Carel Oberholzer, ABB South Africa, May 2013 PCS100FILE/DMPC+3+-+ABB+PCS100+Power+Protectio… ·...

© ABB Group May 13, 2013 | Slide 1

PCS100 Power Protection Discrete Automation & Motion South Africa

Carel Oberholzer, ABB South Africa, May 2013


Power Protection Agenda

1. Introduction of power protection

2. Overview PCS100 platform

3. Solutions for Power Protection

• PCS100 AVC Active Voltage Conditioner

• PCS100 UPS-I Industrial UPS system

Power Quality Problem

The most common PQ problem facing

industry is sag events.

Brief power disruptions account for up to

70 percent of all unscheduled downtime in

modern manufacturing. Studies show that

these events are caused by voltage sags

lasting less than two seconds.”

Facilities do not get advance warnings of

impending sags

Power events don’t come with a warning

Sag Characteristics and profile

Various Origins

1) Transmission connected faults

2) Remote / local distribution system faults

3) Local distribution system faults

4) Non-faults eg: large motor starting

5) Short interruptions

6) Fuses

Unpredictable Causes

Weather,

Construction,

Network failure, etc.

Sag profile and event meaning

Power available, but bad quality

Duration of <1s

Commonly unbalanced

propagates throughout system

Power Protection against voltage disturbance Protect YOUR production lines and processes



Product Portfolio PCS100 Converter – one technology many products

Product Groups

Power Protection Frequency

Conversion STATCOM

Battery Energy

Storage

PCS100

Product Line AVC & UPS-I SFC STATCOM ESS

Major Market Segments Flat panel, LCD

and ship/memory

Datacenter

24/7 industry

Speciality boats

Dockisde OPS

Industry

Wind OEMs & parks

Solar EPCs

Distribution grid

Industry

Renewable energy

back-up (wind/solar)

Utilities

Industry

Picture

Load Power Range 125kVA – 20 MVA 125kVA – 5MVA 100kVA – 10MVA 100kVA – 50 MVA

Input voltage of power

electronics

208-480V

(any LV or MV with standard

transformer)

208-480 VAC


transformer)

208-480 VAC


transformer)

208-480 VAC


transformer)

Market Positioning + AVC > 400 MVA

installed base

+ SFC > 100 MVA

installed base

+ 1st order Dec. 2009

with Suzlon Wind

Energy

Strategic Alliances

with key battery

suppliers.

PCS100 Platform The Concept


The PCS100 converter platform is a modular

structure

Flexible sizing of converters by adding power

modules

Simple Service

Highly reliable with redundancy

Converter pairs (rectifier and inverter) housed in

800mm x 800mm cabinets

Multiple cabinets used to construct system

based on the power requirement

Options for racks to integrate converters into

container enclosures

Master


Power Protection - PCS100 AVC Sags, surges and poor voltage protection

Reduce the cost of sag events

Ensure quality supply to load despite supply

Applicable to industrial loads using significant power

Target voltage sags

Improve plant operation and reduce waste and damage

Regulates voltage (no long term under-voltage over-voltage and unbalance)

Removes voltage fluctuations - no process variation.

Economic and secure

Low cost of ownership (efficiency, footprint, cost)

Load never gets dropped

Very high availability

Simple servicing

PCS100 AVC – Active Voltage Conditioner Purpose

PCS100 AVC – Active Voltage Conditioner


Overview Protects sensitive loads - corrects voltage wave form Sags, surges, unbalance, flicker and poor regulation - corrected in

milliseconds Rated 160kVA - 30MVA. High power and performance inverter based system.

Key advantages

98-99% Efficiency

Simple user controls

Cannot drop the load

Short circuit protected

Extensive diagnostics

Fault log

Voltage event data logging

Ethernet connectivity

Modular construction and small footprint

Very little maintenance

No batteries

PCS100 AVC – Active Voltage Conditioner Single Line Diagram


secondary

primary

Distribution

Transformer

Input

Transformer

( Non 400 / 480 V

Su pply )

Rectifier Fuse

Input Circuit Br eaker

3ph Utility

Supply 3ph Output Load

Bypass

Rectifier and Inverter

Sag/Swell Animation

Boost

Transformer

50% retained voltage single

phase sag

70 % retained voltage three

phase sag


PCS100 AVC – Active Voltage Conditioner Full web and plant system

Technician

commissioning

support tool

Plant SCADA

accessing data registers

Plant wide access from

web browser

USB interface

USB port

Firewall Worldwide web

Resident webpage in

graphic display module

Modbus/TCPIP

over Ethernet


PCS100 AVC – Active Voltage Conditioner Reference clients (Electronics)

More than 400 MW of voltage conditioners supplied to semiconductor

FABs in Asia and North America over the last three years

Power Protection - PCS100 UPS-I Sags & short term outage protection

PCS100 UPS-I, Industrial UPS Overview


Ideal solution

deep sags

short term outages

Uses energy storage via an inverter boosting load

Fully offline system

Inactive unless required

Surge Threshold. Adjustable.

Typically 110%

Sag Threshold. Adjustable.

