Maschinenfabrik Reinhausen Germany Power Quality Power Quality and Reliability Dr.-Ing. Mike Ifland / MR PQ Germany Israel/ Dec. 4 st 2014 Page 1 of 23
Agenda I MR Introduction I MR PQ Fields of activity I Maschinenfabrik Reinhausen Power Quality Solutions I Project Example Harmonic Filter System I Summary Page 2 of 23
1. MR Introduction 1.1 Our worldwide clients / Your market opportunities Maschinenfabrik Reinhausen GmbH (parent company) I Founded in 1868, MR trademark since 1901 I I I I I Majority family ownership in fifth generation World market leader in transformer switching 3.160 employees in MR and 26 affiliated companies (35 sites) 82 % of employees in Germany, 90 % export business Group turnover of 650 million EUR, highest available rating (banks) > 50 % of worldwide electricity consumption passes through a MR product > 80 % of all our products ever delivered are still in operation today Page 3 of 23
Brand Products Task Range Vision Goal 1. MR Introduction 1.2 Fields of activity Increasing corporate value in global niches of electrical power engineering while preserving our independence Marketing of proprietary technologies No transformers without a MR product Preferred system integrator VALUE FACTURING Decision Support for Manufacturing Excellence POWER COMPOSITES Composite Materials and Insulators MESSKO INSTRUMENTS Equipment Control and Assessment TRANSFORMER CONTROL Control of Power Transformers POWER QUALITY Solutions at Grid Nodes HIGHVOLT TESTING Testing and Measurement Technologies l Integration of Shop Floor Data Models into ERP l Optimization of Automated Manufacturing Processes l Mechanical & Electrical Endurance by GFRP l Composite Insulators for HV / MV Equipment l l Sensors, Accessories, Oil Analytic Laboratory and Secondary Brands Process Measuring and Control Technologies for Industry Applications l Actuators, Electronics and Data Management l Transformer Services l Filters and Reactive Power Compensation l Power Flow Control in Distribution Networks l Shop Floor Testing Systems for Grid Components l Mobile HV / MV Systems for On-Site Testing Page 4 of 23
1. PQ Fields of activity 1.1 Target industries / customers I Chemical industry I Steel industry I Cement industry I Utilities I Pulp & Paper I Mining I Windfarms I Oil & Gas I Power plants I Railway Page 5 of 23
1. PQ Fields of activity 1.2 Different clients facing different power quality problems Transients Reactive power I Switching events I Chemical Athmospheric overvoltage industry I Transient currents/voltages I Phase shifting voltage/current Cement industry I Leading (capacitive) I Lagging (inductive) I Pulp & Paper I Caused by powerful single phase loads Voltage drops Flicker I Commutating effects I Start of huge motor drives I Steel industry I Utilities I Caused by powerful welding machines, presses I Other fluctuating and repeating loads I Mining I Caused by long-term load fluctuations Unbalance Voltage/Current Harmonics I Windfarms I Caused by harmonic sources like converter drives, furnaces, millions of switched mode power supply units. I Power Evaluation plants will distinguish harmonic voltage/current Voltage variation I Oil & Gas Turn key solutions provided by I Railway Page 6 of 23
