AVC 2. Active Voltage Conditioner. ABB Group - 1 -

Transcription

1 AVC 2 Active Voltage Conditioner ABB Group - 1 -

2 AVC 2 Product Presentation 1. AVC 2 Overview 2. PQ Event Theory 3. Performance 4. Case Studies 6. Return on Investment 7. AVC2 Deep Sag 8. End ABB Group - 2 -

3 AVC 2 Overview ABB Group - 3 -

4 AVC 2 Specifications Full correction, three-phase sags down to 70% retained voltage Full correction, single-phase sags down to 55% retained voltage Partial correction, three-phase sags down to 30% retained voltage Partial correction single-phase sags down to 0% retained voltage Continuous ONLINE regulation Over and under voltage regulation Correction for voltage vector phase angle errors created by faults in the supply ABB Group Voltage unbalance correction

5 AVC 2 Features Fast (sub-cyclic) response Simple user controls Rugged overload capability Short circuit protected Extensive diagnostics Fault log Voltage event data logging Ethernet connectivity Modular construction ABB Group - 5 -

6 Modular Construction Minimum spares required High commonality of parts Fast replacement ABB Group - 6 -

7 Single Line Diagram 3ph Utility Supply Input secondary Sag/Swell Animation 3ph Output Load Distribution Transformer Input Circuit Breaker primary Boost Transformer Auto Transformer Bypass (Non 400/480V Supply) Environmental Rectifier and Inverter ABB Group System Wiring Diagram Click on grey boxes for more information Rectifier Fuse

8 Typical Factory Configuration UPS ABB Group - 8 -

9 Graphic Display Module The optional Graphic display offers: Easy access to information Visual representation of the system Event log, date and time stamped Fault log, date and time stamped Factory tags and location data Web Browsing Serial Communications ABB Group - 9 -

10 Graphic Display Module AVC Online AVC in Bypass ABB Group

11 Graphic Display Module Event Log Event Summary ABB Group

12 Plant Wide AVC 2 System Browsing Ability to call up individual AVC s Monitor in real time View event logs with date and time stamp Download event logs View data summary of multiple systems at once ABB Group

13 Full Web and Plant System USB port USB interface Technician Commissioning Support Tool Resident Webpage in Graphic Display Module Plant SCADA Accessing Data Registers Modbus/TCPIP over Ethernet Plant wide access from Web browser Firewall Worldwide web ABB Group

14 Rating Table Options Available 600V Medium Voltage 40% correction Product Overview Product Overview Product Overview Layout Product Overview Product Overview Product Overview Product Overview Product Overview Layout Product Overview ABB Group Home Product Overview Click on grey boxes for more information

15 Home Power Quality Event Theory ABB Group

16 Power Quality (PQ) The power supply has become reliable! Long interruptions and blackouts are rare. Hence increased focus on 2nd order problems. Power factor, harmonics, sags, surges, distortion, RFI Factory equipment has become less tolerant. CNC automatic machinery, PLC s, robotics, processor controlled tools ABB Group

17 Transmission Faults Single Phase - Ground 68% of Faults 2 Phase - Ground Fault 19% Balanced 3 Phase 13% ABB Group

18 Sag Warnings The most common PQ problem facing industry is Sag events. According to EPRI, sags account for >92% of PQ events. Facilities do not get advance warnings of impending sags. There is a solution!!! ABB Group

19 Equipment Immunity Standards 1. Semi-F IEC Voltage Dips (sags) 3. ITIC ABB Group Home

20 Certification Team SEMI F47! ABB Group IEC, UL, VDE

21 Home AVC 2 Performance ABB Group

22 50% Retained Voltage Single Phase Sag Transmission Line Sag AVC Input AVC Output Phase and Magnitude Correction ABB Group Performance Graphs

23 70% Balanced 3 Phase Sag Performance Transmission Line Sag AVC Input AVC Output Magnitude Correction ABB Group Performance Graphs

