PPHVC Power Quality Solutions ABB PQC-STATCON Benefits and advantages
Reasons for investing in power quality Poor power quality costs Sector Financial loss per incident Semi-conductors production(*) 3 800 000 Financial trade(*) 6 000 000 per hour Computer center(*) 750 000 Telecommunication(*) 30 000 per minute Steel industry(*) 350 000 Glass industry(*) 250 000 Offshore platforms 250 000 500 000 per day Dredging/land reclamation 50 000 250 000 per day (*) European Copper Institute 2002 Abb group May 20, 2013 slide 2
Reasons for investing in power quality Examples of impact of poor power quality Losses/ year CO 2 emissions/year Small/medium transformers Large transformers LV cables (per 100 m) 3000 30 T 10 000 100 T 1500 15 T Motors 10% additional losses 10% additional emissions Note: Actual results may be different from examples. Values given do not constitute a performance guarantee and depend on local conditions May 20, 2013 Slide 3
Reasons for investing in power quality Power factor and unbalanced loads Higher penalty due to poor power factor Setting-up high power quality target by utilities Rebate on electricity bills for achieving higher power factor (e.g. India, Bangladesh etc.) Lowering the operating and maintenance cost of the electrical installations Release more production capacity Potential fuel savings from captive generators for low power factor loads May 20, 2013 Slide 4
Technical problems created by poor power factor P, Q h LOAD Source P Real power Q Reactive power H Harmonics Protecting devices may trip due to overload The voltage output of the transformer may become too low, loads may refuse to start Impermissible voltage variations on the feeding network especially for dynamic loads Utility requirements for power factor (cos ϕ) and voltage variations may not be met, resulting in connection refusal Technical problems in weak networks, e.g. captive generators, over compensation problems May 20, 2013 Slide 5
Technical problems created by unbalance Protecting devices may trip The diesel generators will fall out of synchronisation Line losses will go up considerably Increase in mechanical stress on transformer cores The tripping of motors due to negative torque May 20, 2013 Slide 6
Unbalance & reactive power compensation Eliminating unbalance - energy efficiency perspective 3 Phase Source 2-Ph Load P (kw) 3 Phase Source 3-Ph Load P (kw) (Assuming Line Resistance is R) System Losses comparison with balance / Unbalance Loads 50 % reduction in losses May 20, 2013 Slide 7
Where do fast reactive power variations & unbalance come from? Examples: Steel plants ( small arc & induction furnaces, rolling mills) Automobile industry (welding loads) Railways (unbalance single phase loads) Off shore applications Many other process industries May 20, 2013 Slide 8
ABB PQC-STATCON range Product portfolio PQCS PQCT PQCT-Light (PQCL) Answer to key power quality problems Instantaneous, stepless inductive and capacitive dynamic reactive power compensation Balancing of unbalanced loads Your Benefits Trouble-free operation of electrical system and less down-time Compliance with regulations Possible reduction of running costs and CO2 emissions May 20, 2013 Slide 9
PQC-STATCON technology and benefits Stepless power factor correction with settable target for inductive and capacitive loads Technical reasons Sensitive installations require transient free & precise reactive power compensation More and more loads tend to have capacitive power factor Your Benefits Reduces system losses Integrity of sensitive installations UPS systems can run at nominal rating Generators run without tripping May 20, 2013 Slide 10
PQC-STATCON technology and benefits Incorporation of load balancing technology Balancing line to line Technical reasons Unbalanced load current increases the feeder line current losses Equipment failure/premature ageing Your Benefits System losses Installation down-time Stress in line conductor Installation lifetime Meeting the utility guideline to avoid penalty / refusal of connection May 20, 2013 Slide 11
PQC-STATCON technology and features Instantaneous and precise control Green PQC-STATCON Current Blue Supply Voltage Magenta Step Response Response time: 8.062ms (Rise) Instantaneous reaction to step changes Fast dynamic response ( < 1 cycle) Excellent steady state / transient stability Native closed loop operation, open loop operation is also possible Four cascaded control loops Response time: 8.002ms (Fall) May 20, 2013 Slide 12
PQC-STATCON technology and benefits Designed for demanding applications Compact design High grade components Technical reasons Unfavorable ambient conditions Can be installed at small locations Long service lifetime Your Benefits Optimal protection of any installation under any conditions Low maintenance and servicing costs May 20, 2013 Slide 13
