Page 1 of 23 01.12.2014 Introduction MR PQ in Israel I I I

Israel/ Dec. 4st 2014

Maschinenfabrik Reinhausen Germany

Power Quality

Power Quality and Reliability

Dr.-Ing. Mike Ifland / MR PQ Germany

Page 2 of 23 01.12.2014 Introduction MR PQ in Israel I I I

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 3 of 23 01.12.2014 Introduction MR PQ in Israel I I I

1. MR – Introduction 1.1 Our worldwide clients / Your market opportunities

> 80 % of all our products ever delivered are

still in operation today

> 50 % of worldwide electricity consumption

passes through a MR product

Maschinenfabrik Reinhausen GmbH (parent company)

I Founded in 1868,

MR trademark since 1901

I Majority family ownership

in fifth generation

I World market leader

in transformer switching

I 3.160 employees in MR and

26 affiliated companies (35 sites)

I 82 % of employees in Germany,

90 % export business

I Group turnover of 650 million EUR,

highest available rating (banks)

Page 4 of 23 01.12.2014 Introduction MR PQ in Israel I I I

1. MR – Introduction 1.2 Fields of activity

No transformers without a MR product Marketing of proprietary technologies

Increasing corporate value in global niches of electrical power engineering while preserving our independence

VALUE FACTURING

Decision Support for Manufacturing Excellence

TRANSFORMER CONTROL

Control of Power Transformers

POWER COMPOSITES

Composite Materials and Insulators

MESSKO INSTRUMENTS

Equipment Control and Assessment

POWER QUALITY

Solutions at Grid Nodes

HIGHVOLT TESTING

Testing and Measurement Technologies

Preferred system integrator

Tas

k

l Integration of Shop Floor Data Models into ERP

l Optimization of Automated Manufacturing Processes

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

l Mechanical & Electrical Endurance by GFRP

l Composite Insulators for HV / MV Equipment

l Sensors, Accessories, Oil Analytic Laboratory and Secondary Brands

l Process Measuring and Control Technologies for Industry Applications

Ran

ge

Vis

ion

Goa

l B

rand

l Actuators, Electronics and Data Management

l Transformer Services

Pro

duct

s

Page 5 of 23 01.12.2014 Introduction MR PQ in Israel I I I

I Chemical industry

I Cement industry

I Pulp & Paper

I Windfarms

I Power plants

I Steel industry

I Utilities

I Mining

I Oil & Gas

I Railway

1. PQ – Fields of activity 1.1 Target industries / customers

Page 6 of 23 01.12.2014 Introduction MR PQ in Israel I I I

1. PQ – Fields of activity 1.2 Different clients facing different power quality problems

I Chemical industry

I Cement industry

I Pulp & Paper

I Windfarms

I Power plants

I Steel industry

I Utilities

I Mining

I Oil & Gas

I Railway

Unbalance

Voltage/Current Voltage variation

Harmonics

Transients

Reactive power

Voltage drops

Flicker

I Switching events

I Athmospheric overvoltage

I Transient currents/voltages

I Phase shifting voltage/current

I Leading (capacitive)

I Lagging (inductive)

I Caused by powerful single

phase loads

I Caused by harmonic sources

like converter drives, furnaces,

millions of switched mode power supply units.…

I Evaluation will distinguish harmonic

voltage/current

I Commutating effects

I Start of huge motor drives

I Caused by powerful

welding machines, presses

I Other fluctuating and

repeating loads

I Caused by long-term

load fluctuations

Turn key solutions

provided by

Page 7 of 23 01.12.2014 Introduction MR PQ in Israel I I I

1. PQ – Fields of activity 1.3 Power Quality problems electrical equipment

I Chemical industry

I Cement industry

I Pulp & Paper

I Windfarms

I Power plants

I Steel industry

I Utilities

I Mining

I Oil & Gas

I Railway

Turn key solutions

provided by

Harmonic distortions – Effects on

the network

Malfunction of protection and control devices

Additional losses:

- life span reduction

- destruction of equipment

Malfunction of ripple control

devices

Page 8 of 23 01.12.2014 Introduction MR PQ in Israel I I I

1. PQ – Fields of activity 1.4 The solution circle

I Customized solutions Taking care of specific problems

Page 9 of 23 01.12.2014 Introduction MR PQ in Israel I I I

2. MR Power quality solutions 2.2 Metal encapsulated Indoor Equipment (Harmonic filters)

Harmonics

I Harmonic filter system for indoor application / POCOS

Harm. Filter

238 Hz

1600 kvar

SM

VSD 22 MW

4800 rpm

110/10 kV

31.5 MVA

10.5 %

10 kV 50 Hz 3 ~

Harm. Filter

345 Hz

1000 kvar

Harm. Filter

575 Hz

2400 kvar

Harm. Filter

575 Hz

2400 kvar

Harm. Filter

575 Hz

2400 kvar

Harm. Filter

238 Hz

1600 kvar

SM

VSD 22 MW

4800 rpm

110/10 kV

31.5 MVA

10.5 %

10 kV 50 Hz 3 ~

Harm. Filter

345 Hz

1000 kvar

Harm. Filter

575 Hz

2400 kvar

Harm. Filter

575 Hz

2400 kvar

Harm. Filter

575 Hz

2400 kvar

110 kV 50 Hz 3 ~

Overhead line

3 km

Overhead line

20 km

SCC 498 MVASCC 1082 MVA

MAIN POWER STANDBY POWER

SCC 186 MVASCC 235 MVA

•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 10 of 23 01.12.2014 Introduction MR PQ in Israel I I I

