AVC and UPS_Thomas Liu
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Power Quality Solutions , Thomas Liu 劉佳炘 0955-614-833
Power Protection Products PCS100 AVC ( Active Voltage Conditioner ) © ABB Group April 13, 2015 | Slide 1
No Protection From PQ Events 未經保護的電力品質事故
Utility 電源
© ABB Group April 13, 2015 | Slide 2
Home
Who Needs An AVC? 誰需要AVC ?
Factories, facilities and commercial operations that are dependant on a good quality power supply so they can produce quality products without interruption need the ABB AVC.
高度要求電力品質的工廠、設備與公司行號。當這 些客戶的連續生產受到中斷時,產品品質會受到很 大影響。這些場合非常需要AVC解決方案。
Home
© ABB Group April 13, 2015 | Slide 3
PCS100 AVC Sag (Dip) Protection 電壓驟降保護
Utility Sag 電壓驟降
Injection Transformer 注入式變壓器
Bypass 旁 路
Rectifier and Inverter 整流和逆變
AVC Structure © ABB Group April 13, 2015 | Slide 4
Home
PCS100 AVC Swell Protection 電壓驟升保護
Utility Swell 電壓驟升 Injection Transformer 注入式變壓器 Bypass 旁 路
Rectifier and Inverter 整流和逆變
AVC Structure © ABB Group April 13, 2015 | Slide 5
Home
Industries and Examples 產業範例
Semiconductor 半導體 Chip Manufacturing (Vacuum pumps, Lithography, RFI machine) 晶片製造(真空泵浦,光刻,RFI設備)
Oil
石油
Test and Assembly (Regulated voltage for reliable testing) 測試和封裝步驟(需要穏定的電壓以保證測試的可靠度)
Gas
氣體
Flat Panel Displays (LCD or Plasma) 平板顯示器(液晶或電漿)
Photovoltaic (PV) 太陽能電池
Polysilicon (wafer saw damage and polishing) 多晶矽(矽晶切割線損壞和拋光)
Textile (loom protection) 紡織(織布機保護)
Hospital 醫院 MRI scanners etc (prolongs life) 核磁共振掃描儀等(延長其使用壽命)
High speed packaging 高速包裝
Plastics 塑料 Extruders, multilayer film 擠出機,多層薄膜
Pharmaceutical 製藥
Automotive 汽車
Painting, robots, sags caused by welders 塗漆,機器人,焊接造成壓降
Printing 印刷
© ABB Group April 13, 2015 | Slide 6
Chemical 化工
setup time missed deadlines 重新啓動機器浪費時間,延遲交期
Home
Cause of Power Quality Problems 電力品質問題的起因
The Utility attempts to supply sag and swell free power to the end user. However even with extensive maintenance programs the Utility cannot prevent power quality problems from affecting the end user. 盡管台電耗費許多人力和大筆金錢維護電力網路,嘗試提供穏定電壓給用戶。仍無法避免電力品 質問題造成用戶的困擾。
Some Causes of PQ problems 電力品質問題的產生原因
© ABB Group April 13, 2015 | Slide 7
Weather related events 天氣事件
Lightning 閃電
Heavy rain 暴雨,Snow 下雪
High wind 大風,Typhoon 颱風
Earthquake 地震
Single Phase Sags the most common PQ event 單相壓降是最常見的電力品質事件
Accidents 偶發事件
Vehicle 車禍
Construction, cranes, excavation 建築施工,起重機,開鑿機
Human error 人為失誤
Animals in contact with lines 動物誤觸
Other 其它
Large motors starting 大電動機啓動
Short-circuit faults 短路故障
Switching operations 線路切換
Distribution equipment failure 配電裝置故障
Home
PCS100 AVC Active Voltage Conditioner Overview
© ABB Group April 13, 2015 | Slide 8
Overview PCS100 AVC specifications 40% type
© ABB Group April 13, 2015 | Slide 9
Full correction, three-phase sags down to 60% retained voltage
Full correction, single-phase sags down to 40% retained voltage
Partial correction, three-phase sags down to 30% retained voltage
Partial correction single-phase sags down to 0% retained voltage
Continuous “ONLINE” regulation
Over and under voltage regulation
Correction for voltage vector phase angle errors created by faults in the supply
Voltage unbalance correction
Overview PCS100 AVC features
© ABB Group April 13, 2015 | Slide 10
Fast (sub-cyclic) response
Simple user controls
Rugged overload capability
Short circuit protected
Extensive diagnostics
Fault log
Voltage event data logging
Ethernet connectivity
Modular construction
Overview Modular construction
© ABB Group April 13, 2015 | Slide 11
Minimum spares required
High commonality of parts
Fast replacement
Overview Single line diagram
Input Sag/swell animation 3ph utility supply
3ph output secondary
Distribution transformer
primary
Input circuit br eaker
Boost transformer
Bypass Auto transformer (non 400/480V supply ) Rectifier and inverter
Environmental
System wiring diagram
© ABB Group April 13, 2015 | Slide 12
Rectifier fuse
Load
Overview Typical factory configuration
PCS100 AVC
The PCS100 AVC protects UPS operation and gives extended battery life
© ABB Group April 13, 2015 | Slide 13
UPS
Overview Full web and plant system USB interface USB port
Technician commissioning support tool
Resident webpage in graphic display module Plant SCADA accessing data registers
Modbus/TCPIP over Ethernet
Plant wide access from web browser
Firewall
© ABB Group April 13, 2015 | Slide 14
Worldwide web
10 Years of SAG Data
© ABB Group
10 Year Data from A Major Semiconductor FAB
Percent of nominal voltage
100% 90% 80% 70% 60% 50% 40% 30% 20% 10%
0% 1
10
100
Duration Cycles
© ABB Group April 13, 2015 | Slide 16
1000
40 % PCS100 AVC Response To The Events
Percent of nominal voltage
100% 90% ≥ 45% full correction
80% 70% 60% 50% 40% 30% 20% 10%
0% 1
10
100
Duration Cycles
© ABB Group April 13, 2015 | Slide 17
1000
40 % PCS100 AVC Response To The Events
Percent of nominal voltage
100% 90% 80% 70% 60% 50% 40% 30%
0 to 45% partial correction
20% 10%
0% 1
10
100
Duration Cycles
© ABB Group April 13, 2015 | Slide 18
1000
PCS100 AVC Case studies
© ABB Group April 13, 2015 | Slide 19
PCS100 AVC Case studies
© ABB Group April 13, 2015 | Slide 20
1.
