T-68 Protecting Your Equipment through

Power Quality Solutions

Dr. Bill Brumsickle
Vice President, Engineering
Nov. 7-8, 2012

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Agenda
What is Power Quality?
Importance of Power Quality to Industrial Users
Power Quality Events & Voltage Sags
Voltage Sag Protection

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Power Quality vs. Power Reliability

Power Reliability: Continuity of electric power delivery measured by the number and
duration of power outages (Zero voltage)
Outages are tracked by Utilities
Power Reliability can be as high as 99.999% availability
Power Quality: Related to fluctuations in electricity, such as momentary interruptions,
voltage sags or swells, flickering lights, transients, harmonic distortion and electrical noise
Fewer such incidents indicate greater power quality
Events go mostly untracked by Utilities
Sag & Momentary events can take out a process as many as 20-30 times per year

The Grid is designed for Reliability, not Quality

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Power Quality
Frequency is regional
Determined by HV & EHV network generators
Problems are rare
Voltage is area-wide
Determined by MV distribution network
Problems occur randomly, but with regularity
Current is local
Determined by facility loads
Problem loads can be identified and resolved

Source: DTE Energy website

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Utility Power Properties of AC Grid

Not always ideal sinusoidal voltages!
Highly interconnected
Transformer and line impedances between
generators and loads
Terminal voltage drops with load current
System faults cause significant voltage sags (dips)
Most wiring is overhead
Susceptible to lightning, animals, wind-blown
tree branches, etc.

Source: NPR: Power Hungry: Reinventing The U.S. Electric Grid May 1, 2009

Insulation fails, equipment fails

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Power Quality Problems

All have physical causes

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Agenda
What is Power Quality?
Importance of Power Quality to Industrial Users
Power Quality Events & Voltage Sags
Voltage Sag Protection

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Electrical Equipment Designed Assuming

Power Quality
Operate with input ac voltage variation of 10%
Possible new requirements:

Operate through some voltage sags

SEMI F47
IEC
Present a unity Power Factor:
Current phase angle near zero
Current harmonic distortion low

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Impact of Power Quality Events

Possible Agency, Utility, or Facility Requirements

Power Factor correction (current phase angle)

Harmonic current limits

Load equipment mis-operation

Voltage sags and momentary interruptions

Voltage distortion (harmonics, notching)
Voltage imbalance or single-phasing
High-frequency voltage transients

Load equipment damage

High-voltage transients
Current inrush following voltage sag

Facility infrastructure damage

High-voltage transients
Current inrush following voltage sag
Overheating due to current harmonics
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Consumer is Responsible for Power

Quality
Utility cannot provide perfect power quality and are not
required to. (e.g., Wisconsin PSC 113.0703)

Customers having equipment or operations that are sensitive to such voltage

fluctuations may find it necessary to install, at their own expense, power
conditioning equipment or other modifications

Job is to Keep the lights on.

Goals

Deliver maximum energy through the existing infrastructure

Maintain +/-10% (on average) voltage at service entrance
Minimize outages longer than 2-5 minutes
60.00 Hz, when averaged over 24 hours
Keep large industrial customers satisfied
Minimize large customers disrupting neighbors power quality

The utility is responsible for reliability, not quality of power.the customer is

responsible for protecting their sensitive equipment at their own expense
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

10

Agenda
What is Power Quality?
Importance of Power Quality to Industrial Users
Power Quality Events & Voltage Sags
Voltage Sag Protection

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

11

Power Quality Issues

Voltage sag (dip) and Momentary interruption
High voltage transients (spikes)
Current distortion (harmonics)
Voltage distortion and voltage flicker caused by distorted
current loads
Voltage unbalance

EPRI (Electrical Power

Research Institute)
Monitored 300 sites for 2+
years.
92% of all events were voltage
sags under 2 seconds
4% of event interruptions from
2 seconds to 10 minutes

Voltage notching
Uncommon issues in the U.S. and high-tech. parks:

brownout
voltage swell
frequency variation

Poor grounding
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12

Voltage Sag (Dip) Characterization

Sag - RMS voltage reduction between 1/2 cycle - 60 sec
Magnitude and Duration
1

Duration: 4 Cycles

0.5

0
0

-0.5

-1

Magnitude: 60% Remaining

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13

Voltage Sag
90%

Magnitude (per unit)

1.0
0.8
0.6
0.4
0.2
0.0
1

10

100

1000

Duration (ms)
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14

Why mostly brief sags and interruptions?

