Joao Pimenta, PGTMM , October 13th, 2016

ABB Power Grids

Capacitors and Filters

© ABB
October 25, 2016 Slide 1
Capacitors in ABB
History
§ 1932, started ASEA/ABB to deliver capacitors
§ This design remained the same until the beginning of
the 60’s. During the 60’s and 70’s the design
accelerated due to the early ASEA projects for HVDC
and FACTS projects.
§ 2000, ABB started to manufactory capacitors at Xi´an
facility, with focus at local HVDC and FACTS projects.

Pictures from old catalogues § 2001, ABB introduced a revolutionary Dry type of
capacitors for DC applications

More than 80 years of experience in the field of capacitors

© ABB
October 25, 2016 Slide 2
Advantage of a good Power Factor

• Current drawn from the network reduced

• Transformers and distribution cables unloaded ( í I)
• Reduced Joule losses ( RI²)
• Cables
• Transformers
• Protect devices
• Voltage drop reduced
• Cables
• Transformers
• Increased power available at transformer terminals
• No penalty from electricity supplier

© ABB
October 25, 2016 Slide 3
Advantage of a good Power Factor
Transformers and distribution cables lightened (íI)

§ Current drawn from the network

reduced
§ Reduction in factor of:
cos j 1
In (%) (1 - ) * 100
cos j 2
§ Cos j 1 = 1 In = 100%
(required useful current)
27% § Cos j íÕ In í
§ For the same kW, In is reduced by 27%
when PF rises from 0.7 to 0.95
0.95 0.7

© ABB
October 25, 2016 Slide 4
Advantage of a good Power Factor
Reduced Joule Losses (RI²)

% reduction in losses

§ Reduction factor of RI² watt (%):

cos j1
RI² watt (%) = 1 - ( cos j 2 ) *100
2

cos j final values

46 § For the same load, the losses are
reduced by 46% when PF rises from 0.7
to 0.95

cos j initial values

© ABB
October 25, 2016 Slide 5
Locating Capacitors on System

Transmission
SC
SVC

Distribution
QBANK SVC SC

Industry
Load SVC CHARM

© ABB
October 25, 2016 Slide 6
Locating Capacitors on System

Capacitor location
1 2&3 4
Technical approach Best
1 2 Flexibility Least Less Best
Savings Least Less Max
Cost per kvar Least Lower Highest

3 4
1. on the plant feeder (HV)

2. on the main LV bus

M M M
3. on the auxiliary/remote bus

4. at the individual load point

© ABB
October 25, 2016 Slide 7
Power Capacitor Unit
Definition of capacitor unit

§Capacitor bank §Capacitor unit §Capacitor element

© ABB
October 25, 2016 Slide 8
Power Capacitor Unit
Optimized capacitor design
Consideration of safety plenty level
§ Film layer (3-layers is normal)
§ Strong puncture- against ability

§ Foil auto-folding of electrode

§ Regular edge stress;
§ Excellent partial discharge ability

§Foil §Folded §Foil bulge edge

§D §D =thickness of film

§a = folded radius
§ Film
© ABB
October 25, 2016 Slide 9 §a
Power Capacitor Unit
Capacitor Unit Construction

§Connection terminal

§Bushing

§Nameplate

§Element

§Internal fuse

§Discharge Resistor

§earth insulation
© ABB
October 25, 2016 Slide 10
Power Capacitor Unit
Technology of Fuse

Internally Fused Externally Fused ABB Design Conventional Design

§Fuse §Discharge Fuseless

§ Resistor

© ABB
October 25, 2016 Slide 11
Power Capacitor Unit
Element failure

A puncture...

...creates a perfect
weld (short-circuit)

© ABB
October 25, 2016 Slide 12
ABB’s unique features
Expertise in all type of fusing technologies

© ABB
October 25, 2016 Slide 13
Application for Open Rack Solution
Voltage Level

• MV or HV Banks
• Limitation of units:
• Voltage: controls the n° of
capacitors in series of the bank;
• Case Insulation: define max.
capacitor in series at the same
rack;

• System Voltage level:

• Minimum air clearances
(Space Required)

• N° of Capacitors in Series
• Capacitor Bank’s height

© ABB
October 25, 2016 Slide 14
Application for Open Rack Solution
Rated Power

• Limitation of units:
• Rated Power: Controls the n° of
capacitors in parallel of the bank

• Rated Power:
• N° of Capacitors in Parallel
• Capacitor Bank’s width and
length (space required)

• Possibility of multi-step solution,

for automatic PF compensation.

