Machine, Panel, and Plant 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 mstephens@epri.com

Cost of Solutions Versus Knowledge of Sensitivity 2

Example PQ Solution Levels Machine or Subsystem Level Power Conditioning Control Level Power Conditioning (1/10 th to 1/20 th of Machine Level Power Conditioner Cost) Control Level Embedded DC Solution (Best done by OEM in design phase) 3

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 4

Dynamic Sag Corrector MegaDySC Draws power from remaining sagged voltage down to 50% of nominal voltage, and injects a series voltage to regulate a sinusoidal output voltage Below 50%, draws power from internal storage capacitors Mega and Pro DySC have on board event logging. Three-Phase Protection 400-3200Amps ProDySC Three-Phase Protection 25-200Amps MiniDySC Single-Phase Protection 1-50 Amps 6

Example DySC Output 500 400 300 200 100 0-100 -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 Input Voltage (Van) t (s) 500 300 100-100 Missing Volts -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) 600 400 200 0-200 DySC Output Voltage -400-600 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 t (s) 7

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) 8

Extended Run-Time Models Are Available 9

Extended Run-Time Models Are Available 10

Example DySC Bypass Configuration 11

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 12

Omniverter AVC Voltage 208,480 or 600V standard with 400/690V options available at 50/60 Hz. Sag correction 30 and 40% (SEMI F47) 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 14

Single Phase Schematic 15

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 16

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. 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 18

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 19

AVC Sag correction & Power conditioner Actual voltage sag event showing AVC input (top) and output (bottom) Before After AVC 20

3- phase sag to 70% 21

3- phase sag to 60% 22

Single phase 50% sag for 130mS 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 24

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. 25

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 26

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 27

CAT UPS

Active Power/CAT UPS Solution Diesel Genset For continuous power after 10-15 seconds CLEANSOURCE CS 600 On-line Temperature: OK Current: OK Voltage: OK Battery: OK UPS Critical Load Utility Power DC Flywheel UPS 29

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. 30

Flywheel System One-line DC Buss IGBT Inverter Motor, Generator To UPS Battery Input & Flywheel Energy Storage Flywheel Sensors Field Drive Bearing Drive DC Monitoring IGBT Control AC Monitoring Control and System Monitoring Comm 120 VAC Flywheel Sensors: Over speed Over voltage Over temperature Vibration Local EPO 31

Flywheel During Discharge DC Buss IGBT Inverter Motor, Generator To UPS Battery Input & Flywheel Energy Storage Flywheel Sensors Field Drive Bearing Drive DC Monitoring IGBT Control AC Monitoring Control and System Monitoring Comm 120 VAC Flywheel Sensors: Over speed Over voltage Over temperature Vibration Local EPO 32

Flywheel During Recharge or Float DC Buss IGBT Inverter Motor, Generator To UPS Battery Input & Flywheel Energy Storage Flywheel Sensors Field Drive Bearing Drive DC Monitoring IGBT Control AC Monitoring Control and System Monitoring Comm 120 VAC Flywheel Sensors: Over speed Over voltage Over temperature Vibration Local EPO 33

Integrated Motor/Generator/Flywheel Magnetic bearing integrated into field circuit Ball bearings easily replaced One moving part (rotor) Removable cartridge armature Simple, Reliable, and Power-dense 34

The Cat UPS Family UPS 300 UPS 300E 480Vac, 60Hz UPS 600 UPS 900 35

Continuous Power System Auto Transfer Switch Non-Critical Load From Utility Cat UPS Parallel On-Line Cat Gen Set Redundant 24 VDC Starting Power Critical Load 36

Dynamic Voltage Regulation +10% Nominal Voltage RMS Voltage sampled every 5 cycles +2% -2% -10% 37

CAT UPS Performance from Test in EPRI Lab 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. 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. 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. 42

Features and Benefits 43

Possible Setups 44

Performance Chart 45

Typical Modes of Operation 46

Technology Comparisons Pentadyne: (Also marketed as Liebert FS) Requires separate UPS unit that is sold in package Magnetically levitated flywheel, no bearings No Vacuum Pump (factory sealed flywheel) 50lb flywheel Spins at 52,000 RPM 190KW for 10+ Seconds One unit size Flywheel standby is 250W 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. Active Power /CAT UPS: UPS is integrated into package electronics Bearing On Board Vacuum Pump Included in system 800lb flywheel Spins at 8,000 RPM 150,300,600,900kW for 10+ seconds - Multiple sizes Flywheel standby power is about 2500W Maintenance: Air filters as needed Vac pump oil, six ounces once a year Major Maintenance every 3 to 4 years, $6,357 dollars per unit for bearing change 47

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 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 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) M- 4272 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. 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 51

There are two options of the MBTS $9450 List price for M-4272 switch alone. 52

MBTS Sequence of Transfer Logic in Sequential Transfer Mode Open Breaker on side with Faulted Feeder 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) 54

Glide Trajectory Estimation of Residual Voltage 55

Example Glide Trajectory Estimation of Residual Voltage at a Plant Residual Voltage 100% 90% 80% % Residual Voltage 70% 60% 50% 40% 30% 20% 10% 0% 0 5 10 15 20 25 30 35 Cycles 56

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 In- Phase 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) 57

Example Transfer Time Based on Example Plant Scenario 1.0 Fast Transfer Scenario 100% % Residual Voltage 90% 80% 70% 60% Residual Voltage 50% Fast Transfer Min (est.) Fast Transfer Max (est.) 40% 30% 20% 10% 0% 0 5 10 15 20 25 30 35 Cycles 3.0 Delayed-in-Phase Transfer Scenario 100% 90% % Residual Voltage 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 2.0 Residual Voltage Transfer Scenario Residual Voltage Residual Voltage Transfer Scenario Min (est.) Residual Voltage Transfer Scenario Max (est.) % Residual Voltage 80% 70% 60% 50% 40% 30% 20% 10% 0% 1 10 100 1000 Residual Voltage Delayed In Phase Transfer Min (est.) Delayed In Phase Transfer Max (est.) 0% 0 5 10 15 20 25 30 35 Cycles Even in Best Case Scenario, plant would still need either SEMI F47 Compliant Equipment or power conditioning on Control Circuits! Cycles 58