ADF Power Tuning Power Tuning 2017-12-14... · 2020-01-26 · — ADF Power Tuning ADF Power Tuning — ADF Power Tuning ADF Power Tunin g The ADF P200 is a compact, wall-mounted

Comsys ADF Power Tuning 1

The shape of power to come

Per Ewers – [email protected]

Global Segment Manager, Comsys AB

2017-12-14

2017-12-13


ADF Power Tuning Movie

2017-12-13

https://youtu.be/5vBx2RjCp18

https://youtu.be/5vBx2RjCp18


Comsys

• Based in Lund, Sweden

• Founded in 2001

• Privately held Company

• 21 employees

• Is growing by over 30% per year during the last 5 years

• The ADF products are developed and manufactured in Sweden

• We have assembly plant in China for the Asian market

• First ADF delivered in 2003. About 2 500 units has been sold in over 48 countries since the commercial start in 2009

• Global network of partners for sales and service support

2017-12-13


Sales strategy overview- we only sell through partners and have more than 50 partners all over the world- ADF has been sold in over 40 countries since 2009

2017-12-13

Global

OEM SI Partner

DATA CENTERINDUSTRYWATER & WASTEWATER

OIL & GASMARINE


Clients already making their energy more efficient with ADF

2017-12-13

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Power isn’t perfect

2017-12-13


When power is in no shape to perform

2017-12-13

Harmonics Reactive power Network unbalance

Transients

(fast disturbances)

Voltage variations

(dips, sags, swells,

brown-outs)

FlickerOscillations

(resonances)


ADF – technology that makes energy more efficient

2017-12-13

Harmonics Reactive power Network unbalance

Transients

(fast disturbances)

Voltage variations

(dips, sags, swells,

brown-outs)

FlickerOscillations

(resonances)


Uncompensated complex industrial load

2017-12-13


Compensated complex industrial load with minimized losses

2017-12-13


ADF working principle

2017-12-13


ADF working principle

2017-12-13

External noise Sound created

by headphones

to cancel out

external noise

Silence


Technology comparison

2017-12-13

ADF MULTIPULSE AFEPASSIVE FILTER

Losses • • • •Total harmonic distortion • • • •Physical size • • • •

•small •medium •large

Meets regulation* • •Specific harmonic selection •Resonance elimination •Flicker compensation •Configurable •*) IEEE519, G5/4, EN61000, etc

Comsys ADF Power Tuning 14 2017-12-13

Maximum distortion levels?


Technology comparison6-Pulse drives

2017-12-13

Energy efficient, but:

• High harmonic content, 35-100%, can cause problems and does not meet regulations


Technology comparison6-Pulse drives + series passive harmonic filters

2017-12-13

Low cost solution, but:

• Filter in line with load, requires a lot of space

• Can be overloaded, with damage as result

• Several passive components in a grid will cause resonance problems

• Non-flexible, installation upgrade = replace filter

• Redundancy, If filter fails, drive stops


Technology comparison6-Pulse drives + shunt passive harmonic filters

2017-12-13

Low cost solution, but:

• Filter in shunt with load, requires a lot of engineering

• Can be overloaded, with damage as result

• Several passive components in a grid will cause resonance problems

• Non-flexible, installation upgrade = replace filter

• No redundancy design possible


Technology comparisonActive Front End drives

2017-12-13

Easy to size solution but:

• Filter in line with load, requires a lot of space

• Front end in line with load results in high losses

• Redundancy, if front end fails, drive stops


Technology comparison 6-Pulse drives + ADF

2017-12-13

• ADF is installed in parallel with load, compact installation

• Can easily be scaled up at later stage

• ADF can be sized for worst case total load

• Redundancy, If ADF fails, drives still run


Low Harmonic Drives

2017-12-13

Passive Filter Multi-Pulse solution Active Front End


Low Harmonic Drives

2017-12-13

• Single drive is not the problem

• So why compensating on a single drive?

• The sum of all loads at the transformer level makes the problem

• Voltage is centralized and the problem is transported on the voltage


Low Harmonic SolutionAHF on PCC (Point of common coupling = centralized)

2017-12-13

• One filter to rule them all

• Higher degree of redundancy possible

• Better utilization of space

• Better utilization of filter capacity (for standby drives)

• Works with any drive or load

Lower Cost!!


Product range

2017-12-13

ADF P300 ADF P200ADF P100NADF P100 ADF PPM300 ADF P700 STATCOM

Web User Interface


ADF P100/P100N

2017-12-13

• Wall mounted

• Very space efficient for retrofit

• Cost effective

• 480/690 V, 3ph-3w

• 415 V, 3ph-4w

• Current capability: 70 - 130 ARMS


ADF P300

2017-12-13

• Modular design (PPM)

• Air and liquid cooling

• 3 wire

• Simple installation

• Simple operation through WUI, Smart grid ready

• Current and Sensorless control

• Is able to compensate with high efficiency

• Harmonics (up to 49th harmonic)

• Reactive power

• Unbalance

• Voltage variations (flicker)

• Available in 480 V Air, 120 A – 360 A

• Available in 480 V liquid, 150 A – 450 A

• Available in 690 V Air, 90 A – 270 A

• Available in 690 V liquid, 140 A – 420 A

• UL/cUL certified


ADF P700

2017-12-13

• Modular design for high availability

• Air and liquid cooling

• 3 wire

• Simple installation

• With or without housing

• 2 – 20 MVA compensation power

• 690 V – 130 kV connectivity


ADF P200

2017-12-13

• Air cooling

• 480 V 3ph–3w 120 ARMS

• Sensorless control

• Wideband curve compensation

• Compensation up to 6 kHz!

• World’s fastest active filter!


PPM300 – Integrator friendly

2017-12-13

• ADF OEM Concept is the ultimate low harmonic alternative for OEM’s and System Integrators on the market

• Virtually plug & play for drives

• Combination of modules gives highest possible flexibility 90 A and upwards

• Compensation powers from 80 kVA to 15 MVA can be built with simple building blocks

• Allows system integrators to be flexible and competitive with a small standardized tool set. 100% Drive supplier independent

Voltage 208 – 480 V 480 – 690 V

Air Cooling PPM300-3-A-120/480 PPM300-3-A-90/690

Liquid Cooling PPM300-3-W-150/480 PPM300-3-W-140/690


ADF PPM300v2-3-WLiquid cooled modules

2017-12-13

• Updated water cooled v2 modules

• Features:• All aluminum/rubber/stainless (EPDM

hoses, pipes & connectors

• Improved connectors

• Designed and tested for 10 bar pressure

• Improved current rating at higher frequencies

• Increased cooling media (ambient) temperature

• 140 A @ 690 V

• 150 A @ 480 V


ADF PPM300v2-3-WLiquid cooled modules

2017-12-13

• G ½” M BSPP connectors

• Maximum pressure 10 bar

• Maximum cooling media temperature 45 °C

• Nominal flow 10 l/(min*module)

• Pressure drop:• 1 bar @ 14 l/min

• 0.6 bar @ 10 l/min


ADF Back Channel Cooling

2017-12-13

• ADF Active Filters enables the use of energy saving devices such as variable speed drives

• Active filters will generate lower losses than other harmonic mitigation technologies such as passive filters or active front end drives.

