© ABB Group May 13, 2013 | Slide 1 PCS100 Power Protection Discrete Automation & Motion South Africa Carel Oberholzer, ABB South Africa, May 2013
© ABB Group May 13, 2013 | Slide 1
PCS100 Power Protection Discrete Automation & Motion South Africa
Carel Oberholzer, ABB South Africa, May 2013
© ABB Group May 13, 2013 | Slide 2
Power Protection Agenda
1. Introduction of power protection
2. Overview PCS100 platform
3. Solutions for Power Protection
• PCS100 AVC Active Voltage Conditioner
• PCS100 UPS-I Industrial UPS system
Power Quality Problem
The most common PQ problem facing
industry is sag events.
Brief power disruptions account for up to
70 percent of all unscheduled downtime in
modern manufacturing. Studies show that
these events are caused by voltage sags
lasting less than two seconds.”
Facilities do not get advance warnings of
impending sags
Power events don’t come with a warning
Sag Characteristics and profile
Various Origins
1) Transmission connected faults
2) Remote / local distribution system faults
3) Local distribution system faults
4) Non-faults eg: large motor starting
5) Short interruptions
6) Fuses
Unpredictable Causes
Weather,
Construction,
Network failure, etc.
Sag profile and event meaning
Power available, but bad quality
Duration of <1s
Commonly unbalanced
propagates throughout system
Power Protection against voltage disturbance Protect YOUR production lines and processes
© ABB Group May 13, 2013 | Slide 5
© ABB Group May 13, 2013 | Slide 6
Power Protection Agenda
1. Introduction of power protection
2. Overview PCS100 platform
3. Solutions for Power Protection
• PCS100 AVC Active Voltage Conditioner
• PCS100 UPS-I Industrial UPS system
© ABB Group May 13, 2013 | Slide 7
Product Portfolio PCS100 Converter – one technology many products
Product Groups
Power Protection Frequency
Conversion STATCOM
Battery Energy
Storage
PCS100
Product Line AVC & UPS-I SFC STATCOM ESS
Major Market Segments Flat panel, LCD
and ship/memory
Datacenter
24/7 industry
Speciality boats
Dockisde OPS
Industry
Wind OEMs & parks
Solar EPCs
Distribution grid
Industry
Renewable energy
back-up (wind/solar)
Utilities
Industry
Picture
Load Power Range 125kVA – 20 MVA 125kVA – 5MVA 100kVA – 10MVA 100kVA – 50 MVA
Input voltage of power
electronics
208-480V
(any LV or MV with standard
transformer)
208-480 VAC
(any LV or MV with standard
transformer)
208-480 VAC
(any LV or MV with standard
transformer)
208-480 VAC
(any LV or MV with standard
transformer)
Market Positioning + AVC > 400 MVA
installed base
+ SFC > 100 MVA
installed base
+ 1st order Dec. 2009
with Suzlon Wind
Energy
Strategic Alliances
with key battery
suppliers.
PCS100 Platform The Concept
© ABB Group May 13, 2013 | Slide 8
The PCS100 converter platform is a modular
structure
Flexible sizing of converters by adding power
modules
Simple Service
Highly reliable with redundancy
Converter pairs (rectifier and inverter) housed in
800mm x 800mm cabinets
Multiple cabinets used to construct system
based on the power requirement
Options for racks to integrate converters into
container enclosures
Master
© ABB Group May 13, 2013 | Slide 9
Power Protection Agenda
1. Introduction of power protection
2. Overview PCS100 platform
3. Solutions for Power Protection
• PCS100 AVC Active Voltage Conditioner
• PCS100 UPS-I Industrial UPS system
© ABB Group May 13, 2013 | Slide 10
Power Protection - PCS100 AVC Sags, surges and poor voltage protection
Reduce the cost of sag events
Ensure quality supply to load despite supply
Applicable to industrial loads using significant power
Target voltage sags
Improve plant operation and reduce waste and damage
Regulates voltage (no long term under-voltage over-voltage and unbalance)
Removes voltage fluctuations - no process variation.
Economic and secure
Low cost of ownership (efficiency, footprint, cost)
Load never gets dropped
Very high availability
Simple servicing
PCS100 AVC – Active Voltage Conditioner Purpose
PCS100 AVC – Active Voltage Conditioner
© ABB Group May 13, 2013 | Slide 12
Overview Protects sensitive loads - corrects voltage wave form Sags, surges, unbalance, flicker and poor regulation - corrected in
milliseconds Rated 160kVA - 30MVA. High power and performance inverter based system.