24 AVC 4 Quadrant Control Sag Arrows indicate power flow Load regenerating AVC Voltage Correction +ve Sag Arrows indicate power flow Load consuming Power Load Power -ve Load Power +ve Swell Load regenerating AVC Voltage Correction -ve Swell Load consuming Power Arrows indicate power flow Arrows indicate power flow ABB Group Home

25 Home Case Studies ABB Group

26 Global Markets Korea, STS and AVC to LGP, Hynix, Samsung Dockside Frequency converter Greece 108MVA at Wuxi China Ferrotec Shanghai 1500kVA + 750kVA BP Solar. Maryland ABB Group MVA 26KV Bacardi. Jacksonville 3MVA Rex Printing Fl Qimonda Malaysia Lord of the Rings. New Zealand Amcor NZ

27 Vectek Case Studies 1. Bottling Plant Florida USA 2. Plastic Extruder Auckland New Zealand 3. Solar Panel Manufacturer Maryland USA 4. Semiconductor FAB China 5. DWA Welding Machine Malaysia 6. Printing Press USA 7. Container Crane Hong Kong 8. Discharge Lighting Samoa ABB Group Spandex Production Turkey

28 Case Study One: Bacardi Rum Jacksonville, Florida. ABB Group

29 2MVA, AVC Bacardi Rum, Jacksonville, Florida. ABB Group kVA, 26KV

30 AVC Installed Over Christmas 2003 ABB Group Containerised option.

31 26KV MV Installation ABB Group

32 Medium Voltage AVC ABB Group

33 Bacardi Jacksonville Florida Bacardi Factory Utility Engineers Inspection ABB Group

34 High Speed Bottling Line protected by AVC ABB Group

35 Bacardi Site Data Bacardi produces 75,000 cases per day Working 2 x 10 hour shifts = 3,750 cases/hr 9 Bottling Lines Largest size bottles run at 400/min Miniatures run at 1000/min When an unexpected stoppage occurs it can take over one hour to restore production to normal line speeds Bacardi stated maintenance costs $350k p.a. for replacement parts damaged by unplanned stoppages ABB Group

36 Bacardi Assumptions If lines are down for 40 minutes then 2500 cases are lost in normal 20 hour production day If a value of U$10 per CASE were assumed, this would equate to U$25,000 per event No cost estimates have ever been offered or confirmed by Bacardi The actual figure may be higher, say 40k-50k per event No details are available for scrap costs, lost taxes, rework, overtime to recover lost production etc ABB Group

37 Assumed Bacardi Savings Historically 20 unplanned stoppages p.a. - $500k cost Bacardi volunteered - replacement costs cut by $250k p.a. Jan-Dec events occurred below 87% (IEEE Level) Omniverter corrected 475 of these If only 10% of events would have stopped production this would be 47 $25k each = $1,175k Total Assumed Savings = $1.425 million The Assumed payback period is less than 1 year ABB Group

38 JEA History Of Events >87% >80% >70% >60% Lost Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Total ABB Group Lost events include 7 hurricane induced complete outages

39 Hurricane Frances Sweeps Into Florida Voltage Conditioner Weathers the Storm The AVC installed in Jacksonville Florida had more than electrical sags to handle in its first year of operation. ABB Group

40 Installed On Time, On Budget Input PQ meter showing 1 x 9 s of availability Output PQ meter showing an improvement to nearly 4 x 9 s within only 142 days of operation. ABB Group MVA, 26KV installation

41 Transmission Sag Correction Input V1=82 V2=58 V3=87 ABB Group Output of AVC 30, , , , , , , , , , , V1 V2 V3 Case Studies V1=97 V2=98 V3=97

42 Case Study Two: Amcor Flexibles New Zealand ABB Group

43 Amcor Flexibles Plastic Extrusion Company Auckland New Zealand Installed AVC December KVA 400V 50Hz ABB Group

44 Amcor Flexibles ABB Group Typical blown film plastic extruder

45 Problem Extruded barrier film. Up to 9 layers Nylon particularly problematic Long set-up times 30 minutes to recover a fault Multilayer scrap is non-recoverable Less than 100% rolls are not accepted ABB Group

