Magnetic & Controls
WELCOMES
ALL
TECA DELIGATES
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Mitigation of HARMONICS
in Power Distribution System using
ACTIVE HARMONIC CONDITIONER
Power
Sag
Power
Failure
A total loss
of utility
power
Short term
low voltage
Electric
line
7
O
NOise
.
F uency
vertigh
req
voltage hequency Variatio~
3
Power
Surge
(Spike)
ShortTenn
h91 voltage
above 110%
or nominal
Harmonic
Distortion
DistDItion of
4
Increase
wavetann A ch~
11 Switching
Under- line voltage caused by ~CY
Transient
voltage for extended RFI or EMI stability
teneous
periods of a intetference
(Brownout) few minutes
Increase for a few days
line voltage
for extended
periodsofa
few minutes to 8
fewda
POWER PROBLEM
the normal
waveform
geneI8Ily
e tnnnitIed by
~
nonI~ loads
(notch) m the
range of
nanoseconds
InsIM
POWER QUALITY EVALUATION
Identify Problem category
Voltage Regulation
/Unbalance
Voltage Sags/
Interruptions
Problem categorization
Measurements / Data collection
Identifying range of solution
Utility
Transmission
Evaluate Solution
Optimum Solution
Utility
End-Use
Distribution Customer
Interface
Modeling /
Analysis Procedure
Flicker
Transient
Harmonics
Distortions
Causes
Characteristics
Equipment Impact
End-Use
Customer
System
Equipment
Design /
Specification
Evaluate Technical
Alternatives
Evaluate Economics of Possible solutions against total solution
What are Power System Harmonics?
• Harmonic: a mathematical definition, generally used
when talking about Integral orders of Fundamental
frequencies
• Power system harmonics: currents or voltages with
frequencies that are integer multiples (h=0,1,2,…N) of the
fundamental power frequency
r-----Disrol1ed
waveform (50HZ • Fundamental + 3rd Hannonic)
Fundamenta! (50HZ)
1st harmonic: 50Hz
2nd harmonic: 100Hz
3rd harmonic: 150Hz
5th harmonic: 250Hz
3rd Harmonic (150 HZ
Figure: 1
How are Harmonics Produced ?
 Power system harmonics: presenting deviations from a perfect
sinusoidal-waveform (voltage or current waveform).
 The distortion comes from a Nonlinearity caused by saturation,
electronic-switching and nonlinear electric loads,
Inrush/Temporal/Arc/Converter/Limiter/Threshold Type Loads.
Linear (Inductive) Load
Non-Linear Load
Current
Figure: 2
Current vs. Voltage Harmonics
• Harmonic current flowing through the AC Power
System impedance result in harmonic voltagedrop at the load bus and along the Feeder!!
(Voltage Drop)
+,
/".;\/\
Distorted! Volta.
0 0 ~'-~-_ --1-=----1
,1
'T
PUI'O
Sinusoidl
L...
Loads Producing Harmonic Currents
•
•
•
•
Switching power supplies
Welding machines
UPS
Motor drives
• Converters with controlled
rectifiers
• DC controllers for DC drives
• Old AC drives with thyristor
power converter technology
• Induction furnaces
• Solid State Industrial
Rectifiers
• Industrial Process Control
Systems
• Computer/Servers in Network
• Electronic lighting
ballasts/Controls
• Electric Arc Welding
Equipment
• Saturated
Inductors/Transformers
Why Bother about Harmonics?
 60-70% of all electrical AC Systems in Industry
operate with non-linear type loads
 Power-Quality-PQ Issues & Problems with EB
 Damage to Power Factor Correction
CAPACITORS
 Waveform Distortion can create
SAG/SWELL/NOTCHING/RINGING/…
 All can cause damage effects to CONSUMER
loads and power systems due to OverCurrent/Over-Voltage or Waveform Distortion
 Additional Power/Energy LOSSES
Negative Effects of Harmonics
 Overheating and premature failure of distribution
transformers
 Increasing iron and copper losses or
eddy currents due to stray flux losses
 Skin effect
 Alternating current tends to flow on the
outer surface of a conductor at higher
frequencies.
 Overheating and damage of
neutral ground conductors
 Malfunction of Sensitive Tele-control,
LAN and Protection Relaying.
Negative Effects of Harmonics (cont’ d)
 Overheating and mechanical
oscillations in the motor-load
 Producing rotating magnitude field,
which is opposite to the fundamental
magnitude field.
md trips
trips of
of
 False or spurious Relay operations and
circuit breakers
rcuits, found
found in
 Failure of the Firing/Commutation circuits,
SCR- Thyristor.
