HARMONIC ANALYSIS AND MULTI-STAGE FILTER DESIGN FOR A LARGE

BLEACH PRODUCTION FACILITY

Copyright Material IEEE
Paper No. PCIC-2010-47

Ritchie Pragale, P.E. Thomas J. Dionise, P.E. David D. Shipp, P.E.

Member, IEEE Senior Member, IEEE Fellow Member, IEEE
Eaton Corporation Eaton Corporation Eaton Electrical
1520 S. Bridgegate Drive, Ste 100 130 Commonwealth Drive 130 Commonwealth Drive
Diamond Bar, CA 91765 Warrendale, PA 15086 Warrendale, PA 15086
RitchieOPragale@eaton.com ThomasJDionise@eaton.com DavidDShipp@eaton.com

Abstract – Modern sodium chlorate or sodium A. Project Specifications

hypochlorite-making processes (commonly known as
“bleach”) takes salt and water through an electrolytic
process. The electrolytic process requires a significant
amount of DC power. Bleach production plants, equipped
with rectifiers, can generate potentially damaging
harmonic currents if not mitigated or controlled. This
paper presents a combination of harmonic mitigation
methods applied at a large bleach production facility. The
harmonic mitigation methods consisted of transformer
phase shifting and multi-stage harmonic filter banks
applied at 34.5 kV to satisfy IEEE Std 519-1992 harmonic
distortion limits [1] at the point of common coupling. The
authors faced several challenges with the harmonic filter
design that included various operating conditions within
the facility as well as numerous utility substation loading
and capacitor combinations.
Index Terms – Harmonics, IEEE Std 519-1992, point of
common coupling (PCC), harmonic analysis, phase shifting,
harmonic filter
I. INTRODUCTION
A large industrial facility utilizes state-of-the-art technology
to produce bleach. The facility is equipped with three (3), 6-
pulse rectifiers, rated at 17,000 A and 250 VDC each that can
generate potentially damaging harmonic currents if not
mitigated or controlled. The main concern with harmonics is
either overheating from significant current levels (and high
current distortion) or high voltage distortion levels. Excessive
harmonic levels can result in increased equipment heating,
equipment malfunction and premature equipment failure,
communication interference, and process problems. Several
solutions are presented to comply with IEEE Std 519-1992
harmonic distortion limits and power factor requirements for
the facility. One available solution such as installing power
factor correction capacitors, for example, will correct the power
factor above the level set by utility to avoid power factor
penalties. However, engineering judgment must be used
when applying capacitors in power systems that contain
excessive harmonic currents. Installing capacitors to improve
the power factor can lead to worse problems such as
harmonic resonance. Harmonic resonance results in very
high harmonic currents and voltages at the resonant
frequency, often with catastrophic failure of equipment [1].
The objectives of the analysis were to correct the power
factor to 90% lagging or better to avoid utility power factor
penalties and to ensure that the facility complies with IEEE Std
519-1992 harmonic distortion limits at the point-of-common
coupling with utility under all possible operating conditions.
The authors designed and specified the required filter
components. The harmonic filter design considered in the
study was three (3) independent filters, one (1) for each
rectifier. Study cases were conducted to verify that the final
harmonic filter designs will correct the power factor to 90%
lagging or better and reduce harmonic levels to within
acceptable limits set forth in IEEE Std 519-1992.
B. Utility’s Power Distribution System
The bleach production facility is served by Circuit 354 from
the utility substation as shown in Fig. 1. The utility substation
is double-ended with a normally open tie-switch. The two (2)
230 kV lines supply Transformers #3 (50 MVA) and #4 (45
MVA). Circuit 354 is normally fed from Transformer #4. It can
also be fed from Transformer #3 through the tie-switch. There
are several capacitor banks at the utility substation at the 34.5
kV and 13 kV busses. Capacitors F354-1, F354-2, F355-1,
and F355-2 (34.5 kV) and B5-1, B5-2, B5-3, B6-1, and B6-2
(13 kV) feeder capacitors are fixed on. The following
capacitors are either all on OR all off – B5, B5-4, B5-5, B6,
and B6-1.
C. Facility’s Power Distribution System
A 34.5 kV line called Circuit 354 from the utility substation
is routed to the service entrance pole, and enters the bleach
production facility’s 34.5 kV Switchgear (MV SWGR), which
has a total of six (6) feeders as shown in Fig. 2. Three (3) of
the feeders supply the Rectifier transformers rated at 6010
kVA, 34.5 kV to 250 V each. The transformers are phase-
shifted (primary to secondary phase shift) at -50, -30, and -10
degrees respectively. The rectifiers are 6-pulse and rated at
17000 A, 295 VDC, and 85% power factor each. This design
arrangement produces an 18-pulse effective system at 34.5
kV when all rectifiers are equally loaded. Three (3) of the
feeders supply unit transformers rated at 2500 kVA, 34.5 kV to
480 V. These transformers feed the low voltage (LV) motor
control centers, chiller units, and electric boilers.