Key advantages
98-99% Efficiency
Simple user controls
Cannot drop the load
Short circuit protected
Extensive diagnostics
Fault log
Voltage event data logging
Ethernet connectivity
Modular construction and small footprint
Very little maintenance
No batteries
PCS100 AVC – Active Voltage Conditioner Single Line Diagram
© ABB Group May 13, 2013 | Slide 13
secondary
primary
Distribution
Transformer
Input
Transformer
( Non 400 / 480 V
Su pply )
Rectifier Fuse
Input Circuit Br eaker
3ph Utility
Supply 3ph Output Load
Bypass
Rectifier and Inverter
Sag/Swell Animation
Boost
Transformer
50% retained voltage single
phase sag
70 % retained voltage three
phase sag
© ABB Group May 13, 2013 | Slide 14
PCS100 AVC – Active Voltage Conditioner Full web and plant system
Technician
commissioning
support tool
Plant SCADA
accessing data registers
Plant wide access from
web browser
USB interface
USB port
Firewall Worldwide web
Resident webpage in
graphic display module
Modbus/TCPIP
over Ethernet
© ABB Group May 13, 2013 | Slide 15
PCS100 AVC – Active Voltage Conditioner Reference clients (Electronics)
More than 400 MW of voltage conditioners supplied to semiconductor
FABs in Asia and North America over the last three years
© ABB Group May 13, 2013 | Slide 16
Power Protection Agenda
1. Introduction of power protection
2. Overview PCS100 platform
3. Solutions for Power Protection
• PCS100 AVC Active Voltage Conditioner
• PCS100 UPS-I Industrial UPS system
Power Protection - PCS100 UPS-I Sags & short term outage protection
PCS100 UPS-I, Industrial UPS Overview
© ABB Group May 13, 2013 | Slide 18
Ideal solution
deep sags
short term outages
Uses energy storage via an inverter boosting load
Fully offline system
Inactive unless required
Surge Threshold. Adjustable.
Typically 110%
Sag Threshold. Adjustable.
Typically 87 to 90%
140%
120%
100%
80%
60%
40%
20%
0%
0 1 2 3 4 5 …8
UPS-I Off Line
UPS-I On Line
UPS-I On Line
50%
load
75%
load
100%
load
Utilit
y
Vo
lta
ge
Typical Outage Time for Ultra Capacitors (sec)
© ABB Group May 13, 2013 | Slide 19
Input Output AVC RTS Applied Voltage
secondary
primary
Charger
Distribution
Transformer
UPS-I
Ultra
Capacitors
Coupling
Transformer
Battery
Option
Inverter
Fast Utility
Disconnect
Failsafe
Bypass
Utility Protected
Load
PCS100 UPS-I, Industrial UPS Single line diagram
© ABB Group May 13, 2013 | Slide 20
PCS100 UPS-I, Industrial UPS Operation cycle
SCR’s On Output voltage Utility voltage
UPS-I voltage
Energy flow
Inverter Off
1. Utility voltage within limits
Power to the load is supplied from the Utility
SCR’s Off Output voltage
Utility voltage
UPS-I voltage
Inverter on
Energy flow
2. Utility Outage Occurs
Power to the load is switched to the UPI-I energy storage within ¼ cycle.
3. Utility returns
© ABB Group May 13, 2013 | Slide 21
On detection - load taken over - actively disconnects supply
Transfer ≤1/4 cycle
PCS100 UPS-I, Industrial UPS Response to supply loss
PCS100 UPS-I Input
PCS100 UPS-I Output
© ABB Group May 13, 2013 | Slide 22
Ultra Capacitors
Protection for up to 3 seconds
Design Life: 15 years
Cycle life: >500,000
Safe and compact matching cabinet
A no battery solution
Reduced maintenance
Smaller footprint
PCS100 UPS-I, Industrial UPS Energy Storage
Spiral Lead Acid Battery
Protection for up to 30 seconds
Design Life: 10 years
Cycle life: >1200
Super high discharge rate
Easy service
Sealed
Small foot print
© ABB Group May 13, 2013 | Slide 23
Technician
commissioning
support tool
USB interface
USB port
Firewall
Plant SCADA
Accessing data
registers
Plant wide access from
Web browser
Modbus/TCP
IP over
Ethernet
Internet
Resident webpage
in graphic display
module
PCS100 UPS-I, Industrial UPS Full web and plant system
© ABB Month DD, YYYY | Slide 24
Statcom and ESS for industry Solving power system problems
© ABB Group May 13, 2013 | Slide 25
Common Problems in Industry Problems that ultimately cost money
High VAr requirements
Motors starting
Loads with lagging or leading power factor
Dynamic power factor requirements/Flicker
Automated welding machines
Presses
Crushing machines
Electronic loads with high power pulses
Arc furnaces
Imbalances caused by loads
single or 2 phase loads
regenerative loads (e.g. single phase PV)
Harmonic Currents
© ABB Group May 13, 2013 | Slide 26
ABB Product Overview STATCOM / ESS
STATCOM (Static VAr Compensator)
Power electronics voltage-source converter
Either a source or sink of reactive AC
support electricity networks with poor pf
voltage stabilisation, current balancing and harmonic filtering.
