Reactive+Power+Compensation

ABB Group April 17, 2009 | Slide 1

ABBACUS MECB Metal Enclosed Capacitor Bank for Power Factor Correction


Australia 70% Desert 6th Largest Country

Melbourne to Sydney - 873km (542 miles)

Hobart to Darwin 4399km (2733 miles)

Sydney to Broome 5112km (3176 miles)

Perth to Townsville 5911km (3673 miles) Ayers Rock

Uluru

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*MelbourneCapacitor factory

Perth

Brisbane

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BroomeTownsville

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Adelaide

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Darwin

SydneyIndoor/Outdoor Apparatus

Hobart


Contents

Introduction What is Power Factor?

Applications

Design Criteria1. Product Modularity2. Safety3. Environment


Introduction What is Power Factor?


What is Power Factor?

Power factor is the measurement of how effectively electrical power is being used:

The higher the power factor, the more efficient the plantall the way back to the generator

PresenterPresentation NotesTo appreciate the use and advantage of capacitor banks or reactive power compensators in general, there are a few concepts that needs to be addressed.One of the most important is Power Factor.To put it simply, Power factor is a measurement of how efficiently electrical power is being used.The higher the power factor of a plant, the more efficient the plant is working at. And the utilization of the cables, transformers and generators.



An electrical systems power is composed of different parts:

Active (working) power which performs the useful work

Reactive (non-working) power which creates the magnetic fields for inductive devices

Apparent Power (kVA) = Active power (kW) + Reactive power (kVAr)

Reactive powerActive power

PresenterPresentation NotesLoads in electrical plants draws 2 types of power; active power, which is measured in the unit of kW. And reactive power, which is measured in kVAR.Active power is the component which is used to perform useful work, which is converted into other forms of energy such as mechanical energy when the electrical motor turns.Reactive power, sometimes referred to as non-working power, is the component that creates and maintain electrical and magnetic fields of inductive devices. Therefore, even though reactive power is not directly contributing as a measurement of work performed (by a motor as an example), reactive power is still important for the motor to work.Apparent power, is a quadratic summation of active and reactive power, and is measured in kVA.Therefore, when a motor runs, it is drawing both active and reactive power from the source to perform its function.


What is Power Factor? Low Power Factor is like

kVA - Apparent PowerorBeer - Full glass

kVAr - Reactive PowerorBeer - Foam

kW - Active PowerorBeer - Liquid

PresenterPresentation NotesA simple analogy which can illustrate the concept of active power, reactive power and apparent power is a glass of beer.Imagine that you bought a full glass of beer and the full glass of beer is seen as apparent power. Now in the glass, there is the portion that is liquid, the beer itself. This is the part which fills you up. That could be described as the active power.On the top of the liquid, is the region of foam. This part does not fill you up, but takes up a portion of the glass no less. This could be describe as reactive power.So when you have low power factor in your factory or plant, it will be like you are paying for a glass of beer which has lots of foam and little beer itself. Not a good preposition.



kVA: Total Power

kW: Working Power

kVAr: Reactive Power needed to generate magnetic fields for inductive loads such as motors

Power Factor: The relationship of real power (kW) and total power (kVA) consumed

kVAkWPF =

kW

kva1

kva2

Ckvar

kvar2

kvar1

21

KVA1 = without capacitorsKVA2 = with capacitorsKVA2

< KVA1

PresenterPresentation NotesPower factor can also be represented in a graphical sense.The active power is on the horizontal axis and the vertical axis is the reactive power. The diagonal line therefore represents the quadratic summation of the active power and the reactive power.Power factor is then the cos angle between the active power and the apparent power.As you can observe, as the cos angle becomes smaller, the apparent power approaches the value of active power. This means improvement in the power factor.Another way of viewing power factor is that PF is that it is a ratio of active power (kW) versus apparent power (kVA).



)()(

kVAPowerApparentkWPowerActive

beerofglassFullbeerDrinkable

kVAkWPF =

OR

PresenterPresentation NotesSo back to the beer analogy of power factor, this is what a system with good power factor looks like in comparison to one which has poor power factor.So which glass would you choose? What power factor would you want your plant to be running on?



