CONTROL OF HARMONICS USING DELTA-WYE AND DELTA-DELTA TRANSFORMERS Felix Nepveux Jacobs Engineering Greenville, SC 29607 George Bender

Kimberly-Clark Corporation Owensboro, KY 42301

ABSTRACT Power transformers with properly selected windings can be used to cancel most of the harmonics from large variable speed drives. This significantly reduces the need for harmonic filters and other high maintenance harmonic mitigation equipment, both in new projects and in situations where harmonics must be reduced. This makes it easier to use high power factor diode input drives which have harmonic content levels almost double the levels of low power factor SCR drives. However, harmonics must be reliably estimated to justify power system plans in the design phase of a project. Harmonics in the distribution system can be estimated using methods described in IEEE-519 [1,2], but individual drive data needed for the estimate is hard to find. Test results presented in this paper indicate the effectiveness of the use of delta-wye and delta-delta transformers. The individual drive harmonic data, the resulting system harmonic estimates, and test results are also presented for comparison.

INTRODUCTION During the initial design of a plant it was determined that there may be severe power factor and harmonic problems due to the composition of the expected load. Variable speed drive loads, called static power converters, SPC, in IEEE 519, were estimated at approximately 33% of total plant load. High harmonics and poor power factor were clearly potential problems, and capacitor based power factor correcting harmonic filters were not considered to be the solution of choice. IEEE-519 provides a method for estimating the worst case levels of harmonics for different types of drives and power system configurations. The estimates showed that harmonics could be severe, far beyond IEEE-519 limits, if all drives were powered by delta-wye connected, DY, transformers. It was also found using the IEEE 519 estimating procedure that harmonics could be reduced below IEEE 519 recommended maximum levels by splitting the harmonic producing loads between DY and delta-delta, DD, transformers, without the use of harmonic filters. These were important findings in this project because diode input drives were being considered for use because of their high power factor. Diode input drives operate at 98% or better power factor over most of the load range. Silicone controlled rectifier drives, SCR drives, operate at power factors which vary with load and never exceed approximately 95% power factor even at full load. A 90% total plant power factor was needed to avoid penalties. The total plant load power factor would definitely be improved if 33% of the load operated at 98% power factor. However, diode input drives produce almost double the harmonics of SCR drives. The purpose of this paper is to present examples of estimates of harmonics for various distribution system choices. A comparison is provided between the estimate for the selected system configuration and the final test results. It is hoped that as a result of this paper drive vendors will provide better information on harmonic content of their equipment. It could also be concluded that standardized test

procedures should be available for vendors to use in presenting data on harmonic performance for design purposes and for purchasing evaluations.

THE EFFECT OF DELTA-WYE AND DELTA-DELTA With DY and DD transformers certain harmonics can be forced to combine 180 out of phase and cancel [3]. This is caused by phase angle shifts which occur in DY transformers, but which do not occur in DD transformers. In a DD transformers there is no phase shift from primary to secondary. Currents in the secondary are reflected in the primary with only a voltage difference. In a DY transformer connected for lagging (positive sequence) secondary components, voltage waves are shifted 30 60Hz degrees backwards as they pass through the transformer from primary to secondary. This causes current harmonics which are related to position of the voltage wave to occur later in time in the DY transformer loads, and to be shifted in time relative to similar harmonics produced in loads fed from the DD transformers. The time difference for the fundamental voltage and current is equal to the time of 30 60Hz degrees (30/360 sec.). The shift for the 5th harmonic current, while still in the secondary, is also 30 60Hz degrees, but this is equivalent to 5 times 30, 150, 5th harmonic degrees. The 5th harmonic, being a negative sequence harmonic, shifts another 30 of 5th harmonic degrees backwards in going from the secondary to the primary of the transformer. The total shift for the 5th harmonic from secondary to primary is -150 + -30, = -180, 5th harmonic degrees. The 5th harmonic current, if split between DD and DY transformers should totally cancel at the connection between the transformer primaries. The same effect occurs for the 7th harmonic current. The 7th harmonic current is shifted back 7 times 30, 210, 7th harmonic degrees, then shift forward 30 7th harmonic degrees going to the primary of the DY transformer. The total shift is -210 + 30, = -180 7th harmonic degrees, and total cancellation should also occur for equal DD and DY 7th harmonic currents. IEEE 519 and other sources suggest that only a 90% cancellation can be relied upon to occur for the 5th, 7th, 17th, 19th, etc. harmonics. The 11th and 13th harmonics do not change angle (shift = 360 harmonic number degrees) in passing from secondary to primary of DY transformers, and so do not cancel. The 17th and 19th harmonics again cancel like the 5th and 7th.

