harmonics advanced application training · arcing devices (welders, arc furnaces, florescent...
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© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
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Eaton Application Engineering MeetingApril 2011
HarmonicsAdvanced Application Training
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Utility is responsible for providing “clean” voltageCustomer is responsible for not causing excessive current harmonicsUtility can only be fairly judged if customer is within its current limitsHarmonics cause voltage and current problems in power systemsIEEE Std 519-1992 provides a basis for limiting harmonicsMultiple methods exist for mitigating harmonics and “one size does not fit all”
Introduction - Harmonics
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Harmonics – it’s not that complicated….
E = mc2V = IZVd = Id Zh
Heating Problems
(Load Related) Source Impedance
Misoperation Problems
G U
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Which came first?
• 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
Voltage Distortion Current Distortion
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What’s YOUR (Harmonic) Problem?
• Voltage Problem• Current Problem• Impedance Problem
Solutions exist for every problem but you have to understand the problem first!
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General sources of harmonicsPower electronic equipment (drives, rectifiers, computers, etc.)Arcing devices (welders, arc furnaces, florescent lights, etc.)Iron saturating devices (transformers)Rotating machines (generators)
Sources of Harmonics
Most prevalent and growing harmonic sourcesAdjustable frequency drives (AFD) Switch-mode power supplies (computers) Fluorescent lightning
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Some harmonic sources are internalVFDs, switch mode power supplies, etc.
Internal vs. External Sources
Other harmonic sources are externalCustomers 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)
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Voltage distortion at no load is 4%!
Actual measurements at 480 V main breaker - system with large variable-frequency drives
Harmonic Limits System Issues
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H = NP+/-1
i.e. 6 Pulse Drive - 5, 7, 11, 13, 17, 19,…
Source Typical Harmonics*6 Pulse Drive/Rectifier 5, 7, 11, 13, 17, 19…12 Pulse Drive/Rectifier 11, 13, 23, 25…18 Pulse Drive 17, 19, 35, 37…Switch-Mode Power Supply 3, 5, 7, 9, 11, 13…Fluorescent Lights 3, 5, 7, 9, 11, 13…Arcing Devices 2, 3, 4, 5, 7... Transformer Energization 2, 3, 4* Generally, magnitude decreases as harmonic order increases
Expected Harmonics
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Harmonic Sources – Continuous Current
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Harmonic Sources – Transformer Inrush
Harmonic sources don’t have to be continuous…
Think…
• Soft starters
• Transformers
• Welding
Harmonics can “kick” your $@(()!!#$ (system)
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12
Equipment Failure and MisoperationNotching (electronic control malfunctioning, regulator misoperation)Overheating/Failure (transformers, motors, cables/neutral)Nuisance Operation (fuses, breakers)Insulation deterioration Audible noise in electrical equipment
Harmonic Symptoms/Concerns
Economic ConsiderationsOversizing (equipment is sized larger to accommodate harmonics)Losses/Inefficiencies/PF PenaltiesInconsistent meter reading
Harmonic Resonance with Power Factor Correction Capacitors
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“Harmonics are not a problem unless they are a problem!”
… But Remember
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Std Transformer – Max Temp – 176 F HMT – Max Temp – 105 F
Load 100% Harmonics
Harmonics and Heating
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Voltage Notching
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C
B
A
N0A at 60 Hz
10A at 60 Hz
10A at 60 Hz
10A at 60 Hz
30A at 180 Hz
10A at 180 Hz
10A at 180 Hz
10A at 180 Hz
Neutral Heating – Oversize Equipment
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3rd Harmonic Summation in Neutral
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3rd Harmonic Summation in Neutral
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19
Xs
M
XT
M
Linear Load (Motor) Draws Non-60Hz
(Harmonic) Current
Distorted Current Causes Distorted
Voltage
Harmonics and Motor Heating
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• Motor Heating
• Vibrations
• System Losses
Motor Heating and Vibrations
Like driving with one foot on the gas and one on the brake …
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Generator ConcernsGenerator impedance (16-18%) is generally 3-4 times the equivalent source transformer (5-6%)
Utility Source Generator Source4.4% Vthd 13% Vthd
Same Load
Harmonics and Generators
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Generator Source may
result in larger commutation notches and transients
Notching and Generators
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Utility Source2.3% THD
Generator Source 5.7% THD
Harmonics and Generators
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Harmonics and GeneratorsExample – Generator Sync Failure
Generator 1 (Loaded) Generator 2 (Unloaded)
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Harmonics and GeneratorsExample – Generator Sync Failure
Solution: Series-rated surge protector/ring-wave filter
Blue (top) = Generator 1 Bus Voltage
Red (bottom) = Sync Check VoltageGenerator #1 (Loaded) vs. Generator #2 (Unloaded)
Blue (top) = 120 V Filtered Sync Check Input from Generator 1
Red (bottom) = 480 V Generator Bus Voltage
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Harmonics and Generators
Generator Filter – UPS Filter On/OffUtility Source Generator Source
Harmonic Filter ON Harmonic Filter ON Harmonic Filter OFF
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Power Systems Experience Center
• 3rd Harmonic Filter• HMT Transformers• K-Rated Transformers• Phase shifting transformers
• Passive (Fixed) Filters• Passive (Switched) Filters• Active Filters• Reactors
• Fixed capacitors• Switched capacitors• Static switched capacitor• Broadband Filters
Purpose: to demonstrate and test PQ problems and solutions
• Full-scale power system• Demystify solutions• “Seeing is Believing”• Technical vs. Economic Solutions
www.eaton.com/experience
Equipment (PF/Harmonic Related)
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Power Systems Experience Center – Live Tour
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Specifications
• What are some of the specs that you see???