978-1-4244-6799-0/10/$26.00 ©2010 IEEE 1

 UTIL4 UTIL3
230000.0 V 230000.0 V

P
XFMR 4 P
XFMR 3
S 45000.0 kVA S 50000.0 kVA
230000 / 34500V 230000 / 34500V
10.56% Z 10.56% Z

CBL-0038 CBL-0039

BUS #5 BUS #6
34500V 34500V

C354 FDR CBL-0049 CAP B5 C355 FDR CBL-0050 CAP B6

0AS 1-#4/0, 50ft 7200 KVAR 0AS 1-#4/0, 50ft 9600 KVAR

CBL-0037 P
XFMR SUB B5 CBL-0035 P
XFMR SUB B6
3-#1000, 5ft S 20000.0 kVA 2-#4/0, 40ft S 20000.0 kVA
34500 / 13000V 34500 / 13000V
BUS C354 8.00% Z BUS C355 8.00% Z
34500V 34500V
SUB B6
13000V
C354 LD CAP F355-2 C355 LD
5.3 MVA 1200 KVAR 8.5 MVA
CAP B6-2
CAP F355-1 1800 KVAR
CAP F354-2 1200 KVAR
1200 KVAR SUB B5 CAP B6-1
13000V 4500 KVAR
CBL-0048
1-#1/0, 5ft
CAP B5-3 SUB B5 LD
CAP F354-1 1800 KVAR 5.4 MVA
1200 KVAR
CAP B5-2
600 KVAR CAP B5-5
CBL-DOM PCC 2700 KVAR
3-#1000, 2006ft CAP B5-1
600 KVAR CAP B5-4
TO T HE BLEACH 4950 KVAR
PRODUCTION PLANT

Fig. 1 Utility Substation One-Line Diagram

TO UTILITY SUBSTA TION

MV SWGR
34500V

U3 FDR U4 FDR U5 FDR U8 FDR U6 FDR U7 FDR

R-U3 R-U4 R-U5

CBL-0006 CBL-0004 CBL-0005
CBL-REC1-P CBL-REC2-P CBL-REC3-P 1-#2/0, 7 5ft 1-#2/0, 1 10ft 1-#2/0, 90ft
1-#2/0, 1 30ft 1-#2/0, 90ft 1-#2/0, 1 00ft
XFMR U2301C XFMR U2301A XFMR U2301B
2500.0 kVA 2500.0 kVA 2500.0 kVA
XFMR U2303A XFMR U2303B XFMR U2303C 34500 / 480V 34500 / 480V 34500 / 480V
6010.0 kVA 6010.0 kVA 6010.0 kVA 5.53% Z 5.49% Z 5.60% Z
34500 / 250V 34500 / 250V 34500 / 250V
9.60% Z 9.60% Z 9.60% Z CBL-0009 CBL-0007 CBL-0008
9-#750, 40ft 9-#750, 40ft 9-#750, 30ft
CBL-REC1-S CBL-REC2-S CBL-REC3-S
3-#5000, 5ft 3-#5000, 5ft 3-#5000, 5ft U1-1-1 MCB U2-1-1 MCB

REC 1 REC 2 REC 3 SWGR 1-1-1 SWGR 2-1-1

5015.0 kVA 5015.0 kVA 5015.0 kVA U3-1-1 MCB 480V 480V

SWGR 3-1-1 MCC4 FDR MCC5 FDR

480V
CBL-0011 CBL-0019
3-#500, 25ft 3-#500, 25ft
U3-2-1 FDR U3-2-2 FDR U3-2-4 FDR
TO 1500 kW TO 1500 kW MCC 4 MCC 5
CBL-0020 STBY GEN CBL-0021 STBY GEN CBL-0026 480V 480V
5-#500, 25ft 5-#500, 25ft 5-#500, 25ft

MCC 3
480V

ATS1 ATS2
480V 480V

CBL-0023 CBL-0024
5-#500, 25ft 5-#500, 25ft

MCC 1 MCC 2
480V 480V

Fig. 2 Bleach Production Facility One-Line Diagram

2
 TABLE I
SUMMARY OF SIMULATED CASES

Facility Conditions Utility Substation Conditions

Cases
REC 1 REC 2 REC 3 5SF XFMR 3 XFMR 4 CAP B5 CAP B5-4 CAP B5-5 CAP B6 CAP B6-1
1 X X X X
2 X X X
3 X X X X X
4 X X X X
5 X X X X X
6 X X X X X X
7 X X X X X X X X
8 X X X X X X X
9 X X X X X
10 X X X X X X
11 X X X X X X X
12 X X X X X X

Case 10: Similar to Case 3, except that the utility substation

II. HARMONIC ANALYSIS XFMR 4 (45 MVA) is offline and XFMR 3 (50 MVA) is online
and supplying the bleach production facility. The utility
A. Harmonic Case Evaluation substation B6-1 capacitor (4500 kVAR at 13 kV) is online.

