Joao Pimenta, PGTMM , October 13, 2016 ABB Power Grids ...

© ABBSlide 1October 25, 2016

Joao Pimenta, PGTMM , October 13th, 2016

ABB Power GridsCapacitors and Filters


Capacitors in ABBHistory

Pictures from old catalogues

§ 1932, started ASEA/ABB to deliver capacitors

§ This design remained the same until the beginning ofthe 60’s. During the 60’s and 70’s the designaccelerated due to the early ASEA projects for HVDCand FACTS projects.

§ 2000, ABB started to manufactory capacitors at Xi´anfacility, with focus at local HVDC and FACTS projects.

§ 2001, ABB introduced a revolutionary Dry type ofcapacitors for DC applications

More than 80 years of experience in the field of capacitors


Advantage of a good Power Factor

• Current drawn from the network reduced

• Transformers and distribution cables unloaded ( í I)

• Reduced Joule losses ( RI²)

• Cables

• Transformers

• Protect devices

• Voltage drop reduced

• Cables

• Transformers

• Increased power available at transformer terminals

• No penalty from electricity supplier


Advantage of a good Power FactorTransformers and distribution cables lightened (íI)

0.70.95

27%

§ Current drawn from the networkreduced

§ Reduction in factor of:

In (%)

§ Cos j 1 = 1 In = 100%

(required useful current)

§ Cos j íÕ In í

§ For the same kW, In is reduced by 27%when PF rises from 0.7 to 0.95

100*)2cos1cos1(

jj

-


Advantage of a good Power FactorReduced Joule Losses (RI²)

46

cos j final values

cos j initial values

% reduction in losses

§ Reduction factor of RI² watt (%):

RI² watt (%) =

§ For the same load, the losses arereduced by 46% when PF rises from 0.7to 0.95

100*)2cos1cos(1 2

jj

-


Locating Capacitors on System

TransmissionSC

SVC

Distribution

SCSVC

IndustryLoad SVC CHARM

QBANK


Locating Capacitors on System

Capacitor location1 2&3 4

Technical approach BestFlexibility Least Less BestSavings Least Less Max

Cost per kvar Least Lower Highest

1. on the plant feeder (HV)

2. on the main LV bus

3. on the auxiliary/remote bus

4. at the individual load point

M M M

1 2

3 4


Power Capacitor UnitDefinition of capacitor unit

§Capacitor bank §Capacitor unit §Capacitor element


Power Capacitor UnitOptimized capacitor design

Consideration of safety plenty level§ Film layer (3-layers is normal)

§ Strong puncture- against ability

§ Foil auto-folding of electrode§ Regular edge stress;

§ Excellent partial discharge ability

§a = folded radius

§D

§ Film

§Foil §Foil bulge edge§Folded

§a

§D =thickness of film


Power Capacitor UnitCapacitor Unit Construction

§Bushing

§Element

§Discharge Resistor

§Internal fuse

§earth insulation

§Nameplate

§Connection terminal


Power Capacitor UnitTechnology of Fuse

Internally Fused Externally Fused ABB Design Conventional Design

Fuseless§Fuse §Discharge

§ Resistor


Power Capacitor UnitElement failure

A puncture...

...creates a perfectweld (short-circuit)


ABB’s unique featuresExpertise in all type of fusing technologies


Application for Open Rack SolutionVoltage Level

• MV or HV Banks

• Limitation of units:• Voltage: controls the n° of

capacitors in series of the bank;

• Case Insulation: define max.capacitor in series at the samerack;

• System Voltage level:• Minimum air clearances

(Space Required)

• N° of Capacitors in Series

• Capacitor Bank’s height


Application for Open Rack SolutionRated Power

• Limitation of units:• Rated Power: Controls the n° of

capacitors in parallel of the bank

• Rated Power:• N° of Capacitors in Parallel

• Capacitor Bank’s width andlength (space required)

• Possibility of multi-step solution,for automatic PF compensation.


Application for Open Rack SolutionLocal of Installation

• Indoor or Outdoor;

• Conventional Solution;

• Arrangement optimized foreach installation:

• Cable entry;

• Available Space;

• Air clearances and MagneticClearances;

• Components inside the bank;


Application for Open Rack SolutionSafety

• Fence or Elevation Structuresrequired

• Restrict access to the area;

• Earth and Disconnector Switch(safety maintenance)


Application for Open Rack SolutionCost

• Most cost effective solution forMV and HV capacitor banks;

• Components costs:• Structure vs Panels

• Air core vs Iron core reactors

• Conventional equipment


Open Rack LayoutsMV Capacitor Banks

§Standard features

§Galvanised rack

§Frame capacity: 3, 6 or 9 units

§125kV BIL insulation

§Four welded lifting lugs

§Provision for key components

§Optional features

§Aluminium structural grade


Open Rack LayoutsMV Capacitor Banks


Open Rack LayoutsHV Capacitor Banks – Grounded Y/Y-Y

• High Voltage (≥69kV)

• Elevation Structure (If required)

• 1-ph Stacked Racks (↑ n° SG)

• Fence required (If no elevationstructure)

• CT Unbalance sensing device (ratedvoltage: 0.2 x Un)

• Progressive Insulation (racks withdefined potential)

• Bottom Insulators: ↓ BIL

• Costs: ↓


Open Rack LayoutsHV Capacitor Banks – Ungrounded Y-Y



• Fence required

• 1 x CT Unbalance sensing device(System Full BIL)

• Bottom Insulators: System Full BIL

• Costs: ↑↑

• Attention Point: Seismic Requirements


Open Rack LayoutsHV Capacitor Banks – Grounded H-Bridge



• Fence required (If no elevationstructure)