• Must comply with IEEE519 Standard• Must maintain less than 5% THD• Must use active harmonic cancellation• Customer must not exceed 8% TDD
• What do these all mean???
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Terminology
• Total Harmonic Distortion - THD• Harmonic current distortion in % of fundamental load
current (instantaneous)• Total Demand Distortion - TDD
• Harmonic current distortion in % of max demand load current (15 - 30min)
• Harmonic Current – Ih• Harmonic current distortion for individual harmonic
orders (h)• Fundamental Current - I1
• Current at fundamental frequency (60hz) excluding harmonics
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Terminology
• Short Circuit Current – ISC• Maximum three phase short circuit current available
at the point of common coupling• Demand Load Current – IL
• Sum of max load and harmonic currents• 15 or 30 minute demand, not momentary peak
current• Common to use transformer full load current if
planning for new load• Point of Common Coupling – PCC
• Closest point where another customer may interface with the utility
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Voltage distortion limits @ PCC:
IEEE 519-1992 Recommendations
Application Class Example THD (Voltage)
Special System Hospital 3%
General System WWTP 5%
Dedicated System AFD’s Only 10%
The Institute of Electrical and Electronics Engineers (IEEE) has set guidelines for applying limits to the level of harmonic distortion that a utility customer may inject into the power system. The guidelines pertain to percent harmonic current and voltage distortion at the point of common coupling (PCC), which is defined as the point where the utility connects to multiple customers.
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IEEE 519-1992 RecommendationsIEEE 519-1992 recommends different limits on Individual Harmonics (Ih) and Total Demand Distortion (TDD), depending on the ISC / IL ratio. ISC is the short circuit current at the PCC, and IL is the maximum demand load current (fundamental) at the PCC. More current distortion is allowed at higher ISC / IL ratios, since voltage distortion decreases as the ratio increases.
ISC / IL Ih < 11 11 ≤ Ih ≤ 17 17 ≤ Ih ≤23
23 ≤ Ih ≤35
TDD
< 20 4.0 2.0 1.5 0.6 5.0
20 – 50 7.0 3.5 2.5 1.0 8.0
50 – 100 10.0 4.5 4.0 1.5 12.0
100 – 1000 12.0 5.5 5.0 2.0 15.0
> 1000 15.0 7.0 6.0 2.5 20.0
Harmonic current distortion limits (Ih and TDD in % of IL(≤ 69KV):
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Current Harmonic Limits Vary
• ISC/IL ratio shows relative size of the load compared to the utility system• Larger loads have greater ability to cause voltage
distortion on the utility system
• System short circuit vs. load size (ISC/IL)• Larger load: stricter limits• Weaker system: stricter limits
• Higher order current harmonics• Stricter limits for higher order harmonics
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Harmonic Limits
• Where to assess the limits?• Point of Common Coupling (PCC)
• Which row of current limits applies?• Determine ISC/IL ratio
• How to calculate current harmonics for limit assessment?• Total Demand Distortion (TDD) versus Total
Harmonic Distortion (THD)
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Point of Common Coupling
• PCC is where harmonic limits are assessed• Very misunderstood and misapplied part of
IEEE- 519• Prevent one customer from harming another• Not intended to be applied within a user’s
system• Some customers “voluntarily” comply to IEEE
limits within their own systems
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Point of Common Coupling
ISC/IL ratio• Also proportional to kVASC/kVAL
• kVASC is approximately = kVATransf/ZTransf
• Example:• Transformer kVA = 1000, Z = 5%• kVASC = 1000/0.05 = 20,000• Peak Demand = 500 kVA• Ratio = 20,000/500 = 40
• If the transformer was smaller or the load was larger, the ratio would be smaller and visa versa
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Point of Common Coupling
• PCC is where another customer can be served by the utility
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Total Current – Why is this Important?