The following twelve (12) cases were analyzed in the
harmonic analysis study. The conditions for each of the cases
are summarized in Table I.
Case 1: This is considered the base case, which is the normal
operating scenario at the utility substation and bleach
production facility. All three (3) rectifiers are online with
balanced load and the entire facility is supplied by the utility
substation XFMR 4.
Case 2: When performing maintenance on a single
electrolyzer, the facility will operate with 2 rectifiers at 100%
for approximately 8-10 hours.
Case 3: Similar to Case 1, except that 5-stage filters (see filter
design specifications in Section III) are added on the front-end
of each rectifier transformer.
Case 4: 2 rectifiers online, XFMR U2303A offline. The same
5-stage filter in Case 3 is added on the front-end of rectifier
transformers XFMR U2303B and XFMR U2303C.
Case 5: Similar to Case 4, except that the 7200 kVAR
capacitor at the utility substation 34.5 kV bus is online.
Case 6: Similar to Case 3, except that the 7200 kVAR
capacitor at the utility substation 34.5 kV bus is online.
Case 7: Similar to Case 3, except that the 7200 kVAR
capacitor at the utility substation 34.5 kV bus is online and the
utility substation B5 capacitors (2700 kVAR and 4950 kVAR at
13 kV) are online.
Case 8: Similar to Case 4, except that the 7200 kVAR
capacitor at the utility substation 34.5 kV bus is online and the
utility substation B5 capacitors (2700 kVAR and 4950 kVAR at
13 kV) are online.
Case 9: Similar to Case 3, except that the rectifiers are only
50% loaded.
Case 11: Similar to Case 10, except that the 9600 kVAR
capacitor at the utility substation 34.5 kV bus is online and the
utility substation B6-1 capacitor (4500 kVAR at 13 kV) is
online.
Case 12: Similar to Case 11, except that only 2 rectifiers are
online, XFMR U2303A is offline.
B. Harmonic Case Results
1) Total Harmonic Distortion at the PCC: Twelve (12)
study cases considering five (5) different utility substation
conditions as well as three (3) different facility conditions
were analyzed to ensure satisfactory performance of the
filters. The study results are summarized in Table II. The
study cases allow for a variety of operating conditions for
the facility rectifiers/filters in addition to likely combinations
of the many capacitors at the utility substation. Since the
utility capacitors are electrically near the facility filters, it
was important to consider them in the harmonic analysis
study. Based on the harmonic analysis results, voltage and
current total harmonic distortion (THD) at the PCC were
within the IEEE Std 519-1992 limits [2] for all study cases.
The voltage distortion gives a clear representation of the
impact of harmonics on the electrical distribution system.
The harmonic voltage distortion from an individual
customer is evaluated at the PCC where the utility can
supply other customers. The voltage THD limit is 5% for
customers supplied by 69 kV or less. The harmonic
currents from an individual customer are likewise evaluated
at the PCC. The current THD limits depend upon the
customer’s load with respect to the available fault current
(ISC/IL) at the PCC, which explains why the current
distortion limit for Cases 1, 3, and 6 is 5% compared to 8%
for all other cases.

3
 TABLE II TABLE III
SUMMARY OF DISTORTION AND POWER FACTOR AT SUMMARY OF INDIVIDUAL HARMONIC VOLTAGE AT
PCC THE PCC

Study % VTHD %ITHD Harmonic Case 1 Case 2 Case 3 Case 4

PF Order V % of Fund V % of Fund V % of Fund V % of Fund
Case PCC (%) IEEE Limit (%) PCC (%) IEEE Limit (%) 1 35231.0 100.0% 35592.0 100.0% 35711.0 100.0% 35909.0 100.0%
1 1.50 5.0 2.73 5.0 0.86 5 48.1 0.14% 566.7 1.59% 38.4 0.11% 485.6 1.35%
2 3.05 5.0 7.34 8.0 0.88 7 31.8 0.09% 707.8 1.99% 12.6 0.04% 354.3 0.99%
11 18.4 0.05% 471.2 1.32% 3.1 0.01% 112.5 0.31%
3 0.40 5.0 0.80 5.0 0.95 13 3.9 0.01% 134.3 0.38% 1.5 0.00% 75.3 0.21%
4 1.78 5.0 5.66 8.0 0.95 17 245.0 0.70% 160.7 0.45% 44.3 0.12% 40.1 0.11%
5 2.40 5.0 5.70 8.0 0.95 19 462.0 1.31% 304.4 0.86% 148.4 0.42% 162.8 0.45%
23 0.0 0.00% 20.5 0.06% 0.0 0.00% 27.2 0.08%
6 0.22 5.0 2.17 5.0 0.95 25 0.0 0.00% 7.1 0.02% 0.0 0.00% 8.1 0.02%
7 0.23 5.0 3.08 8.0 0.95 Total (kV) 35235.7 35609.0 35711.8 35915.0
8 2.54 5.0 6.08 8.0 0.95 %VTHD 1.5 3.1 0.5 1.8
VTHD Limit 5.0 5.0 5.0 5.0
9 0.20 5.0 0.80 8.0 0.99
10 0.36 5.0 0.59 8.0 0.95 Harmonic Case 5 Case 6 Case 7 Case 8
11 0.20 5.0 2.00 8.0 0.95 Order V % of Fund V % of Fund V % of Fund V % of Fund
12 2.70 5.0 5.90 8.0 0.95 1 36509.0 100.0% 36320.0 100.0% 36607.0 100.0% 36792.5 100.0%
5 723.6 1.98% 54.6 0.15% 66.0 0.18% 905.4 2.46%
7 477.4 1.31% 16.0 0.04% 8.1 0.02% 190.9 0.52%
11 89.4 0.24% 2.9 0.01% 3.0 0.01% 111.6 0.30%
2) Individual Harmonic Voltage and Current Distortion at 13 37.9 0.10% 0.0 0.00% 1.6 0.00% 76.8 0.21%
the PCC: The % individual harmonic voltage and current 17
19
36.6
21.1
0.10%
0.06%
41.4
34.6
0.11%
0.10%
49.6
15.3
0.14%
0.04%
37.0
9.8
0.10%
0.03%
distortion were within the IEEE limit for all study cases as 23 2.2 0.01% 0.0 0.00% 0.0 0.00% 2.5 0.01%
25 2.3 0.01% 0.0 0.00% 0.0 0.00% 2.4 0.01%
shown in Tables III and IV. Note that when phase shifting Total (kV) 36520.0 36319.9 36606.6 36804.4
transformers with pulse numbers (q) higher than six (6) are %VTHD
VTHD Limit
2.4
5.0
0.2
5.0
0.2
5.0
2.5
5.0
used, the limits for the characteristic harmonic orders are
Harmonic Case 9 Case 10 Case 11 Case 12
increased by a factor of √(q/6). For this reason in Cases 1 Order V % of Fund V % of Fund V % of Fund V % of Fund

