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Israel/ Dec. 4st 2014
Maschinenfabrik Reinhausen Germany
Power Quality
Power Quality and Reliability
Dr.-Ing. Mike Ifland / MR PQ Germany
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Agenda
I MR – Introduction
I MR PQ – Fields of activity
I Maschinenfabrik Reinhausen – Power Quality Solutions
I Project Example – Harmonic Filter System
I Summary
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1. MR – Introduction 1.1 Our worldwide clients / Your market opportunities
> 80 % of all our products ever delivered are still in operation today
> 50 % of worldwide electricity consumption passes through a MR product
Maschinenfabrik Reinhausen GmbH (parent company)
I Founded in 1868, MR trademark since 1901
I Majority family ownership in fifth generation
I World market leader in transformer switching
I 3.160 employees in MR and 26 affiliated companies (35 sites)
I 82 % of employees in Germany, 90 % export business
I Group turnover of 650 million EUR, highest available rating (banks)
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1. MR – Introduction 1.2 Fields of activity
No transformers without a MR productMarketing of proprietary technologies
Increasing corporate value in global niches of electrical power engineering while preserving our independence
VALUE FACTURINGDecision Support
for Manufacturing Excellence
TRANSFORMER CONTROLControl of
Power Transformers
POWER COMPOSITESComposite Materials and
Insulators
MESSKO INSTRUMENTSEquipment Control and
Assessment
POWER QUALITYSolutions
at Grid Nodes
HIGHVOLT TESTINGTesting and
Measurement Technologies
Preferred system integrator
Task
l Integration of Shop Floor Data Models into ERP
l Optimization of Automated Manufacturing Processes
l Filters and Reactive Power Compensation
l Power Flow Control in Distribution Networks
l Shop Floor Testing Systems for Grid Components
l Mobile HV / MV Systems for On-Site Testing
l Mechanical & Electrical Endurance by GFRP
l Composite Insulators for HV / MV Equipment
l Sensors, Accessories, Oil Analytic Laboratory and Secondary Brands
l Process Measuring and Control Technologies for Industry Applications
Rang
eVi
sion
Goa
lBr
and
l Actuators, Electronics and Data Management
l Transformer Services
Prod
ucts
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I Chemical industry
I Cement industry
I Pulp & Paper
I Windfarms
I Power plants
I Steel industry
I Utilities
I Mining
I Oil & Gas
I Railway
1. PQ – Fields of activity 1.1 Target industries / customers
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1. PQ – Fields of activity 1.2 Different clients facing different power quality problems
I Chemical industry
I Cement industry
I Pulp & Paper
I Windfarms
I Power plants
I Steel industry
I Utilities
I Mining
I Oil & Gas
I Railway
UnbalanceVoltage/Current
Voltage variation
Harmonics
Transients
Reactive power
Voltage drops
Flicker
I Switching eventsI Athmospheric overvoltage I Transient currents/voltages
I Phase shifting voltage/currentI Leading (capacitive)I Lagging (inductive)
I Caused by powerful singlephase loads
I Caused by harmonic sourceslike converter drives, furnaces, millions of switched mode power supply units.…
I Evaluation will distinguish harmonic voltage/current
I Commutating effectsI Start of huge motor drives
I Caused by powerful welding machines, presses
I Other fluctuating and repeating loads
I Caused by long-term load fluctuations
Turn key solutions provided by
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1. PQ – Fields of activity 1.3 Power Quality problems electrical equipment
I Chemical industry
I Cement industry
I Pulp & Paper
I Windfarms
I Power plants
I Steel industry
I Utilities
I Mining
I Oil & Gas