Bottling plant
Florida USA
2.
Plastic extruder
Auckland New Zealand
3.
Solar panel manufacturer
Maryland USA
4.
Semiconductor FAB
China/Korea
5.
DWA welding machine
Malaysia
6.
Printing press
USA
7.
Container crane
Hong Kong
Case study : four Semiconductor FAB plants
© ABB Group April 13, 2015 | Slide 21
Case study : four
Overview – reference clients (Electronics)
Over 350MW of voltage conditioners supplied to semiconductor FABs in Asia and North America over the last three years
© ABB Group April 13, 2015 | Slide 22
Case study : four Major projects PCS100 AVC
Hynix Wuxi China
80 x 1000kVA, 1250kVA, 1500kVA 108MVA total Supplied as three separate projects Project 1 2006 Project 2 2007 Project 3 Commissioned May 2008
Hynix M11 Cheongju Korea
© ABB Group April 13, 2015 | Slide 23
52 x 1250kVA, 1500kVA
Commissioned Feb 2008
Space allocated for M12
© ABB Group April 13, 2015 | Slide 24
PCS100 AVC System
© ABB Group April 13, 2015 | Slide 25
PCS100 AVC Rectifier Sine Filter
IGBT
+ Bus
Fuses
L1 L2 L3 RFI Filter
- Bus Soft Start Contactors
Back © ABB Group April 13, 2015 | Slide 26
Inverter
IGBT active rectifier
Bi-directional power flow
Sinusoidal input current
DC output
PCS100 AVC Inverter Fuses
+ Bus
IGBT
Sine Filter Fuses
U V W RFI Filter
- Bus
SCR/Contactor BYPASS
Back © ABB Group April 13, 2015 | Slide 27
IGBT inverter
Bi-directional power flow
Sinusoidal output current
DC input
PCS100 AVC Injection transformer
Back © ABB Group April 13, 2015 | Slide 28
400kVA 480 volt model
Boost Transformer Internally Bypassed
When the AVC is not online the boost transformer primary must be short circuited
Online means the AVC is running providing voltage regulation and sag correction
When internally bypassed the boost transformer “from an electrical perspective” appears as a reactor (inductor) in series with the load
Typical Internal bypass Impedance 150% for 30 seconds
Internal Fault
Equivalent electrical circuit for an internally bypassed AVC Primary Short Circuited Supply
INDEX © ABB Group April 13, 2015 | Slide 29
Load
PCS100 AVC 40% 3 phase balanced event performance graph AVC Output Voltage (Line to Line)*
120%
110%
100% AVC Output Voltage
Utility Voltage
90%
AVC Correction time (s) 90s
80%
80s
70%
70s
60%
AVC in Bypass
60s
AVC Online
50%
50s
40%
40s
30s
30% Correction Time
20%
20s
10%
10s 600ms
0% 10%
70% balanced sag
20%
30%
40%
0s 50%
60%
70%
80%
90% 100% 110% 120% Utility Voltage (Line to Line) 0340-712a
*AVC output at 0.8 PF for 208 volt systems © ABB Group April 13, 2015 | Slide 30
OPEX AVC and Dual Conversion UPS 800kVA 100% Load
kWhr at $2 NT
Chiller System COP 3
800kVA 480V System 800kVA Load 100% Load
AVC
Efficiency
UPS
AVC
Difference
98.70%
93.40%
5.30%
91,104 kW
462,528 kW
371,424 kW
NT$182,208
NT$925,056
NT$742,848
kW Input
30,368 kW
154,176 kW
123,808 kW
OPEX
NT$60,736
NT$308,352
NT$247,616
kW Losses OPEX
Air Conditioning
OPEX Saving
One Year NT$990,464
© ABB Group April 13, 2015 | Slide 31
YEARS
5 NT$4,952,320
10 NT$9,904,640
15 NT$14,856,960
UPS
© ABB Group April 13, 2015 | Slide 32
Thomas Liu 劉佳炘, PE Power Quality, 18/10/2012
PCS100 UPS-I, Industrial UPS Short term outage protection
© ABB Group April 13, 2015 | Slide 33
PCS100 UPS-I, Industrial UPS There is a solution
© ABB Group April 13, 2015 | Slide 34
The PCS100 UPS-I is the ideal solution where very deep sags or short term power outages are a problem
The PCS100 UPS-I uses energy storage coupled through an inverter to allow the downstream load to ride through very deep sags and short term outages
