Power factor correction with Harmonic Filters

Modern electrical equipment demands Power Quality

Modern electrical equipment imposes stringent demands on voltage stability and power quality. The power network has to be free from harmonics and other electrical disturbances. By installing harmonic filters several benefits are obtained: - Higher power factor, improved voltage stability and network losses - Filtering of harmonics in the system - Avoidance of resonance problems and amplification of electrical disturbances. A clean network also imposes much less strain on equipment and lengthens its life span. This means lower maintenance cost and lower cost for replacing worn-out equipment.

What problems can harmonics cause? - Increased losses, e.g. machines will operate at increased temperature and can be overheated - Resonance problems between the inductive and capacitive parts of the power network - Malfunctioning of control systems since electronic meters, relays, etc. are matched to the fundamental frequency - Overloading of capacitors, leading to malfunctioning and premature ageing - Interference with telecommunications and computers - Disturbances in ripple control systems - High currents in neutral conductors.

What are harmonics? Harmonics become apparent when a distorted sinus curve is mathematically analysed. Through Fourier analysis, an arbitrary periodic function can be divided into a number of sine waves. The example below shows that the red distorted curve consists both of the fundamental frequency (e.g. 50 Hz) and of superimposed 5th (250 Hz) and 7th (350 Hz) harmonic frequencies.

Where do harmonics come from? Most types of equipment common in electrical systems today generate harmonics: - Equipment containing electronics that control other apparatus, e.g. variable speed drives, soft starters, static compensators, rectifiers, etc. - Arc furnaces - In certain cases, transformers, reactors and rotating machines. Harmonics are not only found in industrial networks. They can also spread into the distribution network and cause problems for other power users.
Variable speed drives...

...rolling mills...

...and paper machines are examples of industrial equipment generating harmonics.

Each plant needs its own solution

Thorough know-how and experience is required to design harmonic filters properly. Each plant is unique and needs its own special technical solution. Both system and component know-how are essential to find the optimum solution in each individual case. An important component in the filter is the capacitor. Since it copes with the whole harmonic content, it must be designed with the greatest care. From analysis to commissioning ABB Capacitors has the competence to support filter projects from beginning to end. During the entire course of the project we concentrate on cooperation and dialogue with our customer, so that the best solution possible is selected and attained. Analysis We analyse the plant using as inputs single-line diagrams, type and size of loads and mode of operation. The analysis culminates in a measurement plan.

Measurement We carry out measurements in the plant under differing operating conditions. The type of activity pursued determines the scope of measurements. Complex processes can take several days to measure, whereas static processes do not normally involve much time. We utilize sophisticated harmonic analysis equipment and store information for subsequent processing. Calculation The measurements are then mathematically evaluated, using computer programs. Various filter configurations and operation modes are simulated. The calculations result in a report containing a recommendation as to how the filter installation should be designed to achieve the best results and where it should be located. We also calculate the distortion level anticipated after the proposed installation.

What is a harmonic filter?

In simple terms one might say that the filter absorbs harmonics. The filter is built up from passive RLC components, i.e. resistors, reactors and capacitors. They are designed to form a tuned circuit. The tuning frequency is matched to the harmonics in question; normally of the 5th, 7th and 11th order. To avoid resonance, the tuning frequency is usually placed lower than the harmonics occurring in the network. There are basically three types of filter: - The band-pass filter is tuned to one frequency. A special case primarily occurring in low-voltage systems is the de-tuned filter. - The double-tuned filter is tuned to two frequencies. - The high-pass filter filters frequencies above the tuning frequency. In certain cases a high-pass filter can be installed as a C-type filter, which is used when compensating arc furnaces or cyclo converters. A filter installation normally consists of 1 - 3 band-pass filters that filter one frequency each. Combinations with high-pass filters, which is open to higher frequencies, can also be applied.

Design ABB Capacitors calculates and designs the filter. Our own production plant manufactures the capacitor units and we enjoy close cooperation with prominent producers of other components such as reactors and resistors. We can also supply the relay protection for the filter, so that the correct protective level is attained. Commissioning We supervise erection and commissioning. Our undertaking can also include verification measurements to check that the performance the equipment was designed for has been achieved.

The filter design is arrived at with the aid of modern computer equipment.

Band-pass filter

Doubble-tuned filter

High-pass filter

High power quality pays!

A tough competitive climate leads to stringent availability demands being imposed on all industrial installations. Profits are dependent on the avoidance of downtime and breakdowns as far as possible. A reliable and consistent power supply is an important condition for this. The expression high power quality is of vital concern to utilities and industrial plants. A harmonic filter represents a dependable method of achieving high power quality in the form of stable voltage and low distortion. This ensures reliable power supplies and a high degree of availability.

Highly automated industry...

...switchgear...

...and sensitive computer equipment require power supplies that are free from harmonics for operations to run smoothly.

We have unique experience ABB Capacitors has been manufacturing power capacitors since the early 1930s. We have considerable experience in the design of harmonic filters for different plants and industrial sectors. Further, we have comprehensive know-how from all other types of capacitor applications, e.g. HVDC, SVC, shunt and series compensation etc. Our capacitors are of the very highest quality. They are usually equipped with internal fuses, i.e. each capacitor element has an individual fuse. In this way a stable tuning frequency, high availablity and long service life are achieved.

Capacitor filter projects imply close collaboration on our part with the customer since filters must be specially matched to each plant.

Recommendations and standards regarding power network distortion The maximum acceptable voltage distortion and total harmonic distortion (THD) have been specified in various national and international standards and recommendations. In the table below, for example, the values recommended by IEC for industrial plant are given. Odd order non-multiple of 3 n Dn (%) 5 6 7 5 11 3,5 13 3 17 2 19 1,5 23 1,5 25 1,5 >25 0,2 + 12,5/h ABB Capacitors designs and manufactures filters according to various specifications. We will discuss with and advise our customers on the choice of suitable requirements. Differing national requirements and technical considerations may determine the optimum choice.

Compability levels for harmonics in MV industrial networks (class 2) Odd order multiple of 3 n Dn (%) 3 5 9 1,5 15 0,3 21 0,2 >21 0,2 Even order n Dn (%) 2 2 4 1 6 0,5 8 0.5 10 0,5 >10 0,2

Maximum THD 8%

(IEC 61000-2-4)

For more than seventy years, ABB Capacitors has manufactured power capacitors for small and large installations all over the world. ABB Capacitors in Ludvika bears overall responsibility for the capacitor business of the ABB Group. ABB Capacitors is certified according to ISO 9001 (quality) and ISO 14001 (environment). The product range of ABB Capacitors covers most types of capacitors for power applications, for instance: High voltage shunt banks Harmonic filters Series compensation Static var compensators High voltage direct current (HVDC) installations Capacitive voltage dividers (CVDs).

Cover photo: 5:th Harmonic Filter, 36 Mvar, 145 kV, Sweden.

ABB Capacitors AB SE-771 80 LUDVIKA, Sweden Phone +46 240 78 20 00 Fax +46 240 78 36 77 www.abb.com/powersystems

SECAP A03.en Edition 2, 2000-05

Printed with an INDIGO digital printing press at ABB Support AB, Vsters, 0005