An environmental way to tackle the voltage dip problems and solutions. Grupo Zigor

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Edgar Blake
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2 An environmental way to tackle the voltage dip problems and solutions Grupo Zigor

3 AC POWER QUALITY PROBLEMS Reality of a complex AC Distribution

AC POWER QUALITY PROBLEMS Electrical equipment is

(surges/spikes), swells, flickers, unregulated

disturbances (power factor, harmonics, others).

4 AC POWER QUALITY PROBLEMS Electrical equipment is occasionally exposed to transient overvoltages (surges/spikes), swells, flickers, unregulated voltages, voltage dips/sags, interruptions or waveform disturbances (power factor, harmonics, others). Disturbances Critical Industrial Process or Loads Economical Losses & Collateral Damages

5 FREQUENCY OF OCCURRANCE OF AC DISTURBANCES Case of Spain Utility Network DIPS / SAGS > 78% SWELLS INTERRUPTIONS SURGES / < 1% < 1% FLICKERS / HARMONICS < 20%

6 WHAT IS A VOLTAGE DIP OR SAG? According to internationally adopted definition (under European standard EN 50160), a voltage dip (UK), Voltage Sag (US) occurs when the voltage drops to a level below 90% of standard power supply voltage Most voltage dips last < 0.1 second During a voltage dip, power supply not interrupted

7 CAUSES OF VOLTAGE DIP 1. Overhead lines intervened by adverse weather (Lightning), overgrown vegetation and wild animals, etc. 2. Underground cables damaged by third party 3. Failures of power supply equipment 4. Starting of heavy machine or short circuit fault nearby

8 IMPORTANCE OF PRIOR DIAGNOSIS Phases of Engineering for the resolution of problems related to the Power Supply: Measurement and Analysis of the Power Quality at site Technical Audit of the electrical installation. Determining sensitivity of equipment and processes. Green PQ Proposal and Implementation PQ Audits and Studies Green PQ Solutions

9 GREEN OPTIONS WITHIN POWER QUALITY SOLUTIONS

10 GREEN PQ SOLUTION FOR VOLTAGE INTERRUPTIONS DVC SEPEC 107% Vn 93% 90% 1 Surges 2 Flicker 6 Waveform and Faults AVC SET DVR

11 DVC SEPEC BLOCK DIAGRAM I2 Maintenance switch (manual bypass) I1 Bypass I3 3x400V Input switch MIT Charger Inverter Module(s) Output switch 3x400V S1 Brake option Neutral line generator option Batteries N

12 DVC SEPEC WORKING MODES Normal mode Emergency mode Maintenance mode I2 Maintenance switch (manual bypass) I1 Bypass I3 3x400V Input switch MIT Charger Inverter Module(s) Output switch 3x400V S1 Brake option Neutral line generator option Batteries N

13 BLACK-OUT SOLUTION : DVC SEPEC INDUSTRIAL UPS Performance for a black-out with regenerative load, return of energy and a control board equipped with a PLC and network (hubs) communication system.

14 DVC SEPEC : GREEN ADVANTAGES Characteristics of the Dynamic Voltage Compensator SEPEC: High System Efficiency over 99% Relatively small Battery is required when compared with UPS Off-line (Stand-by) static power electronic system Minimum O&M cost (extremely low losses, low maintenance, etc.) Mitigation of Short Interruptions (up to 5 minutes) Very fast response: typical less than 1/4 cycle Compatible with already existing Protection Systems. Compatible with Diesel Generation System (Genset). Compatible with Regenerative Loads (Industrial Motors). Very Low Harmonic Distortion. Advanced System for Management, Control and Diagnosis of batteries.

DVC SEPEC : A CASE STUDY IN CHINA Xiamen Yinlu Foods (Nestle Group) Fujian, China Process Description: Milk / dairy products continuous production line Problem

15 DVC SEPEC : A CASE STUDY IN CHINA Xiamen Yinlu Foods (Nestle Group) Fujian, China Process Description: Milk / dairy products continuous production line Problem solved in case of black-out: Bacteria growth Cleaning of production line Re-start production cost The Green PQ Solution: 2x DVC SEPEC 400kW Installation Year: 2007

DVC SEPEC : A CASE STUDY IN RUSSIA LG Electronics Russia Process Description: Electronics and home appliances continuous production line Problem solved in case of black-out: Frequent voltage drops at

16 DVC SEPEC : A CASE STUDY IN RUSSIA LG Electronics Russia Process Description: Electronics and home appliances continuous production line Problem solved in case of black-out: Frequent voltage drops at the networks of Ruzkoho feeding area Tripping of the cooling pump, resulting in a malfunction of the technological manufacturing process. Re-start production cost The Green PQ Solution: 1x DVC SEPEC 200kW Installation Year: 2015

17 GREEN PQ SOLUTION FOR VOLTAGE SAG / DIP DVC SEPEC 107% Vn 93% 90% 1 Surges 2 Flicker Unregulated Voltage Sag / Dip Interruptions 6 Waveform and Faults

