Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

A PQ Case Study
CS 47 ENG 17

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 1
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

mitigation techniques wherever the

harmonic distortion is reportedly high.
Most of these facilities already had

47
Abstract:
TANGEDCO – Distribution Utility for Tamil
Nadu State has given a regulation
regarding Harmonic Mitigation, under
direction of tariff order by Tamil Nadu
Electricity Regulatory Commission
(TNERC), wherein any
consumer/generator need to meet the
specified Harmonic limits as per norms
stipulated in CEA regulation on grid code.
TANGEDCO measures the level
Harmonics and issues a notice if the value
exceeds the CEA specified limit and if the
consumer is unable to mitigate Harmonics
within the specified limit after notified
period, penalty is imposed every month.
reactive power compensation in terms of
capacitor banks installed. These capacitor
banks too suffered from failure etclike
other electrical equipment failure due to
high harmonic distortion levels.
In some cases based on harmonic
spectrum, installed capacitor banks can be
used to mitigate harmonics. After detailed
and proper analysis of harmonics in the
system mitigation techniques like tuned
harmonic filters or capacitor with reactor
HT
can also used as harmonic filteration
technique.
This case study explores such possibility
that can be beneficial for industry to look
of
at available resources for addressing
harmonic mitigation and optimize their
expenses in deploying fresh investment to
avoid harmonic penalty.

Due to above tariff penalty mechanism

the HT consumers started looking at

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 2
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

Introduction
Distribution Company :

With drastic change in type of load used by electricity consumers in last one decade i.e.
adoption of more non linear loads, generation of current harmonics has increased
significantly. These current harmonics generated by consumers, not only have a negative
impact on the consumers own electrical system but also impacts electricity distribution
companies adversely. Higher levels of current harmonics in the system results in distorted
voltage waveform that results in overall poor distribution grid power quality.

Presence of harmonics in the electricity distribution companies not only increases

distribution losses in the system but also decreases life of electrical equipments.
Malfunctioning of circuit breakers and relayes, overheating of conductors and cables,
premature failure of transformers, motors do have a root cause as harmonics in major
cases. If harmonics in the system are beyond a limit, realibility of the electrical system also
decreases. All above effects of harmonics have an impact on overall operation of consumer
and distribution companies.

Tamil Nadu Generation and Distribution Corporation Limited (TANGEDCO) is first state in
India which has enforced a harmonic control regulation for its HT power consumers
empowered byTa il Nadu Ele tri ity Regulatory Co isio ’s TNERC Tarrif a d Har o i
Level order dates 20th June 2013. Through this order, limits were placed for current and
voltage harmonics and penalty was enforced for violation of prescribed limits. The limits
spe ified for har o i s ere as per Ce tral Ele tri ity Authority’s CEA Notification
TheCe tral Ele tri ity Authority Te h i al “ta dards for Connectivity to the
Grid Regulatio s, 2007 No: 12/X/STD(CONN)/GM/CEA (21-Feb-07).

As per notification:

Voltage Harmonics: The total harmonic distortion for voltage at the connection point shall
not exceed 5% with no individual harmonic higher than 3%.

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 3
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

Current Harmonics: The total harmonic distortion for current drawn from the transmission
system at theconnection point shall not exceed 8%.

Above limits were set in accordance with definition and guidelines provided in IEEE- 519 –
1992.

TANGEDCO also set the same limits as mentioned in the tariff order. Based on these orders,
TANGEDCO started measurement of harmonics on designated consumers and issued notices
where harmonics were found to be beyond these limits. Text from a sample notice to the
consumer is as below.

As per the lause 4 1 i of the Ta il Nadu Ele tri ity “uppply ode, you are lia le to pay
additio al harges for du pi g of har o i s i to TANGEDCO’s distri utio syste ore
than the permissible limit specified the the CEA regulations and if you fail to provide
adequate harmonic suppression units.

Hence it is hereby informed that,

i) As per the provisions contained in the tariff order in T.P.No 1 of 2013 dt.
20.6.2013, the consumers under category of HT-1 & HT-III are liable to pay
compensation charges after three months period from the date of
measurement, if the measured harmonics is beyond the permissible limit as
specified by CEA regulations.
ii) On 03.12.2013, the measurement of current and voltage harmonics was done
by MRT and field engineer using measuring meters/equipment in the
presence of your representatives and it was found that the Total Harmonics
Distortio THD for urre t is …… %, hi h is a o e the per issi le li it of
8% specified by the CEA regulations.
iii) You are requested to provide adequate harmonic filtering equioment to avoid
du pi g of har o i s i to Li e see’s et ork eyo d per issi le li it as
specified by CEA regulations. The three month period from the date of
measurement expires on 02.03.2014.

