Applying Harmonic Solutions to Commercial and Industrial Power Systems

David G. Loucks, P.E. DaveGLoucks@eaton.com Moon Township, PA

2005 Eaton Corporation. All rights reserved.

Overview

Introduction Harmonic Sources Harmonic Symptoms/Concerns (Problems) IEEE 519-1992 Standard Harmonic Solutions

Drive and Rectifier Solutions Solutions for Commercial Power Systems

Avoiding Harmonic Resonance Low Voltage Vs. Medium Voltage Solutions

Harmonic Solutions for Correcting Power Factor

The Economics of Harmonic Reduction Summary Tables and Cost Comparisons

Harmonics are not a problem unless they are a problem!

Harmonics
100%, 60 Hz 20%, 180 Hz

12%, 300 Hz

4%, 420 Hz

%THD I

I 2 I 3 I 4 ...
2 2 2

2%, 660 Hz

I1

100 %
2%, 780 Hz

Harmonic Sources
Harmonic Sources

Most Common

Power Electronic Equipment (drives, rectifiers (UPS), computers, etc.) Arcing Devices (welders, arc furnaces, fluorescent lights, etc.) Rotating Machines (generators)

Variable Frequency Drives

UPS

Computer Power Supplies

Fluorescent Lighting

Voltage Distortion

When current flows from other than an infinite source, the source voltage drops The higher the source impedance or the higher the load current, the greater the drop

Non-Linear Load

Example: 1 switched mode power supply

1 Switched Mode Power Supply Current Harmonics

40A

30A peak 6x 5A rms

0A

-40A 0s 0.1s RMS(I(L4)) 0.2s I(L4) 0.3s 0.4s 0.5s Time 0.6s

60 Hz 4.0A3.6A

Isc =0.7s 22000 0.8s IL = 5A

0.9s

180 Hz 3rd 3.1A 300 Hz 5th 2.25A 420 Hz 7th 540 Hz 9th 1.38A 0.74A

Isc/IL = 4400

2.0A

0A 0Hz I(L4)

0.2KHz

0.4KHz

0.6KHz Frequency

0.8KHz

1.0KHz

1.2KHz

1 Switched Mode Power Supply Current Harmonics

THD % I2 I3 I 4 I5 I6 I7 I8 I9 I1 100 0 3.12 0 2.25 2 0 1.38 2 0 0.74 2 4.14 100 3 .6 3.6 115 %
60 Hz 4.0A3.6A

180 Hz 3rd 3.1A 300 Hz 5th 2.25A

420 Hz 7th 540 Hz 9th 1.38A 0.74A

2.0A

0A 0Hz I(L4)

0.2KHz

0.4KHz

0.6KHz Frequency

0.8KHz

1.0KHz

1.2KHz

1 Switched Mode Power Supply Current Harmonics

0 3.35 2 0 2.67 2 0 1.88 2 0 1.22 2 100 3.79
4.0A

11 .22 7.13 3.53 1.49 4.83 128 % 3.79 3.79

60 Hz 3.79A 180 Hz 3rd 3.35A 300 Hz 5th 2.67A This is with 65 kA available

2.0A

420 Hz 7th 540 Hz 9th 1.88A 1.22A

0A 0Hz I(L4) Frequency 0.2KHz 0.4KHz 0.6KHz 0.8KHz 1.0KHz

1.

Current Distortion vs Available Fault Current

22 kA 115%

65 kA 128%
Why is the current distortion higher with higher available fault current? Is that the same situation with voltage distortion?

Lets increase the source impedance

Remember, our power supply was drawing 5A rms On a 22 kA source, the ratio of Isc/IL= 4400 essentially an infinite source Keeping the same load impedance, lets drop the source short current down (Isc/IL= 20)

100 A rms Source

Voltage Distortion Isc/IL = 4400

THD % V2 V3 V4 V5 V6 V7 V8 V9 V1 100

0 5 . 4 2 0 0 .9 2 0 0 0 0 5.47 100 1.44 % 381 381

20V

10V

22 kA source 1st = 381 V 3rd = 5.4 V 5th = 0.9 V

150Hz 200Hz 250Hz Frequency 300Hz 350Hz 400Hz 450Hz

0V 52Hz 100Hz V(L4:2)

