48:40.04
15:48:40.05
15:48:40.06
15:48:40.07
Volts
-750
-500
-250
0
250
500
750
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
ElectrotekConcepts, Inc. 10
Voltage Character ist ics with Capaci tor Bank
Typical voltage waveforms and spectrums are provided below after the capacitor bank
was switched in. The capacitor creates a resonance between the 7th
and 11th
harmonics,magnifying both of these components. The voltage distortion levels are increased overall
and can exceed 5%. The highest distortion is typically at the 7th
harmonic with the
capacitor bank in due to the magnification.
Event waveform/detail
Meter mode snapshot at 02/25/98 16:20:59.000
CHA V olts
16:20:59.000 16:20:59.005 16:20:59.010 16:20:59.015 16:20:59.020
Volts
-750
-500
-250
0
250
500
750
Event waveform/detail
Total RMS: 473.33 Volts
Total harmonic distortion: 24.32 Volts
Even contribution (H02-H50): 0.59 Volts
Odd contribution (H03-H49): 24.33 Volts
Meter mode snapshot at 02/25/98 16:20:59.000
CHA V olts
THDabs H05 H10 H15 H20 H25 H30
Volts
0
100
200
300
400
500
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
ElectrotekConcepts, Inc. 11
Compar ison of Vol tage Character ist ics
The figure below shows the THD of the voltage on the Line 13 Main Bus and the values
of the 5th, 7
th, 11
th, and 13
thharmonic as percentages of the fundamental with the capacitor
bank on line and with it off line. The chart makes it easier to see how placing the
capacitor bank on line at the Line 13 Main Bus magnifies the 7th and 11th harmonics. The7
thharmonic is virtually non-existent, at 0.02% of the fundamental, with the capacitor
bank off line. The 11th
harmonic was measured at 0.75% without the capacitor banks.
After placing the capacitor banks on line, the 7th
increases to 3.73% and the 11th
increases
to 2.23% of the fundamental.
Line 13 Main Bus
0.00
1.00
2.00
3.00
4.00
5.00
6.00
THDv 5th 7th 11th 13th
Harmonic
VoltageDistortion(%)
No Caps
With Caps
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
ElectrotekConcepts, Inc. 12
Descr ipt ion of the Resonance Problem
The capacitor bank introduces a resonance between the 7th
and 11th
harmonics that
magnifies both of these components. The frequency scan below illustrates the voltage at
the 480 volt bus per amp injected by the drive loads with and without the capacitor bankin service.
Frequency Scan with and Without Capacitor Bank
0.00 3.00 6.00 9.00 12.00 15.00 18.00 21.00 24.00 27.000.0
0.1
0.2
0.3
0.4
Frequency (H pu)
This problem can be avoided by converting the capacitor bank into a tuned filter. The
frequency scan plots below show the effect of the tuned filter in preventing resonances
close to the characteristic harmonics of the drive loads (5th
and 7th).
Frequency Scan Showing Effect of Filter
0.00 3.00 6.00 9.00 12.00 15.00 18.00 21.00 24.00 27.000.0
0.1
0.2
0.3
0.4
Frequency (H pu)
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
ElectrotekConcepts, Inc. 13
3.0 Recommended Power Factor Correction
This section summarizes the power factor correction needs for the existing configuration
with Line 13 and estimates the impacts of a similar line (Line 14) in the future.
3.1 Summary of Reactive Power Requirements
The following table summarizes the load characteristics measured for Line 13 and shows
the impact of the 600 kvar of compensation on the power factor of the overall load. The
table also shows the effect of this capacitor bank if the load is doubled to include the effect
of Line 14 in the future.
The power factor with just Line 13 is corrected to unity with the existing capacitor bank.
With Line 14, the capacitor bank will correct the power factor to about 0.97 lagging when
both lines are running.
Line 13 Line 13 and Line 14
Transformer Size 3750 3750
Transformer Impedance 7% 7.00%
Peak Load (kVA) 1300 2600
Displacement Power Factor 0.9 0.9
Reactive Power (kvar) 567 1133
Real Power (kW) 1170 2340
Compensation (kvar) 600 600
Total Reactive Power with Compensation (kvar) -33 533
Power Factor with Compensation 1.00 0.97
Fifth Harmonic Current (%) 15% 15%
The capacitor should be configured as a tuned bank to prevent excessive distortion and
problems with magnification of capacitor switching transients. The next section gives
parameters for the tuning reactor.
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
ElectrotekConcepts, Inc. 14
4.0 Proposed Filter Design
Plastic Creations has already purchased a capacitor bank for power factor correction. The
capacitor is rated 600 volts so it can easily be used as part of a tuned filter. The proposed
filter design is illustrated in the one line diagram below. The following page gives the
specifications for the filter reactor that should be purchased.