I Railway
Turn key solutions provided by
Harmonic distortions – Effects
on the network
Malfunction of protection and control devices
Additional losses : - life span reduction
- destruction of equipment
Malfunction of ripple control
devices
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1. PQ – Fields of activity 1.4 The solution circle
I Customized solutions Taking care of specific problems
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2. MR Power quality solutions 2.2 Metal encapsulated Indoor Equipment (Harmonic filters)
Harmonics
I Harmonic filter system for indoor application / POCOS
Harm. Filter238 Hz
1600 kvar
SM
VSD 22 MW4800 rpm
110/10 kV31.5 MVA
10.5 %
10 kV 50 Hz 3 ~
Harm. Filter345 Hz
1000 kvar
Harm. Filter575 Hz
2400 kvar
Harm. Filter575 Hz
2400 kvar
Harm. Filter575 Hz
2400 kvar
Harm. Filter238 Hz
1600 kvar
SM
VSD 22 MW4800 rpm
110/10 kV31.5 MVA
10.5 %
10 kV 50 Hz 3 ~
Harm. Filter345 Hz
1000 kvar
Harm. Filter575 Hz
2400 kvar
Harm. Filter575 Hz
2400 kvar
Harm. Filter575 Hz
2400 kvar
110 kV 50 Hz 3 ~
Overhead line3 km
Overhead line20 km
SCC 498 MVASCC 1082 MVA
MAIN POWER STANDBY POWER
SCC 186 MVASCC 235 MVA
• 2 x 22 MW compressor drive with 12- pulse LCI converter
• 10 kV 5 steps with total power 9.8 Mvar
• HF05 (1.6 Mvar) / HF07 (1.0 Mvar) / HF 11 (3 x 2,4 Mvar)
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2. Power Quality Solutions 2.3 GRIDCON ® Modules and Stations (general overview)
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BMW-Brilliance-Automotive Shenyang – China:
I Tuned passive filter, designed for max. 660 A (inductive / reactive power compensation)
I One active filter (500 A): similar effect, lower losses and smaller size
2. Power Quality Solutions 2.4 Low Voltage Developments
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2. Power Quality Solutions 2.5 AcF – Working principle
GRIDCON AcF:service optimized, modular concept with 4 modules per cabinet
Working principle of Active Filters:
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+10 %
+5 %
0 %
-5 %
-10 %
Dev
iatio
n fr
om ra
ted
volta
ge (i
n %
)
Medium voltage grid
Secondarysubstation Low voltage grid
Maximumfeed-in case
Maximumload case
Higher voltage
due to more feed-in
Regulation„downwards“
Regulation„upwards“
20 kV 0.4 kV 0.4 kV20 kV
Lower voltage due to
e-mobility and heat pumps
Outside of allowed voltage band
Outside of allowed voltage band
2. Power Quality Solutions 2.6 GRIDCON ® Transformer
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LV gridSubstation
Controller
PV
=3~
PV
=3~
PV
=3~
G
V
Sensor
abgesetzteSpannungsmessung
Actuator
MV grid
Transformer1
Voltage regulator3
On-load tap-changer2
2. Power Quality Solutions 2.7 GRIDCON ® Transformer - Setup
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3. Project example – harmonic filter system3.1 Requested compensation system
22.9 kV 13 Mvar360 Hz
22.9 kV / 60 Hz / Busbar A
Scope of supply
22.9 kV 10 Mvar60 Hz
Filter 5th Non-tunedcapacitor bank
22.9 kV 13 Mvar360 Hz
22.9 kV / 60 Hz / Busbar B
Scope of supply
22.9 kV 10 Mvar60 Hz
Filter 5th Non-tunedcapacitor bank
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3. Project example – harmonic filter system3.2 First calculation – with specified compensation systems
• 220 kV frequency sweep of substation „Mina Constancia“
• 22.9 kV frequency sweep of substation „Mina Constancia“
• parallel resonance effects in the range of 11th harmonic
• higher harmonic range strongly damped
• impact of generated harmonics of 18/24-pulse converter are negligible
I 11th harmonic
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3. Project example – harmonic filter system3.3 Harmonic predistortion 220 kV / specified compensation system