IEEE 519 RECOMMENDATIONS There were two recommendations of IEEE 519 to be satisfied. The first concerned current harmonics at the connection point between the plant and the utility, the point of common coupling, PCC. Current harmonics at this point affect the utility, and possibly other utility customers also fed from the same line. The second IEEE 519 recommendation concerned voltage harmonics at the plant high voltage bus. Voltage harmonics in the plant 13.8kV bus cause all loads in the plant to carry, and be affected by, harmonic currents. Current harmonics at the PCC can only be reduced by either absorbing the current harmonics produced in the system with filters, or by eliminating harmonics. Using the distribution system to eliminate the harmonics by cancellation was the desired approach. Note also that the allowable level of harmonic current, as stated in IEEE 519, is related to the level of available utility fault current relative to plant full

load current As the ratio of utility fault current to plant fill load current increases, the allowable level of harmonics as a percent of full load current increases. Voltage harmonics in the plant 13.8kV system are the result of the current harmonics drawn through the impedance of the utility tie. Obviously they can be reduced by lowering the harmonic current levels or by lowering the total impedance of the tie to the utility. The impedance of the tie to the utility is a combination of the tie transformer impedance and the impedance of the utility. The impedance of the tie transformer will usually be far greater than the impedance of the utility. Usually, voltage regulation at full load and fault current level are the only considerations on which tie transformer impedance selection is based. With high harmonics the tie transformer impedance should also be selected so that allowable tie harmonic currents produce plant high voltage bus voltage harmonics which are also within IEEE 519 recommended levels.

HARMONIC SOURCES The variable speed drive units, SPC loads, use a three phase full wave input rectifier stages to produce direct current, DC, which is then reconverted to a variable frequency and voltage. The first SPC drives to be used employed silicone controlled rectifiers, SCRs, in the rectifier stage to produce DC, and to control the voltage of the DC. The DC voltage in the SCR drive was controlled by delaying the triggering of conduction in the SCRs in each half cycle. This results in a non-sinusoidal current wave which is delayed relative to the voltage. This causes harmonics and poor power factor. The harmonics found in SCR drives are only odd, and are a fraction of the fundamental current slightly less than 1 divided by the harmonic number. These drives also produce line notches. The drives intended to be used in this system have plain diodes in the three phase input rectifier, and the DC bus voltage is not controlled by the input rectifier. Both the frequency and voltage of the output are controlled by pulse width modulation in the output inverter. These are typically known as Pulse Width Modulated drives, or PWM. The input rectifier draws current in two pulses in each half cycle, with the pulses centered on the voltage wave. Since the current is always in phase with the voltage, the power factor is high, usually 98%. Another benefit of the diode unit is the absence of line notching found with the SCR drives. However, the diode input drives produce approximately double the 5th and 7th harmonic currents of the SCR input drive. Because drive size exceeded the range which could be implemented with PWM units, two drives later had to be changed to SCR. These drives produce the typical harmonics for SCR drives, and the typical disturbances in line voltage and current due to line notching. The test results show these aspects of SCR drives in frightening detail, and provided excellent data for comparison in this paper.