Voltage Distortion Isc/IL = 20

THD % V2 V3 V4 V5 V6 V7 V8 V9 V1 100

0 9.12 0 7.8 2 0 4.12 0 1.7 2 12 .78 100 3 .4 % 377 377

15V

10V

5V

Isc/IL = 20 1st = 377 V 3rd = 9.1 V 5th = 7.8 V 7th = 4.1 V 9th = 1.7 V
100Hz V(L5:2) Frequency 200Hz 300Hz 400Hz 500Hz 600Hz

0V 0Hz

70

Harmonic Distortion Standards

Harmonic Voltage Distortion Limits IEEE Standard 519 1992
Maximum Voltage Distortion in % at PCC* Below 69kV Maximum for Individual Harmonic Total Harmonic Distortion (THD) 69-138kV >138kV

3.0 5.0

1.5 2.5

1.0 1.5

* % of Nominal Fundamental Frequency Voltage

Harmonic Distortion Standards

Maximum Harmonic Current Distortion IEEE Standard 519 1992
Harmonic Order (Odd Harmonics) Isc/IL <20* <11 4.0 11<h<17 2.0 17<h<23 1.5 23<h<35 0.6 35<h 0.3 %TDD 5.0

20-50
50-100 100-1000 >1000

7.0
10.0 12.0 15.0

3.5
4.5 5.5 7.0

2.5
4.0 5.0 6.0

1.0
1.5 2.0 2.5

0.5
0.7 1.0 1.4

8.0
12.0 15.0 20.0

In Percent of Fundamental

Harmonic Limits
PCC (Point of Common Coupling) is defined as the point where another customer can be served

From IEEE519A Draft

Harmonic Limits
Update for IEEE 519

The Point of Common Coupling (PCC) with the consumer/utility interface is the closest point on the utility side of the customer's service where another utility customer is or could be supplied. The ownership of any apparatus such as a transformer that the utility might provide in the customers system is immaterial to the definition of the PCC.
Note: This definition has been approved by the 519 Working Group. http://home.nas.net/~ludbrook/519error.html

From IEEE519A Draft

Harmonic Symptoms/Concerns

Equipment Failure and Misoperation

Notching Overheating/Failure Nuisance Operation Communication / control interference Oversizing Losses/Inefficiencies/PF Penalties

Economic Considerations

Application of Power Factor Correction Capacitors Other Issues

Metering do you really have a problem? Marketing hype buy my product! Specmanship - Misinterpretation of the IEEE-519 Standard

IEEE 519-1992 Standard

MAXIMUM HARMONIC CURRENT DISTORTION IN PERCENT OF IL Individual Harmonic Order (Odd Harmonics) I SC /IL 20 * 20-50 50-100 100-1000 1000 11 4.0 7.0 10.0 12.0 15.0 11h17 2.0 3.5 4.5 5.5 7.0 17h23 1.5 2.5 4.0 5.0 6.0 23h35 0.6 1.0 1.5 2.0 2.5 35 h 0.3 0.5 0.7 1.0 1.4 % TDD 5.0 8.0 12.0 15.0 20.0

>> than 519 recommendations especially in specs (drives for example)

Even harmonics are limited to 25% of the odd harmonic limits above. Current distortions that result in a dc offset, e.g., half-wave converters, are not allowed. * All power generation equipment is limited to these values of current distortion, regardless of actual ISC / IL. Where, ISC = Maximum Short Circuit at PCC. IL = Maximum Load Current (Fundamental Frequency) at PCC.

Voltage or current harmonics ??

PCC?? 102% Current
< 69 kV 69 kV 161 kV 1.5 2.5 161 kV 1.0 1.5

MAXIMUM VOLTAGE DISTORTION IN % AT PCC

Maximum for Individual Harmonic Total Harmonic Distortion (THD) %

3.0 5.0

Reduce Harmonics Save Money???

Aside from the power quality issues (misoperation, damage, etc), harmonics also cost you in other ways.

