MEDIUM-VOLTAGE HIGH-SPEED SOURCE-TRANSFER SWITCHING SYSTEMSA NEW TOOL TO SOLVE POWER QUALITY PROBLEMS

Carl Shapiro ComEd Maywood, IL

Ray O Leary S&C Electric Company Chicago, IL

Janos Rajda Inverpower Controls Limited Burlington, ON

Presented at the POWER DELIVERY/POWER-GEN Intenational 96 Conference Program Orange county Convention Center Orlando, Florida December 6, 1996

621-T65

Medium-Voltage High-Speed Static-Transfer Switching Systems A New Tool to Solve Power Quality Problems

Abstract
The use of two incoming power sources in a primary-selective arrangement has been the most commonly applied means for ensuring continuity of electrical service in industrial, commercial, and government facilities with critical processes. The sources are often connected to switchgear incorporating controls which can recognize loss of the preferred power source and then automatically transfer to the alternate source, thus maintaining a highly reliable source of power. Such source transfer switching generally requires anywhere from 0.3 to 3 or more seconds to complete. However, as processes and process controls have become increasingly sensitive to not only loss of the power source but also to fluctuations in the voltage supplied, the aforementioned method of source-transfer can be too slow to achieve the level of power quality required. This paper will review a medium-voltage High-Speed SourceTransfer Switching System (HSSTSS) and its ability to solve power quality problems at a manufacturing plant in the Midwest which had experienced numerous instances of voltage sags and loss of electrical service. These disturbances created significant disruptions to the manufacturing process, resulting in substantially increased operating costs due to production losses, as well as costly equipment clean-up and restarting. In evaluating the problem, it was determined that no commonly available automatic source-transfer equipment would switch quickly enough to allow the manufacturing process to continue without shutting down. Various options were reviewed and the decision was made to procure and install a 15 kV High-Speed Source-Transfer Switching System. This arrangement consists of a solid state transfer switch, bypass and isolation switchgear, protection, sensing and power supply all in a completely integrated package. The system accomplishes source-transfer in response to voltage fluctuations such as outages, sags, and swells in as little as 4 milliseconds, and provides power to the plant well within the limits of the CBEMA/ITIC curves. This paper will describe in detail the problems encountered, the solutions evaluated, and the performance to date of the new switching system.

well as the production lost during clean-up and restarting, these shutdowns can be very costly. As these manufacturing systems evolved, means to mitigate the most costly effects of power system disturbances have been brought to bear on the problem. For example, products such as UPSs and motor-generator sets have been employed. As power electronic devices and controls develop, new products to solve these power quality problems are being introduced. The medium-voltage High-Speed Source-Transfer Switching System is the newest of these products, and offers new performance, not available before.

Breakdown of voltage disturbances

Voltage sags and swells are the most common form of disturbance, together accounting for almost 90% of the voltage disturbances seen on typical distribution systems.1 Voltage swells are somewhat less frequent than sags and, if moderate (about 20%), generally do not cause problems with power users loads. However, sags on the order of 10% and greater are fairly common and do cause problems. The most common voltage sag event is caused by adjacent-feeder faults. The reason is tied to typical system construction. Most distribution substations are built around one to several transformers. Often the transformers are banked and support many feeders off a common bus. A fault on any of the feeders causes a voltage sag not only on the faulted feeder, but on all the adjacent feeders fed from the same bus. Consider a typical station bus supporting 10 feeders, it stands to reason that, if all feeders are equally likely to experience a fault, an adjacent-feeder fault would be nine times more prevalent than a fault on a given feeder. Further, if the typical frequency of faults on a feeder is once a year (10 faults per year for the 10 feeder bus section), the frequency of voltage sags approaches once a month.