• ADF Active Filters do however bring a heat loss to the room they are installed which can require additional cooling installations.



2017-12-13

• ADF Back Channel Cooling is a concept to remove the generated heat from the room

• With ADF Back Channel Cooling, cooling air for the ADF is drawn from the outside and the heated air is extracted to the outside.



2017-12-13

• With ADF Back Channel Cooling, 80-90% of the heat generated from the ADF will be extracted from the installation room.

• With the addition of a filter box on the intake and a louvre on the extract, IP54 can be achieved.


PPM300: System integration ADF

2017-12-13

• ADF OEM Concept is the ultimate low harmonic alternative for OEM’s and System Integrators on the market

• Virtually plug & play for drives

• Combination of modules gives highest possible flexibility 90 A and upwards

• Compensation powers from 80 kVA to 15 MVA can be built with simple building blocks

• Allows system integrators to be flexible and competitive with a small standardized tool set. 100% Drive supplier independent


System integration ADFBuilding blocks

2017-12-13

• ADF PPM300 power processor modules

• CM 300 controller modules

• SCC2 control computers

• HMI OEM


System integration ADFADF PPM300v2 Form factor

2017-12-13

• Tall and narrow form factor

• Optimize space in cabinet with

230mm wide modules installed

with no space between

• Optimized cooling enables

highest power density with long

life expectancy

• Industrial design


System integration ADFADF PPM300v2

2017-12-13

• The PPM300v2 is the invertermodule

• Choose voltage:• 208 – 480 V

• 480 – 690 (600*) V

• Chose cooling media:• Air

• Liquid

• Module includes fan, pre-charger, contactor

*) UL version


System integration ADFADF SCC2

2017-12-13

• Control up to 3 or 6 modules with one computer

• Ethernet• Integrated Web Server

• ADF Dashboard

• Modbus TCP

• Multi-master support

• Voltage (PT) and CT inputs

• Relay outputs/inputs


System integration ADFHMI-OEM

2017-12-13

• Easy to mount in any panel door

• Two versions available

• HMI-B (Basis HMI with only an

indication button)

• HMI-E (Extended HMI with

indication button and 4.3”

display)


System integration ADFExamples

2017-12-13

• Marine project

• ADF integrated into propulsion system switchgear panel

• IP54

• Complete solution acts as LHD



2017-12-13

• Affinity water

• Water/wastewater treatment

• Integrated in MCC together with fusing, switchgear, and drives



2017-12-13

• Vacon NXC Low Harmonic

• ADF integrated into standard product (OEM)

• Competes (mostly) with AFE solutions

• Available from 260 kW and up

• Example of very deep integration


Handle all applications with basic building blocks

2017-12-13

• Solution scales

from single load…

• … to fully integrated

solution PPM300

M3~

ADF P300

M3~

M3~

M3~

ADF P300

SCC2

PPM300

M3~

M3~

M3~

PPM 300

SCC2

Single load Compensate several loads Fully integrated solution

SCC2

ADF P300

M3~

M3~

M3~

ADF P300

SCC2

ADF P300

ADF P300

SCC2

G GG

Summation CT

PPM300

M3~

ADF P300

M3~

M3~

M3~

ADF P300

SCC2

PPM300

M3~

M3~

M3~

PPM 300

SCC2


SCC2

ADF P300

M3~

M3~

M3~

ADF P300

SCC2

ADF P300

ADF P300

SCC2

G GG

Summation CT


Handle all applications with basic building blocks

2017-12-13

• Very complex setups can be handled

• Parallel systems with multi-master capability

• Design redundancy schemes according to need

PPM300

M3~

ADF P300

M3~

M3~

M3~

ADF P300

SCC2

PPM300

M3~

M3~

M3~

PPM 300

SCC2


SCC2

ADF P300

M3~

M3~

M3~

ADF P300

SCC2

ADF P300

ADF P300

SCC2

G GG

Summation CT


Web user interface

2017-12-13

• ADF Dashboard Web User Interface (WUI) allows control of system via web browser

• Only use your laptop for commissioning!

• Ease of use – easy to support – lower cost of training – lower cost of ownership

• Leverages the remote support capabilities

• Easy to connect to overall system incl. remote access, logging and analysis functions


Commissioning - Automatic diagnostics

2017-12-13

• Automated diagnostics with human-readable error messages simplifies commissioning process

• ADF performs self-test on startup

• Error in connection will quickly be detected

• FFT in Web User Interface

• Commission process is fast and simple – results seen immediately


The ADF compensates for harmonics, PFC and load balancing

2017-12-13


Software 2.0

2017-12-13

• New flat User Interface

• Significantly improved performance

• Simplified event/status window

• Improved protection function

• Increased control performance

• Supports v2B systems


De-rating as a function of frequency

2017-12-13

0

20

40

60

80

100

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49

Harmonic Derating

Schneider

ADF P300

Danfoss

ABB

Power Electronics FQA


Effects of derating in sizing

2017-12-13

• Total harmonics are 104 A

• ABB would need 135 A (129%) filter to compensate

• ADF would need 106 A (102%) filter to compensate

• Power Electronics would need 216 A (208%) filter to compensate

• Derating can have a big effect on the sizing

Harmonic CurrentABB With Derating

ADF With Derating

PE With Derating

5 80 A 80 A 80 A 100 A

7 60 A 84 A 60 A 120 A

11 20 A 44 A 25 A 67 A

13 20 A 52 A 24 A 133 A

Total: 104 A 135 A 106 A 216 A

129% 102% 208%


Summary

2017-12-13

• ADF developed and manufactured in Sweden

• Strong focus. Comsys focus 100% on ADF

• More than 15 years of application experience/knowledge

• Global reach with ADF partner network

• ADF is a flexible solution for power quality problems

• ADF is modular and will fit any project

• ADF is available as stand alone products and as a system integration concept


Thank You


Power Quality:Harmonics

2017-12-13

• Harmonics are multiples of the fundamental frequency

• Fundamental is 50 Hz (EU) or 60 Hz (USA)

• Hence; 5th harmonic is 250 Hz

• Harmonics are a result of non-linear components

• Non-linear components refer to semiconductors in most cases



2017-12-13

• Harmonics can (simplified) be classified as DC-components, zero-sequence harmonics and three-phase harmonics.