Cost of oversized neutrals (2x), transformers (1.25-2x), generators (1.4-2x), UPS (1.5-2x), k-factor transformers, etc. kW losses in cables, transformers and other power system components (1-8% losses).
VTHD = 2.3% VTHD = 5.8%

Utility Source

Generator Source

Symmetrical Components
Harmonic Sequence Harmonic Sequence 1 + 10 + 2 11 3 0 12 0 4 + 13 + 5 14 6 0 15 0 7 + 16 + 8 17 9 0 18 0

Reduce Harmonics Save Money???

Motor damage, losses (heating) from negative sequence currents. High harmonics = low total power factor (utility penalties).
Negative Sequence Current
Tries to Rotate Motor in Opposite Direction Causes Motor Losses, Heating and Vibrations

60 Hz Rotation

5th Harmonic Rotation

Drive and Rectifier Solutions

Line Reactors

K-Rated/Drive Isolation Transformers DC Choke 12-Pulse Converter Harmonic Mitigating Transformers/Phase Shifting

Tuned Filters
Broadband Filters 18-Pulse Converter Active Filters

Solutions for Commercial Power Systems

Neutral Blocking Filter
Harmonic Mitigating Transformers/Phase Shifting Oversized Neutrals

K-Rated/Drive Isolation Transformers Tuned Filters Broadband Filters

Active Filters
Low Distortion Loads (Lighting Ballasts, Drives, etc.)

LEGEND
PFC

Incoming Utility Service

- Power Factor Correction - K Factor Transformer - Tuned Filters MV Switchgear

PFC

MV Power Factor (optional harmonic filter)

Active - Active Filters

- Blocking Filter for 3rd Harmonic

- Blocking Filter for Drives
HMT

- Harmonic Mitigating Transformer - Multi-pulse Drives (12/18/24)

LV Secondary Unit Substation

Bus Voltage without Correction

Active

Control/Sensing for Active or Switched Filter

Bus Voltage with Correction

Transformer w/Neutral Blocker

HMT

K MCC

PFC Active PFC HMT HMT

Panelboard Feeding Computers (3rd harmonics)

Panelboard Feeding 120/208V Harmonic Loads

Electronic Ballasts

AFD

AFD

AFD

Free Standing PF Correction and/or Harmonic Filter

(AFD) Adjustable Frequency Drive (12/18/24 pulse)

LV Switchboard With Harmonic Loads

Expected Harmonics
Source
6 Pulse Drive/Rectifier

Typical Harmonics*
5, 7, 11, 13, 17, 19

12 Pulse Drive
18 Pulse Drive

/Rectifier

11, 13, 23, 25

17, 19, 35, 37 3, 5, 7, 9, 11, 13

Switch-Mode Power Supply

Fluorescent Lights
Arcing Devices Transformer Energization

3, 5, 7, 9, 11, 13
2, 3, 4, 5, 7... 2, 3, 4

* Generally, magnitude decreases as harmonic order increases

H = NP+/-1

i.e. 6 Pulse Drive - 5, 7, 11, 13, 17, 19,

Harmonic Solutions
Oversized Generator
Xs

480 V

Low Distortion Electronic Ballast

Blocking Filter

Active Filter
12 Pulse K-Rated Welder

XT

M
Filter

UPS w/Filter

M + -

Effect of Drive Line Reactors (IEEE519A)

Phase Shifting 12 Pulse

From IEEE519A Draft

CP9000 - 18 Pulse++

Passive Filters (Parallel / Tuned)

Passive Filters (Series / Broadband)

18-Pulse Equivalent
From IEEE519A Draft

6-Pulse Drive

Active Filters

From IEEE519A Draft

Harmonic Solutions for PF

Application of Harmonic Solutions for PF Correction
Reduce Utility Penalties Most Common Reason Today Resonance Issues

Reduce Harmonic = Reduce Vars

LV/MV?

Harmonic Resonance
The Self Correcting Problem
- Blow Fuses - Fail Capacitors

- Damage Transformer

hR

kVA kvar

SC CAP

Harmonic Resonance - Solutions

Apply another method of kvar compensation (harmonic filter, active filter, synchronous condenser, etc) Change the size of the capacitor bank to over-compensate or under-compensate for the required kvar and live with the ramifications.