Fundamental = 100%
Harm
onic = 100%
Fundamental = 100%
Harm
onic = 20%
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Point of Common Coupling
• True PCC will often be at MV transformer primary• Regardless of transformer ownership or meter location
• Not often practical to perform MV measurements• Common to measure on LV secondary
• Do what we can safely and easily• Use ISC/IL ratio from primary to determine current limits• LV measurements are sufficient most of the time• If you pass on the secondary, you will pass on primary
• If dispute between utility and customer, it may be necessary to measure or calculate harmonics at the MV transformer primary
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Total Demand Distortion
• Harmonic meters measure THD• Individual harmonics in % of I1 (fundamental)
• IEEE-519 current harmonic limits use TDD• Individual harmonics in % of IL (load)
• PX Meters measure TDD (…sort of)
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Harmonics 100% , 60 Hz
2% , 780 Hz
20% , 180 Hz
12% , 300 Hz
4% , 420 Hz
2% , 660 Hz
%100...
%1
24
23
22 ×
+++=
IIII
THDI
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TDD and THD definitions are similar
• Only difference is the denominator
1
25
24
23
22
IIIII
THDI++++
=
LI I
IIIITDD
++++=
25
24
23
22
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Total Demand Distortion
• Important to distinguish between TDD and THD (and % of IL and % of I1)
• Prevents user from being unfairly penalized during periods of light load• Harmonics could appear higher as a percent of a
smaller I1 value
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Total Demand Distortion
• Some specifications call for verification measurements at different load levels• Worry that THD increases at lower load
• Lower loading• THD increases, as suspected• TDD decreases• Amps of harmonics decrease
• Full load current is the worst case TDD• No need for measurements at partial load
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Total Demand Distortion – CPX 9000 Example
HARMONIC 30 HZ 40 HZ 50 HZ 60 HZ
THD (% of I1) 26.7 % 14.1 % 9.1 % 5.9 %
TDD (% of IL) 3.6 % 4.1 % 4.5 % 4.8 %
All Harmonics 8.2 9.2 10.1 10.8
RMS 31.9 65.8 110.7 183.1
1 (fundamental) 30.8 65.2 110.3 182.3
2 0.1 0.4 1.2 0.9
3 3.1 3.8 3.9 3.9
5 5.4 6.1 6.8 8.3
7 5.1 5.1 4.9 4.3
11 0.2 0.2 0.5 1.2
13 0.4 0.8 1.0 1.2
17 1.5 2.0 2.1 2.1
19 0.8 1.7 2.5 2.5
23 0.3 0.4 0.4 0.3
25 0.3 0.4 0.7 0.7
29 0.0 0.1 0.1 0.3
31 0.2 0.1 0.2 0.3
35 0.1 0.2 0.3 0.4
37 0.2 0.3 0.4 0.5
225 A Demand Load
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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.
Harmonic Resonance
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48 48© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary48
The “Self Correcting” Problem
Blown FusesFailed CapacitorsDamaged Transformer
Harmonics = Wind (Excites Resonance)
Harmonic Resonance
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49 49© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary49
CAP
SCR kVAR
kVAh =
600 kvarCapacitor
1500 kVA5.0%
480 V
Xs
200 HP DriveSource of Harmonics
500 HP
Harmonic Resonance
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50 50© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
If a capacitor exists on the power system
AND
Harmonic producing loads are in use
You MUST check for harmonic resonance (series and parallel)
Harmonic Resonance
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• Capacitors not only supply reactive power to the loads in an electrical distribution system they also change the resonance frequency of the system.
• Capacitors are also a “sink” for harmonic currents present in a system (series resonance).
• When the resonance frequency of a system with PF correction capacitors is close to the frequency of a harmonic current generating load parallel resonance can occur.
Harmonic Resonance
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52 52© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Harmonic Resonance• AC circuits characteristically have inductive and capacitive components and have the
means to transfer energy between these components. • Harmonic resonance occurs when the inductive reactance of a circuit is equal to the
capacitive reactance. Resonance can be either series or parallel.• Recall that inductive reactance increases as the power system frequency increases and
the capacitive reactance decreases as the power system frequency increases by the following equations:
and
where XL = inductive reactance in ohmsXC = capacitive reactance in ohmsf = power system frequency in HzL = component inductance in henriesC = component capacitance in farads.