The PCS100 UPS-I is an offline system. It is inactive unless the voltage falls by 10% - 13%. This enables it to be very efficient, up to 99%
PCS100 UPS-I, Industrial UPS Single line diagram
Input
Output
UPS-I Applied Voltage Failsafe Bypass
secondary
Utilit y
Distribution Transformer
Utility Disconnect
Coupling Transformer primary
Inverter
Charger Battery Option
Ultra Capacitors
UPS-I © ABB Group April 13, 2015 | Slide 35
Protected Load
PCS100 UPS-I, Industrial UPS Outage protection Utility Sag
Distribution Transformer
Utility Disconnect Coupling Transformer
Inverter
Ultra Capacitor
UPS-I
© ABB Group April 13, 2015 | Slide 36
PCS100 UPS-I, Industrial UPS Operation cycle 1. Utility voltage within limits Power
to the load is supplied from the Utility Energy flow
SCR’s On
Utility voltage
Output voltage
Inverter Off
UPS-I voltage
3. Utility returns
2. Utility Outage Occurs
Power to the load is switched to the UPI-I energy storage within ¼ cycle.
SCR’s Off
Utility voltage
Energy flow
Inverter on
© ABB Group April 13, 2015 | Slide 37
Output voltage
UPS-I voltage
PCS100 UPS-I, Industrial UPS Response to supply loss
PCS100 UPS-I Input
PCS100 UPS-I Output
© ABB Group April 13, 2015 | Slide 38
On detecting a disturbance the inverter takes over the load by actively commutating (turning off) the Utility Disconnect SCR switch
Transfer takes place in less than 1/4 cycle
PCS100 UPS-I, Industrial UPS Energy storage – ultra capacitors Ultra capacitors
Protection for 3 seconds (Typical)
Single string rating 300kW for 1 sec or 240kW (300kVA at 0.8 pf) for 3 sec
Ultra capacitors by LS Mtron, Korea
Design Life: 10 years
Cycle life: >500,000
24 pieces of 32V blocks per string (single or double string enclosures)
+/- 375Vdc
High discharge efficiency
Safe and compact matching cabinet
User benefits Double String Enclosure © ABB Group April 13, 2015 | Slide 39
Reduced maintenance
Smaller footprint
PCS100 UPS-I, Industrial UPS Graphic display module Status Page online
On/Off button status bar
Menu selection buttons Supply voltage
Load voltage
Load current
Storage voltage
Status Page In bypass
© ABB Group April 13, 2015 | Slide 40
Visual representation of the PCS100 UPS-I components
PCS100 UPS-I, Industrial UPS Graphic display module Event & fault log
Event and Fault Log, date and time stamped
Records over 5000 events
Log can be download to a PC and viewed in Excel
Summary of power quality events
Event summary
© ABB Group April 13, 2015 | Slide 41
OPEX UPS-I and Dual Conversion UPS 800kVA 100% Load
UPS-I
kWhr at $2 NT
Chiller System COP 3
800kVA 480V System 800kVA Load
100% Load Efficiency
UPS-I
UPS
Difference
99.30%
93.40%
5.90%
kW Losses
49,056 kW
462,528 kW
413,472 kW
Cost
NT$98,112
NT$925,056
NT$826,944
kW Input
16,352 kW
154,176 kW
137,824 kW
Cost
NT$32,704
NT$308,352
NT$275,648
Air Conditioning
OPEX Saving One Year NT$1,102,592
© ABB Group April 13, 2015 | Slide 42
YEARS 5
10
15
NT$5,512,960
NT$11,025,920
NT$16,538,880
UPS
© ABB Group April 13, 2015 | Slide 43
ABB PowerWave UPS 1kVA to 5.0MVA
10 November 2011 Newave SA
44
ABB PowerWave UPS 1kVA to 5.0MVA General Data
DPA UPScale
Powerwave 33
Power range
10/20/40/80/120kW
60/80/100/120/160/200/2 50/300/400/500 kW
Output power factor
1.0
1.0
Parallel configuration
© ABB Group April 13, 2015 | Slide 45
Up to 10 units
Efficiency
Up to 95.5%
Up to 96%
Input frequency
35-70Hz
35-70Hz
Input distortion THDi
View more...
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