I Histogramm 220 kV
I 5th 1.2%I 7th 0.6%I 11th 3.0%I 13th 1.5%
I 11th harmonic
I Histogramm 22.9 kV
I Voltage 22.9 kV
I 5th 0.13%I 7th 0.52%I 11th
8.40% !!I 13th 1.67%
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22.9 kV 13 Mvar300 Hz
22.9 kV / 60 Hz / Busbar A
Scope of supply
Filter 5th High-Passfiltertuned to 11th/13th
22.9 kV 13 Mvar300 Hz
22.9 kV / 60 Hz / Busbar B
Scope of supply
Filter 5th
22.9 kV 10 MvarHP 10 Ohm / 750 Hz
22.9 kV 10 MvarHP 10 Ohm / 750 Hz
High-Passfiltertuned to 11th/13th
3. Project example – harmonic filter system3.4 Design review of requested compensation system
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3. Project example – harmonic filter system3.5 Calculation – with changed design of compensation/harmonic filter systems
• 220 kV frequency sweep of substation „Mina Constancia“
• 22.9 kV frequency sweep of substation „Mina Constancia“
• decrease of impedance in the range of 11th harmonic by factor 4
I 11th harmonic
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3. Project example – harmonic filter system3.6 Calculation results– with changed design of compensation/harmonic filter systems
• Histogram voltage harmonics 22.9 kV
I 5th 0.12%I 7th 0.61%I 11th 1.13%I 13th 0.35%I 17th 0.03%I 19th 0.02%
• Voltage 22.9 kV
Order harmonics(voltage)
IEC 61000-2-4class 2
Specified System
Recommended System
5 6.0 0.13 0.12
7 5.0 0.52 0.61
11 3.5 8.40 1.13
13 1.5 1.67 0.35
17 1.2 0.03 0.03
19 1.1 0.02 0.02
23 0.9 0.04 0.03
25 0.8 0.03 0.03
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4. MR PQ - Summary
Encapsulated Indoor Equipment•GRIDCON® POCOM, POCOS, POCOL
•custom biult compensation systems with a high degree of standardization
Encapsulated Outdoor Equipment•GRIDCON® Module F,M,C,E
•Applicable as Fixed, Multiple, Concrete, E-House
Dynamic Equipment•customized applications for compensation and filtering of
harmonics•high flexibility in terms of configuration and arrangement
IP00 (Indoor / Outdoor)•Filters with high voltages (<20 kV) and great power output (>10
Mvar) for utilities and industrial applications
Voltage Regulated Distribution Transformer (VRDT)•preventing voltage band violations in both MV and LV networks
•transfer of proven HV technology into MV/LV grids
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Backup
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4. Project example – harmonic filter system4.1 Electrical data
I 220 kV Main feeder
I 22.9 kV 60 Hz Busbar B
I Capacitorbanks(2 x 23 Mvar)
I Sk“min 1248 MVA
I Liquid cooled resistor starters (Ball Mill /SAG Mill)(2 x 32MVA)
I 24-pulse perfect harmonic converter drives
(11 MVA)
I 18-pulse perfect harmonic converter drives
(1.5 MVA)
I 22.9 kV 60 Hz Busbar A
I Sk“min 648 MVA
I Transformer 75/125 MVAI Transformer 75/125 MVA
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2. MR Power quality solutions 2.3 Metal encapsulated Indoor Equipment (Inrush limiting resistors)
MV network behavior during energization of large harmonic filters or converter- / distribution/transmission transformers
Transients
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2. MR Power quality solutions 2.4 Metal encapsulated Indoor Equipment (Load symmetration units)
UnbalanceVoltage/Current
R
X
Load
Load
12U
U23 U31
RA
BR
CR
1I
2I
3I
C1
C2
L1
Customer equipment: Powerful single phase loads
Solution: „Steinmetz-Scheme“
Capacitors/ Reactors with tappings
I C1 & L1 for load symmetration
I C2 for reactive power compensation
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R
X
Load
Load
12U
U23 U31
RA
BR
CR
1I
2I
3I
C1
C2
L1
2. MR Power quality solutions 2.4 Metal encapsulated Indoor Equipment (Load symmetration units)
UnbalanceVoltage/Current
I C1 with tappings
I L1 with tappings