• At 60 Hz, the capacitive components have a much higher impedance than the inductive components.
LjLfjX L ωπ =×= 2
Cj
CfjX C ωπ
1)(2
1−=
×=
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Parallel Resonance – “Amplifier”
Harmonic Current SourceXC XL
CL
CLEQUIVALENT XjjX
XjjXX)()(
−+−×
=
Frequency Scan
1
10
100
1000
10000
100000
60 180 300 420 540 660 780 900 1020 1140 1260 1380 1500
Frequency in Hz
Impe
danc
e in
Ohm
s
Equivalent Parallel Resonant Circuit Frequency Scan for Parallel Resonant Circuit
• The parallel combination of impedance is:
• Since XL and XC have opposite signs, the denominator can equal zero if XL = XC. In reality, the only limiting factor is the difference in resistance between the capacitor and reactor.
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Parallel Resonant Example3rd Harmonic Voltage
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Parallel Resonant Example3rd Harmonic Voltage
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Parallel Resonant Example3rd Harmonic Current
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Parallel Resonant Example3rd Harmonic Current
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58 58© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Parallel Resonant Example4th Harmonic Voltage
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Parallel Resonant Example4th Harmonic Voltage
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60 60© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Parallel Resonant Example4th Harmonic Current
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Parallel Resonant Example4th Harmonic Current
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Parallel Resonant Example13th Harmonic Voltage
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The series combination of impedance is:
Since XL and XC have opposite signs, the summation can equal zero if XL = XC. In reality, the only limiting factor is the difference in resistance between the capacitor and reactor.
Equivalent Series Resonant Circuit Frequency Scan for Series Resonant Circuit
Harmonic Current Source
XC
XL
CLEQUIVALENT XjjXX )(−+=
Frequency Scan
0.1
1
10
100
1000
60 180 300 420 540 660 780 900 1020 1140 1260 1380 1500
Frequency in Hz
Impe
danc
e in
Ohm
s
Series Resonance – “Accidental Filter”
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Series Resonant Example19th Harmonic Current
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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).
Harmonic Resonance - Solutions
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66 66© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary66
Parallel Resonant Frequencies for Various Capacitor Sizes
0
50
100
150
200
250
300
350
400
450
500
0
100
200
300
400
500
600
0 5 10 15 20 25
Harmonic Order
Cap
acito
r Siz
e
Harmonic Resonance Switched Capacitor
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67 67© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Rules of Thumb for CapacitorsAre there harmonics? THDIw/ocap >10% or THDVw/ocap > 3% ?
YES: filtered cap bankNO: standard cap bank
Are there 3rd harmonic currents and is THDI3 > 0.2 THDI5 ?
YES: 2.67 tuned capNO: 4.2 detuned or 4.7 tuned bank
Is Isc/ IL < 20 ? Yes : use detuned 3.78 or 4.2 bankNO: use tuned 4.7 bank
Are there any large size VFDs? Yes : Smallest cap size >40% of largest VFD size
Are there any soft starters Yes : use filtered cap banks or usestandard caps in line with electromechanical bypass with time delay.
Is total cap capacity > 15% of Transformer kVA
Yes : Check for Resonance
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Ferroresonance is a special form of resonance which occurs between the magnetizing reactance of a transformer and the system capacitance. Because the state of the magnetizing flux in a transformer may change from cycle to cycle, the resonant waveshape can also change from cycle to cycle.
Ferroresonance is classified as system overvoltage rather than as a harmonic. The waveform is very distorted but a distinct 60 Hz frequency is present. The voltage magnitude can exceed 2.0 per unit and is sustained.
Ferroresonance
Most Common with Potential Transformers
(PT’s)
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69 69© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Harmonic Solutions – Product Mix Eaton Products Partner Products Access to Products
Harmonic Studies and Design X
Tuned Filters (LV/MV – Fixed/Switched) X
De-Tuned Filters X
Harmonically Hardened Capacitors X
Active Filters (LV) X
Harmonic Mitigating Transformers X
K-Factor Transformers X
Clean Power (18 Pulse) Drives X
3rd Harmonic Blocking Filter X
Broadband Drive Filters X
Line Reactors X
Static Switched (Transient Free) Filters X
Drive Isolation Transformers X
UPS Filter X
UPS Active Front End (9390/9395) X
Zero Sequence Trap X
DC Choke (Drives) X
MV Static VAR Compensator X
MV 24 Pulse Drives X
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70 70© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Line
Voltage
AC/DC
DC Bus
DC/PWMMotor
AC AC (PWM)DC
CONVERTER INVERTER
AC Drive Block Diagram
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71 71© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
AC Drives and Harmonics
ConverterDC Bus &Smoothing Inverter
Determine the line-sideharmonics
Determines load-sideDistortion
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72 72© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
l Distribution transformersl Standby generatorsl Communications
equipmentl Switchgear and relaysl Computers, computer
systemsl Diagnostic equipment
Line-side harmonics can have far-reaching effects on the power system:
AC Drives and Harmonics
ConverterDC Bus &Smoothing
Determine the line-sideharmonics
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• Utilities• Users• Maintenance and facility engineers
Who Cares About Harmonics?