and 6 (q = 18), the displayed individual harmonic current 1

5
36225.8
37.8
100.0%
0.10%
35978.7
40.8
100.0%
0.11%
36719.1
68.3
100.0%
0.19%
36884.4
943.7
100.0%
2.56%
th
limit was adjusted by a factor of √3. For Case 1, the 17 7
11
12.4
3.0
0.03%
0.01%
14.8
2.0
0.04%
0.01%
13.4
2.2
0.04%
0.01%
330.8
69.9
0.90%
0.19%
th
and 19 order harmonic current exceed the standard limit 13 1.5 0.00% 1.4 0.00% 1.3 0.00% 53.2 0.14%
17 21.2 0.06% 43.7 0.12% 40.3 0.11% 35.4 0.10%
(1.5%), but not the adjusted limit (1.5% X √3 = 2.6%). The 19 72.7 0.20% 113.9 0.32% 20.8 0.06% 13.1 0.04%
th
same is true for Case 6; the 19 order harmonic current 23
25
0.0
0.0
0.00%
0.00%
0.0
0.0
0.00%
0.00%
0.0
0.0
0.00%
0.00%
3.4
2.9
0.01%
0.01%
exceeds the standard limit (1.5%), but not the adjusted limit Total (kV) 36225.9 35978.9 36719.1 36898.0
%VTHD 0.2 0.4 0.2 2.7
(2.6%). The adjusted harmonic order limit can be applied VTHD Limit 5.0 5.0 5.0 5.0

for the other cases as well; however, it is not necessary

since the characteristic harmonic orders did not exceed the TABLE IV
harmonic standard limit. SUMMARY OF INDIVIDUAL HARMONIC CURRENT AT
THE PCC
3) Effect of Phase Shifting Transformers: Because of
the phase shifting transformers (primary to secondary Harmonic
Order I
Case 1
% of Fund I
Case 2
% of Fund I
Case 3
% of Fund I
Case 4
% of Fund
phase shift of -50, -30, and -10 degrees) installed at the 1 373.4 100.0% 284.2 100.0% 335.7 100.0% 260.6 100.0%
5 1.3 0.3% 15.6 5.5% 1.1 0.3% 13.4 5.1%
front end of each rectifier, an 18-pulse system is derived 7 0.4 0.1% 9.1 3.2% 0.2 0.0% 4.6 1.8%
from the three (3) 6-pulse rectifiers. If the rectifier loads are 11
13
0.3
0.1
0.1%
0.0%
6.6
4.2
2.3%
1.5%
0.0
0.0
0.0%
0.0%
1.6
2.4
0.6%
0.9%
well balanced, there is very little 5th, 7th, 11, and 13th 17 8.3 2.2% 5.5 1.9% 1.5 0.4% 1.4 0.5%
19 5.7 1.5% 3.7 1.3% 1.8 0.5% 2.0 0.8%
harmonic currents. Assuming that the loads between the 23 0.0 0.0% 1.1 0.4% 0.0 0.0% 1.5 0.6%

