Download Machine and Pane Level Solutions

Machine, Panel, and Plant Level Solutions
Mark Stephens, PE
Manager
Industrial Studies
Electric Power Research Institute
942 Corridor Park Blvd
Knoxville, Tennessee 37932
Phone 865.218.8022
[email protected]
Cost of Solutions Versus Knowledge of
Sensitivity
© 2009 Electric Power Research Institute, Inc. All rights reserved.
2
Example PQ Solution Levels
Machine or Subsystem Level
Power Conditioning
© 2009 Electric Power Research Institute, Inc. All rights reserved.
Control Level
Power Conditioning
(1/10th to 1/20th of Machine Level Power Conditioner Cost)
3
Control Level
Embedded DC Solution
(Best done by OEM in design phase)
Technologies Covered
• Pro DySC (larger version of MiniDySC)
• Eaton SRT/Omniverter AVC
• Active Power Flywheel (a.k.a CAT UPS)
• Pentadyne Flywheel
• Static Transfer Switch
• DVR
• Beckwith Digital Motor Bus Transfer System
© 2009 Electric Power Research Institute, Inc. All rights reserved.
4
Example PQ Solution Levels
Machine or Subsystem Level
Power Conditioning
© 2009 Electric Power Research Institute, Inc. All rights reserved.
Control Level
Power Conditioning
(1/10th to 1/20th of Machine Level Power Conditioner Cost)
5
Control Level
Embedded DC Solution
(Best done by OEM in design phase)
Dynamic Sag Corrector
MegaDySC
Three-Phase Protection
• Draws power from remaining
sagged voltage down to 50% of
nominal voltage, and injects a
series voltage to regulate a
sinusoidal output voltage
400-3200Amps
• Below 50%, draws power from
internal storage capacitors
• Mega and Pro DySC have on
board event logging.
ProDySC
Three-Phase Protection
25-200Amps
MiniDySC
Single-Phase Protection
1-50 Amps
© 2009 Electric Power Research Institute, Inc. All rights reserved.
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Example DySC Output
500
400
300
200
100
0
Input Voltage (Van)
- 100
- 200
- 300
- 400
- 500
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
t ( s)
500
300
Missing Volts
100
- 100
- 300
- 500
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
t ( s)
600
400
DySC Output Voltage
200
0
- 200
- 400
- 600
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
t ( s)
© 2009 Electric Power Research Institute, Inc. All rights reserved.
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0.4
0.45
0.5
Voltage Sag Correction & Ride-Through Times
• Ride-Through Times: (Based on
100% load, 0.7PF at 60Hz line
frequency)
• Standard Runtime:
2 seconds for sags from 87% to
50% of nominal voltage every 60
seconds
– Up to 5 seconds coverage on
Extended Run-Time Models
• 3 cycles for Standard Outage units
from 50%-100% (zero voltage
remaining)
• 12 cycles for Extended Outage
units from 50%-100% (zero
voltage remaining)
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Extended Run-Time Models Are Available
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Extended Run-Time Models Are Available
© 2009 Electric Power Research Institute, Inc. All rights reserved.
10
Example DySC Bypass Configuration
© 2009 Electric Power Research Institute, Inc. All rights reserved.
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Example DySC Pricing
Type
Part Number
Current
Cost
ProDySC 480Vac,
Standard Outage
Panel Mount 3-Wire
18-21kVA
DS30025A480V3SH2000B
25A
$17,325.00
ProDySC
480Vac,
Standard Outage
Panel Mount 3-Wire
36-42kVA
DS30050A480V3SH2000B
50A
$23,075.00
ProDySC
480Vac,
Standard Outage
Floor Mount 3-Wire
73-83kVA
DS30100A480V3SH2000B
100A
$40,825.00
ProDySC
480Vac,
Standard Outage
Floor Mount 3-Wire
165kVA
DS30200A480V3SH2051A
200A
$58,075.00
MegaDySC
480Vac,
Standard Outage
Floor Mount 3-Wire
333kVA
DS30400A480V3SH2000A
400A
$103,575.00
© 2009 Electric Power Research Institute, Inc. All rights reserved.
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Omniverter AVC
• Voltage 208,480 or 600V standard
with 400/690V options available at
50/60 Hz.
• Sag correction 30 and 40% (SEMI
F47)
© 2009 Electric Power Research Institute, Inc. All rights reserved.
13
Omniverter Active Voltage Conditioner
• Inverter controlled power conditioning for high power applications
25 kVA to 5 MVA at Low Voltage and
1 MVA to 50 MVA + at Medium Voltage 2-36kV
• The AVC is a 3 phase device and corrects voltages Line to Line.
• The AVC is a LOAD dedicated device and as a standard does not
provide correction back to the supply
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14
Single Phase Schematic
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How Does The AVC Work ?