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The power company typically supplies a reasonablysmooth sinusoidal waveform:
...but nonlinear devices distort voltage and current waveforms resulting in poor power quality on the distribution grid with further implications
Utilities
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• Harmonics can be thought of as power which does no useful work but requires extra generation and distribution capacity
• With the increased number of motors controlled by inverters and other nonlinear power electronics, utilities are delivering a higher percentage of “harmonic power” without a comparable increase in revenue
• Some utilities have introduced billable charges for harmonic distortion
Utilities
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• Control capital expenses• Needs to be a good citizen in the electrical
community via IEEE-519 compliance• Seek increased uptime and profits• Want to protect electrical assets• Work to add value to facilities• Desire reduced energy expenses
Users
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Harmonics can have far-reaching effects on the power system:
System Concern
Distribution transformers Overheating and efficiency loss, leads to Over-sizing and more increased losses
Standby generator Distortion dramatically reduces capacity, Synch issues with zero crossings for relays
Communications equipment Downtime and loss of productivity
Computers and computer systems Nuisance tripping and downtime
Diagnostic equipment Nuisance tripping and erroneous results
Utility Charges for harmonic pollution
Maintenance and Facility Engineers
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78 78© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Transformer Efficiency - 75 kVA Example
0.955
0.96
0.965
0.97
0.975
0.98
0.985
0.99
15 25 35 50 75 100
% Load
Resistive Load100% Harmonic Load
System Inefficiency with Harmonics
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79 79© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Harmonics and Heating
Std Transformer – Max Temp – 176 F HMT – Max Temp – 105 F
Load 100% Harmonics
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80 80© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Efficiency Testing for 75 kVA Familywith 100% Harmonic Load
91.000%
92.000%
93.000%
94.000%
95.000%
96.000%
97.000%
98.000%
99.000%
Nominal % of Full Load
% E
ffici
ency
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%
15 25 35 50 75 100
Transformer Family Testing –Affect of Harmonic Load on Efficiency
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81 81© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
• Begin with a facility analysis• Then interpret the IEEE-519 as it applies to
your facility• Now select the most cost effective harmonic
mitigation technique• Finally, be sure to analyze the proposed
facility design again and celebrate the cost savings and increased efficiency of optimum harmonic mitigation
What Will It Take?
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• May be as simple as making a determination of the ratio of drive load to the capacity of the utility transformer (harmonic dilution)• If 10% or less, no problem• If 10 – 20%, conduct a harmonic analysis study• If above 20%, mitigation required
• When further study is required, a system analysis service can recommend cost effective harmonic mitigation solutions based on a facility single line diagram.
Facility Analysis
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• Passive filters• Additional inductive reactance• Phase-shifted sources• 12 pulse converters• Active filters• The 18 Pulse Clean Power converter• 24 Pulse MV Drives
There are several alternatives for the attenuation of harmonics, some of which offer distinctive advantages over others. Among the most popular methods are:
How to Eliminate Harmonics
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Harmonic Solutions
Filter
480 V
Xs
M
XT
+ -M
Broadband Filter Active
Rectifier or 18 Pulse
G
Low Distortion Electronic Ballast
Oversized Generator
HMT
Act
ive
Filte
r
12 PulseM
Active Rectifier,
Filter or 12 Pulse UPS
PF Corrected
HMT
Filter
480 V
Xs
M
XT
+ -+ -M
Broadband Filter Active
Rectifier or 18 Pulse
G
Low Distortion Electronic Ballast
Oversized Generator
HMT
Act
ive
Filte
r
12 PulseMMM
Active Rectifier,
Filter or 12 Pulse UPS
PF Corrected
HMT
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85 85© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Harmonic Solutions - Commercial
Commercial Power Systems (and Data Centers)• Oversized Equipment (generator, transformers, neutrals)• K-Rated Transformers• Harmonic Mitigating Transformers• 3rd Harmonic Blocking Filter• Harmonic Filters (required for PF Correction)• UPS Filter• Low Distortion Loads
• UPS Active Rectifier• PF Corrected Power Supplies• Low Distortion Lighting Ballasts
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86 86© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Oversized Equipment
480 V
Xs
XTG
Oversized Generator
OversizedTransformer
2X Neutral
Xs
XTG
Transformer Efficiency - 75 kVA Example
0.955
0.96
0.965
0.97
0.975
0.98
0.985
0.99
15 25 35 50 75 100
% Load
Resistive Load100% Harmonic Load
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87 87© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Standard and K-Rated Transformers• 3rd harmonic current flowing in the
phases adds up in neutral.• On primary, 3rd current is trapped in
delta if balanced. Otherwise, the difference flows in the phases.