• DC-components• Multiples of 2 : 2, 4, 6, …

• Zero-sequence harmonics• Multiples of 3 except DC-components:

3, 9, 15, 21, …

• Three-phase harmonics• “The rest” : 5, 7, 11, 13, 17, 19, 23, 25, …

• Interharmonics• Harmonics of non-integer order



2017-12-13

• DC-components

• Caused by switching loads

• Zero-sequence harmonics

• Caused by single-phase loads

with semiconductors

• Three phase harmonics

• Caused by three-phase

semiconductor loads; drives,

rectifiers, etc



2017-12-13

• Harmonics lead to voltage variations, instability, disturbances, increased losses and shorter lifetime

• Lifetime shortens exponentially with increased harmonics

• Sites are usually oversized to handle harmonics

• Compensation of harmonics means• cancelling the harmonic

• injection of opposite sign identical harmonic current

• Harmonics are considerably more complicated to mitigate than reactive power

• Compensation of harmonics leads to increased reliability of existing passive compensation

badgoodVoltage Quality

Fa

ilure

Ris

k &

Lifetim

e r

eduction

low

high

Regulations


Positive-, Negative- and Zero-sequence

2017-12-13

• Positive- and negative-sequence represents angle direction between the phases

• Summing up all three phases always end up to a zero line

• Different on zero-sequence harmonics (dividable be 3)

• ZS harmonics do not have a phase shift between the phases

• Summing up all threephases will end up with 3x the amplitude of the singlephases

Phase A

Phase B

Phase C

3rd A

3rd B

3rd C

5th A

5th B

5th C

7th A

7th B

7th C

Positive Sequence

Positive Sequence

Negative Sequence

Zero Sequence


Environment conditions

2017-12-13

• Ambient temperature 0 – 40 °C

• Derating at 40 – 50 °C

• May not exceed 50 °C

• Power losses 1.5 kW – 9 kW

• Most of the losses in heat

• Altitude up to 1000 m

• Higher with derating


Air Flow

2017-12-13


IP protection class

2017-12-13

• ADF P100:• IP20 (standard)

• IP21 (option)

• IP54 (project option)


• IP21 (option)

• IP54 (project option)


• IP43 (option)

• PPM300:• IP20 (standard)


Minimum needed connections

2017-12-13


Main connection

2017-12-13


Phase order for installation

2017-12-13

• Phase 2 has to follow Phase 1



• Connection to ADF has to be in a right rotation

• If the grid is left rotating, this needs to be changed in the connection to the ADF


Skin effect

2017-12-13


Suggested cable size

2017-12-13

Number of PPs

Filter capacity Derating factor

1 90 – 150 ARMS X 1.5

2 180 – 240 ARMS X 1.4

3 270 - 360 ARMS X 1.3

• Rough estimation based on mix of different harmonics

• No external factors taken into consideration


Suggested breaker / protection

2017-12-13

• Comsys suggest to always skip one breaker size

• If ADF is 240 A. Next bigger breaker would be 250 A

• Skip 250 A and use one size bigger. That would be 300 A

• Harmonic behavior is different depending on breaker manufacture

• Use high quality breaker manufacture to in ADF installation


Current transformer

2017-12-13

Current transformer specification

Class 1.0 or better

Primary ratio Exceeding the maximum load current including harmonics, reactive power and transients

Secondary ratio 5 A

ADF total CT burden 0.193 VA in ADF P100(N)1.25 VA in ADF P300

Symmetry Three identical CT’s must be used


Current transformer - Burden

2017-12-13

• CT Burden needs to be large enough to handle cable and ADF

• Table in Hardware manual shows needed CT burden for different setups


ADF P300 CT connection

2017-12-13

• Conductor cross section

• Solid min 0.5 mm2

• Solid max 10 mm2

• Stranded min 0.5 mm2

• Stranded min 6 mm2


ADF P100(N) CT connection

2017-12-13

• Conductor cross section

• Solid min 0.5 mm2

• Solid max 6 mm2

• Stranded min 0.5 mm2

• Stranded min 6 mm2


Open Loop vs Closed Loop;Sensorless Compensation

2017-12-13

Closed Loop Open Loop Sensorless


Comparison Open / Closed loop

2017-12-13

Closed loop Open loop Sensor less

+ Easy to setup - Fine-tuning might be needed + Easy to setup

- Can stimulate resonances + Cannot stimulate resonances ? Unclear

- Usually used for compensation up to 25th harmonic

+ More stable also on high frequencies

? Unclear

+ Parallel operation with Multi-Master

+ Parallel operation also without Multi-Master

+ Parallel operation also without Multi-Master

~ 95 % of all installations ~ 5 % of all installations NEW!!


CT position selection

2017-12-13

• Position depends on:

• MV or LV

• Type of compensation

• Harmonic order to compensate

• Load behavior

• Grid resonances

• Passive components in the grid

• Target level

• Installation environment

• Background harmonic level

• The graph should only give an rough idea.

Not a 100% decision graph


CT position/Sensorless selection

2017-12-13

Open Loop Closed Loop Sensorless

Use if: • Flicker compensation• MV compensation• Very dynamic load• Passive filer in close proximity• High order compensation• Only compensate select sub-

grid

• Regular application(harmonics, reactive)

• Load balancing• Central compensation

• Installed CT’s are too big (>10x ADF size)

• Background distortion needs to be removed

• CT-installation too complex• Central compensation

Don’t use if: • Results need to be visible in ADF

• Central compensation

• Flicker• MV compensation• Very large CT (>10x ADF

size)

• THDI is target level


Open loop compensation with phase shift in CT

2017-12-13

Fundamental Vector diagram

5th harmonic

5th harmonic

CompensationCurrent 75%CompensationCurrent 75%phaseshift

CompensationCurrent 75%phaseshift

result25% target


Summation CT

• Use same type of CT for each side

• Use class 0.5 or better

• Be careful with the installation. Wiring is the bigger issue on commissioning day

2017-12-13


Connection example for dual bus-bar

2017-12-13

• When having two grid / bus bars, the connection of the ADF mightget a bit more difficult

• Target is:

• Not to overload the ADF

• Not to oversize the ADF

• Let the ADF run during all

situaltions

• Openation with open and closed

bus-tie


Connection example for dual bus-barClosed loop (Transformer only)

2017-12-13

• CT connection on transformer only

• ADF can see current supplied by transformer

• Problem:• If TX1 not running

• Bus-tie closed

ADF 1 is not running

ADF 2 operates on double load

• ADF would be ”overloaded”

• Need to double the size of ADFs

• Can be unstable if both grids are online and bus-tie is closed


Connection example for dual bus-barClosed loop (Transformer & Bus-tie)