• The AVC consists of an inverter which feeds an injection transformer
connected in series with the utility supply.
• The inverter produces compensating voltage vectors which correct for
utility voltage disturbances (sags, imbalance, flicker, voltage harmonics
and optionally overvoltages, etc).
• For Medium Voltage (MV) applications add a rectifier transformer and
change voltage ratio on injection transformer
• Should the AVC require energy to provide correction it draws this power
from its rectifier.
– There are NO storage devices in the AVC
– NO back feed of any upstream fault
© 2009 Electric Power Research Institute, Inc. All rights reserved.
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Key Features
• Fast response <1msec to initiate correction
• Complete correction to ±1% in 8msec (< 1/2 cycle)
• Continuously variable control (no step changes in output)
• Very efficient (typically > 98.5%)
• A modern microprocessor controlled solution
• High reliability through the use of redundant static switch back-up and
Maintenance Bypass.
© 2009 Electric Power Research Institute, Inc. All rights reserved.
17
AVC is an ON LINE Device
• Unlike most of its competitive devices, which start correction at a
predetermined voltage threshold, the AVC is continuously ON LINE
• It can maintain voltage within ± 1% of nominal
• It can provide continuous correction in the event of a prolonged
under-voltage
• It can correct multiple sag events occurring in rapid succession
• It also corrects other voltage problems
© 2009 Electric Power Research Institute, Inc. All rights reserved.
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Benefits of On-line Operation
• Corrects multiple sequential events
• Does not feed line faults as no storage
• Continuous phase balancing
• Flicker & voltage harmonic correction
• Optional 3-phase over-voltage correction, single phase OV
correction standard
• No resonance with downstream capacitance
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AVC – Sag correction & Power conditioner
Actual voltage sag event showing AVC input
(top) and output (bottom)
Before
After AVC
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3- phase sag to 70%
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3- phase sag to 60%
© 2009 Electric Power Research Institute, Inc. All rights reserved.
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Single phase 50% sag for 130mS
© 2009 Electric Power Research Institute, Inc. All rights reserved.
23
Example Control Level Solutions at the
Distribution Panel and Recommendations
• Sometimes the most effective
solution is to provide
conditioned power for the entire
IPP Panel. Advantages of this
approach include:
– Simplified Cut Over/Fewer
Touch Points
– Single Power Conditioner
for many loads
– When sized to support kVA
of transformer, this
approach will support future
expansion in panels
© 2009 Electric Power Research Institute, Inc. All rights reserved.
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Example Measured Loading of IPP Panel
• Panel Lightly Loaded
– Several Spare CB in Panel
– 480Vac CB Rating is 50A
– 480Vac Phase Currents
• Phase A – 4.89A
• Phase B – 4.11A
• Phase C – 1.67A
• Measurements were taken
when line was running.
• It is possible that some loads
could be cycled off.
© 2009 Electric Power Research Institute, Inc. All rights reserved.
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Example Three Phase Solution – ProDySC
• The Dynamic Sag Corrector
from Softswitching
Technologies
• Deep Sag Coverage especially
when lightly Loaded
• Has Capacitors that allow for
some ride-through for
interruptions
© 2009 Electric Power Research Institute, Inc. All rights reserved.
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Example Three Phase Solution – AVC
• Three-Phase Correction to
50%
• Single-Phase Correction to
25%
• No capacitors, therefore no
deep sag or interruption
ride-through
• Less Expensive than DySC
© 2009 Electric Power Research Institute, Inc. All rights reserved.
27
CAT UPS
Active Power/CAT UPS Solution
For continuous power
after 10-15 seconds
Diesel
Genset
CLEANSOURCE
On-line
Temperature: OK
Current: OK
Voltage: OK
Battery: OK
CS 600
UPS
Utility
Power
© 2009 Electric Power Research Institute, Inc. All rights reserved.
DC Flywheel
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Critical Load
UPS
CAT UPS
•
250kW/300kVA unit costs in the range of $100k-$140k depending upon
accessories and options. Flywheel speed ≈ 8000 RPM. In recent years
there has been a number of installations in US for bridge power application;
provides 15 second protection under rated load condition.
© 2009 Electric Power Research Institute, Inc. All rights reserved.
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Flywheel System One-line
DC Buss
IGBT Inverter
Motor,
Generator
To UPS
&
Battery Input
Flywheel
Energy
DC Monitoring
AC Monitoring
IGBT Control
Flywheel Sensors:
Over speed
Control and System Monitoring
Over voltage
Over temperature
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120 VAC
Comm
Vibration
Local EPO
Drive
Bearing
Field
Drive
Sensors
Flywheel
Storage
Flywheel During Discharge
DC Buss
IGBT Inverter
Motor,
Generator
To UPS
&
Battery Input
Flywheel
Energy
DC Monitoring
AC Monitoring
IGBT Control
Flywheel Sensors:
Over speed
Control and System Monitoring
Over voltage
Over temperature
© 2009 Electric Power Research Institute, Inc. All rights reserved.