• Balanced 3rd currents are called “triplen” harmonics (3rd, 9th, etc.)
• Delta-wye transformers are said to “trap” triplen harmonics in delta. They do not eliminate other harmonics.
• K-rated are typically delta-wye.• K-4 – Drives• K-13 – Computer Loads• > K-13 (K-20, etc.) – Overkill• Historically, K-rated = low
efficiency
WYE CONNECTION
3rd Harmonic Currents Couple
Typical Delta/Wye Transformer
Efficiency Testing for 75 kVA Familywith 100% Harmonic Load
91.000%
92.000%
93.000%
94.000%
95.000%
96.000%
97.000%
98.000%
99.000%
Nominal % of Full Load
% E
ffici
ency
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%
15 25 35 50 75 100
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88 88© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Secondary Treatment of Triplens (HMT’s)
HMT Secondary
• Opposing magnetic fields – triplensaren’t magnetically coupled to primary
• Loads continue to operate as designed• Minimizing impact on electrical
infrastructure
ZIG-ZAG CONNECTION
Currents Couple
Harmonic Mitigating Transformer (HMT)
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Harmonic Mitigating Transformers
TriplenHarmonics
Use differentsecondarywinding totreat these
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90 90© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
5th & 7th
harmonics
Use Phase-Shifting totreat these
TriplenHarmonics
Use differentsecondarywinding totreat these
Harmonic Mitigating Transformers
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91 91© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
HMT 5th and 7th CancellationSay we have a three story building with a variety of loading. How much 5th and 7th cancellation can we expect?
5 Units
4 Units
3 Units
Mai
n
Case 15+ 4+ 3= 12 Units
Normal Delta-Wye
Normal Delta-Wye
Normal Delta-Wye
ZIG-ZAG CONNECTION
HMT-NON 0° Shift
Normal Delta-Wye
Normal Delta-Wye
5 Units
4 Units
- 3 UnitsCase 25+ 4 - 3= 6 Units
ZIG-ZAG CONNECTION
HMT-NON 0° Shift
Normal Delta-Wye
Normal Delta-Wye
- 5 Units
4 Units
3 UnitsCase 3- 5+ 4 +3= 2 Units
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92 92© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Transformer Technology ‘Rule of Thumb’Comparison Chart
Transformer Type Approx. Cost
Energy Usage
Power Quality Attributes
Standard Delta-WyeTP-1, Copper, 115C
1X say 100W None
K-Factor K13Copper, 115C
1.5X - 2X 130W30% more
Designed to Withstand Heating
EffectsHMT
TP-1, Copper, 115C1.5X - 4X 40W
250% less Corrects Root Cause
• YES, The INITIAL cost of an HMT is greater than the other transformers, however the Energy Savings you receive over the life of the HMT (20-30 years) pays back that difference multiple times!
• Similar thinking to using a Compact Fluorescent vs. Incandescent Lamp• Most appropriate for New Construction
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Cost
Commercial facilities requiring PF correction for utility penalties often use one of the following compensation methods:• PF Capacitors (standard or switched) – risk of harmonic resonance• “Harmonically hardened” capacitors – like “K-rated” transformer• Harmonic Filter
• Tuned – to reduce overall harmonic distortion (typically 4.7th “tuning”)• De-tuned – to avoid resonance (typically 4.2nd “tuning”)
• Active Harmonic Filter (both harmonic compensation and PF correction)
Harmonic Filter (PF Correction)
Capacitors Harmonic Filters Active FiltersHardened Capacitors
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94 94© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
How Does a Filter Work?