DC motor-drives and AC drives withI SCR-Thyristor.
__
n
Negative Effects of Harmonics (cont’ d)
 Mal-Operation instability of voltage regulator.
 Power factor correction capacitor failure
 Reactance (impedance)-Zc of a capacitor bank decreases as
the frequency increases.
 Capacitor bank acts as a sink for
higher harmonic currents.
 The System-Series and parallel
Resonance can cause dielectric
failure or rupture the power factor
correction capacitor failure due to
Over-Voltages & Over-Currents.
How to Quantify Harmonic Distortion?
• THD: Ratio of the RMS of the harmonic content to
the RMS of the Fundamental
%THD=-~~_/~·;_+~/~;+_._
..
+~~~ xlOO
I,
• Current THD-I
• Voltage THD-V
Pfrrue =
%THD=
~V; + V:+ ..+ V~
xlOO
VI
1
• j1+(THD,I100f
= pfdiSP• pfdist
Standards for Harmonics Limitation
IEEE/IEC
 IEEE 519-1992 Standard: Recommended Practices
and Requirements for Harmonic Control in Electrical
Power Systems
Table 1: Current Harmonic Limits
Ratio
Iscc / Iload
Harmonic odd
numbers (<11)
Harmonic odd
numbers (>35)
THD-i
< 20
4.0 %
0.3 %
5.0 %
20 - 50
7.0 %
0.5 %
8.0 %
50 - 100
10.0 %
0.7 %
12.0 %
>1000
15.0 %
1.4 %
20.0 %
Standard of Harmonics Limitation (cont’d)
 IEEE 519-1992 Standard: Recommended Practices and
Requirements for Harmonic Control in Electrical Power
Systems (Voltage Distortion Limits)
Table 2: Voltage Harmonic Limits
Bus Voltage
Voltage Harmonic limit
THD-v (%)
as (%) of Fundamental
<= 69Kv
3.0
5.0
69 - 161Kv
1.5
2.5
>= 161 Kv
1.0
1.5
Power Quality – The effect
• 3-phase: motor drives, converters, UPS systems,
induction furnaces, welding machines…
®
10.1 A <D 45.5 A @ 50.1 A @ 46.7 A
<I'
5.0ms 11= +31 12, -20 13= -24 IN' -12
TK>
CF
rnr~
;:5!;
)
~
Stromverlauf Frequenzumrichter
Frequency converter: input current
®
Ah05 <D 38.6% @ 33.5% @ 38.7%
15.6A
15.3A
16.0A
51.4 A <D111.8A @111.2A @105.6A
Oberschwingungsstrome
Frequenzum richter
Frequency converter: current harmonics
<D
Ah03
14.7%
16.3A
®
16.1%
17.6 A
+174°
"4
20
®
14.2%
15.4A
+156°
A
0
-.~
--
3l
II
l2
10
l3
v
<1= 5.Oms n = +192 12: -46 13: -83 IN: +62 )
THO
UPS:
CF
---:::=
Stromverlauf
input
current USV-Anlage
I
V
3
5
7
9
VA
II
13 IS 17 19 21 23 25cn
u
Oberschwingungsstrome
UPS: current harmonics USV-Anlage
Mitigation Of Harmonics
 ISOLATION-INTERFACE TRANSFORMERS
 The potential to “voltage match” by stepping up or stepping
down the system voltage, and by providing a neutral ground
reference for nuisance ground faults
 The best solution when utilizing AC or DC drives that use
SCR/GTO/SSR.. as IGBT based bridge rectifiers
 Delta-Delta and Delta-Wye Transformers
 Using two separate utility feed
transformers with equal
non-linear loads
 Shifting the phase relationship to
various six-pulse converters through
cancellation techniques
rLile
A
B
C
Mitigation Of Harmonics (cont’d)
11kV 150MVA 50Hz
Passive Filter:
 Built-up by combinations of
capacitors, inductors (reactors)
and resistors
Active Harmonic Filter :
5th
7th
 Inserting negative phase compensating
harmonics into the AC-Network, thus eliminating
the undesirable harmonics on the AC Power
Network.
 Most effective way on Harmonic mitigation, along
with improvement of displacement & distortion
factor.