© ABB
October 25, 2016 Slide 15
Application for Open Rack Solution
Local of Installation

• Indoor or Outdoor;
• Conventional Solution;
• Arrangement optimized for
each installation:
• Cable entry;
• Available Space;
• Air clearances and Magnetic
Clearances;
• Components inside the bank;

© ABB
October 25, 2016 Slide 16
Application for Open Rack Solution
Safety

• Fence or Elevation Structures

required
• Restrict access to the area;
• Earth and Disconnector Switch
(safety maintenance)

© ABB
October 25, 2016 Slide 17
Application for Open Rack Solution
Cost

• Most cost effective solution for

MV and HV capacitor banks;
• Components costs:
• Structure vs Panels
• Air core vs Iron core reactors
• Conventional equipment

© ABB
October 25, 2016 Slide 18
Open Rack Layouts
MV Capacitor Banks

§Standard features
§Galvanised rack
§Frame capacity: 3, 6 or 9 units
§125kV BIL insulation
§Four welded lifting lugs
§Provision for key components
§Optional features
§Aluminium structural grade

© ABB
October 25, 2016 Slide 19
Open Rack Layouts
MV Capacitor Banks

© ABB
October 25, 2016 Slide 20
Open Rack Layouts
HV Capacitor Banks – Grounded Y/Y-Y

• High Voltage (≥69kV)

• Elevation Structure (If required)
• 1-ph Stacked Racks (↑ n° SG)
• Fence required (If no elevation
structure)
• CT Unbalance sensing device (rated
voltage: 0.2 x Un)
• Progressive Insulation (racks with
defined potential)
• Bottom Insulators: ↓ BIL
• Costs: ↓

© ABB
October 25, 2016 Slide 21
Open Rack Layouts
HV Capacitor Banks – Ungrounded Y-Y

• High Voltage (≥69kV)

• 1-ph Stacked Racks (↑ n° SG)
• Fence required
• 1 x CT Unbalance sensing device
(System Full BIL)
• Bottom Insulators: System Full BIL
• Costs: ↑↑
• Attention Point: Seismic Requirements

© ABB
October 25, 2016 Slide 22
Open Rack Layouts
HV Capacitor Banks – Grounded H-Bridge

• High Voltage (≥69kV)

• 1-ph Stacked Racks (↑ n° SG)
• Fence required (If no elevation
structure)
• 3 x CT Unbalance sensing device
(rated voltage must coordinate with
bridge midpoint voltage level)
• Progressive Insulation (racks with
defined potential)
• Bottom Insulators: ↓ BIL
• Costs: ↑↑

© ABB
October 25, 2016 Slide 23
Methods of Capacitor Control
Fixed vs. Switched Capacitors

Generally, it is more economical to 6

correct to near-unity power factor:

5

• At minimum load through the

4
application of fixed capacitors

MVAR
3

• At higher loads through the

application of switched capacitors 2

• Ideal solution…fixed capacitors 1

compensate the fixed portion of

load, while switched capacitors 0
0 24
compensate peaks and troughs Hour

© ABB
October 25, 2016 Slide 24
MECB 36 SD 10 (with internal detuned reactors)
Indoor/Outdoor, IP54, Switched, One Stage

© ABB
October 25, 2016 Slide 25
33kV ABBACUS MECB

© ABB
October 25, 2016 Slide 26
PQC-STATCON
Shunt compensation
PQC-STATCON offers:
§ Enhancement of the grid – shunt
technology makes the grid act in a
more robust, flexible and predictable
way
§ Control of reactive power injection or
absorption
§ Unbalance compensation
§ Dynamic voltage control
§ Low noise levels
§ Optimized losses
§ Solution to MV/HV through Step up
transformers
§ Flicker mitigation (Case to case basis,
pls consult factory)
© ABB
October 25, 2016 Slide 27
Field report: Welding Loads - Automotive
FIAT Automobiles, India
Customer requirement
• Fast response reactive power compensation for weld
shop

• To maintain power factor close to unity

• Reliable reactive power system with power saving mode

during lean hours / shift

ABB Solution
Ø Installation of 0/600 kvar & 0/1200 kvar Instantaneous
stepless compensation consisting of 50% PQCT-STATCON
and 50% filter bank.

• Pf is maintained to unity.

• STATCON in energy saving mode goes in sleep mode

during no load condition

• Voltage stabilization of bus.