Filter
480 V
Xs
M
XTG
Generator
M
MM
Total HarmonicCurrent Divides Here
Filter Current Flows Here (On Phase
Conductors)
Harmonic Current Divides by Ratio of
Harmonic Impedances
12A24A6A
18A
12A (5th Harmonic)12A12A
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Computer Simulation/Modeling
Parallel resonance causes “amplification” of harmonic currents and high voltage distortion Increasing kvar
Parallel Resonance with Capacitors
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96 96© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Filter Design Considerations
Frequency Scan (Normal and Generator Source)
5th and 7th Filter
Filters control resonance, redirect harmonic currents and reduce voltage distortion
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Filters Control Parallel Resonance PointFrequency Scan – Staged Filter
25-125 kvar Filter
Parallel resonance harmonic is usually about 1 order below the “tuning” frequency
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UPS Filter
Harmonic Filter ON Harmonic Filter OFF
UPS front end (rectifier) tuned filter• 6-pulse – tuned to 5th
• 12-pulse – tuned to 11th
Generally switched on/off at 25-35% loadMay be turned off when on generator (avoid leading PF)
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99 99© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
• Rectifier Solutions – UPS, Drives, Battery Chargers • Active front end on UPS (Powerware 9390/9395) and some drives • Industry driven toward component (load) solutions
• Generators do not need to be oversized with Active Rectifier UPS
Low Distortion Loads
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100 100© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Data Centers/Servers – PF Corrected (Harmonic Filter)• Switch Mode Power Supplies (SMPS) have changed over to PF
Corrected Power Supplies
Industry driven toward component (load) solutions
Low Distortion Loads
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101 101© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Harmonic Solutions – Industrial
Industrial System (Drives and Rectifiers)• Line Reactors • Drive Isolation/Harmonic Mitigating Transformers• Clean Power (18 Pulse) Drives • Broadband Drive Filters• PF Solutions
• Harmonically Hardened Capacitors • Tuned Filters LV/MV• De-Tuned Filters LV/MV• Static Switched (Transient Free) Filters
• Active Filters
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102 102© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Drive without line reactor Drive with line reactorBest “cost/kVA” solution for drive harmonics
Drive and Rectifier Solutions
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103 103© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Reactor/Isolation Transformer
Order Magnitude Angle1 33.41 -163 0.90 -1865 9.92 1017 2.00 -18211 1.87 -15413 1.10 -12717 0.67 -7019 0.67 -50
Order Magnitude Angle1 33.41 -143 0.60 -1605 15.97 1147 7.48 -11011 1.77 -8913 1.40 -117 0.87 6019 0.57 122
w/ isola trans
w/o isola trans
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104 104© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Effect of Drive Line ReactorsEffect of Line Reactors
0%
20%
40%
60%
80%
100%
1 3 5 7 9 11 13 15 17 19
Harmonic Order
Cur
rent
- %
of F
unda
men
tal
0.5%3.0%5.0%
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105 105© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