11th
Mitigation Of Harmonics by IORA
(Active Harmonic Filter)
CAUSES
•
•
•
•
•
ONE
SOLUTION
RECTIFIER LOAD
WELDING OPERATIONS
LARGE HP MOTOR STARTING
PROCESS LOADS (i.e. MIXERS,
CRUSHERS, CHIPPERS, SHREDDERS)
ARC FURNACES, INDUCTION
FURNANCES
RESULTING IN






VOLTAGE FLICKER, SAGS
POOR PF & LOAD UNBALANCE
INABILITY TO START MOTORS
INCREASE IN ENERGY COST
INCREASE OPEX
EFFECT ON GENERATOR
PERFORMANCE …and MANY
MORE
Active Harmonic
Correction
PRINCIPLE OF OPERATION
Fu
ood
PRINCIPLE OF OPERATION
mains
compensation current
CTs
neutral
load
ECOsine™ Active
21
ACTIVE HARMONIC FILTER
• Active compensation of harmonic currents achieved
through Floating point 32-Bit DSP & CAN BUS comm.
Digital control technology with FFT analysis
•
•
•
•
•
Dynamically fast
Entire frequency spectrum compensated up to the 49th order
FFT decomposes the current into its frequency components
Possible to individually compensate for each harmonic
Application: VFD, Welding machines, induction furnaces,
continuous loads, Rectifiers & UPS..
• Active compensation of reactive power
Responds with almost no delay and without resonance
Optionally selectable
February 2009
ECOsine™ Active
22
Mitigation Of Harmonics by IORA (Active
Harmonic Filter)
HVC
15000
C)
c:
C)
J~
10000
_'/"
~
<a
5000
c:
"0
C'G
_.
Q)
0
~
>
!-c'1
<I)
(/)
-5000
;/ "\/
••
,/
,;/
'"
1
~
~~
I
1
~
• • • • •
1
1
<0
"
1
1
CO
" "
1
1
,,<:>
1
\,
,/
\.
1
.(l.-
I/.
~
'I\
1
1
~
1
1
I-•
---+-
Fixed Kvar
---
Load
........
"CO
,..____.
-• • • • • • • • • •
-10000
Time in cycles
 Action is instantaneous and can be attenuated at the
point of Harmonic generation.
 Individually programmed for Harmonic mitigation, pf
correction, Load balancing and waveform correction.
lORA
Result Kvar
Effect of AHF…
•
Distorted waveform- Before
IORA switched ON for mitigation
• Cleaned waveform -After IORA
switched ON for mitigation
Active Harmonic Conditioner
Connection diagram
Current transformers can be
placed upstream or
downstream of the filter
Network
Uncompensated load
Compensated load
February 2009
ECOsine™ Active
25
CASE STUDY -1
CLIENT:
DANA TECHNOLOGIES PUNE
FACITLITY:
LOAD:
TEST LAB FOR VEHICLE GEAR
DC MOTORS with 6-pulse
Rectifier & Regenerative load
PROBLEM:
Pf < 0.1
KVA demand increased
No possibility of adding Jig on 330kva
transformer.
SOLUTION:
IORA 600 AMP
Pf improved from 0.1 to 0.6
I
.
•
Load current reduced from 750A to 175A
.
.
1:
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0.25
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•
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0.20
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r-
9/20/2013
11:48:54.000 AM
·..··
•
,,
4:06.000 (min:s)
.
: ! 1:: ..::
,AM
~,
1S0 ,
300
···.. ···.. ··
250 .••••.•.••.••••.••••.••••••
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912012013
11:48:54.000 AM
I
4.06.000 (min:s)
49s/Oiv
·
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,
"
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4:0S.000(min:s)
49slOiv
KVA REDUCED FROM 282KVA to 66KVA
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11:48:54.000PM
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9/2012013
11:53:00.000
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1t52:59(X
_
CASE STUDY -2
CLIENT:
ADCO FORGING PUNE
FACITLITY:
LOAD:
FORGING & CASTING
350kW INDUCTION FURNANCE
PROBLEM:
Pf < 0.8
High Harmonics >30%
Breaker tripping & control card failure.
SOLUTION:
IORA 200 AMP
With only THDi correction
(at Load end)
After
.
:
I
13 - --- -- ------
.
.
,
.
.
.
,
.
.
j--- ---1-------( -----r------1----- -!------ j ---- --1-------[------[- -----1----- -!------; ---- -1--- ---t-- ----~------1- -----(--- -j -- - ---1- ----.
.
.
--.:. .•. ---: -- - ..• ; _
.
.
,
.