Details of sags
The magnitude of a voltage sag is determined by the location of the fault causing the sag. Faults on the line feeding a facility fall into two categories: those between the facility and the substation, (which will drive the voltage at the facility to zero); and those downstream of the facility (which will result in deep sags to near zero voltage). But faults on the line feeding the facility are much less frequent than adjacent-feeder faults. Adjacent-faults close to the substation will drive the bus voltage closer to zero than faults which are remote from the substation. The reason for this can be readily seen in Figures 1 and 2. The bus voltage during a fault is approximately determined by the voltage divider set up between the source

Process disruptions and costs

In the never-ending quest for greater efficiency, many industries have developed large complex continuous manufacturing processes. This trend in manufacturing is ubiquitous across industries as diverse as established smokestack industries, manufacturing goods such as wire and glass, and new high-tech industries manufacturing goods such as integrated circuits. Common threads amongst these industries include a highly automated process which is capable of operating 24 hours a day, 365 days a year and a propensity to come to a screeching halt with power disturbances, which, decades ago, were considered minor. Because of the significant cost of the product which is in process at any given time as

National Power Laboratory Study 1990 to present

impedance (mostly transformer impedance) and the line impedance between the substation bus and the fault. If the fault location is farther from the substation, there is more line impedance and the voltage divider yields a higher bus voltage.

has product loss and significant downtime for cleanup and startup. The manufacturer had begun to consider their own onsite generation. But, before taking on responsibility for power generation they asked their power provider, ComEd, to help evaluate alternatives wich would allow them to reduce power disturbance related losses, yet remain on the ComEd system. ComEd committed to a program aimed at customer retention and a search for a cost effective solution that improves power quality was undertaken. Because, the majority of the plant s voltage disturbance problems were caused by voltage sags, and in particular, sags caused by adjacent-feeder faults, the solutions evaluated had to primarily address adjacent-feeder faults, and secondarily address plant-feeder faults. The search involved investigation of the following devices: 1. 2. 3. 4. 5. 6. 7. 8. Superconductive Magnetic Energy Storage Rotary UPS Motor Generator Set with Flywheel Distribution Static Condenser Dynamic Voltage Restorer Static Series Voltage Regulator Low Voltage Static Transfer Switch Medium Voltage Static Transfer Switch

Adjacent-feeder fault

Z-source Substation Bus

Feeders Z line (bus-to-fault)

Figure 1 Typical feeder layout with the leftmost feeder faulted

Z source
15. kV 3. 12. kA

V bus Z line

Z line Z line Z source

1 0.9 0.8 0.7 0.6

V bus Z line

0.5 0.4 0.3 0.2 0.1 0 0 1 2 3 4 5 6

The prices and operating voltages for the evaluated solutions are shown in Table 1. TABLE 1 Summary of Power Quality Improvement Solutions
Z line

Device Superconductive Magnetic Energy Storage Rotary UPS Motor Generator Set with Flywheel Distribution Static Condenser Dynamic Voltage Restorer Static Series Voltage Regulator Low Voltage Static Transfer Switch Medium Voltage Static Transfer Switch

Figure 2 Per unit bus voltage for a line fault as a function of the line impedance between the bus and the fault

Operating Voltage 480 V

Installed Cost $5,000,000

Figure 2 also illustrates the fact that most of the adjacent-feeder faults result in moderate sags. These results are generally consistent with measured performance of utility systems. 2

480 V 480 V 12.5 kV 12.5 kV 480 V 480 V 12.5 kV

$2,500,000 $1,300,000 $2,000,000 $2,000,000 $1,450,000 $1,100,000 $1,100,000

A power quality solution for a plastics manufacturer

A manufacturer, in the Chicago area, was faced with production losses in the order of a several hundred thousand dollars per year due to minor power disturbances. The manufacturer uses a highly automated continuous process to produce plastic film used to package consumer products. The film is made to a specific thickness with very tight tolerances. During voltage changes of sufficient magnitude and duration, the motors used to move the product change speed at different rates. When this happens, the thickness tolerance is lost and the manufacturer

EPRI Distribution Power Quality (DPQ) Project

The plant s process lines are served from three outdoor transformers, each at a secondary voltage of 480/277 volts.