Typically 87 to 90%

140%

120%

100%

80%

60%

40%

20%

0%

0 1 2 3 4 5 …8

UPS-I Off Line

UPS-I On Line

UPS-I On Line

50%

load

75%

load

100%

load

Utilit

y

Vo

lta

ge

Typical Outage Time for Ultra Capacitors (sec)


Input Output AVC RTS Applied Voltage

secondary

primary

Charger

Distribution

Transformer

UPS-I

Ultra

Capacitors

Coupling

Transformer

Battery

Option

Inverter

Fast Utility

Disconnect

Failsafe

Bypass

Utility Protected

Load

PCS100 UPS-I, Industrial UPS Single line diagram


PCS100 UPS-I, Industrial UPS Operation cycle

SCR’s On Output voltage Utility voltage

UPS-I voltage

Energy flow

Inverter Off

1. Utility voltage within limits

Power to the load is supplied from the Utility

SCR’s Off Output voltage

Utility voltage

UPS-I voltage

Inverter on

Energy flow

2. Utility Outage Occurs

Power to the load is switched to the UPI-I energy storage within ¼ cycle.

3. Utility returns


On detection - load taken over - actively disconnects supply

Transfer ≤1/4 cycle

PCS100 UPS-I, Industrial UPS Response to supply loss

PCS100 UPS-I Input

PCS100 UPS-I Output


Ultra Capacitors

Protection for up to 3 seconds

Design Life: 15 years

Cycle life: >500,000

Safe and compact matching cabinet

A no battery solution

Reduced maintenance

Smaller footprint

PCS100 UPS-I, Industrial UPS Energy Storage

Spiral Lead Acid Battery

Protection for up to 30 seconds

Design Life: 10 years

Cycle life: >1200

Super high discharge rate

Easy service

Sealed

Small foot print


Technician

commissioning

support tool

USB interface

USB port

Firewall

Plant SCADA

Accessing data

registers

Plant wide access from

Web browser

Modbus/TCP

IP over

Ethernet

Internet

Resident webpage

in graphic display

module

PCS100 UPS-I, Industrial UPS Full web and plant system

© ABB Month DD, YYYY | Slide 24

Statcom and ESS for industry Solving power system problems


Common Problems in Industry Problems that ultimately cost money

High VAr requirements

Motors starting

Loads with lagging or leading power factor

Dynamic power factor requirements/Flicker

Automated welding machines

Presses

Crushing machines

Electronic loads with high power pulses

Arc furnaces

Imbalances caused by loads

single or 2 phase loads

regenerative loads (e.g. single phase PV)

Harmonic Currents


ABB Product Overview STATCOM / ESS

STATCOM (Static VAr Compensator)

Power electronics voltage-source converter

Either a source or sink of reactive AC

support electricity networks with poor pf

voltage stabilisation, current balancing and harmonic filtering.

An ESS (Energy Storage System) In essence also a STATCOM with energy storage

Supplies real power

Recharge battery system

Can deliver reactive power & pf

STATCOM Features Summary

Reactive current

Full inductive or capacitive

current available

For power factor correction

Fast response

Voltage balance/clamp Feature

Current Balance Feature

LV and MV connection

Up to 30 % nominal current

available for unbalanced

current correction

Harmonic Correction

Flicker Mitigation


© ABB

Month DD, YYYY | Slide 28

Starting Motors How can a STATCOM help

For a direct online MV or LV motor start the motor will initially

require approximately

800% of rated kVA

Typically made up of 300% nominal kW and 740% x nominal

kVAR

A Statcom can supply the kVAr requirement during starting and

running thus the utility will not have to supply this current.

800HP 600kW MV motor starting

Reference: Paper by

Energy Storage Systems (ESS)



Common Problems in Industry Avoiding costly upgrades to increase production

Energy consumption managed - avoid peak charges

expand production capabilities without upgrades to infrastructure

lower cost electricity utilised

Reduced max kVA = reducing fixed supply charges

Stabilized voltage

Possible to “black start”

Allows island mode - production continues

Note it is not a sag protection system.

PCS100 Energy Storage System Overview

An ESS has the ability to

shave the kW and KVAr

peak off the demand when

motors and other large

loads are started.

Load shifting, the ESS can

supply the load in parallel

with generators or the utility

and recharge the storage

when the load decreases at

a later time.


PCS100 Power Product Range Issues and Solutions

© ABB


PCS100

Statcom

PCS100

ESS (Energy Storage

System)

PCS100

SFC (Static Frequency

Conversion)

PCS100

AVC (Active Voltage

Conditioner)

PCS100

UPS-I (Uninterruptable

Power Supply)

VAr Support Yes Yes - - -

Peak Shaving kVAr only kW and kVAr - - -

Frequency

conversion

- - Yes - -

Voltage

Conditioning

Yes with

limitations

Yes Yes -

Outage Protection - Yes with

limitations on

transfer

- - Yes

Harmonic Filtering Yes to 7th - - - -

Current balancing Yes Yes - - -

Displacement PF

correction

Yes Yes Yes - -

PCS100 STATCOM Container, 2MVAr medium voltage coupled


References


PCS100 STATCOM Northgate Minerals, Canada, 6x 4.5 MVAr


PCS100 ESS Battery & ABB PCS Integrated “BESS System”



PCS100 ESS Chile, 20 MW (5x4 MW) Li-Ion for frequency regulation

PCS100 UPS-I & AVC Documents inside.abb.com / power electronics / power quality


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