Harmonic Correction Selection for Drives in MCCs

125 Hp and up
Parallel / Passive Filter
(10-20% Distortion)

Series Passive Filter

(8-12% Distortion*)

Active Correction
(5-20% Distortion)

50 Hp
18 Pulse Drive
(5% Distortion*)

30 Hp * per Drive 10 Hp Recommendation based on price and MCC integration

10

15

20

Drive Quantity

Fundamental Neutral Summation

Harmonic Summation in Neutral

Neutral Heating Oversize Equipment

10A at 180 Hz 10A at 60 Hz

A B C

10A at 180 Hz 10A at 60 Hz 10A at 180 Hz 10A at 60 Hz

0A at 60 Hz 30A at 180 Hz

Neutral Blocking Filter - Blockade

TRANSFORMER ENCLOSURE PHASE C

60Hz AND NON-TRIPLEN HARMONIC CURRENTS

60Hz CURRENT & NON TRIPLEN HARMONIC CURRENT

PHASE B

Neutral Blocking Filter

PHASE A

NO 3rd HARMONIC CURRENTS CIRCULATE IN DELTA WINDING TO BUILDING STEEL

SAFETY GROUND

COMPUTER

COMPUTER

COMPUTER

60Hz IMBALANCE CURRENT ONLY

Individual Phase Currents

Neutral Harmonic Currents

Solution Summary Tables

Type 2 Comparison of Solution Options (and Effectiveness) by CORRECTIVE EQUIPMENT
Shunt/Parallel Filters Series Filters/Reactors Transformer Solutions Other Drives, Rectifiers, 3-Phase UPS Computers Fluorescent Lighting Welding/Arcing Loads System Solutions

Table 3 Comparison of Solution Options by LOAD TYPE

Cost of Harmonic Correction

Description
K-Factor Reactor Capacitors (LV) Switched Capacitors (LV) Single-Tuned Fixed Filter (LV) Single-Tuned Switched Filter (LV) Single-Tuned Fixed Filter (MV) Single-Tuned Switched Filter (MV) Blocking Filter (3rd's) Blocking Filter (Drives) Active Harmonic Filter Phase-Shifting Transformers

Typical $/kVA*
20 3-4 12 25 35 40-50 12 15 100 100 150 50

Note that prices are generalized for comparison only but not absolute. Some equipment must be fully rated for loads - others can be partially rated Capacitors are shown for reference only.

Solutions: AF Drives Pros

Cons

Drives and Rectifiers Includes 3-Phase UPS Loads

Inexpensive For 6-pulse standard drive/rectifier, can reduce May require additional Line Reactors compensation harmonic current distortion from 80% down to about 35-40% Offers series reactance No advantage over K-rated/Drive (similar to line reactors) reactors for reducing Isolation and provides isolation for harmonics unless in pairs transformer some transients for shifting phases Not always an option Slightly better than AC for drives DC Choke line reactors for 5th and 7th Less protection for harmonics input semiconductors Cost difference approaches 18-pulse 85% reduction versus 12-Pulse Convertor drive and blocking standard 6-pulse drives filters, which guarantee IEE 519 compliance Harmonic cancellation Harmonic highly dependent on load Substantial (50%-80%) Mitigating balance reduction in harmonics Transformers/Phase Must have even when used in tandem Shifting multiples of matched loads

Solutions: AF Drives (continued) Pros Cons

Tuned Filters Drives and Rectifiers Includes 3-Phase UPS Loads (continued) Bus connected accommodates load diversity Provides PF correction Makes 6-pulse into the equivalent of 18-pulse Requires allocation anaylysy Sized only to the requirements of that system Higher cost Requires one filter per drive High Cost

Broadband Filters

Excellent harmonic control for drives above 18 Pulse Converter 100HP IEEE 519 compliant Handles load/harmonic diversity Active Filters Complete solution up to 50th harmonic

High cost

Solutions: 1 Power Supplies Pros Cons

Neutral Blocking Filter Eliminates the 3rd harmonic from load Relieves system capacity Possible energy savings 3rd harmonic recalculated back to the load When used as phaseshifted transformers, reduces other harmonics Reduces voltage flattopping Tolerate harmonics rather than correct Typically leased expensive Tolerate harmonics rather than correct High Cost May increase voltage distortion