46 Cost Scrap material $2000 / event minimum Depending on roll build. 4 hrs/roll 24/7 operation. Electrician callout per event Unless restored within 30 mins, pulldown of extruder ABB Group

47 The Solution Trailed 300kVA on one of 6 extruder lines Operations staff demanded unit for their line 1000KVA Installed Dec 1998 (10 years of reliable service!) Amcor MD before the AVC, the slightest flicker of the lights and we had trouble, but now we never worry May 2005, Amcor installed another 1000kVA unit at their expanded plant. This was 7 years after buying the first unit. ABB Group

48 Case Study Three: BP Solar Maryland ABB Group

49 BP Solar Cell Manufacturing ABB Group

50 Frederick, Maryland ABB Group

51 Production Of A Solar Cell Silicon Ingots are first cast in an Electric furnace and then mounted on the saw carriage As presented to the saw they are valued at $2000/brick ABB Group

52 Abrasive Wire Saw ABB Group Endless loop abrasive wire saw, simultaneously slices 2 bricks over a 4 hour period.

53 Assembly Process ABB Group wafer processed and ready for assembly into matrices ready for mounting and interconnection.

54 The Problem 15 wafer saws susceptible to sags Wire breaks damaged 2 bricks Replacing the wire took 6 hours ABB Group

55 The Cost Broken saw wire 2 bricks x $2000 Up to 15 saws on site Plus lost production down stream Plus downtime Maintenance costs $4000 to $40,000 per event ABB Group

56 The Solution 1600kVA AVC installed Aug 2002 ABB Group

57 The Results BP Solar say the results were dramatic. Productivity losses on protected saws were eliminated Pay back was under one year Production managers asked why only half the plant was protected ABB Group

58 Show of Faith During thunderstorms, unprotected plant was shutdown Finally, after 3 years, BP Solar purchased a second unit to protect the remaining plant ABB Group Case Studies

59 Case Study Four: Semiconductor FAB Plants ABB Group

60 Semiconductor FAB Plants ABB Group The most sensitive industry to voltage sags

61 The Problem The series nature of the process Any disturbance results in a total loss Major events, in excess $1million No rework, days to recover Hugely competitive business ABB Group

62 The Traditional Solution UPS s large floor space low efficiency high capital cost significant operational costs If the UPS fails, the load is often dropped! Uses batteries for storage. ABB Group

63 AVC Solution 98-99% efficiency Small foot print Extremely high integrity Cannot drop the load. Low maintenance No batteries ABB Group

64 Overview Reference Clients (Electronics) ABB Group Over 350MW of voltage conditioners supplied to semiconductor FABs in Asia and North America over the last three years.

65 Major Projects AVC Hynix Wuxi China kVA, 1250kVA, 1500kVA 108MVA total Supplied as three separate projects Project Project Project 3 Commissioned May 2008 ABB Group Hynix M11 Cheongju Korea 52 x 1250kVA, 1500kVA Commissioned Feb 2008 Space allocated for M12

66 1.5MVA 480V AVC Input isolator Bypass Switch Output isolator ABB Group Optional Bypass ACV kVA-480V-50Hz

67 Process Protection 650KVA Protecting semiconductor FAB line 75KVA Protecting Vacuum Pumps ABB Group AVC is actually inside the clean room

68 50 x 650kVA AVC In FAB Plant Logging for one month including a snow storm Sag Depth 175kVA 75kVA 50kVA 25kVA Avg 10-20% % % % >50% Note: Most events are around 30% to 40% No events exceeded 50% ABB Group

