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8AVC2 Product Presentation
1. AVC2 Overview
2. PQ Event Theory
3. Performance
4. Case Studies
6. Return on Investment
7. AVC2 Deep Sag
8. End
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8AVC2 Specifications
� Full correction, three-phase sags down to 70% retained voltage
� Full correction, single-phase sags down to 55% retained voltage
� Partial correction, three-phase sags down to 30% retained voltage
� Partial correction single-phase sags down to 0% retained voltage
� Continuous “ONLINE” regulation
� Over and under voltage regulation
� Correction for voltage vector phase angle errors created by faults in the supply
� Voltage unbalance correction
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8AVC2 Features
� Fast (sub-cyclic) response
� Simple user controls
� Rugged overload capability
� Short circuit protected
� Extensive diagnostics
� Fault log
� Voltage event data logging
� Ethernet connectivity
� Modular construction
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8Modular Construction
� Minimum spares required� High commonality of parts� Fast replacement
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8
secondary
primaryDistribution Transformer
Input
Auto Transformer
(Non 400/480V Supply)
Rectifier Fuse
Input Circuit Breaker
Click on grey boxes for more information
Environmental
3ph UtilitySupply 3ph Output Load
Bypass
Single Line Diagram
Rectifier and Inverter
Sag/Swell Animation
Boost Transformer
System Wiring Diagram
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8Graphic Display Module
� The optional Graphic display offers:
� Easy access to information
� Visual representation of the system
� Event log, date and time stamped
� Fault log, date and time stamped
� Factory tags and location data
� Web Browsing
� Serial Communications
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� Ability to call up individual AVC’s
� Monitor in real time
� View event logs with date and time stamp
� Download event logs
� View data summary of multiple systems at once
Plant Wide AVC2 System Browsing
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Technician Commissioning Support Tool
USB interface
USB port
Firewall
Plant SCADA Accessing Data Registers
Plant wide access fromWeb browser
Modbus/TCPIP over Ethernet
Worldwide web
Resident Webpage in Graphic Display Module
Full Web and Plant System
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Click on grey boxes for more information
Layout
Layout
Rating Table� Options Available
� 600V
� Medium Voltage
� 40% correction
Product Overview
Product Overview
Product Overview
Product Overview
Product Overview
Product Overview
Product Overview
Product Overview
Product Overview
Product Overview
Home
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8
� The power supply has become reliable!
� Long interruptions and blackouts are rare.
� Hence increased focus on 2nd order problems.� Power factor, harmonics, sags, surges, distortion, RFI
� Factory equipment has become less tolerant.� CNC automatic machinery, PLC’s, robotics, processor controlled tools
Power Quality (PQ)
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Single Phase -Ground � 68% of Faults
2 Phase - Ground Fault � 19%
Balanced 3 Phase�13%
Transmission Faults
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� The most common PQ problem facing industry is Sag events.
� According to EPRI, sags account for >92% of PQ events.
� Facilities do not get advance warnings of impending sags.
� There is a solution !!!
Sag Warnings
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8Equipment Immunity Standards
1. Semi-F47 0706
2. IEC6100-4-34 Voltage Dips (sags)
3. ITIC
Home
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850% Retained Voltage Single Phase Sag
Transmission Line Sag AVC Input AVC Output
Phase and Magnitude Correction
Performance Graphs
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870% Balanced 3 Phase Sag Performance
Magnitude Correction
Transmission Line Sag AVC Input AVC Output
Performance Graphs
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8AVC 4 Quadrant Control
Load Power +veLoad Power -ve
AV
C V
olta
g e C
orre
c tio
n +v
eA
VC
Vol
tag e
Cor
rec t
ion
-ve Load consuming
Power
Load regenerating
Sag
Arrows indicate power flow
Load regenerating
Load consuming Power
Arrows indicate power flow
Arrows indicate power flow Arrows indicate power flow
Sag
Swell Swell
Home
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8Global Markets
Korea, STS and AVC to LGP, Hynix, Samsung
Dockside Frequency converterGreece
2MVA 26KV Bacardi. Jacksonville
108MVA at Wuxi China
1500kVA + 750kVA BP Solar. Maryland
Qimonda Malaysia Lord of the Rings. New Zealand
Amcor NZ
Ferrotec Shanghai
3MVA Rex Printing Fl
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8Vectek Case Studies
1. Bottling Plant Florida USA
2. Plastic Extruder Auckland New Zealand
3. Solar Panel Manufacturer Maryland USA
4. Semiconductor FAB China
5. DWA Welding Machine Malaysia
6. Printing Press USA
7. Container Crane Hong Kong
8. Discharge Lighting Samoa
9. Spandex Production Turkey
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8Medium Voltage AVC
����������
��������� ���
����������������� �����������������
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Bacardi Factory Utility Engineers Inspection
Bacardi Jacksonville Florida
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8Bacardi Site Data
� Bacardi produces 75,000 cases per day
� Working 2 x 10 hour shifts = 3,750 cases/hr
� 9 Bottling Lines
� Largest size bottles run at 400/min
� Miniatures run at 1000/min
� When an unexpected stoppage occurs it can take over one hour to restore production to normal line speeds
� Bacardi stated maintenance costs $350k p.a. for replacement parts damaged by unplanned stoppages
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8Bacardi Assumptions
� If lines are down for 40 minutes then 2500 cases are lost in normal 20 hour production day
� If a value of U$10 per CASE were assumed, this would equate to U$25,000 per event
� No cost estimates have ever been offered or confirmed by Bacardi
� The actual figure may be higher, say 40k-50k per event
� No details are available for scrap costs, lost taxes, rework, overtime to recover lost production etc
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8Assumed Bacardi Savings
� Historically 20 unplanned stoppages p.a. - $500k cost
� Bacardi volunteered - replacement costs cut by $250k p.a.