32
120 VAC
Comm
Vibration
Local EPO
Drive
Bearing
Field
Drive
Sensors
Flywheel
Storage
Flywheel During Recharge or Float
DC Buss
IGBT Inverter
Motor,
Generator
To UPS
&
Battery Input
Flywheel
Energy
DC Monitoring
AC Monitoring
IGBT Control
Flywheel Sensors:
Over speed
Control and System Monitoring
Over voltage
Over temperature
© 2009 Electric Power Research Institute, Inc. All rights reserved.
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120 VAC
Comm
Vibration
Local EPO
Drive
Bearing
Field
Drive
Sensors
Flywheel
Storage
Integrated Motor/Generator/Flywheel
Ball bearings
easily replaced
Magnetic bearing
integrated into
field circuit
One moving part
(rotor)
Removable
“cartridge”
armature
Simple, Reliable,
and Power-dense
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34
The Cat UPS Family
UPS 300
480Vac, 60Hz
UPS 300E
UPS 600
UPS 900
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Continuous Power System
Non-Critical
Load
Auto Transfer
Switch
From
Utility
Cat UPS
Parallel On-Line
Critical
Load
Cat
Gen Set
Redundant 24 VDC
Starting Power
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36
Dynamic Voltage Regulation
+10%
+2%
Nominal Voltage
RMS Voltage sampled
every 5 cycles
-2%
-10%
© 2009 Electric Power Research Institute, Inc. All rights reserved.
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CAT UPS Performance from Test in EPRI Lab
© 2009 Electric Power Research Institute, Inc. All rights reserved.
38
Pentadyne Flywheel
What is it?
• The Pentadyne Voltage Support Solution™ is
a flywheel-based energy storage system. It
operates as a mechanical battery that stores
energy in the form of a rotating mass. This
energy is immediately converted to useful
power when needed.
© 2009 Electric Power Research Institute, Inc. All rights reserved.
40
Pentadyne VSS+DC
• A short duration energy storage device
that can supplement or completely
eliminate the need for lead-acid batteries
in UPS applications.
• If used as the sole source of energy
storage it vastly improves reliability,
longevity and uptime availability.
• It can change downtime maintenance
from many hours, many times per year to
a single one-hour interval once every six
years.
© 2009 Electric Power Research Institute, Inc. All rights reserved.
41
What Can It Do?
•
•
•
•
•
•
•
Configured as a two-terminal DC system
Used as a functional replacement for a bank of
chemical batteries used with Uninterruptible
Power Supply Systems (UPSs)
VSS+DC can work in parallel with a bank of
chemical batteries for increased DC bus
reliability and redundancy
It receives recharge and float power from the
two-terminal DC bus and returns power to the
same DC bus whenever the voltage droops
below a programmable threshold level
Multiple VSS+DC units can be put in parallel for
higher power output, longer ride-through
duration and/or redundancy.
Can be used in many DC applications to provide
power quality or energy recycling.
Designed not to require major service for 20
years in a UPS application.
© 2009 Electric Power Research Institute, Inc. All rights reserved.
42
Features and Benefits
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Possible Setups…
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Performance Chart
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Typical Modes
of Operation
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Technology Comparisons
•
Pentadyne: (Also marketed as Liebert FS)
•
Active Power /CAT UPS:
•
Requires separate UPS unit that is sold in
package
•
UPS is integrated into package electronics
•
Magnetically levitated flywheel, no bearings
•
Bearing
•
No Vacuum Pump (factory sealed flywheel)
•
On Board Vacuum Pump Included in system
•
50lb flywheel
•
800lb flywheel
•
Spins at 52,000 RPM
•
Spins at 8,000 RPM
•
190KW for 10+ Seconds
– One unit size
•
150,300,600,900kW for 10+ seconds Multiple sizes
•
Flywheel standby is 250W
•
Flywheel standby power is about 2500W
•
Maintenance:
– Operation check in first 6 months
– Service every 6 yrs, approximately
$1,500 per flywheel.
– Yearly maintenance contract price is
$460 per year per flywheel.
•
Maintenance:
– Air filters as needed
Vac pump oil, six ounces once a year
© 2009 Electric Power Research Institute, Inc. All rights reserved.
–
47
Major Maintenance every 3 to 4 years,
$6,357 dollars per unit for bearing
change
Static Transfer Switch
• Solid State thyristor or GTO switches
transfer between independent
distribution sources for interruptions
and sags
• 1/4 to 1/2 cycle response
• medium voltage, ≤600 A
• no energy storage
• electronics require cooling
• ~ $350k to $700k each
© 2009 Electric Power Research Institute, Inc. All rights reserved.