Why improve

The lower the power factor, the more reactive power the Utilities need to provide. This can result in:

Larger equipment (i.e. poles and wires) required to supply power

System capacity problems leading to brown-outs

Higher operating costs due to maximum demand charges kVAr (kVA) tariff and energy loss

PresenterPresentation NotesBut here are the real world reasons why having a high power factor is important.The impacts can be viewed from the point of view of an utility as well as an end-user.As a utility or a generation of power, if your end-user is not improving their power factor, your investments will have to cater for the generation, transmission and distribution of both active and reactive power. This means larger equipment like transformers and cables.This higher demand of power has the potential of pushing the limit if the system to its limits thereby, causing brown-outs.As an end-user, the power providers will transfer the cost of their investment in having to install larger equipment in the form of higher tariffs and penalties.



Reactive power

Active power

Available activepower

Transformer Motors

Transformer Motors Capacitor

Without capacitor

Withcapacitor

PresenterPresentation NotesCapacitors produce reactive power through its charge and discharge cycles when connected to alternating voltage. By installing capacitors, network capacities can be freed.This means that power transformers can operate at a reduced capacity, allowing the option either more loads to be connected to it. Or by operating under less stress, the service life of the transformer can be prolonged.New transformers can be sized for a lower apparent, reducing capital investmentsBy increasing the power factor, cables with a small sectional area can be used.


Applications


Applications

Metal Enclosed SolutionsValue Proposition

Power factor correctionReducing operating costs increasing energy efficiencyBetter use of existing plant

Key ApplicationsMiningHeavy industryChemicalPulp & PaperShippingCementPlasticsPetro-Chemical

PresenterPresentation NotesSo what is the value of installing capacitors?For energy to be used efficiently in a plant, good power factor has to be maintained.Capacitors are the simplest and most economical method of improving power factor.By freeing capacities in the network, capital investment can deferred and thereby reducing operating cost,Existing equipment can be better utilized.Key industrial applications where it is beneficial to keep good power factors are mining, heavy industries, chemical, pulp & paper, shipping, cement, plastics, petro-chemical and other.In addition, metal enclosure of these banks meant that the components are protected and can cope with the harsh environment of these industries.


Design Criteria


Design Criteria

Designed for voltages up to 24kV

Output power < 13MVAr

Insulation up to 125kV BIL

Busbar system type tested

Integrated primary and secondary systems

Switching, capacitors, reactors, protection and control

Flexibility in design

Range of voltages, step sizes, networks configurations etc.

Current limiting inrush or detuned harmonic reactors

Indoor or outdoor

PresenterPresentation NotesThe ABB metal enclosed capacitor, the ABBACUS, is designed for voltages up 24kV and for a rating up to 13MVAR.The insulation level is 125kV BIL.The busbar is tinned copper and is mechanically rated to withstand a fault level of 25kA and thermally rated to withstand 20kA for 3secs.All the primary and secondary components are integrated in the capacitor bank.The ABBACUS is flexible in terms of voltage ranges (1-24kV), step sizes, and network and protection configurations.Depending on the level of harmonics present on the network, the ABBACUS can be equipped with inrush reactors or detuned reactors.The IP for an inrush bank is IP44 while the detuned bank has an IP rating of IP54. Both is suitable for either an indoor or outdoor installation.


Design Criteria

Incomer module

Control and protection

Power module(s):

Inrush design

Detuned design

OR

PresenterPresentation NotesThis slide shows the how the compartments of the ABBACUS is designated.The left most module is the incoming module which houses the isolator and the earth switch, which provides visual isolation from the incoming cables and general earthing for the capacitor bank. The isolator and earth switch are mechanically interlocked for safety.Other components which can be installed in the incoming nodule are the circuit breaker to protect the MV capacitor banks and surge arresters, against multiple over-voltage strikes.The ABBACUS also incorporates the control cubicle which is accessible by opening the front door. A full range of ABB control and protection relays are available.

The power module houses the capacitor units, fuses, inrush or detuned reactors and unbalance CT.The fuses can be eqquipped with fuse failure indication, if required.