.
t-----r- ----- ~----- -: ------(.. ----1-----
.
.!...- ---.!...-.
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---"""__
,.V'~~~~i~d.
3 ------
.
.
,
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.
.
. .
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.
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o~------~--~--~------------~--~--~--------~--~--~--~--------~--~--~--~------------~--~--~------------~~
8/17/2013
10 seconds
IDiv
THDi reduced from 30% to 7% & THD v from 7% to 4%
no
ItHS
a
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factor
:: F: F F F F F F F F F F'T=1~'uu·F':Fr~1:Power
improvement from 0.8
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to 0.93
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:
:
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:
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:
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:
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~~~~~~
30 •• cond. /DIY
5!1.r.~~~
Neowatt
CASE STUDY -3
CLIENT:
FACITLITY:
LOAD:
EXEL SOFTWARE
IT CALL CENTER
SERVERS ,RACK,AND COMPUTERS
PROBLEM:
Pf < 0.97 with APFC
High Harmonics >23-25%
pf not improving beyond 0.97
SOLUTION:
IORA 300 AMP
Load Current without Filter (925A – 960A)
Load Current with Filter (875A – 925A)
1.05
1000
1.00
950
0.95
kA
A
900
0.90
850
0.85
12/16/2013
4:59:14.000 PM
5:45.000 (min:s)
1 min/Div
800
12/16/2013
5:04:59.000 PM
12/16/2013
5:13:14.000 PM
THDi (23- 25%) & THDv (>5%)
3:45.000 (min:s)
45 s/Div
12/16/2013
5:16:59.000 PM
THDi (< 4%) & THDv (<2.5%)
4.50
25.0
4.00
20.0
3.50
%
%
15.0
3.00
2.50
10.0
2.00
5.00
12/16/2013
4:59:14.000 PM
5:45.000 (min:s)
1 min/Div
12/16/2013
5:04:59.000 PM
12/16/2013
5:13:14.000 PM
3:45.000 (min:s)
45 s/Div
12/16/2013
5:16:59.000 PM
KVA & KW without filter
KVA & KW with filter
760
760
740
740
720
720
700
700
kW
kVA 680
kW
kVA 680
660
660
640
640
620
620
600
12/16/2013
4:59:14.000 PM
5:46.000 (min:s)
1 min/Div
12/16/2013
5:05:00.000 PM
12/16/2013
5:13:14.000 PM
Pf (0.97) without filter
3:46.000 (min:s)
45 s/Div
12/16/2013
5:17:00.000 PM
Pf (@0.998) with filter
1.06
1.04
1.05
1.02
1.00
0.98
1.00
0.96
0.94
0.92
0.95
0.90
0.88
12/16/2013
4:59:14.000 PM
5:46.000 (min:s)
1 min/Div
12/16/2013
5:05:00.000 PM
0.90
12/16/2013
5:13:14.000 PM
3:46.000 (min:s)
45 s/Div
12/16/2013
5:17:00.000 PM
DESIGN PHILOSOPHY
32-bit Floating Point DSP
controller design with
Space Vector Pulse Width
Modulation (SVPWM).
With CAN
Without CAN
CAN bus reduces
cablings and
improves reliability
flO
II
II
CONSTRUCTION & COMPONENT PLACEMENT

Modular design-Reduced MTTR
 Flexibility
Due to independent power modules, the rectifier and the
inverter part can be sized individually.
 High power to Low power separation
 True fan redundancy due to distributed horizontal mounting.
also helping in Fan replacement without shutdown.
 Life items Like fans, DC capacitor front accessible for easy
replacement.
 Efficient thermal cooling..
HUMAN MACHINE INTERFACE (HMI)

 7 Inch TFT Colour Display
True RMS readings for more that 25
vital parameters
 Easy to understand Mimic diagram
 Inbuilt 5nos configurable PFCs
 Internal SD card slot for life time data storage
 USB port connectivity for Data card compatibility.
STANDARD RATING – IORA 3000
MODEL NO.
RATING (Amp.)