SVX Drives – Equivalent Reactance500V Type 480 V 60 HzFr4 0003 0.65%
0004 0.98%0005 1.31%0007 1.63%0009 1.33%0012 1.71%
Fr5 0016 1.63%0022 2.18%0031 2.99%
Fr6 0038 3.16%0045 3.88%0061 4.59%
Fr7 0072 3.73%0087 4.41%0105 5.33%
Fr8 0140 3.00%0168 4.00%0205 4.80%
Fr9 0261 3.35%0300 4.26%
Fr10 0385 2.94%0460 3.77%0520 3.75%590 2.89%
HAND – OFF – AUTOTX & BYPASS OUT
BYPASS IN
BYPASS IN
XL AND BYPASS OUT
TX IN
1% XL IN 3% XL IN 5% XL IN
INDUSTRIALBUS
DRIVE 1
45 KVAHMTNON
0 DEG.
Industrial power system
Drive Solution DemonstratorPhase Shifting & Line ReactorsDrive 1
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106 106© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
6-pulse converter with 3% Reactor waveform: Harmonic Contenth5 = 42.5%
h7 = 29.38%h11 = 6.10%h13 = 4.06%h17 = 2.26%h19 = 1.77%h23 = 1.12%h25 = 0.86%
Note that diode converter bridges produce harmonics according to the rule h = nk +/- 1, where h is the harmonic produced, n is the
number of diodes and k is an integer. Harmonic content is approximately 50% of that
produced by a converter without choke.0
10
20
30
40
50
h5 h7 h11 h13 h17 h19 h23 h25
Harmonic Distribution
AC Drives and Harmonics
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107 107© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Phase Shifting/Cancellation12 Pulse, 18 Pulse or 24 Pulse Cancellation by Design
12 Pulse Example
#1 #2
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108 108© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Harmonics and Cancellation
Without Cancellation
24 Pulse Cancellation
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109 109© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
18 Pulse Design
Eaton “Clean PowerDrive” – CPX9000
Voltage
Current
18 Pulse Rectifier
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Method• 18-Pulse converter design which draws an almost purely
sinusoidal waveform from the source
Benefits• Meets the IEEE standards in every case• Attenuates all harmonics up to the 35th• Insensitive to future system changes• Increases life of drive through incredibly stable DC bus voltage
(18 small inputs instead of 6 large ones)
Concerns• Not cost effective at small HP levels (50HP and smaller)
18 Pulse Converters
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111 111© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
18-pulse “Clean Power” waveform:Harmonic Content
h5 = .16%h7 = .03%h11 = .24%h13 = .10%h17 = .86%h19 = 1.00%h23 = 0.05%h25 = 0.05%
Note that the reduction in harmonics is so dramatic below 17th harmonic that the scale actually drops to 1.0 as max. 18 pulse clean
power drives will meet IEEE519 in all practical instances, with some sizes as low as 3% ITHD
0
10
20
30
40
50
h5 h7 h11 h13 h17 h19 h23 h25
Harmonic Distribution
AC Drives and Harmonics
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112 112© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Drive Dedicated (Broadband) Filter
Standard Drive Drive with Dedicated Filter
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113 113© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
From IEEE519A Draft
Active Filters
• “Senses” harmonics and injects equal and opposite harmonic current into the line
• Tests PF and corrects by injecting phase displaced fundamental current
• Fast response for dynamic loads
• Typically highest cost
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114 114© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Lab Simulations and Videos
http://www.eaton.com/experience
• 4 drives without phase shifting• 4 drives with phase shifting (24 pulse system)• Active Fitler• 18 pulse (clean power) drive • Tacoma Narrows Bridge – Resonance Example
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115 115© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Cost of Harmonic CorrectionDescription Cost $/kVA Cost p.u.
Reactor 3 1Capacitors (LV) 12 4
Filter (MV) 12 4Filter (MV) Switched 15 5K-Rated Transformer 20 7
Capacitors (LV) Switched 25 8Filter (LV) 35 12
Filter (LV) Switched 45 15Harmonic Mitigating Transformer 50 17
Blocking Filter (3rd's) 100 33Broadband Filter (Drives) 100 33
Active Filter 150 50
Note that prices are generalized for comparison onlySome equipment must be fully rated for loads - others can be partially ratedCapacitors are shown for reference only
Per unit costs compared to reactor pricing
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116 116© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Conclusion
• Useful to measure and limit harmonics• IEEE Std 519-1992 defines limits• Confusion on how to apply the limits• Be clear when discussing harmonics
• Current or voltage?• Expressed as percent or in actual quantities?• If percent, % of I1 or % of IL?
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117 117© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Conclusion
• Intent of IEEE-519• Ensure utility provides a “clean” voltage• Limit harmonic current from customers
• Goal of IEEE-519• Prevent one customer from causing problems for
another, or for the utility
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118 118© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Conclusion
• Limits assessed at the PCC• PCC is the point where another customer can
be served• Regardless of metering location• Regardless of equipment (transformer) ownership
• ISC/IL ratio must be known to determine which harmonic current limits apply
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119 119© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Conclusion
• TDD versus THD• TDD: Harmonics expressed as % of IL• THD: Harmonics expressed as % of I1
• IEEE 519 harmonic current limits written in terms of TDD, and % of IL• Prevents users from being unfairly penalized during
periods of light load
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120 120© 2011 Eaton Corporation. All rights reserved.- Eaton Proprietary
Help (for Harmonics)!
• SKM Harmonics • Taught by Carnovale/Dionise – Warrendale• http://www.skm.com/training.shtml (Oct. 5-6, 2011)
• EESS• Tom Dionise• Visuth Lorch• David Shipp
• Products (Capacitors and Harmonic Filters)• Shree Sathe• Dave Simmons
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Wrap Up• Harmonic solutions vary greatly in effectiveness and cost
(technical vs. economic tradeoff)
• Commercial power systems often involve single phase harmonics (from lighting and computer loads).
• Transformers are usually the most appropriate solution for commercial systems
• Industrial power system harmonics are usually caused by drives and other 3-phase rectifier loads.
• Line reactors and harmonic filters are generally used in conjunction with phase shifting transformers for Industrial systems.
• Energy savings has become the buzz with PF correction and harmonic solutions – be careful…
• Learn more at: www.eaton.com/experience
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