� Jan-Dec 05 490 events occurred below 87% (IEEE Level)
� Omniverter corrected 475 of these
� If only 10% of events would have stopped production
this would be 47 events @ $25k each = $1,175k
� Total Assumed Savings = $1.425 million
� The Assumed payback period is less than 1 year
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8JEA History Of Events
� Lost events include 7 hurricane induced complete outages
>87% >80% >70% >60% LostJan 3 2 3 1 1Feb 2 3 1 2 0Mar 3 2 1 4 1Apr 1 4 0 0 1May 10 2 1 4 0Jun 13 16 15 10 1Jul 112 15 1 5 3
Aug 16 9 2 5 0Sep 57 35 12 24 7Oct 4 4 0 2 0Nov 14 26 10 2 0Dec 13 5 0 0 0Total 248 123 46 59 14
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8Hurricane Frances Sweeps Into Florida
Voltage Conditioner Weathers the StormVoltage Conditioner Weathers the Storm
The AVC installed in Jacksonville Florida had more than The AVC installed in Jacksonville Florida had more than electrical sags to handle in its first year of operation.electrical sags to handle in its first year of operation.
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8Installed On Time, On Budget
2MVA, 26KV installation
Input PQ meter showing 1 x9’s of availability
Output PQ meter showing animprovement to nearly 4 x 9’s within only 142 days of operation.
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8Transmission Sag Correction
V1=82V1=82V2=58V2=58V3=87V3=87
V1=97V1=97V2=98V2=98V3=97V3=97
Input
V1 V2 V3
-25,000.00
-20,000.00
-15,000.00
-10,000.00
-5,000.00
0.00
5,000.00
10,000.00
15,000.00
20,000.00
25,000.00
30,000.00
V1=97V1=97V2=98V2=98V3=97V3=97
Output of AVC
Case Studies
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8Amcor Flexibles
� Plastic Extrusion Company
� Auckland New Zealand
� Installed AVC December 1998
� 1000KVA 400V 50Hz
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8Problem
� Extruded barrier film. Up to 9 layers
� Nylon particularly problematic
� Long set-up times
� 30 minutes to recover a fault
� Multilayer scrap is non-recoverable
� Less than 100% rolls are not accepted
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8Cost
� Scrap material $2000 / event minimum
� Depending on roll build. 4 hrs/roll
� 24/7 operation. Electrician callout per event
� Unless restored within 30 mins, pulldown of extruder
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8The Solution
� Trailed 300kVA on one of 6 extruder lines
� Operations staff demanded unit for “their” line
� 1000KVA Installed Dec 1998 (10 years of reliable service!)
� Amcor MD “before the AVC, the slightest flicker of the lights and we had trouble, but now we never worry”
� May 2005, Amcor installed another 1000kVA unit at their expanded plant. This was 7 years after buying the first unit.
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8Production Of A Solar Cell
� Silicon Ingots are first cast in an Electric furnace and then mounted on the saw carriage
� As presented to the saw they are valued at $2000/brick
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8Abrasive Wire Saw
Endless loop abrasive wire saw, simultaneously slices 2 bricks over a 4 hour period.
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8Assembly Process
6” wafer processed and ready for assembly into matrices ready for mounting and interconnection.