IORA 30
30 Amp @ 400V AC
IORA 60
60 Amp @ 400V AC
IORA 75
75 Amp @ 400V AC
IORA 100
100 Amp @ 400V AC
IORA 200
200 Amp @ 400V AC
IORA 300
300 Amp @ 400V AC
IORA 400
400 Amp @ 400V AC
IORA 600
600 Amp @ 400V AC
Comparison: Active & Passive filters
Parameters
Capacitor filter
Tuned filter
Active filter
Type
Passive
Passive
IGBT based 32 bit DSP
controlled
Compensation
Only compensates power
factor
Compensates Harmonic Multiple
tuned filters are required, one for
each harmonic
Compensates PF and
Harmonics. One filter can
compensate multiple
harmonics simultaneously
Suitability
Not suitable in case of more
voltage distortion and current
distortion
Performance varies over frequency
variation and variation in voltage
distortion. Performance is
dependent on load level
Performance remains
constant over frequency and
voltage variation.
Suitable in any type of
environment
Resonance
Possibility of resonance. This
results in premature failure of
capacitor.
Possibility of resonance if tuned at
higher frequency. Performance
depends on source impedance
No possibility of resonance.
Stable operation
Size and weight
Bulky in size
Bulky in size when multiple
harmonics are to be compensated
Light weight. Size does not
change even if required to
compensate more harmonics
Life
Limited life in case of more
voltage and current
harmonics
More life as compared to capacitor
filter
Longer life, since
performance remains
constant and resonance is
avoided
Cost
Cheap
Costlier as compared to capacitor
filter
Initial cost is more as
compared to both the filters
No load condition
Imposes capacitive PF when
load is reduced. Contactors
are required to compensate
for leading pf.
Imposes leading PF at fundamental
frequency. So not suitable for
generator source. Compensated
filter is required for generator.
Performance is tuned at full load
No capacitive PF at no load.
Smooth PF compensation.
No problem to Generator
source.
Performance remains
constant over load variation
Contd.,…
Parameters
Capacitor filter
Tuned filter
Active filter
3rd
harmonic
compensation
Not possible
Becomes very bulky
Same filter can be used to
compensate 3rd harmonic
without increasing the size
Selectivity
And harmonic
Compensation
No selectivity
Physical components are required to
be changed
Stability through software.
Cost vs. performance is
easily possible. This makes it
more cost effective and
flexible
Capacity increase
Possible by adding more
capacitor
Redesigning is required for change
of load.
More units can be added later
on for increasing capacity
Safety
To take care of resonance
problem, lot of fuses must be
used. Also resonance causes
failure of other sensitive
circuits
Breakers and fuses must be added
per tuned filter. Also transient
voltage absorbers must be used to
avoid failure of other circuitry in
case of resonance
Only one set of Breakers and
fuses are required for all
harmonics
Power loss
Low loss
More loss
Moderate losses
Conclusions
The harmonic distortion principally comes
from Nonlinear-Type Loads. The application
of power electronics is causing increased
level of harmonics due to Switching!!
Harmonic distortion can cause serious
Failure/Damage problems, and are important
aspect of power operation that requires
Mitigation!!
Active Harmonic combined with Passive filter
(Hybrid solution) can give you real value for
money in mitigating Harmonics.
Conclusions
contd..
 ROI on an average (depending on the process
and application) is within 18-24 months*.
 Direct Benefit:
 No Penalty / notice from Electricity Board
 Effective improvement of pf (near unity)
attracts bonus/incentive.
 Overall reducing eddy current losses in
the main transformer (10-12%)
 Control on KVA demand
 In-Direct Benefit:
 Reduced maintenance of pf capacitor and
critical component, hence you get
extended life.
 Overall spurious tripping / failure rested.
(*: Condition applied)
INTRODUCTION
TEAM of Veteran POWER ELECTRONIC TECHNOCRATS –
carrying over 3 DECADES experience
Expertise in Product DESIGNING, ENGINEERING,
MANUFACTURING, MARKETING and SERVICING with world
class quality.
Same team who provided path breaking solutions
with tag of “INDIA’S FIRST”
1ST 600KVA IGBT FRONT END UPS system.
1st 600Amp Active Harmonic power Conditioner
1st 400Amp with N Intelligent Static Transfer Switch
PREVIOUSLY……
1st 500KVA Seismically qualified redundant UPS for NPC
1st 100KW Solar Off grid Inverter for REV
1st 250KW Solar Grid Tied Inverter
--
~TJ.\NR RR
1:(
TQM8TI
TATI T
(16~400AMP)
ITS;H
NT~RPRI~~
3-600KVA)
MAGNETIC & CONTROLS
2/30A, Selvam engg complex,Mettupalayam
road, Opp Govt Hospital,Thudiyalur
Coimbatore - 641 034, Tamil Nadu , India
Email.Id: magneticcontrols@gmail.com
P.T.Manikandan
Mobile: +91-9244655525