Computers/ Switch-mode Power Supplies

Harmonic Mitigating Transformers

Requires fully rated circuits and over sized neutrals to the loads

Oversized Neutral/Derated Transformer K-Rated Transformer

Upstream and downstream equipment fully rated for harmonics Does not reduce system harmonics

Solutions: Fluorescent Lighting Pros Cons

3rd harmonic recalculated back to the load When used as phaseshifted transformers, reduces other harmonics Reduces voltage flattopping Tolerate harmonics rather than correct Reduce harmonics at the source

Harmonic Mitigating Transformers Fluorescent Lighting K-Rated Transformer Low Distortion Ballasts

Requires fully rated circuits and over sized neutrals to the loads Does not reduce system harmonics Additional cost and typically more expensive than system solutions

Solutions: Welding, Etc. Pros Cons

Active Filters Welding/ Arcing Loads Tuned Filters Fast response and broadband harmonic corrention Reduces voltage flicker SCR controlled tuned filters simulates an active filter response Provides PF correction Lower cost compared to other systems Excellent choice for new design or upgrade High cost SCR controlled units are high cost but fixed filters are reasonable System analysis required to verify application No PF correction benefit

Tuned Filters System Solutions Harmonic Mitigating Transformers Active Filters

Ideal solution and handles Highest cost system diversity

Review of Solutions
SOLUTION Shunt/Parallel Filter Solution ADVANTAGES DISADVANTAGES Typically sized to reduce the most prevalent harmonics to an acceptable level Requires system Provides PF correction knowledge and analysis Avoids resonance by selecting tuned frequency Excellent cancellation for 2nd through 50th harmonic currents Highest cost Cannot be overloaded Handle diversity of loads

Passive Harmonic Filters

Active Harmonic Filter

Review of Solutions - 2
SOLUTION Series Filters/Reactors Active Harmonic Filter ADVANTAGES Excellent power conditioning for removing source voltage harmonics Eliminated 3rd harmonic current from load Makes 6-pulse into 18pulse equivalent Inexpensive For 6-pulse standard drive/rectifier can reduce harmonic distortion from 80% to 35% to 40% Better than AC line reactors for 5th and 7th harmonics DISADVANTAGES Highest cost High cost May increase voltage distortion loads High cost Requires one filter per drive May require additional compensation Not always an option for drives Less protection for input semiconductors

Neutral Blocking Filters

Broadband Blocking Filters

AC Line Reactors

DC Reactors for Drives

SOLUTION Transformer Solutions Isolation Transformers

ADVANTAGES

DISADVANTAGES

Transformer Derating

Harmonic Mitigating Transformers/Phase Shifting

Neutral Cancellation Transformer Zero sequence Trap 18 Pulse Drive Systems K-Factor Transformers

No advantage over reactors Offers series reactance and for reducing harmonics provides electrical isolation unless used in pairs for phase shifting Does not remove the Lowest cost solution harmonics Harmonic cancellation highly dependent on load Substantial (50% to 80%) balance reduction in harmonics when used in tandem Must have even multiples of unmatched loads 3rd harmonic recalculated back to the load Can reduce the 5th and 7th Requires fully rated harmonics when used as circuits downstream to the phase shifting pairs loads Reduces voltage flattopping Excellent harmonic control for drives above 100HP Higher Cost IEEE 519 compliant Tolerate harmonics rather Does not reduce system than correct harmonics

Review of Solutions - 4

SOLUTION Other

ADVANTAGES Live with high 3rd harmonics

DISADVANTAGES Downstream panels and shared neutrals must be oversized Transformer windings and neutral must be sized for high harmonics

Oversized Neutrals

Wrap-up
Power quality problems are costly ($$$) Energy management considerations should include power factor analysis Power factor correction capacitors are typically cost effective solutions to energy management Harmonics must be considered when applying capacitors Harmonics problems are increasing with the addition of power electronic loads on the power system Model the power system based on typical data or measurements

Verify computer model with measurements

Lets Be Careful Out There!!!

Thank You! Questions?