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 4
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

iv) As per the regulation 4, (1) (iv) of Tamil Nadu Electricity Supply Code, if you
fail to provide adequate harmonic filerting equipment to avoid dumping of
har o i i to Li e see’s et ork eyo d the per issi le li its as spe ified y
CEA regulations, you are liable to pay compensation at 15% of the respective
tariff on expiry of the three months perios and as and when you bring down
the harmonics within the limit, the levy of compensation charges will be
withdrawn.

Consumer:

There is a general perception among the industries that mitigation of harmonics is a capital
intensive project. However depending on severity of harmonics, type of harmonics and
objective of consumer, there are number of solutions available in the market which can
meet the requirement. Each solution has its own benefits and limitations. Various harmonic
mitigation techniques that are available can be listed as below. Few technologies need to be
adopted at design stage where as few technologies can be implemented as a retrofit or
additional component/equipment.

 Line reactors.
 Isolation transformers.
 K-Factor transformers.
 Phase shifting transformers.
 Tuned harmonic filters.
 Low pass harmonic filters.
 Active harmonic filters

As mentioned each solution has its own advantages and limitations. There is no single
solution that is better than other solution. A careful and detailed study of the harmonics in
the system along with consumer requirement can result in selection of best possible
solution. The selected solution could be either one or combination of few technologies
mentioned above.

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 5
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

Section below shows brief about each technology and its application.

Line reactors:

Line reactors are one of the simplest and lowest cost technology for mitigation of
harmonics. These are used at the load end and in line with the load that is generating
harmonics. Line reactors are very common with variable frequency drives. They operate on
the principle of increasing impedance of the circuit. If a plant has a 1000 kVA transformer
with an impedance of 7%, and a drive of 100 kVA. This drive will have approximate
impedance of only 0.7%. As transformer impedance will be very small relative to each load,
a line reactor in series will improve impedance of the circuit.

One of major advantage of line filter is their low(est) cost and reduction in harmonic levels
to a great extent. Another advantage is that since they are installed right at the load end,
harmonic distortion is reduced in the distribution system. One of their major limitation is
with normal impedance (5-6%), they can reduce total current harmonics distortion up to
35%. Also their harmonic mitigation capacity reduces drastically with reduction in load
current.

Isolation Transformer:

Isolation transformer are one of very effective means of not only mitigating harmonics but
also other power quality issues like transients, common mode noise and zero sequence
currents.

Operating principle of isolation transformer is also based on line reactor, which increases
system impedance. The leakage inductance of isolation transformers increases circuit
impedance so that harmonics are reduced to a great extent. Typically, a delta – wye
configuration is used in isolation transformers. Since, primary is delta connected and
secondary is wye configuration, zero sequence currents (Triplen harmonics) are not
transferrent to the primary side of the network.

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 6
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

Due to capacitive coupling between winding and shield with proper grounding, transients,
common mode noise and zero sequence currents are not reflected on the other side of the
transformer.

Isolation transformer has added advantage of eliminating other power quality issues in
addition to harmonics over line reactors. Their harmonic mitigation capability is same as of
line reactor but can be very useful where zero sequence currents and other power quality
issues as mentioned above are present. Their cost of be around 5 -6 times higher as
compared to line reactor.

Tuned Harmonic Filter:

Tuned harmonic filters are basically combination of capacitor and reactor (inductor) which
are connected in series to form a tuned circuit. This tuned filter is connected in parallel to
the main system. As the LC circuit is tuned to particular frequency to form resonance, it
offers lowest impedance to that particular frequency (harmonic). Harmonic current instead
of flowing to the utility, flows to the filter.

Low Pass (De-tuned) Harmonic Filter:

All above mentioned methods filters out particular order of frequency. Low pass filter or de-
tuned filters have capability to attenuate all order of harmonic frequencies. De-tuned
harmonic filters are combination of series and shunt elements of reactors and capacitors.

The shunt circuit prevents attraction of harmonics from other sources where are series
circuits filters of primarily 5th and 7th order harmonic. They are one of most economical
means of mitigating harmonics.