This means that each device operating at 480 volts would require one unit at each service point. Two of the service points are in a very congested area on the east side of the plant (see Figure 3) and locating additional equipment in this area would be difficult. The 480 volt solution also required relocation of the service entrance cables. All 480 volt units, except for the Micro-SMES, require a weather proof enclosure or an indoor location. This causes an additional problem because there is no indoor space available for the equipment. The lack of space effectively rules out the 480 volt solution.
N

cause a sag on one feeder, should not affect the other feeder. In the case of ComEd s system, sags on the transmission system are likely to sag both feeders brought to the customer s site, but transmission sags are much less frequent than distribution system sags, and the HSSTSS solution remains viable since it is effective for a large majority of the sags experienced by the customer. Power quality measurements indicate that the subject plant has had problems with voltages which are within the CBEMA/ITIC curves. Specifically, a sag of 10% for a 0.5 second duration caused some plant equipment to shutdown. The HSSTSS was, therefore, set to provide the more stringent needs of the load. As very moderate sags (such as 10%) are found to be a problem, one must be careful that the normal day-to-day voltage variations, especially under system low-voltage or brownout conditions, will not bring both sources to a problem level. Finally the voltage regulation at the customer s site must be sufficiently good that when the load is moved from one source to the other the regulation does not significantly change source voltages. The worst manifestation of a regulation problem would be a hunting situation, wherein a transfer for a minor sag might cause the alternate source to sag, also in a minor way. With the release of load from the preferred source, the voltage might increase to the level where it appears to be better than the alternate source, and a reverse transfer back to the preferred source might take place; a series of forward and reverse transfers could result. Dead-bands in the control will avoid this problem, however they must be carefully coordinated with the regulation as well as the minimum sag for which the HSSTSS is expected to react. The effect of voltage regulation can be mitigated by utilizing a split-bus HSSTSS configuration, thereby reducing the amount of load transferred. In the subject HSSTSS, the split-bus option was used. The primary functional requirement of the HSSTSS as shown in Figure 4 is to switch the load currents from one feeder to another through the high speed operation of two source static switches, SS1 and SS2 and a bus-tie static switch SS3. The three static switches, SS1 and SS2 and SS3, along with the Inverpower control are collectively referred to as the static transfer switch (STS) and form the heart on the HSSTSS. The bypass and isolation switches (BP 1, 2, & 3 and IS A, B, C, & D in Figure 4) as well the S&C Micro-AT control form the basis of the cooperating switchgear which allows full flexibility in operation and maintenance of the HSSTSS, including seamless power continuity to the load, even in the event of a problem with the STS.

Plastics Manufacturer

cable pole transformer

Figure 3 Site layout

The medium voltage static transfer switch addresses the power quality problem in the most cost effective solution. It provides the high speed source transfer which the manufacturer needs for maintaining product tolerance. It provides power to the process in the event of a long term 12 kV source outage or reclosing cycle operation that the other medium voltage solutions do not allow. It also allows the process load to be transferred to the bypass gear for any maintenance on the static units and the bypass can function as a standard, lower speed source transfer. Finally, the training time of the operating personnel is reduced because the bypass is composed of switchgear units that are currently used on the distribution system.