three (3) rectifiers are well balanced, the system will 25

Total (A)
0.0
373.6
0.0% 0.6
285.0
0.2% 0.0
335.7
0.0% 0.7
261.0
0.3%
th th
generate mostly 17 , 19 , and higher harmonic currents %ITHD
ITHD Limit
2.7
5.0
7.3
8.0
0.8
5.0
5.7
8.0
because of the 18-pulse system. For example, consider
Harmonic Case 5 Case 6 Case 7 Case 8
Case 1 with no filtering and all three (3) rectifiers with Order I % of Fund I % of Fund I % of Fund I % of Fund
balanced load. The resulting 18-pulse system is clearly 1
5
255.5
10.9
100.0%
4.3%
328.8
0.8
100.0%
0.3%
325.7
0.7
100.0%
0.2%
253.2
9.0
100.0%
3.6%
evident in the current waveform shown in Fig. 3 and the 7 5.1 2.0% 0.2 0.1% 0.4 0.1% 9.4 3.7%
11 5.4 2.1% 0.2 0.1% 0.0 0.0% 1.5 0.6%
current harmonic spectrum of Fig. 4. See similar results for 13 4.3 1.7% 0.1 0.0% 0.1 0.0% 3.6 1.4%
other cases with three (3) rectifiers with balanced loads as 17
19
2.0
4.1
0.8%
1.6%
2.3
6.7
0.7%
2.0%
8.1
5.9
2.5%
1.8%
6.0
3.7
2.4%
1.5%
shown for Cases 3, 6, 7, 9, 10, and 11 in Table IV. The 23 1.1 0.4% 0.0 0.0% 0.0 0.0% 1.0 0.4%
25 0.6 0.2% 0.0 0.0% 0.0 0.0% 0.5 0.2%
benefit of the three (3) phase shifting transformers can also Total (A) 255.9 328.9 325.9 253.6
be seen in Table II where Cases 1, 3, 6, 7, 9, 10, and 11 %ITHD
ITHD Limit
5.7
8.0
2.2
5.0
3.1
8.0
6.1
8.0
have low current THD (less than 4%).
Harmonic Case 9 Case 10 Case 11 Case 12
Order I % of Fund I % of Fund I % of Fund I % of Fund
1 207.3 100.0% 332.6 100.0% 324.5 100.0% 252.4 100.0%
5 1.0 0.3% 1.0 0.3% 0.6 0.2% 8.6 3.4%
7 0.2 0.0% 0.1 0.0% 0.4 0.1% 10.0 4.0%
11 0.0 0.0% 0.1 0.0% 0.1 0.0% 3.3 1.3%
13 0.0 0.0% 0.0 0.0% 0.1 0.0% 3.9 1.5%
17 0.7 0.2% 1.6 0.5% 2.5 0.8% 2.2 0.9%
19 0.9 0.2% 0.4 0.1% 6.0 1.9% 3.8 1.5%
23 0.0 0.0% 0.0 0.0% 0.0 0.0% 1.0 0.4%
25 0.0 0.0% 0.0 0.0% 0.0 0.0% 0.5 0.2%
Total (A) 207.3 332.6 324.6 252.8
%ITHD 0.8 0.6 2.0 5.9
ITHD Limit 8.0 8.0 8.0 8.0

4
 Fig. 3 Case 1, PCC Voltage and Current Waveforms for
Three Rectifiers with Balanced Load
Fig. 4 Case 1, PCC Voltage and Current Harmonic
Spectrum for Three Rectifiers with Balanced Load
4) Effect of One Rectifier Offline: Operating with just two
(2) rectifiers fails to achieve the full benefit of the phase
shifting transformers. As expected, the resulting waveform
th th th th
is quasi 12-pulse with more 5 , 7 , 11 , and 13 harmonic
current content compared to the scenarios with all three (3)
rectifiers online with balanced load. For example, consider
Case 4 with filtering and one rectifier offline (2 rectifiers
with balanced load). The result is a quasi 12-pulse system
as shown in the current waveform of Fig. 5 and the current
harmonic spectrum of Fig. 6. See similar results for other
cases with two (2) rectifiers with balanced loads as shown
for Cases 2, 5, 8 and 12 in Table IV.
5) Effect of Unbalanced Rectifier Load: Operating with
two (2) or three (3) rectifiers online with unbalanced loads
will result in quasi 12-pulse (for 2 rectifiers) or 18-pulse (for
3 rectifiers) current waveforms. As the load unbalance
th th
increases, there will be more 5 , 7 , 11 , and 13
th
harmonic currents flowing in the system.
6) Series and Parallel Resonance Due to Utility
Capacitor Combinations: Series and parallel resonance
points are caused by the LC combination of the 45 MVA
transformer and feeder capacitors (34.5 kV), and the 20
MVA transformer and feeder capacitors (13 kV) as shown
for Case 1 in Fig. 7. As more capacitors are connected on
the 34.5 kV and 13 kV busses (i.e. CAP B5, B6, B5-4, B5-
5, and B6-1), the series and parallel resonance points will
shift to the left (lower harmonic order). When the parallel
resonance points lie on or near the harmonic order of the
characteristic harmonic currents of the rectifier, parallel
resonance will be excited. For Case 1, the parallel
resonance points of concern are shown in Table V, most of
Fig. 5 Case 4, PCC Voltage and Current Waveforms for
Two Rectifiers with Balanced Load
Fig. 6 Case 4, PCC Voltage and Current Harmonic
Spectrum for Two Rectifiers with Balanced Load
which lie on the harmonic order corresponding to a
characteristic harmonic current of the rectifier. The number
of rectifiers online and their load balance will result in either
an 18-pulse or quasi 12-pulse system and determine which
of the parallel resonance points is excited. This variability
in both the parallel resonance points as well as the exciting
harmonic currents required the installation of the power
factor correction in the form of filters rather than capacitors.
7) Avoiding Parallel Resonance Through Harmonic
Filter Design: To avoid the issues of parallel resonance,
and variable parallel resonance, the power factor correction
for the rectifiers was designed in the form of 5-stage
harmonic filters. The details of the 5-stage harmonic filter
design are described in Section III. Of interest at this point
is the impact of the filter design on controlling the parallel
resonance points and avoiding the characteristic harmonic
th currents of the rectifiers. For Case 4 with the application of
the harmonic filters, the parallel and series resonance
points are shown in the frequency scan of Fig. 8 as well as
in Table V. By proper selection of the series resonance
through filter design as explained in [3], the parallel
resonance points no longer lie on the harmonic order of
characteristic harmonic currents of the rectifier. In this way,
the filter design controls the parallel resonance points and
avoids parallel resonance for the variety of capacitor
combinations possible.
8) IEEE Std 18 Evaluation of Harmonic Filter Design:
Although the primary purpose of the 5-stage harmonic filter
design was to control parallel resonance, the filter will be a
th
low impedance path for the 5, 7, 11, 13 and 17 harmonics
and must be designed to handle these currents
5
continuously. For this reason, the 5-stage harmonic filter TABLE VI
was evaluated on the basis of IEEE Std 18 for both normal CASE 4, SERIES AND PARALLEL RESONANCE
and contingency situations. For all cases studied, the 5- (FILTERS IN THE FACILITY)
stage harmonic filters are applied within the IEEE Std 18
limits [4] for voltage, current, and apparent power with Parallel Resonance Series Resonance
sufficient margin to allow for the contingencies considered. Frequency Frequency
The filter currents are less than 100% rated for all cases
Order (h) (Hz) Order (h) (Hz)
except when only 2 of 3 filters/rectifiers are in service
(Cases 4, 8, and 12). As expected, when one (1) 4.4 264 4.7 282
filter/rectifier is offline, the remaining two (2) filters see 6.2 372 6.8 408
elevated levels of harmonic current. In Case 4, stage-2 8.2 492 10.7 642
th
(tuned to 7 harmonic) sees 123% of rated current. Case 4 11.5 690 12.6 756
results are shown in Table VII. In Case 8, stage-1 (tuned 13.4 804 16.8 1008
th
to 5 harmonic) sees 126% of rated current. In Case 12, 20.0 1200 31.7 1902
stage-1 sees 129% of rated current, and stage-2 sees
123% of rated current. The overcurrent protection is set for TABLE VII
135% of rated current, and the capacitors are designed for CASE 4, IEEE STD 18 EVALUATION OF HARMONIC
180% of rated current, so these contingencies do not FILTER CAPACITORS
present a problem.
Study Capacitor Voltage Current kVA
Case Location V Rated % I Rated % kVA Rated %
U2303A-5 0 39490 0.0% 0.0 6.59 0.0% 0.0 450.0 0.0%
U2303A-7 0 39490 0.0% 0.0 4.39 0.0% 0.0 300.0 0.0%
U2303A-11 0 39490 0.0% 0.0 6.59 0.0% 0.0 450.0 0.0%
U2303A-13 0 39490 0.0% 0.0 4.39 0.0% 0.0 300.0 0.0%
U2303A-17 0 39490 0.0% 0.0 6.59 0.0% 0.0 450.0 0.0%
U2303B-5 37764 39490 95.6% 6.9 6.59 104.6% 425.2 450.0 94.5%
U2303B-7 36990 39490 93.7% 5.4 4.39 123.2% 287.5 300.0 95.8%
Case 4 U2303B-11 36272 39490 91.9% 6.9 6.59 105.1% 389.9 450.0 86.6%
U2303B-13 36160 39490 91.6% 4.5 4.39 101.8% 256.1 300.0 85.4%
U2303B-17 36054 39490 91.3% 6.7 6.59 101.0% 380.0 450.0 84.4%
U2303C-5 37764 39490 95.6% 6.9 6.59 104.6% 425.2 450.0 94.5%
U2303C-7 36989 39490 93.7% 5.4 4.39 123.0% 287.4 300.0 95.8%
U2303C-11 36272 39490 91.9% 6.9 6.59 105.4% 390.1 450.0 86.7%
U2303C-13 36160 39490 91.6% 4.5 4.39 102.0% 256.2 300.0 85.4%
U2303C-17 36054 39490 91.3% 6.7 6.59 101.0% 380.0 450.0 84.4%
IEEE Limit 110% 180% 135%