48
Series Voltage Boost Devices
• Synthesizes missing part of waveform
• Medium voltage applications, up to 40 MVA
• May contain energy storage, usually DC capacitors
• Ride-thru for 0.2
to 1.0 sec
• 1/4 cycle response
• Up to 60% boost
• ~$600K per boost
MVA
© 2009 Electric Power Research Institute, Inc. All rights reserved.
49
Beckwith Digital Motor Bus Transfer System
(MBTS)
• This is an interruption
protection scheme – not a
voltage sag ride-through
solution.
• The Beckwith Digital Motor Bus
Transfer System (MBTS) M4272 is used to transfer
between two plant feeders.
• This switch can provide inphase switching between the
back-emf from the plant and
the alternate feeder.
© 2009 Electric Power Research Institute, Inc. All rights reserved.
50
MBTS Standard Features
of Automatic Transfer
• The system provides the following Automatic Transfer logic and features:
– Transfer initiated by protective relay external to the MBTS
– Automatic Transfer after a loss of the motor bus supply voltage based on the
programmable undervoltage element. This provides a selectable backup
feature if a manual or protective relay transfer is not initiated.
• Fast Transfer with adjustable phase angle limit
• In-Phase Transfer at the first phase coincidence if Fast Transfer is not possible
• Residual Voltage Transfer at an adjustable low residual voltage limit if Fast
Transfer and In-Phase Transfer are not possible
• Fixed Time Transfer after an adjustable time delay
• Programmable Load Shedding with no time delay for Fast Transfer
• Programmable load shedding prior to initiating In-Phase Transfer, Residual
Voltage Transfer, and Fixed Time Transfer
• Adjustable setpoints for delta voltage limit and delta frequency limit
• Verify the new source (the source to which the bus is being transferred) is
healthy and within acceptable
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51
There are two options of the MBTS
• $9450 List price for M-4272 switch alone.
© 2009 Electric Power Research Institute, Inc. All rights reserved.
52
MBTS Sequence of Transfer Logic in
Sequential Transfer Mode
Open Breaker on side with Faulted Feeder
© 2009 Electric Power Research Institute, Inc. All rights reserved.
53
Glide Trajectory Estimation of Residual
Voltage During an Interruption
• Examining the response of the plant when a
voltage interruption occurred when the
Incoming Circuit Breaker (ICB) opens.
• We will examine how long it take to reach
various voltage levels
– 80% Level (Trip AB PLC-5)
– 70% Level (Trip AC “ice cubes”)
– 50% Levels (SEMI F47 level)
– 25% Level (Level Required for
– 0% Level (complete spin down)
© 2009 Electric Power Research Institute, Inc. All rights reserved.
54
Glide Trajectory Estimation of Residual Voltage
© 2009 Electric Power Research Institute, Inc. All rights reserved.
55
Example Glide Trajectory Estimation of
Residual Voltage at a Plant
Residual Voltage
100%
90%
% Residual Voltage
80%
70%
60%
50%
40%
30%
20%
10%
0%
0
5
10
15
20
Cycles
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56
25
30
35
MBTS Transfer Estimates at a Plant
• The MBTS will attempt to transfer
in fast transfer first. If this does not
work it will do either Delayed InPhase or Residual Voltage
Transfer.
• With the low Inertia load of the
Example Plant Load, the order of
operation that the MBTS will
attempt is most likely
– 1) Fast Transfer
– 2) Residual Voltage Transfer
when voltage is less than 25%
– 3) Delayed-in-Phase Transfer
(may never happen in Plants
scenario)
© 2009 Electric Power Research Institute, Inc. All rights reserved.
57
Example Transfer Time Based on Example
Plant Scenario
1.0 Fast Transfer Scenario
100%
90%
2.0 Residual Voltage Transfer
Scenario
% Residual Voltage
80%
70%
60%
Residual Voltage
50%
100%
Fast Transfer Min (est.)
Fast Transfer Max (est.)
40%
90%
30%
80%
% Residual Voltage
20%
10%
0%
0
5
10
15
20
25
30
35
Cycles
% Residual Voltage
3.0 Delayed-in-Phase Transfer Scenario
70%
Residual Voltage
60%
50%
Residual Voltage Transfer
Scenario Min (est.)
40%
Residual Voltage Transfer
Scenario Max (est.)
30%
100%
20%
90%
10%
80%
0%
0
70%
60%
50%
Delayed In Phase Transfer
Min (est.)
40%
Delayed In Phase Transfer
Max (est.)
20%
10%
0%
10
100
1000
Cycles
© 2009 Electric Power Research Institute, Inc. All rights reserved.
10
15
20
25
30
35
Even in Best Case Scenario, plant
would still need either SEMI F47
Compliant Equipment or power
conditioning on Control Circuits!
30%
1
5
Cycles
Residual Voltage
58