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By Prof. Saad M. Alghuwainem Prof. Hossam E.A. Talaat Department of Electrical Engineering
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ACKNOWLEDGEMENT
The authors are greatly indebted to Saudi Basic Industry Company (SABIC) and to the college of engineering research centerKing Saud University for their financial support and assistantship in completing this project.
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TABLE OF CONTENTS
Page
Chapter 1: Introduction
1.1 General 1.2 Research Topic and Significance 1.3 Objectives of the Project 1.4 Organization of the Report 1 2 4 4
Chapter 6: Conclusions
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SUMMARY
A voltage dip is a brief (0.5-30 cycles) drop in voltage magnitude, usually caused by a fault somewhere on the power system transmission or distribution network. Voltage dips are the most important power quality problem facing many process industry companies. Equipment used in modern industrial plants (process controllers, programmable logic controllers, adjustable speed drives) is actually becoming more sensitive to voltage dips as the complexity of the equipment increases and the equipment is interconnected in sophisticated processes. Even relays and contactors in motor starters can be sensitive to voltage dips, resulting in shut down of a process. This research conducts the characterization of voltage dips and its impact on industrial processes with special attention on the mitigation techniques. The Dynamic Voltage Restorer (DVR), being reliable and cost effective, is adopted to be the optimal solution for the voltage dip phenomenon. A new compensation strategy for the DVR has been proposed in this research. Its idea is based on the minimization of the energy supplied from DVR irrespective of the balance of the three-phase voltages supplied to the load. The evaluation of the proposed compensation strategy for DVR revealed its superiority from energy minimization point of view as compared to other strategies including the minimum energy technique with balanced compensation.
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Chapter 1 INTRODUCTION
1.1 General
Voltage dips, also known as voltage sags, are short- duration reductions in rms voltage. In this report the two terms are intermingled meaning the same. Disruptive voltage dips are usually caused by fault conditions on the utility transmission and distribution systems or within a customers facility. Motors starting within the customer facilities can also result in voltage dips for neighborhood customers. The characteristics of these voltage dips are predictable and can be prevented. The duration of the dip caused by motor starting is generally longer, but the voltage drops are usually small and do not cause serious problems at the customer locations. It is relatively easy to design the system such that dips due to motor starting do not pose any problems. Voltage dips due to short-circuit faults have become one of the most important power quality problems facing industrial customers. As the complexity of the electronics equipment used in the industrial plant increases, the equipment is becoming more sensitive to voltage dips. It is important to understand the difference between an interruption (complete loss of voltage) and a voltage dip. Interruptions occur when a protective device actually interrupts the circuit serving a particular customer. This will normally only occur if there is a fault on that circuit. Voltage dips occur during the period of a fault for faults over a wide part of the power system. Faults on parallel feeder circuits or on the transmission system will cause voltage dips but will not result in actual interruptions. Therefore, voltage dips are much more frequent than interruptions. If equipment is sensitive to these voltage dips, the frequency of problems will be much greater than if the equipment was only sensitive to interruptions. This research describes the voltage dip characteristics and the sensitivity of equipment. With this information, the range of fault locations on the power system that can cause problems can be estimated. Options for improving equipment performance in the presence of voltage dips include power conditioning and/or equipment design modifications. Both of these options are described.
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A voltage dip is most of the time described by two essential characteristics, magnitude and duration. However, the dip magnitude is not constant, due to the induction motor load present in many industrial systems. It has been shown in references [1, 2] that it is often difficult to define a constant dip magnitude for dips in an industrial system. Apart from the drop in voltage magnitude, the voltage also shows a jump in phase angle [3] and three-phase imbalance [4]. When an imbalanced voltage dip occurs at a certain voltage level (e.g., 33 kV) and is then transferred down to the equipment terminals (e.g., 660 V), the magnitude and phase-angle jumps in the three phases will change in the process. The transformer winding connections between the point of the fault and the equipment terminals swap the three phase voltages in case of an imbalanced dip. A single line-toground fault (SLGF) on the primary side of a delta/wye or wye/delta transformer will change into a phase-to-phase fault on the secondary side. Reference [4] has shown that the voltage dips experienced by three-phase loads, like adjustable-speed drives, can be classified into four types characterized by a magnitude and a phase-angle jump. From this classification, it is possible to determine the voltages at the equipment terminals for a given fault at a higher voltage level. It can, for example, be shown that, for an SLGF, the lowest phase voltage after a transformer is never less than 33%. This is due to the loss of zero-sequence voltage when the dip is transferred through a transformer (the transformer is an exception to this rule). For line-to-line faults (LLFs), it is still possible that the voltage in one of the phases at a lower voltage goes down to zero. The influence of the load on the voltage dip has not been taken into account in either of these studies. Some studies of induction motor load influence on voltage dips have been performed [1, 2]. They were, however, restricted to three-phase faults. Induction motors are a large fraction of the total load, especially in industrial power systems.