Fig. 7 Case 1, PCC Frequency Scan (No Capacitors in the

Facility)
9) Analysis of all possible plant operating scenarios:
TABLE V The analysis has shown that the size, number, and
CASE 1, SERIES AND PARALLEL RESONANCE (NO possible combinations of capacitors at the utility substation
CAPACITORS IN THE FACILITY) result in a variety of series and parallel resonance points as
seen at the PCC. These series and parallel resonance
Parallel Resonance Series Resonance points are of concern and require the application of 5-stage
Case harmonic filters at each rectifier. The analysis has shown
Frequency Frequency
Order (h) Order (h) that harmonic filtering is not required to comply with IEEE
(Hz) (Hz)
Std 519-1992 at the PCC. However, filtering is required to
9.3 558 15.7 942
Base correct rectifier power factor from 85% to above the utility
18.6 1116 31.7 1902
target of 90% and avoid harmonic resonance and potential
6.1 366 15.3 918
Base, B5 equipment damage. To allow for variations in rectifier
17.0 1022 21.5 1290
loading, the filtering was sized to correct power factor to
Base, B5, 5.6 336 9.6 573
B5-4
95%.
11.4 681 20.9 1251
Base, B5, 5.1 306 8.0 481
B5-4, B5-5 III. 5-STAGE HARMONIC FILTER DESIGN
10.4 621 20.9 1251

A. Filter Specifications

Three (3) independent 5-stage harmonic filters are

Fig. 8 Case 4, PCC Frequency Scan (Filters in the Facility)
recommended. The total rating for each 5-stage harmonic
filter is 1950 kVAR. Specifications for each filter
recommended are shown in Table VIII. The 5-stage harmonic
filters are identical for each rectifier application. Common
th th
tuning points were selected for each stage: 5 (4.8), 7 (6.8),
th th th
11 (10.8), 13 (12.8) and 17 (16.8). These tuning points
allow for drift due to loss of a capacitor can. They also allow
for a moderate level of the respective harmonic current flowing
into the reactor without requiring excessive reactor ratings.

