ABBACUS MECB

Metal Enclosed Capacitor Bank

for Power Factor Correction
ABB Group
April 17, 2009 | Slide 1

Australia 70% Desert

6th Largest Country

Melbourne to
Sydney - 873km
(542 miles)

Hobart to Darwin
4399km (2733
miles)

Sydney to Broome
5112km (3176
miles)

Perth to Townsville
5911km (3673
miles)

Darwin
*
Broome

Townsville
*

*
Ayers Rock
Uluru
*

*
Brisbane
*

Perth

Adelaide
*

Melbourne
Capacitor factory

.
ABB Group
April 17, 2009 | Slide 2

Sydney
Indoor/Outdoor
Apparatus
Hobart

Contents

Introduction What is Power Factor?

Applications
Design Criteria

ABB Group
April 17, 2009 | Slide 3

1. Product Modularity
2. Safety
3. Environment

Introduction What is Power Factor?

ABB Group
April 17, 2009 | Slide 4

What is Power Factor?

Power factor is the measurement of how effectively

electrical power is being used:

ABB Group
April 17, 2009 | Slide 5

The higher the power factor, the more efficient the

plantall the way back to the generator

What is Power Factor?

Reactive power
Active power

ABB Group
April 17, 2009 | Slide 6

An electrical systems power is composed of different parts:

Active (working) power which performs the useful work

Reactive (non-working) power which creates the

magnetic fields for inductive devices

Apparent Power (kVA) = Active power (kW) + Reactive

power (kVAr)

What is Power Factor?

Low Power Factor is like

kVAr - Reactive Power

or
Beer - Foam

kVA - Apparent Power

or
Beer - Full glass

ABB Group
April 17, 2009 | Slide 7

kW - Active Power
or
Beer - Liquid

What is Power Factor?

kW

kVA: Total Power

kW: Working Power

kVAr: Reactive Power

needed to generate
magnetic fields for inductive
loads such as motors

Power Factor: The

relationship of real power
(kW) and total power (kVA)
consumed

2
1

kvar2
kva2
kvar1
kva1
Ckvar

KVA1 = without capacitors

KVA2 = with capacitors
KVA2 < KVA1
PF =

ABB Group
April 17, 2009 | Slide 8

kW
kVA

What is Power Factor?

Active Power ( kW )
Apparent Power ( kVA)
OR

Drinkable beer
Full glass of beer
PF =

ABB Group
April 17, 2009 | Slide 9

kW
kVA

What is Power Factor?

Why improve

ABB Group
April 17, 2009 | Slide 10

The lower the power factor, the more reactive power

the Utilities need to provide. This can result in:

Larger equipment (i.e. poles and wires) required to

supply power

System capacity problems leading to brown-outs

Higher operating costs due to maximum demand

charges kVAr (kVA) tariff and energy loss

What is Power Factor?

Without
capacitor

Reactive power
Transformer

Motors

Available active
power

With
capacitor

Transformer
ABB Group
April 17, 2009 | Slide 11

Active power

Motors Capacitor

Applications

ABB Group
April 17, 2009 | Slide 12

Applications

Metal Enclosed Solutions

Value Proposition
Power factor correction
Reducing operating
costs increasing
energy efficiency
Better use of existing
plant

Key Applications

ABB Group
April 17, 2009 | Slide 13

Mining
Heavy industry
Chemical
Pulp & Paper
Shipping
Cement
Plastics
Petro-Chemical

Design Criteria

ABB Group
April 17, 2009 | Slide 14

Design Criteria

Designed for voltages up to 24kV

Output power < 13MVAr

Insulation up to 125kV BIL

Busbar system type tested

Integrated primary and secondary systems

ABB Group
April 17, 2009 | Slide 15

Switching, capacitors, reactors, protection and control

Flexibility in design

Range of voltages, step sizes, networks configurations

etc.

