PQC Application Notes

Steel Facility Voltage & Current

Voltage Current

20000 400
Harmonic Filter System Application
15000 300
Summary
10000 200

Andrzej Polanski, P.Eng.

5000 100

Amps (peak)
Volts (peak)
Large Steel Mill facilities require relatively large 0 0
0.0 45.1 90.2 135.3 180.4 225.6 270.7 315.8
amounts of reactive power to operate. Resultant
-5000 -100
low network efficiency decreases effective
network capacity, creates overloads of network -10000 -200

distribution equipment, and inflates Utility bills -15000 -300

with low power factor penalties. -20000 -400

Degrees

Power Factor Correction (PFC) system applications Voltage - Harmonic Spectrum Current - Harmonic Spectrum
14000 250
provide a fast solution to low power factor problems.
12000
However, several application issues need to be considered 200

10000
when capacitors are to be applied in industrial networks.

Amps (rms)
150
Volts (rms)8000
These include load profile characteristics, network
6000
frequency responses associated with capacitor installation 100

4000
and correction system design based on overall objectives 50
2000
as well as load and power distribution system
0 0
characteristics. 1 3 5 7 9 11 13 15
17 19
Harmonic 21 2 2 2 2 31 1 3 5 7 9 11 13 15
Harmonic
17 19 21 2 2 2 2 31

The following paragraphs summarize the design process

and results of a Medium Voltage (MV7000) automatic Figure 1. Uncompensated 12.47 kV Main bus - voltage and
current waveforms and harmonic spectra.
PFC bank application at a Steel facility in Blytheville, AR.

Manufacturer’s Load Profile PFC & Harmonics

A steel pipe manufacturing facility in Blytheville, AR Measured harmonic voltage distortion levels exceed
utilizes equipment to fabricate various diameter steel IEEE 519-1992 recommended limit of 3% for each
tubes. Flat steel sheets are cut, shaped, seem welded, and individual harmonic component. Voltage distortion is
heat cured. The facility has a 12.47 kV Main switchgear caused by current harmonics passing through network
arrangement distributing power to low voltage power impedance. For the same amount of current harmonics,
centers. The manufacturing process consumes on average soft (high impedance) networks will experience higher
3600 kW at 0.80 lagging power factor. The reactive power voltage distortion than stiff (low impedance) networks.
requirement is 2700 kVAR. Power Quality measurements Medium voltage power factor correction equipment
indicated considerable harmonic distortion levels. The application must be evaluated based on the network
current THD (%) exceeded 16% and voltage THD(%) frequency response and possible resonance conditions.
exceeded 4% at the Main 12.47 kV bus (Table 1). Since power factor correction was the main objective here,
2700 kVAR automatic capacitor system was required.
Harmonic # Voltage Current However, network frequency response evaluation based on
Distortion [%] Distortion [%] the total capacitor bank kVAR size indicated possible low
3rd 0.14 0.61 frequency resonance conditions which can create
5th 3.85 15.21
significant harmonic magnification. Resonance conditions
7th 1.02 3.87
11th 1.22 4.41 may increase voltage distortion to levels high enough to
THD 4.24 16.51 cause some of the low voltage control equipment to
Table 1. Uncompensated load harmonic data. malfunction. The manufacturing process depends on
flawless and efficient operation of entire electronic control
Figure 1 provides voltage and current waveforms and system.
corresponding harmonic spectra. Based on the above, filtered PFC system application was
justified and 2700 kVAR, 12.47 kV automatic 5th
harmonic filter was chosen.

December, 2000
 PQC – ReactiVarTM Application Notes

MV7000 Bank Characteristics Conclusion

The manufacturing process and load profiles dictated an
automatically switched correction system. Therefore,
three stage filtered bank configuration was chosen with
1x560 kVAR and 2x1120 kVAR stages, respectively.
Each stage utilizes 400A, 13.8 kV, three-pole vacuum
contactor for switching. Three single-phase iron core
reactors tuned to 4.7th harmonic are placed in series with
capacitors for each stage. Single phase, 7.62 kV rated,
individually fused capacitor cells are used in ungrounded
Wye configuration. The Square D VarLogic controller
automatically controls stage operation. Each stage is
Square D ReactiVar MV7000 harmonic filter application
proved to be a successful solution for low power factor and
harmonic problem at the Blytheville facility. In this case
the automatically controlled, metal enclosed medium
voltage harmonic filter installation proved to be relatively
economical way not only to achieve power factor
improvements but also for harmonic filtering purposes.
Voltage Current
Voltage & Current
20000 250
15000
200

protected against phase unbalance and phase loss by three- 150

10000
phase current unbalance relay (46D). All of the above 100
components are housed in NEMA 1 enclosure equipped 5000
50
with front doors, rear removable panels, and viewing

Amps (peak)
Volts (peak)
windows. Main incoming section features Square D HVL 0
0.0 45.1 90.2 135.4 180.5 225.6 270.7 315.9
0

non-load break disconnect switch (unfused) and houses -5000

-50

12,470:120 V control power transformer (CPT). The -100

entire assembly is Kirk key interlocked to prevent -10000
-150
unauthorized and out of sequence entry into the bank.
-15000
-200

Harmonic Filter Effect -20000

Degrees
-250

The 5th harmonic filter application, equipped with 14000 Voltage - Harmonic Spectrum 180 Current - Harmonic Spectrum

4.7th harmonic reactors, not only prevents harmonic 12000

160

140
magnification but also provides significant harmonic 10000
120
filtering. Table 2 below summarizes harmonic levels with

Amps (rms)
Volts (rms)

8000 100

filter bank in full operation. 6000

80

60
4000
Harmonic # Voltage Current 40

2000
Distortion [%] Distortion [%] 20

3rd 0.20 1.60 0

1 3 5 7 9 11 13 15 17 19 2 1
Harmonic 2 2 2 2 31
0
1 3 5 7 9 11 13 15
Harmonic
17 19 21 2 2 2 2 31

5th 0.51 6.58

7th 0.70 1.92 Figure 2. Compensated 12.47 kV Main bus - voltage and current
11th 0.58 1.52 waveforms and harmonic spectra.
THD 1.45 7.38
Table 2. Compensated load harmonic data.
References
Over 50% of 5th harmonic current is removed together with
overall power factor improvement to 0.97 lagging. The 1. IEEE Recommended Practices and Requirements for
voltage distortion levels dropped well below IEEE 519 Harmonic Control in Electrical Power Systems. IEEE
recommended limits. Figure 2 provides pictorial Std 519-1992, New York, NY 1993.
representation of voltage and current waveforms and 2. IEEE Guide for Application of Shunt Power
harmonic levels after filter installation. Note voltage Capacitors. IEEE Std 1036-1992, New York, NY
magnitude rise associated with capacitor applications. 1993.
This voltage increase, based on total PFC bank size and 3. IEEE Guide for the Protection of Shunt Capacitor
network short circuit availability, can cause overvoltage Banks. IEEE C37.99-1990, New York, NY 1991.
even during heavy load periods. Maximum voltage
magnitudes with capacitor bank fully energized need to be
evaluated prior to capacitor installation to assure that
overvoltage will not cause problems. In cases when
voltage magnitudes may exceed allowable limits, it is
necessary to adjust upstream transformer taps to keep
voltage magnitudes within acceptable limits. Therefore, it
is beneficial to work closely with local utility when
medium voltage PFC bank installation is planned to co-
ordinate possible utility distribution equipment
adjustments.

December, 2000