HARMONIC ESTIMATES

Using the IEEE-519 estimating procedure involves several steps [4]. First, tables of harmonics for each type of drive must be selected. The different types of harmonic producing loads are then grouped by type, SCR or PWM. Different factors are used if the drives are all powered by the same type of transformer, or if the drives are split between DY and DD transformers. The factors in the harmonic tables are then used to determine how much harmonic current is contributed to total plant load from each grouping of drives. The estimated totals of each harmonic are then simply summed and used to

determine compliance with individual harmonic level requirements and with total harmonic distortion requirements. The degree of accuracy of these estimates was difficult to establish. It must first be noted that the IEEE519 estimating procedure results in a worst case estimate. In the IEEE 519 procedure it is assumed that all drives operate as one single unit, all with the same firing angles and loads so that harmonics from all units add, or subtract, totally in phase with each other. It has been found that the diversity of firing angles and loads found in a multiple drive situation makes it impossible to exactly predict the harmonic levels. It has also been found that this diversity reduces the total system harmonics found in operating systems from estimated values. Estimates of system harmonics depends on estimates of harmonics of individual drives. Estimates of different types of drives vary widely between different versions of IEEE-519, and between several IEEE papers [5-7] and vendor guidelines. It is stated in IEEE-519 that the use of harmonic factors for SCR drives equal to 1 divided by the harmonic number, 1/h, is sometimes used, but is excessive, and lower values are listed as typical. However, even guesses were unavailable from standards and from vendors for diode input drives during the planning stage of this project. The harmonic level estimates are listed in five cases. In Case 1 the harmonic levels are estimated for all SPC loads powered from DY transformers, with the estimating factors based on SCR drives with 1/h estimating factors. Case 2 is the same as Case 1 except the typical estimating factors for SCR drives from IEEE 519-1981 are used. In Case 3, the loads are split between DY and DD transformers, with the estimating factors modified for 10% of the 5th and 7th, etc., harmonic levels. Cases 4 and 5 are the same as 2 and 3 except with estimating factors for diode input drives. Table 1 below is a tabulation of the five cases, using approximate actual plant loads instead of loads estimated in 1993. The approximate total plant load at the PCC is 120 amps, with 40 amps of that load from static power converter, SPC, loads. The results in Table 1 are based on load data for the finished project, and indicate that harmonic mitigation should not be necessary if DY and DD transformers are used. Initial estimates were also made in 1993 of harmonics for the middle of the project. These predicted interim harmonic levels were lower than the final results above. It was later found (in 1995) that the interim estimates were high, as expected.. The voltage THD at the 13.8kV bus was 1.3%, with diode input drives, at the end of the project, compared to the 3.20% estimate above, with no harmonic filters. The harmonic estimating worksheets are included in Figures 1 - 5. Table 1. Summary of Harmonic Estimates

CASE 1 2 DRIVE SCR 1/h SCR TRANS. all DY all DY THD %I at 161KV PCC 9.85 7.18 %V at 13.8KV 13.48 5.83

3 SCR DY/DD 1.97 2.96

4 Diode all DY 19.82 13.59

5 IEEE 519 Diode LIMITS: DY/DD 2.70 3.20 4.00 5.00

TEST RESULTS

The equipment tested is a multiple unit coordinated variable speed paper machine drive powered from five transformers with provisions for two future transformers and drive sections. System data is listed in Table 2. The drive transformers are all fed from one 13.8kV breaker and feeder cable. The mixing and cancellation of harmonic currents should occur in the feeder cable before appearing in the plant high voltage bus. There are diode input drives with both GTO and IGBT type PWM inverters, and two SCR/LCI drives. Table 2. Drives and Transformers Trans. Drive No. KVA Winding Input 22 1500 D-D Diode 24 2500 D-D Diode 26 2500 D-Y Diode 27 2000 D-D SCR 28 3000 D-Y SCR