Active Harmonic Filter:

Active harmonic filters are latest among all technologies for mitigation of harmonics. They
continuously monitor load current along with fundamental and harmonic current. Based on
the order of harmonic and their magnitude, they will inject equivalent magnitude of
individual harmonics with phase shif of 180 degrees. These injected currents will nullify the

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 7
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

harmonics in the system. Active harmonic filters can filter out harmonics up to 50 th order of
harmonics. So AHFs need some energy to drive itself.

As acti e filters uses fast s it hi g IGBT’s, they produ es oise hile s it hi g hi h a

cause disturbances in the system. These noise signal can also be harmful to the sensitive
equipments. Presence of high voltage distortion can also affect performance of active
harmonic filter. In terms of cost, they are costliest among all available options.

Apart from above technologies, some other techniques apply principle of de-rating where
equipments are capable of handling harmonics. One of the example is K-rated transformers
which basically de-rates a transformer to withstand higher temperatures generated due to
harmonics.

Background
The case study involves one of the leading leather shoe manufacturing plant in Tamil Nadu.
The plant receives power at 11kV which is stepped down to 440 volts. Base demand of the
plant was 320 kVA where as sanctioned demand is 400 kVA. Average registered demand
during the last 12 months was around 328 kVA.

Rated capacity of the transformer is 500 kVA.

Figure – 1 shows basic SLD of the plant.

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 8
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

Load at the pla t o stitutes ai ly otors ith dri es. VFD’s or dri es are o li ear loads
which generates current harmonics. As Tamil Nadu distribution company has norms for
harmonic that are being injected in the grid by the consumers. They carry out routine
measurements at the consumer incomer (PCC) and if harmonics are found to be high, they
ask the consumer to reduce the harmonics.

The shoe manufacturing plant also got a notice from TANGEDCO asking them to reduce the
harmonics below specified limit. Specified limit of current harmonics by TANGEDCO is 8%. It
is mandatory for all HT consumers to keep current and voltage harmonics as specified by the
TANGEDCO.

Based on the notice, the shoe manufacturing plant carried out detailed harmonic study of
the plant.

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 9
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 10
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

Harmonic Study Summary:

The facility receives power from electricity board at 11kV and stepped down to 440 Volts
using a transformer.

A detailed harmonic study was carried out by the plant. During the study, harmonics were
measured at different locations in the plant. The measurements were carried out at
following locations.

1. Main incomer
2. SSB – 1
3. SSB – 2
4. SSB – 3
5. Lighting load
6. Air Compressors

Section below shows measurement details at individual sections.

Main Incomer:

At the ai i o er, easure e ts ere arried out ith apa itors i ON o ditio a d
OFF o ditio . Graph – 1 & 2 shows voltage and current waveforms at the main incomer
he apa itors are ON a d OFF .

Figure – 2 Wa e for he apa itor is ON Figure – 3 Wa e for he apa itor is OFF

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 11
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

As see fro the a e for , the urre t a efor is distorted he apa itors are i ON
condition.

Figure 4 & 5 shows i di idual order of har o i s ith apa itor ON a d OFF .

Figure – 4 I di idual order of har o i s he apa itors are ON

Figure – 5 I di idual order of har o i s he apa itors are ON

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 12
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

As see fro the a o e graphs he apa itors are i ON o ditio , the % THD voltage
and current are 3.28% and 13.53%. Whe apa itors are OFF , % THD oltage a d urre t
values are 2.44% and 3.48%. Predominant harmonics were 5th and 7th order.

Above measurements clearly indicates that significant current harmonics are not generated
by the load but are amplified due to capacitor banks. The plant could not isolate capacitor
a k as hile apa itor a ks ere i OFF o ditio , po er fa tor dropped to 0.79 from
0.98 which would result in higher maximum demand by the plant.

Table – 1 shows summary of measurement at other locations in the plant.