2017-12-13

• CT connection on transformer and bus-tie

• ADF can see load current

• ADF would need to be sizedacording to load

• Overdimensioning is not needed

• Problem is the more complexCT setup


Connection example for dual bus-barOpen Loop

2017-12-13

• CT connection on load

• ADF can see load current



• CT setup is simpler

• Commissioning is morecomplex


Connection example for dual bus-barSensorless control

2017-12-13

• No CTs connected



• No CT setup needed

• Easy commissioning

• Problem, parallel operation ofADF in sensorless operation can cause problems


More complex CT setups

2017-12-13

• Compensation per Generator (set)

• Problem is G3 is off and “right busbar” is supplied via bus-tie



2017-12-13

• Extra CT on bus-tie makes sure ADF is only seeing the current on the corresponding bus-bar



2017-12-13


Parallel operation

2017-12-13

• Separation between frequencies (closed loop)• Two or more systems should not compensate on the same frequency

• Each system works as a single system on a dedicated frequency

• E.g. System 1 compensates 5th and 7th harmonic; System 2 compensates on 11th, 13th and PFC

• Problem: If one system fails, the harmonic stays uncompensated (secondary compensation set can be uses)

• Parallel operation in open loop• ADF knows how many systems are installed and only takes a part of the compensation current

• All systems need to be installed the same way

• If one system fails, this compensation current will not been taken over

• Sub-system compensation• Application gets divided into subsystems small enough so only one ADF is needed

• Multi-Master parallel operation


Connection diagram for parallel operation

2017-12-13

• CT connection should be looped through all ADFs

• In case of Multi-Master operation, Ethernet cable between X22 and X23


Multi-Master operation

2017-12-13

• New system features stateful Multi-Master operation• Master is automatically selected during startup

• Propagation of settings

• If a system trips or goes down, another automatically and dynamically takes over as the new master

• Multi-Master Master/Slave approach eliminates issues with synchronization and parallel system competition

• Uses CAN-bus for synchronization and negotiation

• Standard Cat.5 cable (FTP) can be used for tying systems together


Multi-Master operation

2017-12-13

• Simple interface!

• Migration of settings to all systems

• Redundant multi-master configuration

• Parallel system with automatic and instantaneous identification of master

• Uses CAN-bus for synchronisation


Multi Master network

2017-12-13

• Maximum 15 ADFs in a network

• Maximum length ofthe entire cable canbe 100 m

• Termination on the beginning and end needed

• Cable type: Ethernet cable CAT5 or betterwith FTP type or better


AUX Transformer

2017-12-13

• AUX transformer is not connected on delivery!!

• ADF P300-120/415_TCE-----20• 415 V 215/230/245/385/400/415

• 480 V 380/400/420/440/460/480

• 600 V 475/500/525/550/575/600

• 690 V 690


Fuses

2017-12-13

Product line 480 V, IEC Fuse type (AUX) Brand

ADF P300 / ADF P100(N) Ferrule fuse link, 10x38, aM, 500VAC, 10A Cooper Bussman CBC10M10

Product Line 690 V, IEC

ADF P300 / ADF P100(N) Ferrule fuse link, 10x38, gG, 690VAC, 10A Mersen FR10GG69V10

Product Line 480/600 V UL/cUL

ADF P300Ferrule fuse link, UL-approved class CC cat. JDDZ 10 A motor or transformer protection fuse

Cooper Bussman CBLP-CC-10

All Product Lines Fuse type (Mains) Brand

ADF P300 NH000, 250 A, 690 V aR type Cooper Bussmann CB170M1571D


ADF Dashboard hidden links

2017-12-13

• Access to log files on SD card

• http://169.254.254.254/dynamic/card_list

• Access to trend files on SD card

• http://169.254.254.254/dynamic/card_list?dir=/trend

• Trigger log manually

• http://169.254.254.254/log.html

http://169.254.254.254/dynamic/card_list

http://169.254.254.254/dynamic/card_list?dir=/trend

http://169.254.254.254/log.html


Trend files

2017-12-13

• Measurementspoint every 10 minutes

• 6000 points = 1000 hours = 42 days(1.7 MB)

• This trend shows a clear change in the load after around17 days


Log File

2017-12-13

• 400 ms of recording

• 300 ms before and 100 ms after error

• 14 kHz measurement detail

• All importantinternal details arerecorded

• Full settings arerecorded


Rule of thumb for sizing

2017-12-13

• Quickest way of estimating an ADF size is a “¼ rule of thumb”

• Take the drive size and convert in current.

• Take ¼ of this current and use this as ADF size

• For a low THDV take ¼

• For a low THDI take ⅓

• Example: 400 kW drive at 480 V with THDvas target

• 𝐼𝐴𝐷𝐹 =𝑃𝐷𝑟𝑖𝑣𝑒

𝑉𝑛𝑜𝑚∗ 3∗1

4=

400 𝑘𝑊

480 𝑉∗ 3∗1

4= 120 𝐴


ADF Sizing Tool for DrivesOverview

2017-12-13

ADF Sizing Tool for drives

REV 9.1 2017-01-02

Project section Notes

Project

Customer

Date

Prepared

Source section

Trafo/Generator (LV) Voltage Rating

Frequency uk / X''d Min. 2 out of 3

# Parallel Isc

Other

Liquid cooling UL/cUL

Altitude (if > 1000 m) Wall mounted

Ambient temperature

Load section

96 %

80 %

500.00 kW

75.00 kW

10

SpaceX

2020-05-26

Elon Musk

No

No

No

n-l

inea

r lo

ads

1

2

3

4

5

6

7

EN

100 %

100 %

400 V 2000 kVA

6.00 %

1

50 Hz

3

2

Lin

ear

Load

1

2

3

4

5

6

7

8

9

10

Mars Station

No

0 m

25 °C

2.00 %

3.00 %

}

Name Size [kW] PFQty

TypeQtyNo.

No.

Size [kW] Effcy. Sum Z% Utilization

8

9

6-pulse VFD

6-pulse VFD


REV 9.1 2017-01-02

Before Compensation Target

Target Regulation Manual

Ifundamental Isk

Iharm SCR

I_RMS Reactive

PF disp

THDI PF disp Use

THDV

ADF Selection

Needed modules THDV

Margin for Target

Min. ADF A

After Compensation THDV

PF disp THDI

ADF Settings

IEEE 519 (Auto)