69 50 x AVC 1250kVA Korea ABB Group

70 >100MW AVC s in Two Plant Rooms in China ABB Group

71 108MVA in Three Plant Rooms ABB Group

72 Voltage Sag 13:00hr Aug KV sag by 58% -24% -33% - 58% Duration Time: 0.3sec Over 300 pieces of production machinery protected. ABB Group

73 Tooling Protection China ABB Group

74 Case Study Five: Diode Welding Machines Malaysia ABB Group

75 The Problem Loss of production Product quality Power supply sags cause most diode welding machines to trip Random tripping of machines for no apparent reason The Product ABB Group High speed welding machines

76 System Issues 46 machines operate at once Power supply sags cause most diode welding machines to trip Random tripping of machines due to weld quality Voltage variations with load also cause inconsistent weld quality One machines input current Multiple machines input current ABB Group

77 Pre Study Pre study results and conditions AVC not coupled to load AVC response to Sags Recording of sag and machines tripped No event detected No event detected No event detected No event detected No event detected ABB Group

78 ROHM Wako Electronics Kota Baharu ABB Group AVC protection of all machines

79 Case Study Six: High Speed Printing Press Florida ABB Group

80 Rex Printing, Jacksonville FL A high speed printing press in Florida Multiple sags during the Storm Season The cost / event was not large, however, the number of events was 3000KVA, 480Vac, 60Hz Vectek AVC ABB Group

81 High Speed Printing Press ABB Group Hi-speed, multi-colour printing presses

82 3MVA AVC Controller Section ABB Group

83 Out Door 3MVA Installation ABB Group

84 Case Study Seven: Container Crane Hong Kong ABB Group

85 Container Crane Hong Kong Air Cargo Handling Automatic Stacker Reclaimer Crane Hong Kong Installed AVC March kVA 400V 50Hz ABB Group

86 Hong Kong Airport 1000 s of containers per day ABB Group

87 ABB Group Automatically stacked and reclaimed, by robotic container crane system

88 Weather Created Voltage Disturbances Crane malfunctions:- Jambs a container mid cycle Crane has to be manually reset Staff have to physically enter the crane Risk of personal injury. Safety Issue Damaged Container and Crane Airliner penalty charges for delayed flights ABB Group

89 AVC Solution Eliminates Voltage Sags from Crane Corrects sags when crane lifting (motoring) Corrects sags when crane is lowering (regenerating) ABB Group

90 ABB Group Case Study Eight: Protecting Church Vapour Lighting

91 Protecting Church Vapor Lighting in Samoa ABB Group Island power was causing premature light bulb failure (some lights actually falling from the ceiling onto the congregation!)

92 ABB Group

93 Spandex Manufacturing Plant: TURKEY ABB Group

94 New Spandex plant in Turkey Sags in the Industrial estate are causing problems. Spandex production is another continuous process An ABB AVC is chosen as the preferred solution ABB Group

95 450kVA AVC installed in the switchroom ABB Group

96 Number of events seen in very short time period! ABB Group

97 ABB Group

98 AVC 2 system ABB Group

99 Specifications: Load Capacity 200 to 2400kVA To 10MVA custom design Displacement power factor of connected load 0 lagging to 0.9 leading Crest factor 3 at 100% current Overload capacity from 100% supply 150% for at least 30 second, once per 500s ABB Group Single Line

100 Specifications: Input Supply ABB Group Nominal output voltage (V) According to model 480V 60Hz, 380 to 415V 50Hz 208V 60Hz, Options 208V, 50Hz 480V 50Hz 600V Medium Voltage Power System 3 Phase, center ground referenced Supply overvoltage category 3 Fault capacity >40kA (model specific) Outage ride through 500ms Maximum supply voltage Single Line 110% of nominal supply voltage