An ESS (Energy Storage System) In essence also a STATCOM with energy storage
Supplies real power
Recharge battery system
Can deliver reactive power & pf
STATCOM Features Summary
Reactive current
Full inductive or capacitive
current available
For power factor correction
Fast response
Voltage balance/clamp Feature
Current Balance Feature
LV and MV connection
Up to 30 % nominal current
available for unbalanced
current correction
Harmonic Correction
Flicker Mitigation
© ABB Month DD, YYYY | Slide 27
© ABB
Month DD, YYYY | Slide 28
Starting Motors How can a STATCOM help
For a direct online MV or LV motor start the motor will initially
require approximately
800% of rated kVA
Typically made up of 300% nominal kW and 740% x nominal
kVAR
A Statcom can supply the kVAr requirement during starting and
running thus the utility will not have to supply this current.
800HP 600kW MV motor starting
Reference: Paper by
Energy Storage Systems (ESS)
© ABB Month DD, YYYY | Slide 29
© ABB Group May 13, 2013 | Slide 30
Common Problems in Industry Avoiding costly upgrades to increase production
Energy consumption managed - avoid peak charges
expand production capabilities without upgrades to infrastructure
lower cost electricity utilised
Reduced max kVA = reducing fixed supply charges
Stabilized voltage
Possible to “black start”
Allows island mode - production continues
Note it is not a sag protection system.
PCS100 Energy Storage System Overview
An ESS has the ability to
shave the kW and KVAr
peak off the demand when
motors and other large
loads are started.
Load shifting, the ESS can
supply the load in parallel
with generators or the utility
and recharge the storage
when the load decreases at
a later time.
© ABB Group May 13, 2013 | Slide 31
© ABB
Month DD, YYYY | Slide 32
Load Leveling and Peak Shaving Time shifting energy demand
From NGK presentation
PCS100 Power Product Range Issues and Solutions
© ABB
Month DD, YYYY | Slide 33
PCS100
Statcom
PCS100
ESS (Energy Storage
System)
PCS100
SFC (Static Frequency
Conversion)
PCS100
AVC (Active Voltage
Conditioner)
PCS100
UPS-I (Uninterruptable
Power Supply)
VAr Support Yes Yes - - -
Peak Shaving kVAr only kW and kVAr - - -
Frequency
conversion
- - Yes - -
Voltage
Conditioning
Yes with
limitations
Yes Yes -
Outage Protection - Yes with
limitations on
transfer
- - Yes
Harmonic Filtering Yes to 7th - - - -
Current balancing Yes Yes - - -
Displacement PF
correction
Yes Yes Yes - -
PCS100 STATCOM Container, 2MVAr medium voltage coupled
© ABB Group May 13, 2013 | Slide 34
References
© ABB Month DD, YYYY | Slide 35
PCS100 STATCOM Northgate Minerals, Canada, 6x 4.5 MVAr
© ABB Group May 13, 2013 | Slide 36
PCS100 ESS Battery & ABB PCS Integrated “BESS System”
© ABB Group May 13, 2013 | Slide 37
© ABB Group May 13, 2013 | Slide 38
PCS100 ESS Chile, 20 MW (5x4 MW) Li-Ion for frequency regulation
© ABB Group May 13, 2013 | Slide 39
PCS100 ESS Chile, 20 MW (5x4 MW) Li-Ion for frequency regulation
© ABB Month DD, YYYY | Slide 40
PCS100 UPS-I & AVC Documents inside.abb.com / power electronics / power quality
© ABB Group May 13, 2013 | Slide 41
© ABB Group May 13, 2013 | Slide 42