35

47 0%47

0.4%1.6 V0.4%1.6 V

41 0%

43 43 0%

41

0%

37 37 0%

35 0.4%

29 0%

31 31 0%

29 0.6%

0.5%

0.6% 0.5%

0.5%

2.0 V

1.8 V

0.5%

0.5%

2.0 V

1.8 V13.8 A

0.6%2.3 V0.6%2.3 V 23 0%

25 25 0%

23 0.9%

0.7%

0.9%

0.7%

23.7 A

19.8 A 0.5%2.1 V0.5%2.1 V

0%

19 19 0%

17

1.3%4.7 V1.3%4.7 V

1.6%

1.4%

42.8 A

37.0 A

0.8%

0.8%

3.0 V

2.9 V

0.8%

0.8%

3.0 V

2.9 V

171.6%

1.4%

11 0%

13 13 0%

11 1.6%6.0 V1.6%6.0 V4.9%

3.3%

130.2 A

87.6 A

4.9%

3.3%

130.2 A

87.6 A

1x ADF P300-240/480

NaN

5 27%

7 7 0%

5 6.0%

3.2%

22.7 V

12.2 V

8.1%

3.2%

30.7 V

12.2 V

27.6%

7.8%

737.3 A

209.6 A

20.4%

7.8%

545.3 A

209.6 A

NaN

0.99 22.77 % 25 1.3% 49 0.5% 49 NaN

7.32 % 23 1.4% 47 0.6% 47

THDI Before

19 1.8% 43 0.6% 43 NaN

NaN

13 3.0% 37 0.8% 37 NaN

11 3.5% 35 0.8% 35

17 2.0% 41 0.7% 41

8.0% 23 2.0%

8.97% 11 4.0%

13 4.0%

17 3.0%

7 5.0% 31 1.0% 31 NaN

20.0% 25 2.0%

192 A 5 6.0% 29 1.1% 29 NaN

2674 A 48.1 kA EN 61000-2-4 Class 2 THDV

770 A 17.3 8.0%

THDI After THDV Before THDV After

2783 A

0.99 5 5.0%

28.80% 1.00 No 7 5.0%

EN 61000-2-4 Class 2 19 3.0%

2

42.8 A

37.0 A

23.7 A

19.8 A

16.2 A

10.7 A

16.2 A

13.8 A

9.8 A

10.7 A

9.8 A

6.0 A

0.5%

0.4%

0.4%

0.3%

0.3%

0.2%

7.5 A

6.8 A

0.3%

0.3%

0.3%

1.5 V

1.3 V

1.2 V

1.2 V

0.4%

0.3%

0.2%

7.5 A

6.8 A

6.0 A

0.3%

0.4%

0.3%

0.3%

0.3%

1.5 V

1.3 V

1.2 V

1.2 V

0.4%

0%

5%

10%

15%

20%

25%

30%

3 7 11 15 19 23 27 31 35 39 43 47

THDI

THDI Before THDI After Regulation

0%

1%

2%

3%

4%

5%

6%

7%

8%

9%

3 7 11 15 19 23 27 31 35 39 43 47

THDV

THDV Before THDV After Regulation

ADF Sizing 2020-05-26

www.comsys.se REV 9.1

Mars Station

SpaceX

THE SHAPE OF POWER TO COME


ADF Sizing Tool for DrivesFunctions

2017-12-13


REV 9.1 2017-01-02

Project section Notes

Project

Customer

Date

Prepared

Source section

Trafo/Generator (LV) Voltage Rating

Frequency uk / X''d Min. 2 out of 3

# Parallel Isc

Other

Liquid cooling UL/cUL

Altitude (if > 1000 m) Wall mounted

Ambient temperature

Load section

TypeQtyNo. Size [kW] Effcy. Sum Z% Utilization

8

9

6-pulse VFD

6-pulse VFD

Mars Station

No

0 m

25 °C

2.00 %

3.00 %

}

EN

100 %

100 %

400 V 2000 kVA

6.00 %

1

50 Hz

3

2

10

SpaceX

2020-05-26

Elon Musk

No

No

No

n-l

inea

r lo

ads

1

2

3

4

5

6

7

500.00 kW

75.00 kW

96 %

80 %

• Excel based sizing tool

• Estimation for current and voltage harmonics

• Support for:• 6-pulse drives

• DC drives

• DOL

• Wide range of regulations to select from

• Support for manual regulation setup

• FFT shown for THDI and THDV; before and after compensation

• Suggestion for ADF to reach target level

• Suggestion for ADF settings


Effects of line impedance and Short Circuit Ratio on THDI

2017-12-13

• Higher SCR always increases the THDI

• Increase of THDI on low AC/DC impedance is stronger

• 6% AC impedance has nearly flat curve


Sensorless Control: Background

2017-12-13

• Active Filters inject a counter-current to compensate for a grid/PQ issue

• Typically, active filters are current control

• Voltage control = sensorless control(in our case; elimination of CT)

• Calculates compensation current based on load current


Sensorless Control: Background (2)

2017-12-13

• Most common goal of ADF:Lower the VOLTAGE harmonics!

• So, we measure current to kill current harmonics, and “hope” that the voltage improves

• This works, but the idea is flawed


Sensorless Control: How it works

2017-12-13

• Voltage control is more efficient when the goal is to achieve a certain voltage level

• Due to mixing of background distortion and load distortion, current control never works in correct phase angle

• In current control, ADF is bound to follow load current only

• This limits ultimate results, and may be a waste of power (depending on phase angles)

Resultant vector

Load distortionBackground

distortion

Resultant vector

ADF Reduction

Follow load distortionBackground

distortion

Load distortion

Current Control


Sensorless Control: How it works

2017-12-13

• Voltage control enables filter to work in exactly correct phase angle, minimizing current used

• The compensation current “follows the resultant” in voltage control

• This results in more being done with less current, or a bigger reduction with the same amount of current

Resultant vector

ADF Reduction

Follow load distortionBackground

distortion

Load distortion

Current Control

Resultant vector

ADF Reduction

Follows resultant distortion

Background

distortion

Load distortion

Voltage Control


Sensorless Control:Harmonic Spectrum

2017-12-13

0

5

10

15

20

25

30

35

3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49

Harmonic Voltage

0

50

100

150

200

250

300

3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49

Harmonic Current


Sensorless Control:Harmonic Spectrum

2017-12-13

0

5

10

15

20

25

30

35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Harmonic Voltage

-300

-250

-200

-150

-100

-50

0

3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49

Harmonic compensation current


Sensorless vs Current Control: Pros & Cons

2017-12-13

Current Control Voltage Control

Pros + Able to isolate sub-grid+ Prevent interference by CT-placement+ Fine-tuning of compensation easy+ Pre-distortion level can be calculated when

system is on+ Clever use of summation CTs give interesting

application opportunities+ Small risk of increasing VTHD in feeding grid

+ Efficient use of ADF current (!)+ Combat background distortion+ Use in sub-grid isolation+ Stability

Cons - Inefficient in applications with high background distortion and/or special phase angles

- Requires CTs

- Cannot isolate load- May interfere with upstream equipment- Cannot easily fine-tune degree of compensation- Voltage reference (pre-distortion) is lost- Lack of track-record (new!)- VTHD may increase on feeding grid


Highlights, installations 2015/16

2017-12-13

VCCC in Australia (Hospital)Seacor Namibia (Marine, PSV)Tizir Norway (Steel)

Global Casting Sweden (Steel) Nonghyup Korea (Data Center) Zhongyeda China (Charging station)

Vacon Singapore (LHD) Bakker Netherlands (Marine) Oasys USA (Oil & Gas) Flemming Germany (Marine, LNG)

Vacon LHD in France (Water & Wastewater)


Global THD solution Lürssen Werft

2017-12-13

Application:

Global filtering

Loads

VFD controlled rudders and

engine room HVAC.