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In some industrial process, a power interruption of only a very short duration and magnitude can adversely affect the process. In fact, durations as low as 100 ms with a voltage drop of 25% may only be perceivable as a blink of lights, yet such a voltage dip can initiate a chain reaction of industrial shutdowns and failures that can be catastrophic to a facilitys daily profitability. Equipment shutdowns and failures can be easily correlated with incidents of lightning storms in the surrounding region. Adjustable-speed drives probably are the type of equipment most sensitive to voltage dips. Not only are these drives very sensitive, it is also generally assumed that it is difficult to make them more tolerant against dips. The sensitivity of drives to dips is mentioned in several papers [5], [6]. Testing of drives has been performed as well in [7] and [8].
Emphasis is on the DC-bus voltage and on the drop in speed of the motor load driven by the drive. DC-bus undervoltage is the main reason for drive tripping during a voltage dip. In case the electrical part of the drive can tolerate a voltage dip, the underspeed criterion of the mechanical load may become the limiting factor. In most ac adjustable-speed drives, the three ac voltages are fed to a three-phase diode rectifier. The output voltage of the rectifier is smoothed further by means of a DC capacitor. Occasionally, a DC line inductance is present to smooth the rectifier current and so reduce the harmonic distortion in the current taken from the supply. The DC voltage is inverted to an ac voltage of variable frequency and magnitude, by means of a so-called voltage-source converter (VSC). The most commonly used method for this is pulsewidth modulation (PWM). Many adjustable-speed drives are very sensitive to voltage dips. Tripping may occur due to several phenomena. The drive controller or protection will detect the sudden change in operating conditions and trip the drive to prevent damage to the power electronic components. Tripping of the drive is mainly on DC-bus undervoltage. The increased ac currents during the dip or the post-dip overcurrents charging the DC capacitor will cause an overcurrent trip or blowing of fuses protecting the power electronics components. The process driven by the motor will not be able to tolerate the drop in speed or the torque variations due to the dip.
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The main causes of drive trips at the moment are still the control system and the protection. Some of the more modern drives restart immediately when the voltage comes back; others restart after a certain delay time or only after a manual restart. The various automatic restart options are only relevant when the process tolerates a certain level of speed and torque variations. The effect of a balanced dip on a three-phase rectifier is that the maximum ac voltage no longer exceeds the DC-bus voltage. Thus, the capacitor continues to discharge. This discharging continues for a number of cycles, until the capacitor voltage drops below the maximum of the ac voltage. After that, a new equilibrium will be reached. It is important to realize that the discharging of the capacitor is only determined by the load connected to the DC bus, not by the ac voltage. Thus, all dips will cause the same initial decay in DC voltage. However, the duration of the decay is determined by the magnitude of the dip. The deeper the dip the longer it takes before the capacitor has discharged enough to enable charging from the supply. As long as the absolute value of the ac voltage is less than the DC-bus voltage, all electrical energy for the load comes from the energy stored in the capacitor.
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through a comparative study with other strategies. Chapter SIX includes the conclusions and main findings of the research.
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Fig. 2.1 Voltage Dip Caused by a Non-Symmetrical Fault (a)-(c) Phase-to-Phase Voltage waveforms during Fault. (d) The Fundamental Frequency Magnitude of Voltage. (Depicted From Reference [13])
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2.2.2 Induction Motor Starting During starting, motors draw approximately five-times their full-load running current, and at a very low power factor. This starting current causes shallow voltage dips. The magnitude of the voltage dip depends on the characteristics of the induction motor and the strength of the system at the point that the motor is connected. Fig. 2.2 shows the voltage waveforms during a voltage dip due to induction motor starting. The measurement was performed in a 400 V network. The fundamental frequency voltage magnitude of all phases drops approximately 10% of the pre-event value and then recovers gradually as the current that is drawn by the motor decreases.