Drive Inverter GTO IGBT GTO LCI LCI

Load HP 1-1250 1900 total 2-1000 1-2000 1-3000

SCR-LCI RESULTS AND ESTIMATES The individual drive transformer current harmonic estimates and actual readings for the two SCR input drives are listed in Table 3. The tested values appear to be very close to estimated values for the 5th and 7th harmonics, but then are higher than estimated for the higher harmonics. There also appears to be an inverse relation between harmonics and load. Predicted values are from IEEE 519-1981, Figure 3, typical values, with the 27th and higher harmonics estimated from IEEE 519-1992 Table 13.1. These test results are included in Figures 6 and 9. Voltage data for each harmonic, and voltage and current waveforms, are included in Figures 7, 8, 10, and 11. Table 3. Current Harmonics LCI-1 LCI-2 102% 35% Tested Tested Levels Levels 100.0 100.0 18.8 23.7 12.7 10.1 6.8 8.7 4.7 5.9 2.5 5.2 1.8 4.2 0.3 0.8 3.6 0.4 3.1 LCI-1 Harm. Predicted No. Levels 27th 29th 0.7 31st 0.6 rd 33 35th 0.6 37th 0.5 41st 0.5 rd 43 0.4 47th 0.4 49th 0.4 THD Tested Levels 0.6 0.5 LCI-2 Tested Levels 0.3 2.6 2.2 0.2

Percent Loaded Harm. Predicted No. Levels Fund. 100.0 5th 17.5 7th 11.1 th 11 4.5 13th 2.9 17th 1.5 19th 1.0 st 21 23rd 0.9 25th 0.8

24.3

29.2

DIODE-GTO AND DIODE-IGBT RESULTS AND ESTIMATES

The individual drive transformer current harmonic estimates and actual readings for the PWM drives are listed together in Table 4. These drives all have diode input rectifiers. The 5th and 7th estimating factors were conservative but the factors for the higher harmonics apparently need to be increased. There again appears to be an inverse relation between load and harmonics. The predicted values for diode input drives are based on estimating factors from a paper by Jarc and Schieman [6]. The Jarc and Schieman paper was the only source available of any prediction of harmonics in diode drives. The Jarc and Schieman values for SCR units appeared high compared to IEEE 519 values, so the 5th and 7th harmonic values for the diode units, after conversion to % of fundamental values, were multiplied by the same ratio found in IEEE 519-1981 Figure 3 for typical to theoretical harmonics. The Jarc and Schieman values are lower than IEEE 519-1981 at the 11th and 13th harmonic, so SCR estimating values were used . The Jarc and Schieman paper does not list values beyond the 13th ,harmonic, so the SCR estimating values were again used, with the hope that this would be mildly conservative. These results are included in Figures 12, 13, and 14. Table 4. Current Harmonics GTO-1 IGBT Percent Loaded 65% 23% Predicted Tested Tested Fund. 100.0 100.0 100.0 3rd 2.2 5th 52.7 27.5 44.1 7th 26.9 8.2 23.6 th 9 0.3 0.8 11th 4.5 7.6 6.2 13th 2.9 4.1 6.9 17th 1.5 3.3 4.9 th 19 1.0 2.4 2.0 21st 0.2 0.4 23rd 0.9 1.9 2.0 25th 0.8 1.4 0.4 th 27 2.5 29th 0.7 0.8 1.0 31st 0.6 0.8 35th 0.6 THD 30.4 51.3

GTO-2 40% Tested 100.0 2.6 42.0 18.6 0.6 8.2 4.4 4.2 2.3 2.5 1.5 1.1

47.3

CURRENT HARMONICS ON 13.8KV AND 161KV(PCC) SUPPLY The estimated current harmonics for total plant load, from Case 5, are shown in Table 5. In this Case the diode input drives and loads split between DY and DD transformers. The 5th and 7th harmonics are close to predicted levels. The higher harmonics were not recorded by the test instrument, but high harmonics were recorded with this same test instrument at other nodes of the system both before and after the ties were tested, therefore it must be concluded that the higher harmonics were not present. This does not mean that estimating factors should be reduced in all cases for the higher harmonics since they do appear in lower voltage sections of the distribution system which are nearer the harmonic sources. Possibly the higher harmonics could be reduced by assigned factors which differ for various voltage levels. For portions downstream of the high voltage bus which do not have harmonic sources the higher harmonics should be left out, which means that the factors could not be based entirely on voltage level. However, it