Design Criteria

Mild steel enclosure

Indoor only

Inrush reactors

Voltage 1-12kV

IP31

Fixed and switched

Aluminium enclosure

Type tested busbar system

Indoor or outdoor

Inrush or detuned reactors

Voltage 1-24kV

Up to IP54

Fixed and switched


1. Product Modularity


Product Modularity

Repeatable modular design with defined:

Incomer module

Power modules

Integrated control & protection module

Customer benefits

Compact foot print

Re-locatable

Expandable

Proven performance over 15 years reliability

Reduced site installation and commissioning time


Product Modularity

Contactors

Power Modules

Step 1 Step 2

Incomer Module

Fuses

Reactors

Capacitors

Circuit Breaker

Earth-switch

Isolator


Product Modularity

Real estate saving

A typical 24kV, 10MVAr Metal Enclosed Capacitor Bank will occupy less than 65% of the floor space required of an equivalent outdoor capacitor bank


2. Safety


Safety

Type tested busbar design

Proven IP rating

Reduced risk of site liabilities

Less time onsite

Live parts enclosed

Key interlocking

Solenoid / mechanical

Timed option

Key exchange system

Padlockable

Roof vents for arc fault gasses


3. Environment


Environment Carbon Emissions

This will reduce the CO2 emission by 2,214 tonnes per year.

This does not include further CO2 emission savings due to decreases in cable losses from the generator to the substation, or transformer losses.

Industrial plant operating 24hrs/day

Maximum demand of 20MVA

Existing power factor of 0.80

Apply an 11kV, 9MVAr MECB

Target power factor 0.98


ABBACUS MECB The future of reactive compensation for industrial applications & distribution utility systems


Pole Mount Capacitor Systems


Pole Mount Capacitor System Features

Voltage stability

Power factor correction

Increase in system capacity

Reduction in line losses or kW/hrs


Pole Mount Capacitor System Types

Fixed bank

Used when the reactive load requirement is constant

Manual disconnect or load break fused cutout

Switched bank

Used when the reactive load is variable

Vacuum switch and controller


Distributed Load


Voltage Drop Due to Transformer & Secondary


Voltage Drop with Capacitor


Pole Mount System Configuration

Ungrounded Y

Grounded Y

Delta


Pole Mount Capacitor System Usual Practice

Delta and ungrounded systems

Ungrounded Y banks are the most common

For grounded systems

Grounded Y banks are generally used

Where system fault currents are excessive, ungrounded Y banks are used


Considerations

Normal service

The equipment is rated for a maximum of 55C ambient

Maximum permissible overvoltage is 110% of rating

Maximum permissible power loading is 135% or rating

Excessive voltage

Operation under overvoltage conditions shortens the life of capacitors

Resonance

Harmonic absorption can stress capacitors


Considerations

Inrush and fault currents

The inrush current capability of the switch is important, especially in back-to-back switching conditions

Location of high fault level capabilities are to be avoided (i.e. 6kA maximum)

Fuse selection

Inrush reactors or suitable pole spacing


Key Components

Capacitors

In-line rack

Vacuum switch

Junction box

Control voltage transformer

Surge arrester

C200A controller

Current limiting reactor

Fuse cutout


ABB Power Capacitors

Unfused design

50 to 750kVAr

Up to 21kV

50/60Hz

Built-in discharge resistors

Max. 50/150kV BIL

Single or Three phase

Stainless steel 304 tank

Non-PCB fluid


C200A Capacitor Controller - Features

User friendly interface

Control

Automatic, manual

Schedule, temp, volt, var

Primary, override

Combinations of the above

Measurement & monitoring

Data logging 9000 events

Protection

Local communication

Easy programming & commissioning


C200A Utility Software: Monitor Tab


C200A Utility Software: Operation Tab


Control Setup


User-friendly Interface

Navigation is easy and intuitive

Communication PortPower and Capacitor Status IndicatorsLCD Display

AUTO/MANUAL Mode

Navigation Keypad

Manual OPEN & CLOSE switches

Switch status Indicators


PS15 & PS25 Capacitor Vacuum Switch


PS15 & PS25 Capacitor Switch Key Features

PS15 15.5kV ungroundedPS25 25kV ungroundedABB vacuum interrupter technologyMagnetic actuatorMechanical or electrical latchingHydrophobic cycloaliphaticepoxy (HCEP) resin insulatorValue-adding features at no extra costNo oil, gas or foamMaintenance free