6
 TABLE VIII B. Selection of Capacitors
5-STAGE HARMONIC FILTER SPECIFICATIONS
The capacitor sizes were selected based on standard
5th Harmonic Filter Harmonic I (Amps) kVAR sizes displayed in IEEE Std 18 [4], Standard for Shunt
Capacitor VLL 39,490 Volts 1 7.18
Total capacitor kVAR 450 kVAr 3 1.08 Power Capacitors, Table 1. The suggested reactor rated
System frequency 60 Hertz 5 5.39 fundamental and harmonic current are also shown in Table
Harmonic tuning 4.7 Order 7 2.51 VIII. The higher VLL rating of 39,490 V versus the system
Capacitor rated current 6.6 Amps 11 2.87
135% of Capacitor rated current 8.9 Amps X 1.35 13 2.51
voltage of 34,500 V allows for voltage rise when the capacitor
Harmonic frequency 282 Hertz 17 0.72 is applied as a filter. The selection of the appropriate voltage
Reactance per phase 156.879 Ohms 19 0.72 rating for capacitors in a filter bank and advantages of such a
Capacitance per phase 0.765 uF 23 0.36
Inductance per phase 416.136 mH/phase 25 0.36
selection is discussed in [5]. The capacitor sizes were also
Taps ±5 Percent selected to allow for two (2) standard capacitor can sizes (i.e.
System VLL 34,500 Volts 100 kVAR and 150 kVAR both rated 22,800 V). These are
Winding Material Copper Winding
standard capacitor can sizes and should simplify
7th Harmonic Filter Harmonic I (Amps) maintenance. The site electricians will only have to maintain
Capacitor VLL 39,490 Volts 1 4.79 an inventory of 100 kVAR and 150 kVAR capacitors.
Total capacitor kVAR 300 kVAr 3 0.72
System frequency 60 Hertz 5 1.68
Harmonic tuning 6.8 Order 7 3.59 TABLE IX
Capacitor rated current 4.4 Amps 11 1.68 RECOMMENDED CAPACITOR SIZES
135% of Capacitor rated current 5.9 Amps X 1.35 13 0.72
Harmonic frequency 408 Hertz 17 0.24
Reactance per phase 112.418 Ohms 19 0.24 Harmonic Number of Capacitor Size Total
Capacitance per phase 0.510 uF 23 0.24 Filter Stage Capacitors (kVAR) (kVAR)
Inductance per phase 298.198 mH/phase 25 0.24
Taps ±5 Percent 5 3 150 450
System VLL 34,500 Volts 7 3 100 300
Winding Material Copper Winding 11 3 150 450
11th Harmonic Filter Harmonic I (Amps)
13 3 100 300
Capacitor VLL 39,490 Volts 1 7.18 17 3 150 450
Total capacitor kVAR 450 kVAr 3 1.08
System frequency 60 Hertz 5 1.08
Harmonic tuning 10.8 Order 7 1.08 C. Overcurrent and Unbalance Protection
Capacitor rated current 6.6 Amps 11 5.39
135% of Capacitor rated current 8.9 Amps X 1.35 13 2.51 The capacitors must be connected wye-ungrounded.
Harmonic frequency 648 Hertz 17 1.08
Reactance per phase 29.711 Ohms 19 1.08 Unbalance protection (59N) must be installed in the neutral of
Capacitance per phase 0.765 uF 23 1.08 the ungrounded-wye of each filter bank stage. The unbalance
Inductance per phase 78.810 mH/phase 25 1.08 protection can be set to alarm on the loss of one capacitor
Taps ±5 Percent
System VLL 34,500 Volts
can, and trip the filter bank on the loss of 2 or more capacitor
Winding Material Copper Winding cans [6].
13th Harmonic Filter Harmonic I (Amps)
Capacitor VLL 39,490 Volts 1 4.79
D. Surge Protection for Reactors and Capacitors
Total capacitor kVAR 300 kVAr 3 0.72
System frequency 60 Hertz 5 0.72 Surge protection must be applied at the Main 34.5 kV Bus,
Harmonic tuning 12.8 Order 7 0.72
Capacitor rated current 4.4 Amps 11 1.68
reactor and capacitor bank for the 5-stage harmonic filter,
135% of Capacitor rated current 5.9 Amps X 1.35 13 3.59 primary side of the rectifier transformers, and unit
Harmonic frequency 768 Hertz 17 0.72 transformers, 480 V switchgears and MCCs in order to
Reactance per phase 31.727 Ohms 19 0.72
Capacitance per phase 0.510 uF 23 0.72
minimize the effect of the transient overvoltages during any
Inductance per phase 84.159 mH/phase 25 0.72 circuit switching.
Taps ±5 Percent
System VLL 34,500 Volts
Winding Material Copper Winding IV. CONCLUSION
17th Harmonic Filter Harmonic I (Amps)
Capacitor VLL 39,490 Volts 1 7.18
Total capacitor kVAR 450 kVAr 3 1.08
The paper has shown that the size, number, and possible
System frequency 60 Hertz 5 1.08 combinations of capacitors at the utility substation result in a
Harmonic tuning 16.8 Order 7 1.08 variety of series and parallel resonance points at the PCC.
Capacitor rated current 6.6 Amps 11 1.08
135% of Capacitor rated current 8.9 Amps X 1.35 13 1.08
These series and parallel resonance points are of concern due
Harmonic frequency 1008 Hertz 17 5.39 to the harmonic current sources at the bleach producing
Reactance per phase 12.278 Ohms 19 2.51 facility which vary with rectifier combinations and loadings.
Capacitance per phase 0.765 uF 23 1.08
Harmonic resonance results in very high harmonic currents
Inductance per phase 32.570 mH/phase 25 1.08
Taps ±5 Percent and voltages at the resonant frequency. It is important to
System VLL 34,500 Volts analyze the system when major changes or upgrades (i.e.
Winding Material Copper Winding
new transformer, feeders, capacitor banks, etc.) are made at
the facility and the utility substation. To avoid the issues of
parallel resonance, power factor correction for the rectifiers
was designed in the form of 5-stage harmonic filters, one at