Current limiting inrush or detuned harmonic reactors

Indoor or outdoor

Design Criteria

Incomer module

Control and protection

ABB Group
April 17, 2009 | Slide 16

Power module(s):

Detuned design

OR
Inrush design

Design Criteria

ABB Group
April 17, 2009 | Slide 17

Mild steel enclosure

Aluminium enclosure

Indoor only

Type tested busbar system

Inrush reactors

Indoor or outdoor

Voltage 1-12kV

Inrush or detuned reactors

IP31

Voltage 1-24kV

Fixed and switched

Up to IP54

Fixed and switched

1. Product Modularity

ABB Group
April 17, 2009 | Slide 18

Product Modularity

ABB Group
April 17, 2009 | Slide 19

Repeatable modular design with defined:

Incomer module

Power modules

Integrated control & protection module

Customer benefits

Compact foot print

Re-locatable

Expandable

Proven performance over 15 years reliability

Reduced site installation and commissioning time

Product Modularity

Fuses

Contactors

Reactors
Circuit Breaker
Earth-switch
Capacitors

Isolator

Step 1

Incomer Module

ABB Group
April 17, 2009 | Slide 20

Step 2

Power Modules

Product Modularity

ABB Group
April 17, 2009 | Slide 21

Real estate saving

A typical 24kV, 10MVAr Metal Enclosed Capacitor Bank

will occupy less than 65% of the floor space required of an
equivalent outdoor capacitor bank

2. Safety

ABB Group
April 17, 2009 | Slide 22

Safety

Type tested busbar design

Proven IP rating

Reduced risk of site

liabilities

Live parts enclosed

Key interlocking

ABB Group
April 17, 2009 | Slide 23

Less time onsite

Solenoid / mechanical

Timed option

Key exchange system

Padlockable

Roof vents for arc fault

gasses

3. Environment

ABB Group
April 17, 2009 | Slide 24

Environment
Carbon Emissions

ABB Group
April 17, 2009 | Slide 25

Industrial plant operating

24hrs/day

Maximum demand of 20MVA

Existing power factor of 0.80

Apply an 11kV, 9MVAr MECB

Target power factor 0.98

This will reduce the CO2 emission by 2,214 tonnes per year.

This does not include further CO2 emission savings due to

decreases in cable losses from the generator to the substation, or
transformer losses.

ABBACUS MECB
The future of reactive compensation for industrial
applications & distribution utility systems

ABB Group
April 17, 2009 | Slide 26

Pole Mount Capacitor Systems

ABB Group
April 17, 2009 | Slide 27

Pole Mount Capacitor System

Features

ABB Group
April 17, 2009 | Slide 28

Voltage stability

Power factor correction

Increase in system capacity

Reduction in line losses or kW/hrs

Pole Mount Capacitor System

Types

ABB Group
April 17, 2009 | Slide 29

Fixed bank

Used when the reactive load requirement is constant

Manual disconnect or load break fused cutout

Switched bank

Used when the reactive load is variable

Vacuum switch and controller

Distributed Load

ABB Group
April 17, 2009 | Slide 30

Voltage Drop Due to Transformer & Secondary

ABB Group
April 17, 2009 | Slide 31

Voltage Drop with Capacitor

ABB Group
April 17, 2009 | Slide 32

Pole Mount System Configuration

Ungrounded Y

Grounded Y

Delta

ABB Group
April 17, 2009 | Slide 33

Pole Mount Capacitor System

Usual Practice

Delta and ungrounded systems

ABB Group
April 17, 2009 | Slide 34

Ungrounded Y banks are the most common

For grounded systems

Grounded Y banks are generally used

Where system fault currents are excessive, ungrounded

Y banks are used

Considerations

Normal service

The equipment is rated for a maximum of 55C ambient

Maximum permissible overvoltage is 110% of rating

Maximum permissible power loading is 135% or rating

Excessive voltage

Resonance

ABB Group
April 17, 2009 | Slide 35

Operation under overvoltage conditions shortens the

life of capacitors
Harmonic absorption can stress capacitors

Considerations

ABB Group
April 17, 2009 | Slide 36

Inrush and fault currents

The inrush current capability of the switch is important,

especially in back-to-back switching conditions

Location of high fault level capabilities are to be

avoided (i.e. 6kA maximum)