1. PQ Fields of activity 1.3 Power Quality problems electrical equipment Malfunction of protection and control devices Additional losses: I Chemical - life span reduction industry - destruction of equipment I Cement industry Harmonic distortions I Pulp Effects & Paper on the network Malfunction of ripple control devices I Steel industry I Utilities I Mining I Windfarms I Power plants I Oil & Gas Turn key solutions provided by I Railway Page 7 of 23
1. PQ Fields of activity 1.4 The solution circle I Customized solutions Taking care of specific problems Page 8 of 23
2. MR Power quality solutions 2.2 Metal encapsulated Indoor Equipment (Harmonic filters) I Harmonic filter system for indoor application / POCOS Harmonics MAIN POWER STANDBY POWER Overhead line 3 km Overhead line 20 km 110 kv 50 Hz 3 ~ SCC 1082 MVA SCC 498 MVA 110/10 kv 31.5 MVA 10.5 % 110/10 kv 31.5 MVA 10.5 % 10 kv 50 Hz 3 ~ SCC 235 MVA 10 kv 50 Hz 3 ~ SCC 186 MVA Harm. Filter Harm. Filter Harm. Filter Harm. Filter Harm. Filter 238 Hz 345 Hz 575 Hz 575 Hz 575 Hz 1600 kvar 1000 kvar 2400 kvar 2400 kvar 2400 kvar Harm. Filter Harm. Filter Harm. Filter Harm. Filter Harm. Filter 238 Hz 345 Hz 575 Hz 575 Hz 575 Hz 1600 kvar 1000 kvar 2400 kvar 2400 kvar 2400 kvar SM VSD 22 MW 4800 rpm SM VSD 22 MW 4800 rpm 2 x 22 MW compressor drive with 12- pulse LCI converter 10 kv 5 steps with total power 9.8 Mvar HF05 (1.6 Mvar) / HF07 (1.0 Mvar) / HF 11 (3 x 2,4 Mvar) Page 9 of 23
2. Power Quality Solutions 2.3 GRIDCON Modules and Stations (general overview) Page 10 of 23
2. Power Quality Solutions 2.4 Low Voltage Developments BMW-Brilliance-Automotive Shenyang China: I Tuned passive filter, designed for max. 660 A (inductive / reactive power compensation) I One active filter (500 A): similar effect, lower losses and smaller size Page 11 of 23
2. Power Quality Solutions 2.5 AcF Working principle Working principle of Active Filters: GRIDCON AcF: service optimized, modular concept with 4 modules per cabinet Page 12 of 23
Deviation from rated voltage (in %) 2. Power Quality Solutions 2.6 GRIDCON Transformer 20 kv 20 kv Secondary 0.4 kv 0.4 kv Medium voltage grid substation Low voltage grid +10 % Outside of allowed voltage band +5 % 0 % Regulation downwards Maximum feed-in case -5 % Regulation upwards Maximum load case -10 % Outside of allowed voltage band Page 13 of 23
2. Power Quality Solutions 2.7 GRIDCON Transformer - Setup MV grid Substation LV grid 3 Voltage regulator abgesetzte Spannungsmessung Controller Sensor Actuator V 1 Transformer PV G 2 On-load tap-changer 3~ = PV 3~ = PV 3~ = Page 14 of 23
3. Project example harmonic filter system 3.1 Requested compensation system 22.9 kv / 60 Hz / Busbar A 22.9 kv / 60 Hz / Busbar B Scope of supply Scope of supply 22.9 kv 13 Mvar 360 Hz Filter 5th 22.9 kv 10 Mvar 60 Hz Non-tuned capacitor bank 22.9 kv 13 Mvar 360 Hz Filter 5th 22.9 kv 10 Mvar 60 Hz Non-tuned capacitor bank Page 15 of 23
3. Project example harmonic filter system 3.2 First calculation with specified compensation systems 220 kv frequency sweep of substation Mina Constancia I 11 th harmonic 22.9 kv frequency sweep of substation Mina Constancia parallel resonance effects in the range of 11th harmonic higher harmonic range strongly damped impact of generated harmonics of 18/24-pulse converter are negligible Page 16 of 23
3. Project example harmonic filter system 3.3 Harmonic predistortion 220 kv / specified compensation system I 5th 1.2% I 7th 0.6% I 11th 3.0% I 13th 1.5% I Histogramm 220 kv I 11 th harmonic I Histogramm 22.9 kv I Voltage 22.9 kv I 5th 0.13% I 7th 0.52% I 11th 8.40%!! I 13th 1.67% Page 17 of 23