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8The Problem
� 15 wafer saws susceptible to sags
� Wire breaks damaged 2 bricks
� Replacing the wire took 6 hours
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8The Cost
� Broken saw wire 2 bricks x $2000
� Up to 15 saws on site
� Plus lost production down stream
� Plus downtime
� Maintenance costs
� $4000 to $40,000 per event
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8The Results
� BP Solar say “the results were dramatic. Productivity losses on protected saws were eliminated”
� “Pay back was under one year”
� “Production managers asked why only half the plant was protected”
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8Show of Faith
� During thunderstorms, unprotected plant was shutdown
� Finally, after 3 years, BP Solar purchased a second unit to protect the remaining plant
Case Studies
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8The Problem
� The “series” nature of the process
� Any disturbance results in a total loss
� Major events, in excess $1million
� No rework, days to recover
� Hugely competitive business
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8The Traditional Solution
� UPS’s
� large floor space
� low efficiency
� high capital cost
� significant operational costs
� If the UPS fails, the load is often dropped!
� Uses batteries for storage.
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8AVC Solution
� 98-99% efficiency
� Small foot print
� Extremely high integrity
� Cannot drop the load.
� Low maintenance
� No batteries
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8Overview – Reference Clients (Electronics)
Over 350MW of voltage conditioners supplied to semiconductor FABs in Asia and North America over the last three years.
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Hynix Wuxi China� 80+ 1000kVA, 1250kVA, 1500kVA
� 108MVA total
� Supplied as three separate projects
� Project 1 2006
� Project 2 2007
� Project 3 Commissioned May 2008
Hynix M11 Cheongju Korea� 52 x 1250kVA, 1500kVA
� Commissioned Feb 2008
� Space allocated for M12
Major Projects AVC
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81.5MVA 480V AVC
ACV-2-1500kVA-480V-50Hz
Input isolator
Bypass Switch
Output isolator
Optional Bypass
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75KVA Protecting
Vacuum Pumps
650KVA Protecting
semiconductor FAB line
Process Protection
AVC is actually inside the clean room
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850 x 650kVA AVC In FAB Plant
Logging for one month including a snow storm
Sag Depth 175kVA 75kVA 50kVA 25kVA Avg10-20% 1 4 2 4 2.820-30% 7 6 9 4 6.530-40% 19 16 20 21 19.040-50% 5 6 1 3 3.8>50% 0 0 0 0 0.0
Note: Most events are around 30% to 40%
No events exceeded50%
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Voltage Sag 13:00hr Aug. 11. 2005
Over 300 pieces of production machinery protected.
153KV sag by 58%153KV sag by 58%
-- 58%58% Duration Time: 0.3secDuration Time: 0.3sec
--33%33%
--24%24%
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8The Problem
� Loss of production
� Product quality
� Power supply sags cause most diode welding machines to trip
� Random tripping of machines for no apparent reason
The Product
High speed welding machines
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8System Issues
� 46 machines operate at once
� Power supply sags cause most diode welding machines to trip
� Random tripping of machines due to weld quality
� Voltage variations with load also cause inconsistent weld quality
One machines input current Multiple machines input current
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8Pre Study
� Pre study results and conditions� AVC not coupled to load
� AVC response to Sags
� Recording of sag and machines tripped
No event detected
No event detected
No event detected
No event detected
No event detected
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8Rex Printing, Jacksonville FL
� A high speed printing press in Florida
� Multiple sags during the “Storm Season”
� The cost / event was not large, however, the number of events was
� 3000KVA, 480Vac, 60Hz Vectek AVC
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8Container Crane Hong Kong
� Air Cargo Handling
� Automatic Stacker Reclaimer Crane
� Hong Kong
� Installed AVC March 2007
� 300kVA 400V 50Hz
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8 Automatically stacked and reclaimed,by robotic container crane system
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8Weather Created Voltage Disturbances
� Crane malfunctions:-
� Jambs a container mid cycle
�Crane has to be manually reset
�Staff have to physically enter the crane
�Risk of personal injury. Safety Issue
�Damaged Container and Crane
� Airliner penalty charges for delayed flights
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8AVC Solution
� Eliminates Voltage Sags from Crane
� Corrects sags when crane lifting (motoring)
� Corrects sags when crane is lowering (regenerating)
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Protecting Church Vapor Lighting in Samoa
Island power was causing premature light bulb failure (some lights actually falling fromthe ceiling onto the congregation!)
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New Spandex plant in Turkey
•Sags in the Industrial estateare causing problems.