12 kV

Radial Distribution

69 kV

Reclosing breakers

F1
" C"
20 MVA
F2

V = Vs Zline*I
Fault results in short voltage
sags and interruptions for
most customers, affecting
up to 200 mile radius

" B"

1500kVA
480 VOLTS
THREE PHASE FAULT
" A"

F3

VOLTAGE
1. 0
0. 5

VOLTAGE AT "C"
AND ON F1 & F3
VOLTAGE AT "B"

0. 0

0 BEGIN F2
FAULT OPENS

TIME

V=0.67 p.u.
V=0.40 p.u.

F2
F2
CLOSES OPENS

FAULT
F2
CLEARS CLOSES

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15

Why Sag Durations are short

Clearing Time in Cycles
Type of Fault

Typical Minimum

Typical Time Delay

Number of Retries

Clearing Device
Expulsion Fuse

0.5

0.5 to 60

None

Current Limiting Fuse

0.25 or less

0.25 to 6

None

Electronic Recloser

1 to 30

0 to 4

Oil Circuit Breaker

1 to 60

0 to 4

SF6 or Vacuum Breaker

35

1 to 60

0 to 4

Source: IEEE Std 493

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

16

Sags at High-Tech Mfg. Sites

Very few outages, still
many sags!
1000 sag events from
15 Semi plants
Avg. 5.4 events below
CBEMA per yearwith
transmission-level
service!
SEMI F47

source: International SEMATECH & EPRI, 1999

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Impact of Voltage Sags

Sensitivity of various 3-ph. 4kW drives to single-phase sag

(rated speed, torque) [Djokic]

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18

Impact of Voltage Sags

% of Nominal Voltage

AC Relay Voltage Sag Tolerance Curves

100
90
80
70
60
50
40
30
20
10
0
0

50

100

150

200

250

300

350

400

450

500

Duration of Sag (milliseconds)

Upper range

Average

Lower Range

Source: IEEE Std 1346-1998

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

19

Data Corruption

Source: Djokic

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

IEEE P1668 a new standard

Recommended Practice for Voltage Sag and Interruption
Ride-through Testing for End-use Electrical Equipment
Less than 1,000 Volts
A standard for the response of electrical equipment to voltage sags
Expected to include:
Guidance for evaluation of equipment sensitivity to voltage sags and
interruptions
Minimum performance criteria to specify during the purchasing process
Levels of performance for acceptance of the product
Voltage tolerance curves for three-phase equipment: more useful than CBEMA
or ITIC

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Effect of Voltage Sags on Equipment

Most common effect is equipment drops offline
PLC shutdown
Open contact or relay (As little as 80% remaining voltage for 1 Cycle)
A secondary effect is that when voltage returns, high current inrush can occur because the Softcharge circuit is bypassed
RF Amplifiers, Gradient Amplifiers, and Low Voltage Power Supplies subjected to repeated
hitsFail.
Typical rectifier circuit diagram:

Voltage SAGS can shut-down and/or damage equipment!

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

22

Voltage Sags Effect Equipment

Example: Inrush current measured for 1kVA electronic load
Inrush after Sag

Normal Inrush

Volts

Amps

Volts

Amps

5
10

Peak inrush 10A

Soft-charge
circuit is active

0
20
40

Peak inrush 50A

Soft-charge
circuit bypassed

Note the scale change necessary to get the sagged results on the same page!

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

23

Only some machines shut down. Why?

Fabrication or Assembly Line Layout:

480-b

Machine 1

Machine 2

Machine 3

Machine 4

Machine 5

Machine 6

480-a

Machine power distribution and power supplies vary:

L1
L2
L3

:Y
Tranf.

Controls
Power

L2

Rect.
Controls
Power

L1

Tranf.

Rect.

Tranf.

Controls
Power

Tranf.

Rect.
Controls
Power

L3
L1

Tranf.

Rect.

Rect.
Controls
Power

L3
N

Rect.

Controls
Power

L2
N

Tranf.

L2
L3

Controls
Power

L1

Tranf.