ABB Vacuum Technology

ABB Calor Emag

20 Years experience

Used in other ABB products

Vacuum interrupter designed to minimise the risk of re-strike during capacitor switching

Life expectancy

25,000+ close-open operations


Position Indicator / Manual Trip Lever

The switch can be manually isolated by pulling down on the trip lever

An electrical signal is required to re-close the switch after manual operation

Sturdy stainless steel lever & accessories

Trip lever doubles as a visual indicator

Located at the bottom of the switch housing

Easily accessible to site personnel

Easily viewed by site personnel


No Oil, Gas or Foam

No risk of environmental contamination

Vacuum medium for switching

Magnetic actuator in air

Lightweight

Storage and transportation made easier


Maintenance Free

Vacuum technology

25,000+ close-open maintenance free operations

Magnetic actuator

Permanent magnets

One main moving component driven by permanent magnets

Durable components

Stainless steel housing

Stainless steel external components


PS15 Specifications

Voltage rating

15.5kV ungrounded

27kV grounded

Insulation

Open contact: 95kV B.I.L

Line to ground: 125kV B.I.L

Continuous current rating

200 Amps


PS25 Specifications

Voltage rating

25kV ungrounded

43kV grounded

Insulation

Open contact: 125kV B.I.L

Line to ground: 150kV B.I.L

Continuous current rating

200 Amps


Specifications

Mechanically / electrically latched operation

Control circuit

Nominal voltage: 120V and 240V AC

Nominal open/close times: < 100ms

Nominal current: 10 Amps

Switch status option

Voltage free contact

Type tested to ANSI C37.66

Powertech Labs


Accessories

Wildlife protective covers

Auxiliary limit switches for switch status

Junction box

Connection cables (including connectors)


Added Product Range Coming Soon

The latest offering from ABB will include capacitor vacuum switches with the following addedfunctionality:

400 Amps continuous current rating version

100 - 125V DC Nominal operating voltage at 50/60Hz


Key Benefits to Customers

Peace of mind

ABB brand name

Proven technology

ANSI C37.66 certified

Value for money

Combines the best of what competitors have to offer

Total ABB package

Capacitors

VT

C200A controller

ABBACUS MECBMetal Enclosed Capacitor Bankfor Power Factor CorrectionAustralia 70% Desert6th Largest CountryContentsIntroduction What is Power Factor?What is Power Factor?What is Power Factor?What is Power Factor?Low Power Factor is likeWhat is Power Factor?What is Power Factor?What is Power Factor?What is Power Factor?ApplicationsApplicationsDesign CriteriaDesign CriteriaDesign CriteriaDesign CriteriaSlide Number 18Product ModularityProduct ModularityProduct ModularitySlide Number 22Safety3. EnvironmentEnvironmentCarbon EmissionsABBACUS MECBThe future of reactive compensation for industrial applications & distribution utility systemsPole Mount Capacitor SystemsPole Mount Capacitor SystemFeaturesPole Mount Capacitor SystemTypesDistributed LoadVoltage Drop Due to Transformer & SecondaryVoltage Drop with CapacitorPole Mount System ConfigurationPole Mount Capacitor SystemUsual PracticeConsiderationsConsiderationsKey ComponentsABB Power CapacitorsC200A Capacitor Controller - FeaturesC200A Utility Software: Monitor TabC200A Utility Software: Operation TabControl SetupUser-friendly InterfacePS15 & PS25Capacitor Vacuum SwitchPS15 & PS25 Capacitor Switch Key FeaturesABB Vacuum TechnologyPosition Indicator / Manual Trip LeverNo Oil, Gas or FoamMaintenance FreePS15 SpecificationsPS25 SpecificationsSpecificationsAccessoriesAdded Product RangeComing SoonKey Benefits to CustomersSlide Number 56

Documents

Reactive+Power+Compensation