ADF is now standard

Result:

< 8% THDU


Damen - Offshore Patrol Vessel for CICPA – Dubai x 2

2017-12-13

Application:

Global compensation. RINA classification.

ADF = 26%

of total load.

Result:

< 8% THDU


Reference cases Norway 2015/2016

2017-12-13

Application:

• Delousing barge – Vard x 2

• Feeding application – Steinsvik x 4

• Live fish carrier – Danfoss x 1

• Diving vessel – Vard x 1

Result:

< 8% THDu


Comsys –Marine references – 41+ ships

Ship Type Ships Application

MPSV 7 Global THD filter

Offshore Patrol Vessel 2 Global THD filter

RoRo 2 HVAC drives

Superyacht 4 Global THD filter

Tankers 20 Cargo pumps, thrusters

LNG Tankers 2 Gas compressor station

Fishing vessel 3 Thruster, compressors

Subsea rock installation

vessel

1 Excavator drives


Benchmark – work vesselLiquid cooled ACS800 – total VFD:13 MW

Ref.customer: Bakker Sliedrecht, Netherlands


Live Fish Carrier

2017-12-13

• Seihav is a Live Fish Carrier constructed and built by Fitjar mekaniske verkstad AS in Norway.

• The process onboard relies on the use of both a seawatercirculation pump system and vaccum

Fitjar Mekaniske sought a partner with a proven solution and tested technology.


Live Fish Carrier

2017-12-13

Solution:

• Two ADF P100 units (one on portside and one on starboard

Challanges:

• Fit into the main engine room

• Avoid overheating

• Ensure redundancy

• Meet DNV GL requirement for a TVHD limit of 8% and an individual harmonic limit of5%

With powerful compensation capabilities, a compact size and proven success in the marine segment, ADF Power Tuning madethe ideal solution for Seihav.


Deep Sea Vessel

2017-12-13

• Deep Explorer II is designed and “and certified for subsea projects in the demanding North Sea/Canada market.”

• Equipped with the latest innovative features and technology

• Considerd to be among the most modern and versatile deep sea vessel in the world


Deep Sea Vessel

2017-12-13

Deep Explorer II was built with many different suppliers having delivered their individual scope of work—with none having considered their contribution to the THD (total harmonic distortion) pollution on the vessel’s grid.

• Notified by DNV GL* that it did not comply with harmonic regulations.

• DNV GL warned that they could experience tripping issues if they did not consider a strong enough harmonic mitigation solution.


Deep Sea Vessel

2017-12-13

• One ADF P100-100 on each side of the vessel

• Installed with Sensorless Control

Result

Vard experienced the installation flexibility they needed. Additionally, due to the simplicity of the Sensorless Control option, installation was significantly smoother and more streamlined, especially given the limited availability of space aboard the vessel.


Deep Sea Vessel

2017-12-13

“Thanks to the responsiveness and flexibility of Comsys, we solved this precarious situation within the time frame of three months successfully.”

Frank Raknes, Project Manager


Fish Delousing Vessels

2017-12-13

• Used at fish farms along Norwegian coastline

• Delousing capacity of 3000-4000 tons of salmon per hour

• Limit and replace the use of chemical delousing trough alternative friendly methods

100% chemical-free



2017-12-13

• Many drives onboardcontrolling multible pumps.

Risk

• The collective load wouldgenerate a high level ofharmonics.

• The load could harm valuableequipments



2017-12-13

Requirements

• Quick Installation

• Solution that could easily be retrofitted.

Solution

• 2 x ADF P100 mounted in separate locations.

• Sensorless Control


Jack-up Drilling Platform

2017-12-13

Tam Dao 03 is a LETOURNEAU™ Super 116E jack-up drilling platform operating in the South Chinese Sea.

• Regulate the rig’s heaviest activities, including the mud pumps, draw works, and top drive.



2017-12-13

• The Electrical load is heavyand demanding

• DNV requirement, must achivea TVHD of less then 8% under all operating conditions

• In need for a filter solution that will continuously track the load and adapt, in all operating conditions.



2017-12-13

• 4 x ADF P300, rated for up to 690V

Result

• ADF ensures that Tam Dao 03 never exceeds more than 8% TVHD

• 5th harmonic was less than 2% on the voltage

• Exceed the DNV requirements with a comfortable margin


1200 A ADF @ 60M Jack-up rig

2017-12-13

Application: VFD controlled drilling

Loads:

6 x Vacon NXP1300

2 x Vacon NXP1500

2 x Vacon NXP1700

Active Filter:

4 x ADF P300-300/690V

Result:

VTHD < 5 %

Single harmonic < 3 %


Offshore Oil Rig, Baltic Sea

2017-12-13

Arkticheskaya, a jackup rig with a rated drilling depth of 21,500 ft.

• Struggled with multibleharmonic disturbances and insufficient current

• Unable to run the operation at full capacity

When reactive power goes uncorrected, many

experience grid instability, increased electrical

costs, and limited transmission capacity.


Offshore Oil Rig

2017-12-13

• Arkticheskaya’s two generators couldn’t cover the load of the main consumers

• Gazprom flot was forced to run Arkticheskaya’s extra generator to compensate for the insufficient current created by reactive power

• Eight DC drives putting high demand on the grid

• While reactive power was a key issue for Arkticheskaya, the capacitors on the rig’s on-board passive filters exploded, leaving Gazprom flot in need of a new solution.


• 16 x ADF P100

• Quick installation

• Reached PF of 0,8 at max load duringstable drilling

In such a dynamic, demanding environment, passive filters are insufficient. The active compensation capabilities of the ADF P100’s compensate the rig’s reactive power and the harmonics produced by the DC drives.


Seacor Glory

2017-12-13

• Seacor Glory is a dieselelectric offshore cargo ship equipped with DC (direct current) motors and is presently operating in the Gulf of Mexico

• Seacor Marine’s main operation involvesoffshore oil and gas exploration and production


Seacor Glory

• Was refurbishedbetween 2014 and 2015

• ABS electrical and mechanical directives

• Seacor Glory’s vesseltype and grid typenecessitates an 8% voltage THD limit and 5% individual voltageharmonic limit.