Harmoni
Current c current
Voltage – % –
Location Capacitor (V) (Amp) THDv % THDi PF kVA Amperes
Main incomer ON 404.3 404 3.28 13.53 0.98 255.22 54.66
OFF 405.2 496.1 2.44 3.48 0.79 334.99 17.26
SSB 1 410.6 257.3 3.61 6.41 0.75 175.19 16.49
SSB 2 391.6 34.75 4.32 13.48 0.81 19.18 4.68
SSB 3 421.2 46.63 4.69 9.08 0.74 26.17 4.23
Compressor 1 431.5 60.07 5.86 11.92 0.82 41.99 7.16
Compressor 2 430.7 59.91 4.75 10.24 0.82 43.29 6.13
Lighting Load 402.7 79.53 4.23 29.49 0.73 40.96 23.45
UPS 417.5 14.79 4.58 135.41 0.56 9.53 20.03
Table – 1 Summary of harmonic measurement

As seen from the table – 1, total percentage harmonic distortion at current main incomer is
13.53% which is more than limit specified by TANGEDCO. Measurements at different load
centers and shows % THDi more than 8%. In terms of harmonic current, major contributors
are lighting load, UPS and SSB-1.

Based on harmonic measurement study, plant team decided to mitigate harmonics.

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 13
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

Selection of Solution:
After carrying out harmonic study and based on the outcome, plant team decided to
mitigate harmonics. Next challenge for the plant team was to select a technology that would
be technically and financially feasible.

Theplant team had three options available for mitigation of harmonics. The available
options were:

1. Active harmonic filter

2. Passive harmonic filter
3. Detuning filters

The plant team compared above three technologies based on different parameters like
technical feasibility, harmonic mitigation capability, ease of operation, maintenance cost,
operating cost and initial cost.

Table – 2 shows comparison summary of above technologies.

Passive harmonic
Technology Active harmonic filter filter De-tuned filter
Technically feasibile YES YES YES
Harmonic mitigation 5th, 7th 11th and 5th, 7th 11th and
capability Up to 50th order of harmonics 13th 13th
Ease of operation Very Easy Very Easy Very Easy
Maintenance cost High in case of any failure Low - LC Circuit Low - LC Circuit
High - Power consumption of
Operating cost IGBT's Negligible Negligible
Initial cost. 800,000 400,000 200,000
Table – 2 Comparison of various technologies

Harmonic spectrum of the plant consisted of mainly 3 rd, 5th and 7th order harmonics as
predominant harmonics. Other harmonics present in the system were 11 th and 13th .

Based on above comparison, the plant team decided to install detuned filters of 100 ampere
capacity.

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 14
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

Post Implementation Results:

After installation of detuned filter, the plant team carried out harmonic measurement at the
incomer. Figure – 6 shows voltage and current wave form after installation of detuned filter.

Figure – 6 Voltage and current waveform after installation of detuned filter

Figure 7 shows individual harmonic order.

Figure – 7 Individual order of harmonics

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 15
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

Table 3 shows summary of post mitigation result.

Current - Harmonic current

Location Voltage Amperes % THDv % THDi PF kVA - Amperes
Main
incomer 419 531.5 2.4 4.69 1.00 347.89 24.93

As seen from the table, after installation of detuned filter, total percentage current
harmonic distortion has come down to 4.69% which is well below the limit specified by
TANGEDCO. Photographs below shows detuned harmonic filter installed at the facility.

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 16
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

Conclusion:
It can be concluded from the case study that harmonic mitigation is not a costly and capital
extensive project. With detailed study, proper understanding of the subject and
implementation technologies, a cost effective and technically strong solution can be
adopted.

About the Author:

Shaikh Shamsher Ali
Shamser is an Ex-Indian Naval Artificer having 33 years hands-on
experience in energy conservation, project management,
operations & maintenance, sales & marketing, manufacturing and
profit center operations. He has worked in India, UK and Middle
East in Marine, Oil & Gas, Utilities and Heavy Fabrications sectors.
He is BEE Certified Energy Auditor & Energy Manager, PMI USA
Certified Project Manager and Professional Engineer from UK
chapter. Presently he is pursuing his PhD in energy conservation from University of
Petroleum & Energy Studies at Dehradun. He has worked with 3 ESCOs for over 10 years in
India & abroad and presently working as freelance energy conservation consultant with 3
companies engaged in energy conservation business in India. Shamser makes regular
presentation on power quality, harmonic mitigation, energy conservation, energy efficient
lighting and maintenance management systems at various seminars / platforms. He also
trains students and professionals in soft skills.

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 17
Case study 47

De-tuned Capacitor Bank – Economical Way to Mitigate Harmonics

Disclaimer: The sole responsibility for the content of this document lies with the authors. It does not represent the opinion of
the Asia Power Quality Initiative and /or ICA-I/ICA network. APQI and ICA network are not responsible for any use that may
be made of the information contained therein.

A PQ Case Study
APQI (C) Copyright (Print Date) All Rights Reserved 18