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Case studyPQF for Fuel Pumping StationBAFS

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The inquiry

n Mar 2004, ATAP sales team was working on a project that required a number of VFDs to be installed in a new plant.

n There’s some change in VFD’s requirement and the customer was concerned on harmonic’s effects.

n ATAP asked for our assistance.

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The project - BAFS

n Bangkok Aviation Fuel System is the new fuel pumping station for The Second Bangkok International Airport. (under construction)

n The customer has insufficient space for transformers of 12-Pulse Drives.

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The initial information

n Option 1 - Build one more building more cost, more space, operational difficulties, efficiency, ridiculous ?

n Option 2 - Use 6-Pulse Drives instead harmonics ?

n 12-P Drive : THDI 10 - 15%

n 6-P Drive : THDI 30 – 50%

n 12-P Drive needs phase shifting transformers

n 12-P Drive is more expensive

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The study (1)

?

System datan Tr. 24/0.4 kV, 2500 kVA, 10% Uccn Pumps 4 x 260 kWn Spare 2 x 260 kW

Requirement of filtersn G5/3n VFD running 1 - 4 pumps randomlyn Future extension 1 - 2 pumpsn Fit in 2 x 1 sq. m.n Remote control & monitoring

Constraintsn Very good PF (0.98)n Very high harmonicsn Very wide load rangen Tough G5/3n Limited space

Passive filter not possible !

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The study (2)

h I U I U I U1 100.0 % 100.0 % 100.0 % 100.0 % 100.0 % 100.0 %5 38.7 % 3.0 % 28.0 % 7.9 % 24.4 % 24.4 %7 17.1 % 1.8 % 9.3 % 3.6 % 8.3 % 8.3 %

11 8.2 % 1.4 % 5.8 % 3.6 % 4.4 % 4.4 %13 5.2 % 1.0 % 3.5 % 2.5 % 3.1 % 3.1 %17 3.9 % 1.0 % 1.8 % 1.8 % 1.4 % 1.4 %19 2.6 % 0.8 % 1.5 % 1.6 % 1.3 % 1.3 %23 2.1 % 0.7 % 0.9 % 1.1 % 1.0 % 1.0 %25 1.5 % 0.6 % 0.8 % 1.1 % 0.8 % 0.8 %29 1.1 % 0.5 % 0.7 % 1.2 % 0.5 % 0.5 %31 0.8 % 0.4 % 0.6 % 1.0 % 0.5 % 0.5 %35 0.5 % 0.3 % 0.5 % 1.0 % 0.4 % 0.4 %37 0.5 % 0.3 % 0.4 % 0.8 % 0.3 % 0.3 %41 0.3 % 0.2 % 0.3 % 0.7 % 0.3 % 0.3 %43 0.4 % 0.3 % 0.3 % 0.6 % 0.3 % 0.3 %47 0.3 % 0.2 % 0.2 % 0.7 % 0.2 % 0.2 %49 0.4 % 0.3 % 0.2 % 0.6 % 0.2 % 0.2 %

THD 43.8 % 4.3 % 30.5 % 10.4 % 26.4 % 13.4 %

1 VFD (260 kW) 4 VFD (1040 kW) 6 VFD (1560 kW)VFD's harmonics data (DriveSize 2.2)

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The study (3)

G5/3h I VFD I AF I net I VFD I AF I net I VFD I AF I net I5 160 104 56 524 468 56 622 566 56 567 71 31 40 184 144 40 211 171 40 4011 34 15 19 113 94 19 112 93 19 1913 22 6 16 62 46 16 79 63 16 1617 16 10 6 42 36 6 36 30 6 619 11 5 6 29 23 6 32 26 6 6

Total 44.2% 110 18.4% 35.1% 502 4.5% 27.5% 603 3.0%

G5/3 Z neth U VFD U net U VFD U net U VFD U net U Ohm5 2.2 0.8 7.3 0.8 8.6 0.8 4.0 0.0327 1.4 0.8 3.6 0.8 4.1 0.8 4.0 0.04511 1.0 0.6 3.4 0.6 3.4 0.6 4.0 0.07013 0.8 0.6 2.2 0.6 2.8 0.6 4.0 0.08317 0.8 0.3 2.0 0.3 1.7 0.3 4.0 0.10919 0.6 0.3 1.5 0.3 1.7 0.3 4.0 0.122

Total 3.1 1.4 9.4 1.4 10.8 1.4 5.0

1 VFD (260 kW) 4 VFD (1040 kW) 6 VFD (1560 kW)

Network harmonics with Active Filter (Net-Q)Current (A)

Voltage (%)

1 VFD (260 kW) 4 VFD (1040 kW) 6 VFD (1560 kW)

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The solutionPerformancen Exceed G5/3 requirementn 40 ms respond time to load changen 0 – 100% continuous load rangen Extendable latern Not overloadablen Full system parameter monitoringn Remote control via MODBUSn Filter up to 50th harmonicsn Filter 20 harmonics simultaneouslyn High accuracy – 2nd to 50th

n Safety closed loop controlActive Filtern PQFI 700 A, 415 V 50 Hz, 3 phn 1.6 x 0.6 sq. m. foot print

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The competitor

n The competitor offered 12-Pulse Drives that don’t required phase-shift transformer

n We found out later that it is fake 12-Pulse Drive

6-Pulse VFD Passive filter+

Named12-Pulse filter !

12-Pulse VFD=

DrivesDrives

5th5th 7th7th

Series ReactorSeries Reactor

High pollutionHigh pollution

Tuned filterTuned filter

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The final solution

450 A

5 VSDs

GTr A Tr B

C

MC

CB

630

A

450 A

C

MC

CB

630

A

Option # 3, 450A+450A & 450A+450A

PQF 1450 A

4 pumps

6 VSDs

4 pumps

PQF 1a450 A

450 A

C

MC

CB

630

A

450 A

C

MC

CB

630

A

PQF 2a450 A

PQF 2450 A

- 4 sets of CT- 1 sets of SCT 5+5=5- 1 sets of SCT 5+5+5=5 G

VFD6x

PQF PQFPQF PQF

CT connection diagram for option#2 & 3

VFD5x

SCT

SCT

n N+1 concept applied

n Easiest operation