•Spandex production is another “continuous process”
•An ABB AVC is chosen asthe preferred solution
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�
Specifications: Load Capacity
� 200 to 2400kVATo 10MVA custom design
� Displacement power factor of connected load0 lagging to 0.9 leading
� Crest factor 3 at 100% current
� Overload capacity from 100% supply150% for at least 30 second, once per 500s
Single Line
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� Nominal output voltage (V)According to model
� 480V 60Hz, 380 to 415V 50Hz
� 208V 60Hz,
� Options208V, 50Hz480V 50Hz600VMedium Voltage
� Power System3 Phase, center ground referencedSupply overvoltage category 3Fault capacity >40kA (model specific)
� Outage ride through 500ms
� Maximum supply voltage
110% of nominal supply voltage
Single Line
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� Nominal output voltage (V)Set to match nominal input supply voltage
� 3ph regulation range+/-10% continuous
� 3ph regulation accuracy+/-1% typical to +/-2% maximum
� 30% Model 3 Phase balance sag/swell Correction ability� from 70% remaining voltage
+30% for at least 30s� -10% continuous� 1ph to ground correction ability
From 55% remaining voltage� +45% for at least 30s� -15% continuous� Sag correction accuracy (within specified range) +/- 10% of correction
ratio� Sag correction response
Initial <250 micro secondsComplete < 0.5 cycle
� Equivalent series impedance (operating)< 4%
� Efficiency >98% (typically 99%)Single Line
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� Capacity100% of kVA rating
� Maximum overload capacity in bypass10 minutes 125%1 minute 150%1s 500%200ms 2000%
� Transfer timeInverter to Bypass < 0.5msBypass to inverter < 250ms
� Equivalent series impedance in bypass< 2.5% typical
Single Line
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� Enclosure� IP20 standard� IP21 by optional roof kit
� Pollution degree rating 2
� Minimum Operating temperature� 0oC, 32oF
� Minimum Operating temperature� 40oC
� Maximum Operating temperature� 40oC� Above 40oC de-rate at 2% per oC to a maximum of 50oC� Fahrenheit 104oF� Above 104oF derate at 2% per 1.5oF to a maximum of 122oF
� Capacity derating with elevation� 1.2% every 100m above � 1000m to 3000m Maximum
� Humidity <95% non condensing� Noise <75dba
Single Line
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0.5 to 1B System 1.5 to 2B System side by side 1.5 to 2B System back to back
Rating Table
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- Bus
+ BusIGBT
ContactorsSoft Start
Sine Filter
FilterRFI
Fuses
L3L2L1
Rectifier
� IGBT active rectifier
� Bi-directional power flow
� Sinusoidal input current
� DC output
Single Line Inverter
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Fuses
SCR/Contactor
UVW
Fuses
RFIFilter
Sine Filter
BYPASS
IGBT+ Bus
- Bus
� IGBT inverter
� Bi-directional power flow
� Sinusoidal output current
� DC input
Single Line
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30% AVC-2 Single Phase Event Performance Graph
TX 30o
30%
20%
10%
0%
70%
60%
50%
40%
80%
110%
100%
90%
50% 60% 70% 80%10% 20% 30% 40% 90% 100% 110% 120%
AVC Output Voltage(Line to Line)
30s
20s
10s
0s
50s
40s
AVCCorrection time (s)
120%
AVC Online
600ms
CorrectionTime
AVC Output (L1 - L3)
AVC Output (L1 - L2, L3 - L2)
Utility Voltage (Line to Neutral)0340-711b
Utility Voltage L1 toneutral reducing,for comparison
50% Retained Voltage Line to Line Neutral Graph
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30% AVC-2 Single Phase Event Performance Graph
TX 30o
30%
20%
10%
0%
70%
60%
50%
40%
80%
110%
100%
90%
50% 60% 70% 80%10% 20% 30% 40% 90% 100% 110% 120%
AVC Output Voltage(Line to Neutral)
30s
20s
10s
0s
50s
40s
AVCCorrection time (s)
120%
AVC Online
600ms
CorrectionTime
AVC Output (L2 - N)
AVC Output (L1 - N, L3 - N)
Utility Voltage (Line to Neutral)0340-711b
Utility Voltage L1 toneutral reducing,for comparison
50% Single Phase Sag
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30%
20%
10%
0%
70%
60%
50%
40%
80%
110%
100%
90%
50% 60% 70% 80%10% 20% 30% 40% 90% 100% 110% 120%
AVC Output Voltage(Line to Line)*
30s
20s
10s
0s
50s
40s
AVCCorrection time (s)
120%
AVC in Bypass AVC Online
AVC OutputVoltage
600ms
CorrectionTime
UtilityVoltage
Utility Voltage (Line to Line)0340-711a
*AVC output at 0.8 PF for 208 volt systems
30% AVC-2 3 Phase Balanced Event Performance Graph
70% Balanced Sag