3. Project example harmonic filter system 3.4 Design review of requested compensation system 22.9 kv / 60 Hz / Busbar A 22.9 kv / 60 Hz / Busbar B Scope of supply Scope of supply 22.9 kv 13 Mvar 300 Hz 22.9 kv 10 Mvar HP 10 Ohm / 750 Hz 22.9 kv 13 Mvar 300 Hz 22.9 kv 10 Mvar HP 10 Ohm / 750 Hz Filter 5th High-Passfilter tuned to 11th/13th Filter 5th High-Passfilter tuned to 11th/13th Page 18 of 23
3. Project example harmonic filter system 3.5 Calculation with changed design of compensation/harmonic filter systems 220 kv frequency sweep of substation Mina Constancia I 11 th harmonic 22.9 kv frequency sweep of substation Mina Constancia decrease of impedance in the range of 11th harmonic by factor 4 Page 19 of 23
3. Project example harmonic filter system 3.6 Calculation results with changed design of compensation/harmonic filter systems Histogram voltage harmonics 22.9 kv I 5th 0.12% I 7th 0.61% I 11th 1.13% I 13th 0.35% I 17th 0.03% I 19th 0.02% Voltage 22.9 kv Order harmonics (voltage) IEC 61000-2-4 class 2 Specified System Recommended System 5 6.0 0.13 0.12 7 5.0 0.52 0.61 11 3.5 8.40 1.13 13 1.5 1.67 0.35 17 1.2 0.03 0.03 19 1.1 0.02 0.02 23 0.9 0.04 0.03 25 0.8 0.03 0.03 Page 20 of 23
4. MR PQ - Summary Encapsulated Indoor Equipment GRIDCON POCOM, POCOS, POCOL custom biult compensation systems with a high degree of standardization Encapsulated Outdoor Equipment GRIDCON Module F,M,C,E Applicable as Fixed, Multiple, Concrete, E-House Dynamic Equipment customized applications for compensation and filtering of harmonics high flexibility in terms of configuration and arrangement IP00 (Indoor / Outdoor) Filters with high voltages (<20 kv) and great power output (>10 Mvar) for utilities and industrial applications Voltage Regulated Distribution Transformer (VRDT) preventing voltage band violations in both MV and LV networks transfer of proven HV technology into MV/LV grids Page 21 of 23
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Backup Page 23 of 23
4. Project example harmonic filter system 4.1 Electrical data I 220 kv Main feeder I Sk min 1248 MVA I Transformer 75/125 MVA I Transformer 75/125 MVA I 22.9 kv 60 Hz Busbar B I 22.9 kv 60 Hz Busbar A I Sk min 648 MVA I Capacitorbanks (2 x 23 Mvar) I 24-pulse perfect harmonic converter drives (11 MVA) I Liquid cooled resistor starters (Ball Mill /SAG Mill) (2 x 32MVA) I 18-pulse perfect harmonic converter drives (1.5 MVA) Page 24 of 23
2. MR Power quality solutions 2.3 Metal encapsulated Indoor Equipment (Inrush limiting resistors) Transients MV network behavior during energization of large harmonic filters or converter- / distribution/transmission transformers Page 25 of 23
2. MR Power quality solutions 2.4 Metal encapsulated Indoor Equipment (Load symmetration units) Customer equipment: Powerful single phase loads Unbalance Voltage/Current Solution: Steinmetz-Scheme Capacitors/ Reactors with tappings I 1 R A U 12 U 23 U 31 R B I 2 C1 L1 C2 R X Load Load I C1 & L1 for load symmetration I C2 for reactive power compensation I 3 R C Page 26 of 23
2. MR Power quality solutions 2.4 Metal encapsulated Indoor Equipment (Load symmetration units) Unbalance Voltage/Current I 1 I C1 with tappings R A U 12 I 2 C1 C2 R Load I L1 with tappings U 23 U 31 R B L1 X Load I 3 R C Page 27 of 23