18 DIP AVC SET DVR - BLOCK DIAGRAM 703EN00

19 AVC SET DVR - DYNAMIC RESPONSE 703EN00

20 AVC SET DVR : GREEN ADVANTAGES Characteristics of the Dynamic Voltage Restorer: No battery / RoHS compliance Efficiency approx 98% Maximum ROI and less footprint compared with UPS Minimum O&M cost (low losses, low maintenance) Capable to mitigate Sags/Dips ( up to 60% ) Precise Voltage regulation : typical +/- 0.5% Very fast response: typical less than 1/4 cycle On-line Static Power Electronic System Independent Phase Compensation. Voltage balancing capability. Automatic Bypass. Capable to operate with Industrial Regenerative Loads (four quadrant converters)

21 AVC SET DVR / WORKING MODES Bypass Mode Normal Mode 703EN00

22 AVC SET DVR 40% / PERFORMANCE % Nominal V Output Voltage Input Voltage 30% Sag 40% Sag 50% Sag 60% Sag 70% Sag 80% Sag ,000 Time (msec) 703EN00

23 AVC SET DVR 20% 30% 40% 50% 60% / PERFORMANCE

24 AVC SET DVR 20% 30% 40% 50% 60% / PERFORMANCE 3 Phase %V In AVC DVR 20% AVC DVR 30% AVC DVR 40% AVC DVR 50% AVC DVR 60%SP * *

25 AVC SET DVR OIL REFINERY AIR PRODUCTS GROUP (Tarragona, Spain) AVC 2.4MW 6.6kV Process Description: Liquid hydrogen continuous production for an oil refinery Intermediate material for oil refinery Problem in case of voltage sag: Emergency stop of hydrogen production due to voltage sag >12% at 6.6kV line, produced by heavy machinery in the oil refinery or summer storms Oil refinery stops as a consequence and takes 3 days to restart production Extremely high non-productive losses in refinery

6kV Prepared to be supplied from any of 2

26 AVC SET DVR OIL REFINERY The Green PQ Solution: 1x AVC SET DVR 2.4MW 6.6kV Prepared to be supplied from any of 2 different MV distribution feeders Sag protection at MV level for all loads excepts non-critical services and outdoor lighting Installed in March 2009 With saved production losses, investment paid back in less than 2 years

27 AVC SET DVR OIL REFINERY The system description: 1x AVC SET DVR 2.4MW 6.6kV + 1x concrete building to host the unit 1x MV switchgear + 1x concrete building to host the switchgears MV transformer 6.6kV/400V + Booster of MV transformer 6.6kV + 1x concrete building

Plastics for agriculture (greenhouse), livestock and construction Problem in case of voltage

28 AVC SET DVR PLASTIC INJECTION SOTRAFA (Almeria) AVC SET DVR 3.6MW 20KV Process Description: Polyethylene film reel continuous production line Application: Plastics for agriculture (greenhouse), livestock and construction Problem in case of voltage sag : Production defects due to voltage fluctuation Production losses due to clogging of ejector nozzle Non-productive hours at cleaning

29 AVC SET DVR PLASTIC INJECTION The Green PQ Solution: 1x AVC SET DVR 3.6MW 20kV 1x MV input transformer 1x MV booster transformer 1x MV Switchgear Installed in December 2012 at the 20KV substation protecting the whole factory

AVC SET DVR : SAMSUNG DISPLAY SAMSUNG DISPLAY DONGGUAN CO.

Panel manufacturer. The FDP production line includes CPT, CDT, LCD, PDP, VFC, etc.

Problem in case of voltage sag: The factory is powered directly from four different 10kV feeders and summer

30 AVC SET DVR : SAMSUNG DISPLAY SAMSUNG DISPLAY DONGGUAN CO. LTD (China) AVC SET DVR 600KVA Process Description: Samsung Display is a world class famous Flat Display Panel manufacturer. The FDP production line includes CPT, CDT, LCD, PDP, VFC, etc. Daily production volume around Euro 10 million. Problem in case of voltage sag: The factory is powered directly from four different 10kV feeders and summer storms occasionally cause voltage sags. Rarely blackout for years. The consequences of an unexpected shut down are significant: WIP scraped, and it may take long time to resume the production line. this problem causes very high economic losses.

its kind) 3 sets of 220V AVC SET DVR of 240kVA 40% sag compensation 2

31 AVC SET DVR : SAMSUNG DISPLAY The solution: 7 Sets 2 sets of 400V AVC SET DVR of 480kVA 50% sag compensation (first installation worldwide of its kind) 3 sets of 220V AVC SET DVR of 240kVA 40% sag compensation 2 sets of 400V AVC SET DVR of 300kVA 40% sag compensation Installed in July 2013

32 AVC SET DVR : SAMSUNG DISPLAY SAMSUNG DISPLAY DONGGUAN CO. LTD (China) AVC SET DVR 480kVA 50% Problem measured & solved

33 AVC SET DVR : CUSTOMER SATISFACTION

34 DVC SEPEC & AVC SET DVR : INSTALLATIONS > More than 90,000 KVA installed around all the world > More than 200 Green PQ Solutions installed in prestigious customers > 15 Different application sectors 34

35 Zigor Corporación, S.A. C/Portal de Gamarra nº Vitoria-Gasteiz, Álava-Araba, Spain Tel: Fax: Zigor Group AMERICA ASIA EUROPE

16 th Annual PQSynergy International Conference and Exhibition 2016

16 th Annual PQSynergy International Conference and Exhibition 2016 Er. Muhammad Najmi Bin Bohari MSc(Power Eng), B.Eng (EEE) P.Eng, MIES, M-CIGRE najmi@powerquality.sg Professional Engineer (Singapore).