2. Power Quality Solutions 2.3 GRIDCON ® Modules and Stations (general overview)

Page 11 of 23 01.12.2014 Introduction MR PQ in Israel I I I

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

2. Power Quality Solutions 2.4 Low Voltage Developments

Page 12 of 23 01.12.2014 Introduction MR PQ in Israel I I I

2. Power Quality Solutions 2.5 AcF – Working principle

GRIDCON AcF:

service optimized,

modular concept with

4 modules per cabinet

Working principle of Active Filters:

Page 13 of 23 01.12.2014 Introduction MR PQ in Israel I I I

+10 %

+5 %

0 %

-5 %

-10 %

Dev

iati

on

fro

m r

ated

vo

ltag

e (i

n %

)

Medium voltage grid

Secondary

substation Low voltage grid

Maximum

feed-in case

Maximum

load case

Regulation

„downwards“

Regulation

„upwards“

20 kV 0.4 kV 0.4 kV 20 kV

Outside of allowed voltage band

Outside of allowed voltage band

2. Power Quality Solutions 2.6 GRIDCON ® Transformer

Page 14 of 23 01.12.2014 Introduction MR PQ in Israel I I I

LV grid Substation

Controller

PV

= 3~

PV

= 3~

PV

= 3~

G

V

Sensor

abgesetzte

Spannungsmessung

Actuator

MV grid

Transformer 1

Voltage regulator 3

On-load tap-changer 2

2. Power Quality Solutions 2.7 GRIDCON ® Transformer - Setup

Page 15 of 23 01.12.2014 Introduction MR PQ in Israel I I I

3. Project example – harmonic filter system 3.1 Requested compensation system

22.9 kV 13 Mvar

360 Hz

22.9 kV / 60 Hz / Busbar A

Scope of supply

22.9 kV 10 Mvar

60 Hz

Filter 5th Non-tuned

capacitor bank

22.9 kV 13 Mvar

360 Hz

22.9 kV / 60 Hz / Busbar B

Scope of supply

22.9 kV 10 Mvar

60 Hz

Filter 5th Non-tuned

capacitor bank

Page 16 of 23 01.12.2014 Introduction MR PQ in Israel I I I

3. Project example – harmonic filter system 3.2 First calculation – with specified compensation systems

• 220 kV frequency sweep of substation „Mina Constancia“

• 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

I 11th harmonic

Page 17 of 23 01.12.2014 Introduction MR PQ in Israel I I I

3. Project example – harmonic filter system 3.3 Harmonic predistortion 220 kV / specified compensation system

I Histogramm 220 kV

I 5th 1.2%

I 7th 0.6%

I 11th 3.0%

I 13th 1.5%

I 11th 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 18 of 23 01.12.2014 Introduction MR PQ in Israel I I I

22.9 kV 13 Mvar

300 Hz

22.9 kV / 60 Hz / Busbar A

Scope of supply

Filter 5th High-Passfilter

tuned to 11th/13th

22.9 kV 13 Mvar

300 Hz

22.9 kV / 60 Hz / Busbar B

Scope of supply

Filter 5th

22.9 kV 10 Mvar

HP 10 Ohm / 750 Hz

22.9 kV 10 Mvar

HP 10 Ohm / 750 Hz

High-Passfilter

tuned to 11th/13th

3. Project example – harmonic filter system 3.4 Design review of requested compensation system

Page 19 of 23 01.12.2014 Introduction MR PQ in Israel I I I

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“

• 22.9 kV frequency sweep of substation „Mina Constancia“

• decrease of impedance in the range of 11th harmonic by factor 4

I 11th harmonic

Page 20 of 23 01.12.2014 Introduction MR PQ in Israel I I I

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 21 of 23 01.12.2014 Introduction MR PQ in Israel I I I

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 22 of 23 01.12.2014 Introduction MR PQ in Israel I I I

Page 23 of 23 01.12.2014 Introduction MR PQ in Israel I I I

Backup

Page 24 of 23 01.12.2014 Introduction MR PQ in Israel I I I

4. Project example – harmonic filter system 4.1 Electrical data

I 220 kV Main feeder

I 22.9 kV 60 Hz Busbar B

I Capacitorbanks

(2 x 23 Mvar)

I Sk“min 1248 MVA

I Liquid cooled resistor starters (Ball Mill /SAG Mill)

(2 x 32MVA)

I 24-pulse perfect harmonic

converter drives

(11 MVA)

I 18-pulse perfect harmonic

converter drives

(1.5 MVA)

I 22.9 kV 60 Hz Busbar A

I Sk“min 648 MVA

I Transformer 75/125 MVA I Transformer 75/125 MVA

Page 25 of 23 01.12.2014 Introduction MR PQ in Israel I I I

2. MR Power quality solutions 2.3 Metal encapsulated Indoor Equipment (Inrush limiting resistors)

MV network behavior during energization of

large harmonic filters or converter- /

distribution/transmission transformers

Transients

Page 26 of 23 01.12.2014 Introduction MR PQ in Israel I I I

2. MR Power quality solutions 2.4 Metal encapsulated Indoor Equipment (Load symmetration units)

Unbalance

Voltage/Current

R

X

Load

Load

12U

U23 U31

RA

BR

CR

1I

2I

3I

C1

C2

L1

Customer equipment: Powerful

single phase loads

Solution: „Steinmetz-Scheme“

Capacitors/ Reactors with tappings

I C1 & L1 for load

symmetration

I C2 for reactive power

compensation

Page 27 of 23 01.12.2014 Introduction MR PQ in Israel I I I

R

X

Load

Load

12U

U23 U31

RA

BR

CR

1I

2I

3I

C1

C2

L1

2. MR Power quality solutions 2.4 Metal encapsulated Indoor Equipment (Load symmetration units)

Unbalance

Voltage/Current

I C1 with tappings

I L1 with tappings