may not be worth the effort at this time of attempting to make a detailed science of estimating harmonics because of the poor data available on drives. The test results are shown in Figures 17 and 18. Table 5. Current Harmonics 13.8kv 161KV Estimated Tested Tested Fund. 100.0 100.0 100.0 3rd 0.2 5th 1.76 1.4 1.3 7th 0.90 0.6 0.7 11th 1.50 0.3 th 13 0.97 0.3 0.3 17th 0.05 19th 0.03 23rd 0.30 th 25 0.27 29th 0.02 31st 0.02 35th 0.20 THD 2.7 1.6 1.5

VOLTAGE HARMONICS AT 13.8KV Table 6 lists the estimated values and test results of the voltage at the plant 13.8kV bus, with the drives operating. The voltage harmonics were close to predicted at the low harmonics, 5th and 7th, but were high or low, or missing, at the higher harmonics. The most important result was the 1.3% voltage total harmonic distortion in a plant with extremely high harmonic loads. These test results are shown in Figures 19 and 20. Table 6. Voltage Harmonics at 13.8KV Bus Estimated Tested Fund. 100.0 100.0 3rd 0.0 5th 1.07 0.8 7th 0.76 0.6 th 11 2.01 0.3 13th 1.53 0.6 17th 0.10 0.2 19th 0.08 0.3 rd 23 0.84 0.4 25th 0.81 29th 0.08 31st 0.08 th 35 0.85 THD% 3.2 1.3

CONCLUSIONS

The splitting of loads between DY and DD transformers successfully reduced the harmonics in the power system to the extent that tuned harmonic traps were not required. The use of DY and DD transformers should be considered for any new project where the harmonic producing loads will be a significant part of total plant load. The replacement of DY transformers with DD transformers should also be considered as an alternative to harmonic traps when harmonics are found to be a problem in existing systems. The system harmonic estimates based on individual drive harmonic estimates found in IEEE 519 were found to be high. In some cases it may be possible that these high estimates could indicate that a project should not be undertaken without harmonic filters. Therefore, estimates of harmonics which are above IEEE 519 limits should be carefully analyzed before committing a plant to buying and operating tuned filters. It should be noted that better estimates of system harmonic levels should be able to be made using modified estimating factors based on test data collected in controlled situations. The loads which were tested in this paper could not be controlled since the plant was operational. It would be helpful if more information on drive harmonic loads were available from the drive vendors who could test their drives at controlled load levels, using standardized test and reporting procedures.

REFERENCES 1. IEEE Guide for Harmonic Control and Reactive Compensation of Static Power Converter, IEEE Standard 519-1981. 2. IEEE Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems, IEEE Standard 519-1992. 3. Isadore K. Dortort, IEEE Trans. Ind. Appl., "Phase Shifting of Harmonics in AC Circuits of Rectifiers," Vol. IGA-4, No.6, pp. 655-658, Nov./Dec. 1968. 4. C. K. Duffy and R. P. Stratford, IEEE Trans. Ind. Appl., "Update of Harmonic Standard IEEE-519: IEEE Recommended Practices and Requirements for Harmonic Control in Electric Power Systems," Vol. 25, No.6, pp. 1025-1034, Nov./Dec. 1989. 5. Ray P. Stratford, IEEE Trans. Ind. Appl., "Rectifier Harmonics in Power Systems," Vol. IA-16, No.2, pp. 271-276, March/April 1980. 6. Dennis A. Jarc and Robert G Schieman, IEEE Trans. Ind. Appl., Power line Considerations for Variable frequency Drives,", Vol. IA-21, No.5, pp. 1099-1105, September/October 1985. 7. Robert A. Hanna, IEEE Trans. Ind. Appl., "Harmonics and Technical Barriers in Adjustable Speed Drives," Vol. 25, No.5, pp. 894, Sept./Oct., 1989.