Fuse selection

Inrush reactors or suitable pole spacing

Key Components

ABB Group
April 17, 2009 | Slide 37

Capacitors

In-line rack

Vacuum switch

Junction box

Control voltage transformer

Surge arrester

C200A controller

Current limiting reactor

Fuse cutout

ABB Power Capacitors

ABB Group
April 17, 2009 | Slide 38

Unfused design

50 to 750kVAr

Up to 21kV

50/60Hz

Built-in discharge
resistors

Max. 50/150kV BIL

Single or Three phase

Stainless steel 304 tank

Non-PCB fluid

C200A Capacitor Controller - Features

ABB Group
April 17, 2009 | Slide 39

User friendly interface

Control

Automatic, manual

Schedule, temp, volt, var

Primary, override

Combinations of the above

Measurement & monitoring

Data logging 9000 events

Protection

Local communication

Easy programming &

commissioning

C200A Utility Software: Monitor Tab

ABB Group
April 17, 2009 | Slide 40

C200A Utility Software: Operation Tab

ABB Group
April 17, 2009 | Slide 41

Control Setup

ABB Group
April 17, 2009 | Slide 42

User-friendly Interface

Communication Port

LCD Display

Power and
Capacitor Status
Indicators

AUTO/MANUAL
Mode

Switch status
Indicators
Manual OPEN &
CLOSE switches

Navigation
Keypad

ABB Group
April 17, 2009 | Slide 43

Navigation is easy and

intuitive

PS15 & PS25

Capacitor Vacuum Switch
ABB Group
April 17, 2009 | Slide 44

PS15 & PS25 Capacitor Switch Key Features

ABB Group
April 17, 2009 | Slide 45

PS15 15.5kV
ungrounded

PS25 25kV ungrounded

ABB vacuum interrupter

technology

Magnetic actuator

Mechanical or electrical
latching

Hydrophobic cycloaliphatic
epoxy (HCEP) resin
insulator

Value-adding features at no
extra cost

No oil, gas or foam

Maintenance free

ABB Vacuum Technology

ABB Calor Emag

20 Years experience

Used in other ABB

products

Vacuum interrupter
designed to minimise the
risk of re-strike during
capacitor switching

Life expectancy

ABB Group
April 17, 2009 | Slide 46

25,000+ close-open
operations

Position Indicator / Manual Trip Lever

ABB Group
April 17, 2009 | Slide 47

The switch can be manually isolated by pulling down on the

trip lever

An electrical signal is required to re-close the switch after

manual operation

Sturdy stainless steel lever & accessories

Trip lever doubles as a visual indicator

Located at the bottom of the switch housing

Easily accessible to site personnel

Easily viewed by site personnel

No Oil, Gas or Foam

No risk of environmental contamination

Vacuum medium for switching

Magnetic actuator in air

Lightweight

ABB Group
April 17, 2009 | Slide 48

Storage and transportation made easier

Maintenance Free

Vacuum technology

ABB Group
April 17, 2009 | Slide 49

25,000+ close-open
maintenance free
operations

Magnetic actuator

Permanent magnets

One main moving

component driven by
permanent magnets

Durable components

Stainless steel housing

Stainless steel external

components

PS15 Specifications

Voltage rating

15.5kV ungrounded

27kV grounded

Insulation

Open contact: 95kV

B.I.L

Line to ground: 125kV

B.I.L

Continuous current rating

ABB Group
April 17, 2009 | Slide 50

200 Amps

PS25 Specifications

Voltage rating

25kV ungrounded

43kV grounded

Insulation

Open contact: 125kV

B.I.L

Line to ground: 150kV

B.I.L

Continuous current rating

ABB Group
April 17, 2009 | Slide 51

200 Amps

Specifications

Mechanically / electrically latched operation

Control circuit

Nominal voltage: 120V and 240V AC

Nominal open/close times: < 100ms

Nominal current: 10 Amps

Switch status option

Type tested to ANSI C37.66

ABB Group
April 17, 2009 | Slide 52

Voltage free contact

Powertech Labs

Accessories

ABB Group
April 17, 2009 | Slide 53

Wildlife protective covers

Auxiliary limit switches for switch status

Junction box

Connection cables (including connectors)

Added Product Range

Coming Soon

ABB Group
April 17, 2009 | Slide 54

The latest offering from

ABB will include capacitor
vacuum switches with the
following added
functionality:

400 Amps continuous

current rating version

100 - 125V DC Nominal

operating voltage at
50/60Hz

Key Benefits to Customers

Peace of mind

ABB brand name

Proven technology

ANSI C37.66 certified

Value for money

ABB Group
April 17, 2009 | Slide 55

Combines the best of

what competitors have
to offer

Total ABB package

Capacitors

VT

C200A controller