7
each rectifier. Although the harmonic filter was not required to
comply with IEEE Std 519 harmonic distortion limits, it was
required to correct the power factor from 85% to above the
utility target of 90% and avoid harmonic resonance and
potential equipment damage. Finally, the 5-stage harmonic
filter was evaluated on the basis of IEEE Std 18 proving the
design had adequate margin for both normal and contingency
situations.
power quality investigations, harmonic analysis and harmonic
filter design for electric arc furnaces, rectifiers, and VFD
applications. Mr. Dionise is the Chair of the Metal Industry
Committee and a member of the Generator Grounding
Working Group. He has served in local IEEE positions and
had an active role in the committee that planned the IAS 2002
Annual Meeting in Pittsburgh, PA. He is a Licensed
Professional Engineer in Pennsylvania

V. ACKNOWLEDGEMENTS David D. Shipp, PE, (S’72-M’72-SM’92-F’02) received the

The authors express their gratitude for the valuable
comments and suggestions of Mr. Visuth Lorch with Eaton
Corporation in Warrendale, PA.
VI. REFERENCES
[1] D. Carnovale, “Power Factor Correction and Harmonic
Resonance: A Volatile Mix,” EC&M, June 2003, pg. 16.
[2] IEEE Recommended Practice and Requirements for
Harmonic Control in Electric Power Systems, IEEE
Standard 519-1992, 1992, tables 10.2 and 10.3, pp. 77-
78.
[3] D. Carnovale, V. Lorch, T. Dionise, T. Gerstnecker,
“Electric Arc Furnace Harmonic Filter Failure, Analysis
and Repair,” AISE Conference Proceedings, Memphis,
TN, October 2002, pp. 4-5.
[4] IEEE Standard for Shunt Power Capacitors, ANSI/IEEE
Standard 18-1992, 1992, section 5.2.3, p. 4.
[5] T. Dionise, V. Lorch, B. Brazil, “Power Quality
Investigation of Back-to-Back Harmonic Filters for A High-
Voltage Anode Foil Manufacturing Facility”, IEEE
Transactions on Industry Applications, March/April 2010,
Volume 46, Number 2, pg. 701.
[6] IEEE Std. C37.90-1990, Guide for the Protection of Shunt
Capacitor Banks, IEEE Standards Board 1990, section
4.2.
B.S.E.E. degree from The Oregon State University, Corvallis,
Oregon, in 1972. He is a Principal Engineer for Eaton
Corporation’s Electrical Services and Systems Division. He is
a recognized expert in power system analysis and has worked
in a wide variety of industries. He has spent many years
performing the engineering work associated with his present
day responsibilities. Responsibilities include a wide range of
services covering consulting, design, power quality, arc flash
and power systems analysis topics. He has written many
technical papers on power system analysis topics and has
received an IAS/IEEE Prize Paper Award for one of these
papers. Twelve technical papers have been published in
IEEE/IAS national magazines and one in EC&M. He is very
active in national IEEE and helps write the IEEE color book
series standards. He spent 10 years as a professional
instructor, teaching full time. He occasionally serves as a legal
expert witness. He is an IEEE Fellow engineer.

VII. VITAE

Ritchie Pragale, PE, (S’00-M’05) received his B.S.E.E.

from California State Polytechnic University in Pomona, CA
and M.S.E.E. from California State University in Long Beach,
CA. He is currently a Power Systems Engineer in the Power
Systems Engineering Department, Eaton Corporation,
Diamond Bar, CA. He performs conventional to complex
engineering assignments that may involve power systems
analysis, consulting and design services, and power quality
investigations of industrial and commercial power systems.
Mr. Pragale is a member of IEEE and a member of Eaton
Power Systems Engineering’s Power Quality Committee. He
is a Licensed Professional Engineer in California.

Thomas J. Dionise, PE, (S’79–M’82–SM’87) received the

B.S.E.E. degree from The Pennsylvania State University,
University Park, in 1978, and the M.S.E.E. degree with the
Power Option from Carnegie Mellon University, Pittsburgh,
PA, in 1984. He is currently a Senior Power Systems
Engineer in the Power Systems Engineering Department,
Eaton Corporation, Warrendale, PA. He has over 26 years of
power system experience involving analytical studies and
power quality investigations of industrial and commercial
power systems. In the metal industry, he has specialized in