101 Specifications: Output Supply ABB Group Nominal output voltage (V) Set to match nominal input supply voltage 3ph regulation range +/-10% continuous 3ph regulation accuracy +/-1% typical to +/-2% maximum 30% Model 3 Phase balance sag/swell Correction ability from 70% remaining voltage +30% for at least 30s -10% continuous 1ph to ground correction ability From 55% remaining voltage +45% for at least 30s -15% continuous Sag correction accuracy (within specified range) +/- 10% of correction ratio Sag correction response Initial <250 micro seconds Complete < 0.5 cycle Equivalent series impedance (operating) < 4% Single Line Efficiency >98% (typically 99%)

102 Specifications: Bypass Capacity 100% of kva rating Maximum overload capacity in bypass 10 minutes 125% 1 minute 150% 1s 500% 200ms 2000% Transfer time Inverter to Bypass < 0.5ms Bypass to inverter < 250ms ABB Group Single Line Equivalent series impedance in bypass < 2.5% typical

103 Specifications: Environmental Enclosure IP20 standard IP21 by optional roof kit Pollution degree rating 2 Minimum Operating temperature 0 o C, 32 o F Minimum Operating temperature 40 o C Maximum Operating temperature 40 o C Above 40 o C de-rate at 2% per o C to a maximum of 50 o C Fahrenheit 104 o F Above 104 o F derate at 2% per 1.5 o F to a maximum of 122 o F Capacity derating with elevation 1.2% every 100m above 1000m to 3000m Maximum ABB Group Single Line Humidity <95% non condensing Noise <75dba

104 Layout 0.5 to 2B 0.5 to 1B System 1.5 to 2B System side by side 1.5 to 2B System back to back ABB Group Rating Table

105 Layout 2.5B to 6B Rating Table ABB Group

106 Rectifier Sine Filter IGBT + Bus L1 L2 L3 Fuses RFI Filter - Bus Soft Start Contactors IGBT active rectifier Bi-directional power flow Sinusoidal input current DC output ABB Group Single Line Inverter

107 Inverter + Bus Fuses IGBT Sine Filter - Bus Fuses RFI Filter U V W SCR/Contactor BYPASS ABB Group Single Line IGBT inverter Bi-directional power flow Sinusoidal output current DC input

108 Injection Transformer 400kVA 480 volt model ABB Group Single Line

109 No Protection Against PQ Events Utility Single Line ABB Group

110 AVC 2 Sag Protection Utility Sag Single Line ABB Group

111 AVC 2 Swell Protection Utility Swell Single Line ABB Group

112 30% AVC-2 Single Phase Event Performance Graph AVC Output Voltage (Line to Line) 120% 110% 100% AVC Output (L1 - L2, L3 - L2) 90% AVC Output (L1 - L3) 80% 70% Utility Voltage L1 to neutral reducing, for comparison 60% 50% AVC Online AVC Correction time (s) 50s 40% 40s 30% Correction Time 30s 20% 20s 10% 10s ABB Group % 600ms TX 30 o 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110% 120% 50% Retained Voltage Line to Line Neutral Graph Utility Voltage (Line to Neutral) b 0s

113 30% AVC-2 Single Phase Event Performance Graph AVC Output Voltage (Line to Neutral) 120% 110% 100% AVC Output (L2 - N) 90% AVC Output (L1 - N, L3 - N) 80% 70% Utility Voltage L1 to neutral reducing, for comparison 60% AVC Online AVC Correction time (s) 50% 50s 40% 40s 30% Correction Time 30s 20% 20s ABB Group % 0% 50% Single Phase Sag 600ms TX 30 o 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110% 120% Utility Voltage (Line to Neutral) b 10s 0s

114 30% AVC-2 3 Phase Balanced Event Performance Graph AVC Output Voltage (Line to Line)* 120% 110% 100% 90% AVC Output Voltage 80% Utility Voltage 70% 60% AVC in Bypass AVC Online AVC Correction time (s) 50% 50s 40% 40s 30% Correction Time 30s 20% 20s 10% 10s ABB Group % 70% Balanced Sag 600ms 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110% 120% Utility Voltage (Line to Line) a *AVC output at 0.8 PF for 208 volt systems 0s