480 Volt Bus
Tuned
Capacitor
Bank
Capacitor Bank:937.5 kvar
600 volts
Inductors:
0.046 mH per phase
rms current rating = 1100 amps
5th harmonic current rating =
775 amps
Circuit Breaker:480 Volt, 2000 A
Proposed Filter Configuration for Lines 13 and 14
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
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Low Voltage Filter Calculations: 600 kvar 480 Volt Filter
SYSTEM INFORMATION:
Filter Specification: 5 th Power System Frequency: 60 Hz
Capacitor Bank Rating: 937.5 kVAr Capacitor Rating: 600 Volts
Rated Bank Current: 902 Amps 60 Hz
Nominal Bus Voltage: 480 Volts Derated Capacitor: 600 kVAr
Capacitor Current (actual): 721.7 Amps Total Harmonic Load: 2500 kVA
Filter Tuning Harmonic: 4.7 th Filter Tuning Frequency: 282 Hz
Cap Impedance (wye equivalent): 0.3840 Cap Value (wye equivalent): 6907.8 uF
Reactor Impedance: 0.0174 Reactor Rating: 0.0461 mH
Filter Full Load Current (actual): 755.9 Amps Supplied Compensation: 628 kVArFilter Full Load Current (rated): 944.9 Amps
Transformer Nameplate: 3750 kVA Utility Side Vh: 2.00 % THD
(Rating and Impedance) 7.00 % (Utility Harmonic Voltage Source)
Load Harmonic Current: 20.00 % Fund Load Harmonic Current: 601.4 Amps
Utility Harmonic Current: 175.5 Amps Max Total Harm. Current: 776.9 Amps
CAPACITOR DUTY CALCULATIONS:
Filter RMS Current: 1084.0 Amps Fundamental Cap Voltage: 502.8 Volts
Harmonic Cap Voltage: 103.3 Volts Maximum Peak Voltage: 606.1 Volts
RMS Capacitor Voltage: 513.3 Volts Maximum Peak Current: 1532.8 Amps
CAPACITOR LIMITS: (IEEE Std 18-1980) FILTER CONFIGURATION:
Limit Actual
Peak Voltage: 120 % 101%
Current: 180% 120%
KVAr: 135% 103%
RMS Voltage: 110% 86 %
FILTER REACTOR DESIGN SPECIFICATIONS:
Reactor Impedance: 0.0174 Reactor Rating: 0.0461 mH
Fundamental Current: 755.9 Amps Harmonic Current: 776.9 Amps
4 8 0 V o l t B u s
6 0 0 k V A r @
6 0 0 V o l t s
X l = 0 . 0 27 2
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
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Appendix A: Low Voltage Power Factor Correction Equipment
Manufacturers
ABBSteve Colvin
1206 Hatton RoadWichita Falls, TX 76302
817-761-3232 / 817-761-3202
Aerovox Group
John Childs
740 Belleville Ave.
New Bedford, MA 02745-6194
508-994-9661 / 508-990-8696
ASC Industr ial
Bruce Marzley / Larry Burch / Chuck Gougler
8967 Pleasantwood Ave NW
North Canton, OH 44720216-499-1210 / 216-499-1213
Commonwealth Sprague
Frank Smith
Brown Street
North Adams, MA 01247
413-664-4466 / 413-664-4465
Control l ix
Paul Griesmer
21415 Alexander Road
Walton Hills, OH 44146
216-232-8757 / 216-232-1893
Freeborn IndustriesRudy Wodrich / Kevin Simpson
6675 Rexwood Road
Mississauga, Ontario
L4V 1V1 Canada
905-677-9272 / 905-677-5448
General ElectricPeter Baltz
14131 Midway Road, Suite 500
Dallas, TX 75244
214-702-5274 / 214-702-5283
Gilbert/K&M
Neal Ciurro / Jess Hancock
P.O. Box 1141
Beckly, WV 25802
304-252-6243 / 304-252-6292
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Plastic Creations Line 13 Harmonics and Power Factor Correction Evaluation
Electrotek C t I 17
Macroamp LesatBob Stuefen / Allan Freebury
P.O. 1512
Ukiah, CA 95482
707-462-2222 / 707-462-3068
Myron ZuckerJim Holley315 East Parent Street
Royal Oak, MI 48067
810-543-2277 / 810-543-1529
RobiconDennis Lorenzi
100 Sagamore Hill Road
Pittsburgh, PA 15239-2982
412-325-7260 / 412-733-8093
TCI
J. P. Thorpe7878 North 86th St.
Milwaukee, WI 53224
414-357-4480 / 414-357-4480
Tech-Tran Corp
Ted Furst / Charles Roney
50 Indel Avenue
Rancocas, NJ 08703
800-257-9420 / 609-267-6751
VAR+ Controls
Bill McConnellMail Box 585
Whitmore Lake, MI 48189
800-KILOVAR / 313-449-8710
Versatex Indus tries
Ted Noutko
P.O. Box 354
Brighton, MI 48116
810-229-5751 / 810-229-7863
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