• Distortion was high –in excess of 20% voltage

• Compact solution wasoptimal

2017-12-13


Seacor Glory

2017-12-13

• 6 x ADF PPM300

• 1 x SCC2 control computer

• Voltage distortion has beenreduced significantly

• Vessel’s power quality has been achived


MaxLab IV

2017-12-13

• Particle Accelerator

• “Brightest X-Ray source in the world”

• Facility operational

• One of two major recent research investments in Lund, the other being ESS (European Spallation Source)


MaxLab IV

2017-12-13

• 300m Linac, 3.7 GeV

• 528m Storage Ring (3 GeV)

• 96m Storage Ring (1.5 GeV)

Maximum Energy: 3.7 GeV

No. of accelerating structures: 39

Overall length: ~ 300 m

Bunch structures:1 x 100 pC at 100 Hz, 10 x 3 x 100 pC at 10 Hz

Bunch lengths (FWHM): 30 fs - 5 ps

Normalized emittance (RMS): < 10 mm mrad


MaxLav IVLoad

2017-12-13

• Load is a rectifier driving a grid synchronized charger circuit driving a klystron modulator

• 18 Modulators on site

• 145 A RMS/modulator

• Horrible current distortion: ~72% THD

• Most of harmonics in orders 3, 5, 7 – but very slowly falling spectrum towards higher frequency

• Conventional closed loop operation


MaxLab IVLoad

2017-12-13

• Harmonics amplitudes present in current:2,3,4,5,6,7,8,9,11,13,15,17,19,21,23,25,27,29…..

• Look at waveform below:(this is ONE out of 18 modulators!)


MaxLab IVCompensated Load Current

2017-12-13

• Harmonics amplitudes present in current:none

• Look at waveform below!


Dynamic Load

2017-12-13

Highly dynamic load:

• An electrical load simulating dynamic behaviors physically, changes extremely fast.

• The load is very dynamic; load current can change from zero to its maximum in approx. 100 ms.

• Full power could not be utilized due to high harmonic disturbances and voltage notches up to 25 %.

• 61000-2-4 violated


Dynamic Load

2017-12-13

Figures show extreme dynamic behavior of the load:

Note timescale!!!


Dynamic Load

2017-12-13

Solution

• 2x ADF P300W-200/480 (current control; open loop)

• 1x ADF P200W-100/480 (voltage control)

• Compensation of all frequencies up to the 100th harmonic order.

• ADF P300 on orders 5 – 49

• ADF P200 orders > 50 and interharmonics


Dynamic Load

2017-12-13

Results

• Voltage notches significantly reduced

• Minimized harmonics


Dynamic LoadLessons Learned

2017-12-13

• Could be seen as “typical case” of bad notching

• However, dynamics of load make compensation challenging

• Important to remember that notches are just harmonics!

• However, dynamically tracking higher order harmonics are challenging

• Note the solution: Open-loop ADF P300W Fast response ADF P200 in Voltage Control mode Fast response

• Note that open loop requires fine-tuning!!

• Results are good, but we believe there are potential for further fine tuning


Dynamic LoadLessons Learned (2)

2017-12-13

• Case could be seen as technical Tour de Force

• However, solves real problem at customer(failure to run two production parts simultaneously)

• Discussion: preferable to have soft or strong grid?• By making grid impedance higher, notches are slower…

… but voltage distortion increases.

• By making grid impedance lower, notches can becomevery fast, but damping is increased

• Opportunity for further research(To find optimization)


Reference Case F&B Mercure Frucht AG

2017-12-13

Chilled fruit and vegetables storage for Lidl. Backup power with generators critical for operation.

• Main load is chiller compressors

• Increased harmonic levels in generator operation

• Resonances in generator operation


Reference Case F&BMercure Frucht AG

2017-12-13

Solution:

• 1 x ADF P300-240/480 for 5th and 7th order harmonics compensation

• 1 x ADF P200-100/480 for resonance suppression


Reference Case F&BMercure Frucht AG

2017-12-13

Current in generator mode without ADF active filters Current in generator mode with ADF active filters


Sandvik Mining and Rock Technology

2017-12-13

• Svedala operation began in 1882.

• complex process to turn a 150+ year old industrial site into a modern operation.

• Involves gradually upgrading it with new products –which simultaneously increases demand on power quality

• Unplanned stops

• Equipment breakdowns


SandvikMining and Rock Technology

2017-12-13

• 9 x ADF P300’s connected through a step-up transformer at 11kV to compensate and enhance productivity of the electric arc furnace

• 2 x ADF P100’s dedicated to C&C machines

• 5 x ADF P300’s in different locations for compensating various VFD (variable frequency drive) loads

• Amount of energy needed to melt the steel decreased

• Overall melting time was shorted

• Payback on the solution was less than a year


Sandvik Mining and Rock Technology

2017-12-13

“Since our relationship with Comsys started, it has evolved over the years and we see them as a long term strategic partner for power

quality. To have a stable, reliable product like the ADF Power Tuning is one important factor, the other is the competence and know-how that exists within Comsys and its extensive partner

network.”


Reference Case W / WWAffinity Water

2017-12-13

Upgrade of water treatment works.

• Installation of drives with low harmonic solution

• Challenge that existing panels needed to be used and cooling in room limited


Reference Case W / WWAffinity Water

2017-12-13

Solution

• ADF PPM modules installed in existing panels

• Heat losses diverted out of the room.


UK Water treatment plant

2017-12-13

• The plant had existing panels (cabinets) withempty space available, but not sufficient space to implement an entirely new solution

• Needed a solution that could take advantage ofthe space available and be integrated into the existing infratsructure

• Drives created harmonic disturbances

Water treatment is one of the largest energy consumers in society. To save energy, there are ongoing upgrade projects. These upgrades involve installing and/or updating to modern, efficient drives to reduce energy consumption of the pumps.


Uk Water Treatment Plant

2017-12-13

• Four 80amp PPM power modules at 690V

• Smoothly up and running withoutissue

“A key part of our decision was the superior efficiency of the active

harmonic filters compared to the alternative active front end drives.”


GRYAAB

2017-12-13

• One of the largest treatment plant in Scandinavia

• When 17 new VFD-controlled pumps were installed at Ryaverket to increase plant capacity, harmonic distortion on the electrical system rose significantly.


GRYAAB

2017-12-13

2 x 600 kVA Comsys ADF Active Filter

• 30% increased plant output

• Secured UPS performanceprovides for reliable production

• Harmonic distortion belowthreshold values

• Reduced energy consumption

Thanks to ADF we can now process 30% more fluids

during periods of peak demand. We also save energy.