©
§©ABB
ABB Group
October
§October25,
25,2016
2016 | Slide 28 Slide 28
 Power factor graph with & without PQC-STATCON
§Source PF of 2.5 MVA transformer (PQC Off)

§Customer benefits

§ Power saving, less wastage of welding

electrodes

§India § Up to 20% of saving in electricity

§Source PF of 2.5 MVA transformer (PQC STATCON on) consumption from grid
§ Reduction in electricity bill due to
§Pune
power factor improvement

©
§©ABB
ABB Group
October
§October25,
25,2016
2016 | Slide 29 Slide 29
Performance Letter from FIAT Automobile

§We are happy to inform you

that with ABB make
STATCON, we are able to
maintain an average
monthly power factor above
0.995 lag to unity(1.0). This
has indubitably improved
performance of our plant
loads by improving the total
power quality.

©
§©ABB
ABB Group
October
§October25,
25,2016
2016 | Slide 30 Slide 30
PQF active filters
Key features
§ Filters up to 50th order of harmonics
§ Selective harmonic filtering
§ Closed loop operation
§ Provides dynamic reactive power and power factor
correction
§ Load balancing feature
§ Graphical display of all power parameters of loads and filter
§ Keeps running at maximum load if load requirement is too
high
§ Easy commissioning

©
§©ABB
ABB Group
October
§October25,
25,2016
2016 | Slide 31 Slide 31
PQF for floatation plant drives
Gold Mining in Greece
§ Operation and exploitation of mines
§ High power motors to crush the minerals
§ Significant level of harmonic currents
§ Bad voltage waveform

©
§©ABB
ABB Group
October
§October25,
25,2016
2016 | Slide 32 Slide 32
Customer benefits
Unit L1-L2 L2-L3 L3-L1
Electrical values without filter
Voltage Vrms 402 401 396

§VR-Y THD(U) % 5.3 5.4 6.0

§IR
L1 L2 L3
Current Arms 948 1001 959
THD(I) % 34.1 31.6 34.0
Global
Active power kW 617
Reactive power kvar 179
Apparent power kVA 657
PF - 0.94
Cos (φ) (or DPF) - 0.96 (Inductive load)

©
§©ABB
ABB Group
October
§October25,
25,2016
2016 | Slide 33 Slide 33
Customer benefits
Electrical values with filter

Unit L1-L2 L2-L3 L3-L1

§VR-Y
Voltage Vrms 397 396 392
§IR
THD(U) % 1.5 1.5 1.9
L1 L2 L3
Current Arms 809 850 817
THD(I) % 7.1 7.1 7.3
Global
Active power kW 524
Efficient filtering of harmonics
Reactive power kvar 154
§ Reduced electrical pollution Apparent power kVA 564
Improved performance of electrical loads PF - 0.96
§ Downtime reduction Cos (φ) (or DPF) - 0.96 (Inductive load)

©
§©ABB
ABB Group
October
§October25,
25,2016
2016 | Slide 34 Slide 34
 Capacitors and Filters
World of ABB

© ABB
October 25, 2016 Slide 35
Capacitors in ABB
Manufacturing, Local assembly units,
Power quality centers and Technical lead centers
Jumet, Belgium
TLC LV / PQC
LV Cap. factory Ludvika, Sweden
TLC MV & HV / PQC
MV & HV Cap. factory
Quebec, Canada
PQC / LAU
Bulgaria Xian, China
Youngwood, PA Galindo, Spain LAU MV & HV Cap. factory
LAU PQC / LAU

Dubai, UAE Bangkok, Thailand

San Luis Potosi, PQC LV Cap. factory
Mexico, PQC / LAU

§No. of MV & HV Cap. Factories : 3 Guarulhos, Brazil Bangalore, India

PQC / LAU MV & HV Cap. factory
§No. of LV Cap. Factories :2
§Local assembly units (LAU) :7
Lilydale, Australia
§Power quality center (PQC) :8 PQC / LAU
§Technical lead center (TLC) :3 TLC MECB

© ABB
October 25, 2016 Slide 36
ABB’s unique features
Performance in extreme ambient conditions
420 kV Substation, Norway
Successful installations in various
extreme ambient conditions like
§ Extreme temperatures..
§ High seismic activity..
§ High altitudes..
§ High pollution and corrosion levels..
§ 100% humidity..
....no problem!

Increased network reliability

due to robust design.

© ABB
October 25, 2016 Slide 37