Rect.
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Detection of Power Quality Events

Monitoring is Key to Knowing the Local Power
Quality
I-Sense, I-Grid Voltage Monitoring
I-Sense voltage monitor device
I-Grid network of monitors and database
servers
information and notification service

Email & text message notification in real time

Web summary, available from anywhere
PDF Reports

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

I-Grid
Use Web browser to:
View event details
Manage accounts and monitors
Generate reports and export data
I-Sense monitors record & report
PQ event data via the Internet

I-Sense Owners
Internet

I-Grid
Servers
&
Database

Web
Utility Engineer

Facility Engineer
Email

Other users
Real-time notifications
Report delivery
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Agenda
What is Power Quality?
Importance of Power Quality to Industrial Users
Power Quality Events & Voltage Sags
Voltage Sag Protection

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

27

Sag Correction Solutions

DySC Protection

Stand-by UPS
Protection

CVT
Protection

On-Line UPS
Protection

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28

28

DySC and UPS Correction Capability

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29

UPS Product Offering

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30

DySC (Dynamic Sag Corrector)

DySC (pronounced Disk) is an adaptive power supply that optimizes the remaining
power during a sag by using patented inverter technology to compensate for the sag
thereby maintaining an uninterrupted flow of optimal power to the load thus maximizing
uptime, minimizing inventory loss and reducing maintenance costs
Up to 5 seconds of ride through
U.S. and International voltages available
Scalable solution

MiniDySC (single-phase; 0.25-12 kVA)

ProDySC (3-phase; 9-167 kVA)

MegaDySC (3-phase; 263-2000 kVA)

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31

DySC - Normal Operation

DySC
DSP Controller

Auto
By-Pass

Utility

Load

Static
Switch

CrossCoupling
Transformer

Power Conversion
Rectifier

Inverter

Core

Component

Activity

DSP Controller

Constantly monitors incoming power, system integrity and load

Static Switch (99% efficient)

Closed. Sends power directly to the load

Cross-Coupling Transformer

Idle

Power Conversion Core

Idle

Automatic By-Pass

Idle

Normal Operation - The DySC monitors power quality continuously,

while the power electronics are in standby 99.99% of the time
Copyright 2012 Rockwell Automation, Inc. All rights reserved.

32

DySC - Voltage Event

DySC
DSP Controller

Auto
By-Pass

Utility

Load

Static
Switch

CrossCoupling
Transformer

Component

Power Conversion
Rectifier

Inverter

Core

Activity

DSP Controller

Detects the leading edge of a voltage sag, immediately routing

power thru the C-C Transformer and Power Conversion Core

Static Switch (99% efficient)

Open

Cross-Coupling Transformer

Pulls additional power from the grid

Power Conversion Core

Rectifies and inverts to recreate a true sinusoidal Output

Automatic By-Pass

Idle

DySC is On in under 2 milliseconds and recreates a true sinusoidal output

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

33

DySC Operation
Normal Operation (Monitoring)
Static Switch ON, Highly efficient
Power electronics OFF
Capacitors charged & ready
No thermal cycling, long life
Low maintenance
Voltage Sag Correction
1-2 millisec. detection
Static switch OFF
Power Electronics ON, to produce
corrected sinusoidal load voltage
Energy from capacitors needed only
for sags below 50%
Example: voltage sag to 60%, full load
We keep load voltage at 100%,
so load power remains 100%
Input Current rises briefly
to (100% / 60%) = 167%
Load energy comes from ac input,
not from capacitors!

V = 100%

V = 60%

V = 100%

167%
(V = 40%)

100%

LOAD
67%

167%

100%

100%
patented

Static bypass 99.99% of the time

Corrects voltage by maintaining power flow (P = V x I)

Most of the time the DySC is in a monitoring mode

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

34

DySC Sag Correction

330 kVA MegaDySC responding to 3-phase 50% voltage sag, duration 4.5 seconds

input
waveforms

output
waveforms

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35

DySC Interruption Correction

input
rms voltage

330 kVA MegaDySC-ER

3-phase interruption
for 250 ms (15 cycles)
90%

output
rms voltage

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

36

For More Information or Questions

Power Quality at Automation Fair 2012

Essential Components (Booth 127): Protection Solutions

Energy Management (Booth 541): Power Quality Monitoring

Backroom Session: Hands-on DySC and I-Sense / I-Grid

More information available at Booths

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Thank you for your attention. Questions?

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