Operation with parallel fixed capacitor banks Cost effective - more kvar / $ 200% 100% 100% 100% + 0% = 0% -100% -100% PQC-STATCON Fixed capacitor Total solution PQC-STATCON doubling the dynamic compensation range with parallel capacitor banks. Operation with parallel fixed capacitor banks (existing/new) May 20, 2013 Slide 14
PQC-STATCON technology and benefits Energy efficient operation Energy save mode Programmable option IGBT converter is switched off after 30 s, during idle condition Cooling system is turned off, after 2 minutes POC-STATCON enters deep sleep mode Delivers rated kvar within 8 cycles(from sleep mode) of load demand May 20, 2013 Slide 15
PQC-STATCON technology and benefits Designed with the customer in mind Main and auxiliary settings Auto-restart function Technical reasons Different settings are possible depending on customer need No need for manual intervention after power outage Your Benefits The equipment works in the most efficient way without need for manual intervention May 20, 2013 Slide 16
PQC-STATCON technology and benefits Full redundancy feature on PQC-STATCON systems by using mastermaster approach Technical reasons Full redundancy required in critical applications (welding loads, rolling mills, furnace applications and other critical processes) Your Benefits Optimal protection of any installation under any conditions Individual units may be switched off while still maintaining acceptable compensation May 20, 2013 Slide 17
PQC-STATCON technology and benefits User Friendly touch screen GUI (Graphical User Interface) which enables easy operation Advanced diagnostic capabilities Fault logger up to 250 fault logs with date & time Access to network measurements Technical reasons Short commissioning time is critical in demanding applications The network quality can be supervised at all times Your benefits Protection available with minimal downtime May 20, 2013 Slide 18
PQC-STATCON technology and its benefits Reliability is an important factor! Protection from Over-current Over current protection DC over voltage protection IGBT short circuit protection Over temperature protection Cooling system failure detection Protection from DC overvoltage IGBT stack failure detection Supply overvoltage/under voltage protection Switchgear acknowledgement feedback errors Unstable grid detection Door open detection May 20, 2013 Slide 19 Rugged protections - PQC-STATCON
PQC-STATCON ratings PQCS S. No Type No. Application Voltage kvar Amp (Ir) 1 PQCS-50-V240 1-Ph 240 50 210 2 PQCS-100-V240 1-Ph 240 100 420 3 PQCS-100-V415 1-Ph 415 100 240 4 PQCS-150-V415 1-Ph 415 150 360 5 PQCS-250-V415 1-Ph 415 250 600 PQCT S. No Type No. Application Voltage kvar Amp (Ir) 1 PQCT-100-V415 3-Ph 415 100 140 2 PQCT-150-V415 3-Ph 415 150 210 3 PQCT-250-V415 3-Ph 415 250 350 4 PQCT-300-V415 3-Ph 415 300 420 PQCT-Light (PQCL) S. No Type No. Application Voltage kvar Amp (Ir) 1 PQCL-70-V415 3-Ph 415 70 100 For MV applications: PQC-STATCON supports operation through step down transformer May 20, 2013 Slide 20
Environmental friendly Case study Railway application: At 18 traction substations of Indian railways a combination of power factor correction equipment and filters were installed Results: Improvement in power factor Reduction of greenhouse gas emissions May 20, 2013 Slide 21
PQC-STATCON helps realize energy savings Case study Fiat India Ltd. Customer inquiry Fast response reactive power compensation for weld shop To maintain power factor close to unity Reliable reactive power system with power saving mode during lean hours / shift ABB response High end solution of PQC-STATCON for fast reactive power compensation. Response time : typical less than 1-2 Cycles 1200 kvar and 600 kvar offered giving Supply PF near to unity STATCON in energy saving mode goes in sleep mode during no load condition Customer benefits Power saving, less wastage of welding electrodes Up to 20% of saving in electricity consumption from grid Reduction in electricity bill due to power factor improvement May 20, 2013 Slide 22
Happy customers of PQC-STATCON (welding loads) We are happy to inform you that with ABB make STATCON, we are able to maintain an average monthly power factor above 0.995 lag to unity(1.0). This has indubitably improved performance of our plant loads by improving the total power quality. May 20, 2013 Slide 23
Conclusions Your benefits of having instantaneous stepless compensation of reactive power and unbalanced loads Reduction of technical problems Compliance with utility regulations Increasing the production efficiency Rendering your installation more environmental friendly ABB Reliability ABB has a vast experience in evaluating and addressing power quality issues and can provide the best possible power quality solutions Together we can improve the power quality of electrical installations May 20, 2013 Slide 24