Application requirements
The HSSTSS solution obviously requires that two medium voltage sources be in position to serve the customer. Although the plant was served by a single 12 kV over-head line, another line was in the neighborhood and was easily extended to the plant site to serve as the second source. The two sources must be relatively independent; specifically, most conditions which

Reverse Transfer
FEEDER W7418 SS1
ISA

FEEDER W748 SS3 SS2

ISD

STATIC SWITCH CONTROLLER ISB S&C MICRO-AT ISC

When both sources have returned to within the prime return" voltage band for a adjustable time period the STS control will initiate an automatic reverse transfer, wherein the closed bustie switch, SS3 opens and the open static switch, SS1 or SS2 associated with previously faulty source closes. Better-of- Two Transfers

BP1

BP3

BP2

The STS control allows the user to define multiple voltage bands into which the sources may be classified. If both sources are outside of their "prime band, the STS control automatically transfers the bus-tied load to the source which lies in the more favorable band. Emergency Stop

Figure 4 One-line diagram of the ComEd HSSTSS

The high speed STS operation allows the plant load to be essentially free from power quality problems, voltages, especially sags of the distribution system encountered at one of the adjacent feeders. Both feeder voltages are continuously measured and appropriate transfers are carried out based upon the adjustable settings of sag limits.

The loss of cooling air or steady state overload may lead to an SCR stack over-temperature situation. When an overtemperature signal is received by the STS control, it will perform an emergency STOP sequence: close the appropriate bypass switches, open the isolation switches and pass control to the S&C Micro-AT. This will allow STS maintenance under isolated conditions, while also insuring power continuity to the load.

The operating modes of the STS are:

Additional features of the HSSTSS system are: Start/Stop Sequencing The high speed transfer feature of the STS may be placed into or taken out of service through START or STOP sequence. With appropriate safety interlocks, mechanical bypass and isolation with which the STS is closely integrated, will continue to feed the load, and provide conventional low speed load transfer capability. The transition from mechanical source transfer to static source transfer is seamless in both directions. Upon the loss of both sources the HSSTSS s cold restart (bootstrap) is fully automatic and seamless. Environmental design Special consideration is paid to the enclosure as well as the heating & cooling systems design to ensure reliable operation under: Rain, sleet, snow, outdoor conditions -40 C to 50 C ambient temperature range All ranges of relative humidity Unusual seismic, vibration or tilting conditions

Forward Transfer The forward transfer operation is one in which either source SS1 or SS2 switch opens and bus-tie switch, SS3 closes. The STS controls constantly monitor the voltage conditions of both sources and initiates a forward transfer whenever one or more of the phase voltages is outside a prime voltage band either in the undervoltage or overvoltage direction. When a forward transfer is initiated by the complete loss of either source, if, after a user adjustable delay time, the source does not recover, the Inverpower STS control will automatically close the appropriate bypass switches, open the isolation switches (to minimize the back feed from the energized to the unenergized source) and pass control to the S&C Micro-AT . Upon restoration of the source, the STS will automatically return to service.

SCR Redundancy Each SCR stack is able to accommodate the failure of a single SCR without loosing the functionality. After a single SCR failure, the STS will issue an alarm; a second SCR failure will initiate an emergency stop, as described above. Control Power Supply The control power supply is ensured from both sources and a small UPS. Loss of control power will initiate the emergency STOP without jeopardizing the continuity of the load service. Electromagnetic Compatibility The Inverpower STS controls and the S&C Micro-AT control meet ANSI/IEEE C37.90.1 surge voltage and fast transient withstand capability design tests. The test waves were applied in both common mode (between line and ground) and differential mode (between line inputs) at each control I/O and control power line.

System Diagnostics The status of the three static switches are continuously monitored and key system data are stored in an event log at each transfer. This information is useful in maintenance and verification of transfer performance.

kVA transformers were initially cut-over. Cut-over of the third transformer was delayed until the production line fed by that transformer could be shutdown. On August 15, an adjacentfeeder fault, involving a tree, caused the transfer of load from the left (sagged) source to the right (healthy) source. The two production lines protected by HSSTSS rode through the disturbance; the third production line not yet protected by HSSTSS shutdown. Interestingly, prior history shows that the two production lines protected by HSSTSS had been more sensitive to sags than the third one which shutdown.

Performance to date
The first commercial installation of a HSSTSS went into service on August 14, 1996. Two of the customer s three 2,500