– Roger Rosenqvist, Project Manager


LKAB

2017-12-13

• Energy savings 4%

• Output capacity increase 8,5%

• Improved productivity

• Water cooling makes ADF operatein the harsh air condition

• Lower maintence costs

• Prolonged equipment lifetime

• More robust transmission network

© LKAB


Kville wind power compensation (Fortum)

2017-12-13

Total installed power:

2,5 MVAr @ 20 kV Dedicated 3,15 MVA step-up trafo

20 kV connection

PCC @ 130 kV

Application: Dynamic Reactive Compensation

Loads:

Windmills

Active Filter:

5 x ADF P300W-300/690V


DanTysk offshore wind farm

2017-12-13

4x STATCOMs @1.5 Mvarfor reactive power support of the windfarm at 33 kV

80 wind turbines with 4 MVA transformer, each 7.2 Mvar total reactive power of 33 kV sea-cables


DanTysk offshore windfarm

2017-12-13

One of the four STATCOMS – 1,5 Mvar based on ADF P300W 690 V water cooled


ReweMeat Processing

2017-12-13

Processes with high automatization often containVFDs which causes harmonics in the power supply. This can affect machinery’s and couldcause downtime in production lines

• VFDs creates harmonics in typical six-pulse-converter behavior

• Harmonics causes commutation notches in the voltage

• Notches causes disturbances in the light an blackouts

• Problems in other equipment stops the process flow


ReweMeat Processing

2017-12-13

• One ADF P300-300

• Capacity of 300 A compensation current

Load current without ADF Load current with running ADF

• Reducing 5th, 7th, 11th and 13th

harmonic

• No commutation notches due to reduced harmonics


Henrad NV

2017-12-13

• The local utility company demanded that the Pst95% value must not exceed 0,7.

• The task was challenging since it’s a rapidlyfluctuating load and also the many different loadpatterns that could occur since its very highnumber of welding machines.

Henrad is a Belgian radiator manufacturer in the Caradon Heating Europe Group that consists five production lines. The production process arepresses, seam welding and spot welding, the nature of the process is very energy demandingand therefore puts great demands on the powergrid.

Comsys provided the most advanced and cost efficient solution at the same time!” – William de Winter, General Operations Manager, Henrad


Henrad NV

2017-12-13

• 6 x ADF P300

• Reduced Pst from 1,6 to 0,63

• Stabilized production

• A medium voltage solution

Pst value with compensationPst value without compensation


Hospital Overijssel, Netherlands

2017-12-13

• Challange: Manufacturers of sensitive equipment state maximum 5% (EN61000-2-4 class 1). Also the hospital is experiencing various PQ problems and overheating transformers and has their own demand of 3%.

• Solution: 3x 2x P300-240A (Multimaster setup for redundancy). THDu dropped significant.



2017-12-13

Voltage without ADF Voltage with ADF

Current without ADF

Current with ADF



2017-12-13

Harmonic limit according toEN 61000 -2-4 class 1

Hospitals limit

Voltage harmonics without ADF

Voltage harmonics with ADF



2017-12-13

• In the calculations, and agreements that have been previously informed that the THDu with the installation of the filters always remain below the 3% maximum peak to 5%. The measurements show that the maximum THDu, in all three supplies, is 2.5% and the peaks remain below 3%. This means that the installation more than meets the requirements.

• There are two ADF filters placed on each supply so that the system is redundant. Both of these filters can take over without interruption. This has also been tested and shows that there is virtually no visible increase in harmonic levels. Also in this case, the harmonic level remains under 3%.

• In the voltage quality standard for non public networks below 35 kV (EN61000-2-4 Class 1) the maximum allowed harmonics level is 5%. Also this is fulfilled.


Mercedes Benz Factory

2017-12-13

• Without an active power quality solution such as ADF Power Tuning, production processes such as the electrolysis at the paint shop, welding, and presses at the body shop would be at risk.

• Mercedes would be at risk for disturbances that could interfere with the power supply (due to unstable voltage and reactive power), overheating equipment, and communications interference.

• Important to ensure that operations function as smoothly as possible

• Wanted to avoid problems before theystarted


Mercedes Benz Factory

2017-12-13

Mercedes was convinced that ADF Power Tuning would provide an operational advantage because of the following reasons:

• Excellent filtering efficiency

• High order harmonic filtering capacity

• Sensorless Control capability (no need for current transformers)

• Modular design

• Easy expansion in the future

• Easy maintenance and service

Solution

• In the paint shop: Three ADF P300 units

• In the body shop: 16 ADF P300 units


Reference case HVAC- VCCC, Australia

2017-12-13

• Hospital and cancer research center

• Extreme target level (2,5% THDi)

• Decentralized solution with 45 active filters in subpanels


Reference case Cranes &Lift- Dongbu steel, South Korea

2017-12-13

• Steel mill with EAF

• Overhead cranes (18 pcs) for loading buckets with scrap metal

• VFD’s installed for controlling the cranes (movement) and electro magnets (hoist)

• One ADF P300-120/480 per crane


Tizir Titanium and Iron Facility

2017-12-13

• Did a facility upgrade

• Added more drives in order to power Tizir’s machinery

• Needed to reduceharmonics at the plant

• Did not use any harmoniccompensation solution



• Main issue Tizir faced wascompliance

2017-12-13

Comsys received the load list and installation information from TiZir, then made a calculation to determine how much A power/harmonic mitigation power was needed on the 690V low voltage grid. Comsys supplied TiZir with a proposal to meet their compensation needs, which TiZir accepted.



2017-12-13

The ADF P300 active filters were supplied in late 2015 and commissioned early 2016. The new and improved TiZirTyssedal plant is successfully up and running, and is fully compliant with the demands of the electrical grid company.

• 2 x ADF P300-270/690


WDI Baustahl

2017-12-13

• The margest steel wire producer in Europe

• Production line comprises various welding equipment, including spot welders from Schlatter AG.

• The abrupt current consumption causes voltage variations, which in turn creates flicker.


WDI Baustahl

2017-12-13

• Showed flicker levels up to Pst 2 and plt 1.4.

• A lot of switching activity in the surrounding electrical grid(made it complicated)

• Flicker will vary with the production type running.


WDI Baustahl

2017-12-13

7 x ADF P300W-300/690• Pst reduced from 2.0 to 0.6.

• Current consumption was lowered 25-40% due to reduced reactive power.

• Voltage dips on the 20 kV rail was lowered from around 500V to around 100V.

A solution was delivered to the customer in cooperation with Schlatter AG, who also delivered the welding lines.

Flicker level before compensation

Flicker level after compensation


Design Guideline

2017-12-13

• Never change the position of the headline

• Keep position of similar content on the same location over slides

• Use existing layouts if possible

• If existing layouts don’t work, use the empty layout slide

• Try to keep content within a certain limit• Use “View” ”Guides” to see the limits

• Share slides with others!!

• Write in notes who created the slide

• If you create a drawing, keep the original available

• Use the “Sections” within PowerPoint


Content guides

2017-12-13


Layouts

2017-12-13

• 11 Layouts exist

• If some other are needed, we can create them

• Copy and Past slides from other presentations will add new Layout AVOID

Documents

ADF Power Tuning Power Tuning 2017-12-14... · 2020-01-26 · — ADF Power Tuning ADF Power Tuning — ADF Power Tuning ADF Power Tunin g The ADF P200 is a compact, wall-mounted