NALCO Project

Calculation of current through harmonic filters

A. Electrical System Description –

The electrical system in TKII scope consists of 1 No MCC panel feeding the
electrical equipment which consists of motor loads (AC squirrel cage type).
While some motors are fixed speed type, few are operated through VFD (6
pulse type – model ACS800 of ABB make) for obtaining variable speed
operation as per process requirement.

The load details are as under –

Total motor load = xxx kW

Total motor load operated through VFD = 647 kW, consisting of 3 No VFDs
supplying 1 No of 315 kW, 1 No of 200 kW and 1 No of 132 kW motors

For improving the overall power factor to 0.9 at the MCC busbar, 1 No power
factor improvement panel consisting of capacitors and relay for automatic
switching of capacitor banks is also provided. The rating of capacitors in APFC
panel is 300 kVAr.

B. Need for provision of harmonic filters –

As per client specifications the harmonic distortion at MCC busbar is to be

kept within the limits specified by IEEE-519.

The data of actual harmonic current and voltage distortion under working
conditions has been made available by M/s ABB. As per the information
furnished the details are as below –

THD – Voltage = 5.5%

THD – Current = 24%

The current distortion is seen to be mainly caused by following harmonic

orders –

5th harmonic = 32% (298 A)

7th harmonic = 11% (102 A)
11th harmonic = 7% (65 A)

Harmonic currents of higher order are found to be negligible.

Considering the above data, it is proposed to install reactors in series with few
capacitor banks to work as filters for absorbing the harmonic currents.

Out of total capacitor rating of 300 kVAr, following capacitor banks are
proposed for using as harmonic filter –

• Filter-1: Common for 5th/7th harmonic = 90 kVAr

• Filter-2 : For 11th harmonic = 10 kVAr
C. SLD of the electrical system is as under –

MCC bus bar

Transformer IH
Xx / 0.415V,
1250 kVA VFDs Filter-1 Filter-2

C. Methodology –

Filter-1:
Since filter-1 is required to be common to 5th & 7th harmonic, the tuning
frequency is proposed to be selected as 270 Hz (5.4 times the fundamental
frequency).

From the capacitor bank kVAr the capacitive reactance at fundamental

frequency (XC-50) is calculated & this value is converted to values for other
harmonic frequencies using following expressions –
(kV)2 (0.415)2 0.1722
XC-50 = ---------------------------- = ------------------------------------ =---------------------- = 1.9136 ohms
(kVAr) x 10-3 90 x 10-3 0.09

XC-250 = XC-50 x (50/250) = 0.3827 ohms

XC-270 = XC-50 x (50/270) = 0.3544 ohms
XC-350 = XC-50 x (50/350) = 0.2734 ohms
XC-550 = XC-50 x (50/550) = 0.1740 ohms

Filter-2:
Since filter-2 is required for 11th harmonic, the tuning frequency is proposed to
be selected as 530 Hz (10.6 times the fundamental frequency).

From the capacitor bank kVAr the capacitive reactance at fundamental

frequency (XC-50) is calculated & this value is converted to values for other
harmonic frequencies using following expressions –
(kV)2 (0.415)2 0.1722
XC-50 = ---------------------------- = ------------------------------------ =---------------------- = 17.222 ohms
(kVAr) x 10-3 10 x 10-3 0.01

XC-250 = XC-50 x (50/250) = 3.4445 ohms

XC-270 = XC-50 x (50/270) = 3.1894 ohms
XC-350 = XC-50 x (50/350) = 2.4604 ohms
XC-550 = XC-50 x (50/550) = 1.5657 ohms
Calculation of reactor / inductance value –

Filter-1:

At 270 Hz, XL shall be equal to XC,

hence XL-270 = 0.3544 ohms

Since XL = 2 x π x f x L, where f = supply frequency & L is in Henry,

XL will change in the ratio of (new frequency / 270).

Using this expression, XL at other frequencies can be easily found as below =

XL-250 = 0.3544 x (250/270) = 0.3281 Ohm

XL-250 = 0.3544 x (350/270) = 0.4594 Ohm
XL-550 = 0.3544 x (550/270) = 0.7219 Ohm

Filter-2:

Using similar method as for Filter-1, we get values as below –

Hence, XL-270 = 3.1894 ohms &

XL-250 = 3.1894 x (250/270) = 2.9531 Ohm

XL-250 = 3.1894 x (350/270) = 4.1343 Ohm
XL-550 = 3.1894 x (550/270) = 6.4968 Ohm

For each harmonic frequency, the net impedance will be difference between XL
and XC.

Hence, net impedance values are –

For Filter-1 :

Z250 = XL-250 - XC-250 = 0.3281 – 0.3827 = - 0.0546Ohm

Z350 = XL-350 - XC-350 = 0.4594 – 0.2734 = 0.1860 Ohm
Z550 = XL-550 - XC-550 =0.7219 – 0.1740 = 0.5479 Ohm

For Filter-2 :

Z250 = XL-250 - XC-250 = 2.9531 – 3.4450 = - 0.4919 Ohm

Z350 = XL-350 - XC-350 = 4.1343 – 2.4604 = 1.6739 Ohm
Z550 = XL-550 - XC-550 =6.4968 – 1.5657 = 4.9311 Ohm

The harmonic currents introduced by the VFD will flow through both filters, with
each filter absorbing current in the inverse proportion of the impedances.
That is, for Filter-1 –
Z-Filter-2 (- 0.4919)
I-Filter-1-250 = I-250 x ---------------------- = 298 x ----------------------
Z-Filter-1 + Z-Filter-2 (- 0.0546 – 0.4919)

= 268.23 A

Similarly, current distribution for currents of other frequencies can be calculated

& results are as below –

I-Filter-1-350 = 91.8 A
I-Filter-1-550 = 10.2 A

& current through Filter-2 are

I-Filter-2-250 = 29.8 A
I-Filter-2-350 = 10.2 A
I-Filter-2-550 = 6.5 A

Note: For simplifying the calculation, the value of resistance in filter circuit is
assumed as zero.

DOUBT –

For each harmonic current introduced by the VFD, the load will comprise of the 2
filter circuits and the distribution transformer & these can be considered as
connected in parallel. Hence the current distribution through the filters will
depend upon the actual value of the transformer impedance also.

Impedance of transformer –

kVA = 1250
Impedance = 5%
Fault kVA = 1250 / 0.05 = 25000
Fault current = 25000 / (1.732 x 0.415) = 34781 A
Transformer impedance = 240 V / 34781 A = 0.0069 Ohm

Since the actual value of transformer impedance is observed as less than the
value of net impedance of Filter-1 & 2 at all harmonic frequencies, will the Filters
be able to absorb the harmonic currents as intended? Or will some part of
harmonic current flow through the transformer also.