Advancements in AC Power Capacitor Manufacturing Techniques Solve Traditional Industry Application Problems

Transcription

1 Advancements in AC Power Capacitor Manufacturing Techniques Solve Traditional Industry Application Problems Applied Power Electronics Conference, 2014 Fort Worth, TX Presented by: John Houdek, Allied Industrial Marketing, Inc.

2 Capacitors and reasons for failures Capacitors have often been considered the weak link in a power system Typical reasons for failures of Power Factor Capacitors are: Over-Voltage Over-Current Over-Temperature Terminal & Wiring failures FRAKO Kondensatoren- und Anlagenbau GmbH 2

3 Over-Voltage One has to differentiate between sustained and transient over-voltage Sustained over-voltage has different causes such as: Large capacitance connected to the system High tap on transformer Lightly loaded transformer FRAKO Kondensatoren- und Anlagenbau GmbH 3

4 Transient Over-Voltage Transient over-voltages occur during switching of capacitors or other devices in the network They cause damage to the capacitors which can be either immediate or latent depending on voltage amplitude and available energy The amplitude depends on the instantaneous peak voltage available at the time of switching Actual point of the voltage sine wave Zero cross = no transient Peak = worst case transient Short Circuit Power available in the network FRAKO Kondensatoren- und Anlagenbau GmbH 4

5 Switching Near Zero Axis FRAKO Kondensatoren- und Anlagenbau GmbH 5

6 Switching Near Peak V N = 600 V rms V N = 849 V peak V peak = 1550 V FRAKO Kondensatoren- und Anlagenbau GmbH 6

7 Over-Current Over-Currents in a capacitor may be caused by Elevated system voltage Harmonic distortion Harmonic resonance FRAKO Kondensatoren- und Anlagenbau GmbH 7

8 Over-Temperature The ambient temperature is crucial for the operation and life expectancy of capacitors Over-Temperatures can be the result of overcurrent/voltage as well as other heat sources inside the electrical enclosure such as: Reactors Contactors Wiring Fuses Further reasons can be insufficient cooling or inadequate ventilation FRAKO Kondensatoren- und Anlagenbau GmbH 8

9 Over-Temperature Curve % Life Expectancy vs. Over temperature 120% % Life 100% 80% 60% +10 C sustained Over-Temperature can reduce life by about 50% 40% 20% 0% C Over Temperature (continuous) FRAKO Kondensatoren- und Anlagenbau GmbH 9

10 Terminal & Wiring failures Screw terminations loosen over time due to heating/cooling, fatigue and vibrations This can cause: High resistance connection Localized I²R heating Burned terminals & wiring Risk of fire FRAKO Kondensatoren- und Anlagenbau GmbH 10

11 Other examples of Capacitor failures Source: Source: FRAKO Kondensatoren- und Anlagenbau GmbH 11

12 Capacitor Manufacturing Most manufacturers of Power Factor Capacitors combine two technical features to protect the capacitor in its operation Self-healing dielectric (mostly MPP film) + Over-pressure disconnection device FRAKO Kondensatoren- und Anlagenbau GmbH 12

13 Capacitor Manufacturing Self healing dielectric Protects against damage caused by minor transients Over-pressure disconnection device Protects against rupture due to build up of pressure, due to a failing self healing process In most capacitors, only two phases are actually disconnected FRAKO Kondensatoren- und Anlagenbau GmbH 13

14 FRAKO Capacitor History Establishing of FRAKO as Frankfurter Kondensatoren GmbH Switch to Capacitors in MPP technology Introduction of the LKT dry-type capacitors Introduction of the FRAKO unique segmented metalization for LKT-type capacitors /13 Production of the first Power Factor Capacitors FRAKO patented the first screwless connection terminal for Power Capacitors FRAKO patented a unique overpressure disconnector for Power Capacitors UL and CSA approval for LKT-type capacitors FRAKO Kondensatoren- und Anlagenbau GmbH 14

15 FRAKO Capacitor Contruction Contact bridge Core Free margin Contact bridge Metalization FRAKO Kondensatoren- und Anlagenbau GmbH 15

16 FRAKO Capacitor Contruction Cover Connectors Insulation & granulate Winding Winding Aluminum casing Winding Threaded bolt M12 by 16mm FRAKO Kondensatoren- und Anlagenbau GmbH 16

17 FRAKO Technology advancements To increase the operational safety and the service life of capacitors, FRAKO developed unique technical advancements Segmented film metalization 3-phase over-pressure disconnecting device Screwless connection Terminal FRAKO Kondensatoren- und Anlagenbau GmbH 17

18 FRAKO Segmented Metallization Comparison of standard MPP and segmented MPP film High amount of discharge energy Limited discharge energy Standard MPP film FRAKO segmented MPP film FRAKO Kondensatoren- und Anlagenbau GmbH 18

19 FRAKO Segmented Metallization Comparison of standard MPP and segmented MPP film Increased risk of breakdowns through multiple layers Minimized risk of breakdowns through multiple layers Standard MPP film FRAKO segmented MPP film FRAKO Kondensatoren- und Anlagenbau GmbH 19

20 FRAKO 3-phase over-pressure disconnection device Normal operation Safely Disconnected 3-phase disconnection = maximum safety FRAKO Kondensatoren- und Anlagenbau GmbH 20

21 Unique FRAKO Triple Safety Features Self-healing MPP film Segmented Metalization 3-phase over-pressure protection + + The combination of these three features ensures a maximum in safety and life expectancy FRAKO Kondensatoren- und Anlagenbau GmbH 21

22 Screwless Wiring Terminal Fast & Secure Wiring Terminal AKD-UL (as optional accessory) Plug-in Fingersafe Anti-Vibration Time saving & cost effective Fast & easy to wire Maintenance-free UL & CSA approved connection FRAKO Kondensatoren- und Anlagenbau GmbH 22

23 Summary Advantages of FRAKO LKT-type Power Capacitors Self healing MPP film Segmented Metalization Limited discharge energy in case of breakdown Minimized risk of breakdown through multiple layers Minimized risk of case ruptures 3-phase over-pressure disconnection device Screwless terminals for lifetime, maintenance-free connection FRAKO Kondensatoren- und Anlagenbau GmbH 23

24 Visit us in the Exhibition Hall Booth 235 Contact us North-America Allied Industrial Marketing, Inc. W62 N248 Washington Ave. # 208 Cedarburg, WI Phone: (GMT-6) Fax: info@alliedindustrialmarketing.com German Headquaters Kondensatoren- und Anlagenbau GmbH Tscheulinstraße 21 A Teningen, Germany Phone: (GMT+1) Fax: info@frako.de FRAKO Kondensatoren- und Anlagenbau GmbH 24

25 Thank you for your time! Any questions? FRAKO Kondensatoren- und Anlagenbau GmbH 25