• 3 x CT Unbalance sensing device(rated voltage must coordinate withbridge midpoint voltage level)

• Progressive Insulation (racks withdefined potential)

• Bottom Insulators: ↓ BIL

• Costs: ↑↑


Methods of Capacitor ControlFixed vs. Switched Capacitors

0

1

2

3

4

5

6

0 24

Hour

MVA

R

Generally, it is more economical tocorrect to near-unity power factor:

• At minimum load through theapplication of fixed capacitors

• At higher loads through theapplication of switched capacitors

• Ideal solution…fixed capacitorscompensate the fixed portion ofload, while switched capacitorscompensate peaks and troughs


MECB 36 SD 10 (with internal detuned reactors)Indoor/Outdoor, IP54, Switched, One Stage


33kV ABBACUS MECB


PQC-STATCONShunt compensation

PQC-STATCON offers:

§ Enhancement of the grid – shunttechnology makes the grid act in amore robust, flexible and predictableway

§ Control of reactive power injection orabsorption

§ Unbalance compensation

§ Dynamic voltage control

§ Low noise levels

§ Optimized losses

§ Solution to MV/HV through Step uptransformers

§ Flicker mitigation (Case to case basis,pls consult factory)


§© ABB Group§October 25, 2016 | Slide 28

Field report: Welding Loads - AutomotiveFIAT Automobiles, India

Customer requirement• Fast response reactive power compensation for weld

shop

• To maintain power factor close to unity

• Reliable reactive power system with power saving modeduring lean hours / shift

ABB SolutionØ Installation of 0/600 kvar & 0/1200 kvar Instantaneous

stepless compensation consisting of 50% PQCT-STATCONand 50% filter bank.

• Pf is maintained to unity.

• STATCON in energy saving mode goes in sleep modeduring no load condition

• Voltage stabilization of bus.



Power factor graph with & without PQC-STATCON

§Source PF of 2.5 MVA transformer (PQC Off)

§Source PF of 2.5 MVA transformer (PQC STATCON on)

§Customer benefits

§ Power saving, less wastage of weldingelectrodes

§ Up to 20% of saving in electricityconsumption from grid

§ Reduction in electricity bill due topower factor improvement

§India

§Pune



§We are happy to inform youthat with ABB makeSTATCON, we are able tomaintain an averagemonthly power factor above0.995 lag to unity(1.0). Thishas indubitably improvedperformance of our plantloads by improving the totalpower quality.

Performance Letter from FIAT Automobile



PQF active filters

§ Filters up to 50th order of harmonics

§ Selective harmonic filtering

§ Closed loop operation

§ Provides dynamic reactive power and power factorcorrection

§ Load balancing feature

§ Graphical display of all power parameters of loads and filter

§ Keeps running at maximum load if load requirement is toohigh

§ Easy commissioning

Key features



PQF for floatation plant drivesGold Mining in Greece

§ Operation and exploitation of mines§ High power motors to crush the minerals§ Significant level of harmonic currents§ Bad voltage waveform



Customer benefits

Electrical values without filter

§VR-Y §IR

Unit L1-L2 L2-L3 L3-L1

Voltage Vrms 402 401 396

THD(U) % 5.3 5.4 6.0

L1 L2 L3Current Arms 948 1001 959

THD(I) % 34.1 31.6 34.0

GlobalActive power kW 617

Reactive power kvar 179

Apparent power kVA 657

PF - 0.94

Cos (φ) (or DPF) - 0.96 (Inductive load)



Customer benefitsElectrical values with filter

§VR-Y

§IR

Unit L1-L2 L2-L3 L3-L1Voltage Vrms 397 396 392THD(U) % 1.5 1.5 1.9

L1 L2 L3Current Arms 809 850 817THD(I) % 7.1 7.1 7.3

GlobalActive power kW 524Reactive power kvar 154Apparent power kVA 564PF - 0.96Cos (φ) (or DPF) - 0.96 (Inductive load)

Efficient filtering of harmonics

§ Reduced electrical pollution

Improved performance of electrical loads

§ Downtime reduction


Capacitors and FiltersWorld of ABB


Capacitors in ABBManufacturing, Local assembly units,Power quality centers and Technical lead centers

§No. of MV & HV Cap. Factories : 3

§No. of LV Cap. Factories : 2

§Local assembly units (LAU) : 7

§Power quality center (PQC) : 8

§Technical lead center (TLC) : 3

Quebec, CanadaPQC / LAU

Youngwood, PALAU

Galindo, SpainPQC / LAU

Jumet, BelgiumTLC LV / PQCLV Cap. factory Ludvika, Sweden

TLC MV & HV / PQCMV & HV Cap. factory

BulgariaLAU

San Luis Potosi,Mexico, PQC / LAU

Xian, ChinaMV & HV Cap. factory

Bangkok, ThailandLV Cap. factory

Bangalore, IndiaMV & HV Cap. factory

Lilydale, AustraliaPQC / LAUTLC MECB

Guarulhos, BrazilPQC / LAU

Dubai, UAEPQC


420 kV Substation, Norway

Increased network reliabilitydue to robust design.

ABB’s unique featuresPerformance in extreme ambient conditions

Successful installations in variousextreme ambient conditions like

§ Extreme temperatures..

§ High seismic activity..

§ High altitudes..

§ High pollution and corrosion levels..

§ 100% humidity..

....no problem!

Joao Pimenta, PGTMM , October 13, 2016 ABB Power Grids ...

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