Carel Oberholzer, ABB South Africa, May 2013 PCS100 Power Protection Discrete Automation & Motion South Africa May 13, 2013 Slide 1
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 May 13, 2013 Slide 2
Power Quality Problem Power events don t come with a warning 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
Sag Characteristics and profile 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 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
Power Protection against voltage disturbance Protect YOUR production lines and processes May 13, 2013 Slide 5
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 May 13, 2013 Slide 6
Product Portfolio PCS100 Converter one technology many products PCS100 Product Line Major Market Segments Picture Power Protection Frequency Conversion Product Groups STATCOM Battery Energy Storage AVC & UPS-I SFC STATCOM ESS 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 Load Power Range 125kVA 20 MVA 125kVA 5MVA 100kVA 10MVA 100kVA 50 MVA Input voltage of power electronics Market Positioning 208-480V (any LV or MV with standard transformer) + AVC > 400 MVA installed base 208-480 VAC (any LV or MV with standard transformer) + SFC > 100 MVA installed base 208-480 VAC (any LV or MV with standard transformer) + 1 st order Dec. 2009 with Suzlon Wind Energy 208-480 VAC (any LV or MV with standard transformer) Strategic Alliances with key battery suppliers. May 13, 2013 Slide 7
PCS100 Platform The Concept Master 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 May 13, 2013 Slide 8
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 May 13, 2013 Slide 9
Power Protection - PCS100 AVC Sags, surges and poor voltage protection May 13, 2013 Slide 10
PCS100 AVC Active Voltage Conditioner Purpose 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 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 May 13, 2013 Slide 12
PCS100 AVC Active Voltage Conditioner Single Line Diagram 3ph Utility Supply Input secondary Sag/Swell Animation 3ph Output Load Distribution Transformer Input Circuit Br eaker primary Boost Transformer Bypass Transformer 50% retained voltage single phase sag 70 % retained voltage three phase sag ( Non 400 / 480 V Su pply ) Rectifier and Inverter Rectifier Fuse May 13, 2013 Slide 13
PCS100 AVC Active Voltage Conditioner Full web and plant system USB port USB interface Technician commissioning support tool Modbus/TCPIP over Ethernet Resident webpage in graphic display module Plant SCADA accessing data registers Plant wide access from web browser Firewall Worldwide web May 13, 2013 Slide 14
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 May 13, 2013 Slide 15
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 May 13, 2013 Slide 16
Power Protection - PCS100 UPS-I Sags & short term outage protection
Utility Voltage 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 140% 120% 100% 80% 60% UPS-I On Line UPS-I Off Line UPS-I On Line Surge Threshold. Adjustable. Typically 110% Sag Threshold. Adjustable. Typically 87 to 90% 40% 20% 100% load 75% load 50% load May 13, 2013 Slide 18 0% 0 1 2 3 4 5 8 Typical Outage Time for Ultra Capacitors (sec)
PCS100 UPS-I, Industrial UPS Single line diagram Input AVC RTS Applied Voltage Output Failsafe Bypass Utility Distribution Transformer Fast Utility Disconnect secondary Coupling Transformer primary Protected Load Inverter Charger Battery Option Ultra Capacitors UPS-I May 13, 2013 Slide 19
PCS100 UPS-I, Industrial UPS Operation cycle 1. Utility voltage within limits Power to the load is supplied from the Utility Energy flow Utility voltage SCR s On Output voltage Inverter Off UPS-I voltage 3. Utility returns 2. Utility Outage Occurs Power to the load is switched to the UPI-I energy storage within ¼ cycle. Utility voltage SCR s Off Energy flow Output voltage Inverter on UPS-I voltage May 13, 2013 Slide 20
PCS100 UPS-I, Industrial UPS Response to supply loss PCS100 UPS-I Input PCS100 UPS-I Output On detection - load taken over - actively disconnects supply Transfer 1/4 cycle May 13, 2013 Slide 21
PCS100 UPS-I, Industrial UPS Energy Storage 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 May 13, 2013 Slide 22 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
PCS100 UPS-I, Industrial UPS Full web and plant system USB port USB interface Technician commissioning support tool Modbus/TCP IP over Ethernet Resident webpage in graphic display module Plant SCADA Accessing data registers Plant wide access from Web browser Firewall Internet May 13, 2013 Slide 23
Statcom and ESS for industry Solving power system problems ABB Month DD, YYYY Slide 24
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 May 13, 2013 Slide 25
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 May 13, 2013 Slide 26
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 27
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 ABB Month DD, YYYY Slide 28
Energy Storage Systems (ESS) ABB Month DD, YYYY Slide 29
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. May 13, 2013 Slide 30
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. May 13, 2013 Slide 31
Load Leveling and Peak Shaving Time shifting energy demand From NGK presentation ABB Month DD, YYYY Slide 32
PCS100 Power Product Range Issues and Solutions 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 Voltage Conditioning - - Yes - - Yes with limitations Outage Protection - Yes with limitations on transfer Yes Yes - - - Yes Harmonic Filtering Yes to 7th - - - - Current balancing Yes Yes - - - Displacement PF correction Yes Yes Yes - - ABB Month DD, YYYY Slide 33
PCS100 STATCOM Container, 2MVAr medium voltage coupled May 13, 2013 Slide 34
References ABB Month DD, YYYY Slide 35
PCS100 STATCOM Northgate Minerals, Canada, 6x 4.5 MVAr May 13, 2013 Slide 36
PCS100 ESS Battery & ABB PCS Integrated BESS System May 13, 2013 Slide 37
PCS100 ESS Chile, 20 MW (5x4 MW) Li-Ion for frequency regulation May 13, 2013 Slide 38
PCS100 ESS Chile, 20 MW (5x4 MW) Li-Ion for frequency regulation May 13, 2013 Slide 39
ABB Month DD, YYYY Slide 40
PCS100 UPS-I & AVC Documents inside.abb.com / power electronics / power quality May 13, 2013 Slide 41
May 13, 2013 Slide 42