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Active Voltage Conditioner - ABB Ltd · Active Voltage Conditioner ... Arrows indicate power flow...

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© ABB Group - 1 - 26-Sep-08 AVC 2 Active Voltage Conditioner
Transcript

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AVC2

Active Voltage Conditioner

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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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AVC2

Overview

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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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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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8Typical Factory Configuration

UPS

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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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AVC Online

AVC in Bypass

Graphic Display Module

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8Graphic Display Module

Event Log

Event Summary

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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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Power Quality Event Theory

Home

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� 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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Certification Team SEMI F47!

IEC, UL, VDEIEC, UL, VDE

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AVC2 Performance

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

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VC

Vol

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Cor

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-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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Case Studies

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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Case Study One:Bacardi Rum Jacksonville, Florida.

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82MVA, AVC Bacardi Rum, Jacksonville, Florida.

2000kVA, 26KV

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8AVC Installed Over Christmas 2003

Containerised option.

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826KV MV Installation

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8Medium Voltage AVC

����������

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����������������� �����������������

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Bacardi Factory Utility Engineers Inspection

Bacardi Jacksonville Florida

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8High Speed Bottling Line protected by AVC

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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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Case Study Two:Amcor Flexibles New Zealand

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8Amcor Flexibles

� Plastic Extrusion Company

� Auckland New Zealand

� Installed AVC December 1998

� 1000KVA 400V 50Hz

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8Amcor Flexibles

Typical “blown film” plastic extruder

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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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Case Study Three:BP Solar Maryland

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8BP Solar Cell Manufacturing

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8Frederick, Maryland

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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 Solution

1600kVA AVC installed Aug 2002

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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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Case Study Four:Semiconductor FAB Plants

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8Semiconductor FAB Plants

The most sensitive industry to voltage sags

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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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850 x AVC 1250kVA Korea

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8>100MW AVC’s in Two Plant Rooms in China

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8108MVA in Three Plant Rooms

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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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8Tooling Protection China

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Case Study Five:Diode Welding Machines Malaysia

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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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8ROHM Wako Electronics Kota Baharu

AVC protection of all machines

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Case Study Six: High Speed Printing Press Florida

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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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High Speed Printing Press

Hi-speed, multi-colour printing presses

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83MVA AVC Controller Section

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8Out Door 3MVA Installation

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Case Study Seven: Container Crane Hong Kong

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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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1000’s of containers per day

Hong Kong Airport

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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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Case Study Eight:Protecting Church

Vapour Lighting

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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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8Spandex Manufacturing Plant: TURKEY

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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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8450kVA AVC installed in the switchroom

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8Number of events seen in very short time period!

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8AVC2 system

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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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-08Specifications: Input Supply

� 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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-08Specifications: Output Supply

� 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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-08Specifications: Bypass

� 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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-08Specifications: Environmental

� 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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-08Layout 0.5 to 2B

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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-08Layout 2.5B to 6B

Rating Table

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106

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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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107

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-08Inverter

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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108

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-08Injection Transformer

Single Line

400kVA 480 volt model

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109

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-08

Utility

No Protection Against PQ Events

Single Line

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110

-26

-Sep

-08

Utility Sag

AVC2 Sag Protection

Single Line

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up -

111

-26

-Sep

-08

Utility Swell

AVC2 Swell Protection

Single Line

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112

-26

-Sep

-08

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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-08

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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114

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-Sep

-08

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


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