Fig. 2.2 Voltage Dip Caused by Induction Motor Starting (a)-(c) Phase-to-Phase Voltage waveforms during Fault. (d) The Fundamental Frequency Magnitude of Voltage. (Depicted From Reference [13])
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2.2.3 Self-Extinguishing Faults Voltage dips due to self-extinguishing faults are the ones that disappear before the fastest possible breaker opening time. Fig. 2.3 shows the voltage waveforms during a selfextinguishing voltage dip. The measurement was performed in a 10 kV network. As the fundamental frequency magnitude of voltage shows the voltage decreases for less than 2 cycles before it disappears without causing operation of the protection system. The healthy phases present an overvoltage.
Fig. 2.3 Voltage Dip Caused by Self-Extinguishing Fault (a)-(c) Phase-to-Phase Voltage waveforms during Fault. (d) The Fundamental Frequency Magnitude of Voltage. (Depicted From Reference [13])
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2.2.4 Transformer Energizing Voltage dips due to transformer energizing have been reported in the literature [14]; but neither the frequency in which this event appears in a power quality survey nor the characteristics of this event in terms of voltage have been presented. The main attention has been given to the effects of the inrush current on the protection relays of the transformer itself [15]. In a transformer under steady-state conditions there is a particular value of flux in the core, for each point on the voltage waveform. When the transformer is energized, the initial value of flux in the core might not necessarily be the steady-state value for this particular point on the voltage waveform. A transient will occur to change the flux in the core to the steady state condition. In general, this will cause the flux to go above the saturation value once each cycle until the average value of the flux for a cycle has decayed to nearly zero. This temporary over-fluxing of the transformer core causes high values of the magnetizing current. This phenomenon is known as magnetizing inrush current. In turn, short duration voltage dips are caused that might result in an unwanted tripping of differential protective relays. As described in [13] and [14] this voltage dip can be long in duration and drive more transformers into saturation. Fig 2.4 shows the voltage waveforms during transformer energizing. The measurement was performed in an 11 kV network. The fundamental frequency voltage magnitude drops for a very short time and recovers gradually as the magnetizing current decreases. The largest drop is approximately 8% of the pre-event voltage.
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Fig. 2.4 Voltage Dip Caused by Transformer Energizing (a)-(c) Phase-to-Phase Voltage waveforms during Fault. (d) The Fundamental Frequency Magnitude of Voltage. (Depicted From Reference [13])
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have rms voltage magnitudes below the dip threshold, the third phase has magnitude above it), and three-phase dips (all three phases have rms voltage magnitudes below the dip threshold). Poly-phase dips then can be divided into symmetrical dips (which means that dipped phases have equal rms voltage magnitudes), and asymmetrical dips (when at least two dipped phases have different rms voltage magnitudes). This is a good example of intuitive dip classification, because differences between the various dip types are self-explanatory. This classification is implicitly incorporated in all power-quality standards, and widely used in a day-to-day practice. A short description of this classification is given in Table 2-2. This classification is related only to rms phase voltages during the dip and it assumes that they do not change during the dip. It does not consider the phase angles of phase voltages, the origin, and propagation of the dip, nor duration of the dip. In the general case, three-phase voltage magnitudes are necessary for the description of dip types in this classification. Table 2-2 Number of Sagged Phases Classification
(depicted from [21])
2.4.2 Classification With Regards to Complex Phase Voltages: Another dip classification, based on the analysis of propagation and changes of four basic dip types due to the four general fault types in an idealized power systems, is proposed in [5] and given in Table 2-3. Instead of using the rms phase voltage values, it uses complex phase voltages (magnitudes and phase angles). All dip types from this classification have at least two-phase voltage magnitudes equal during the dip.
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As a direct consequence, dip type 4 from previous classification (asymmetrical two-phase dip) is excluded from this classification. Dip types A, B, and E from this classification are the same as dip types 3, 1, and 2 from previous classification, respectively. Dip type C is practically dip type 2 (symmetrical two-phase dip), but with the phase shift in two dipped phases. The three remaining dip types (D, F, and G) from this classification correspond to general dip type 5 from previous classification (asymmetrical three-phase dip), except they all have phase shift in two phases with equal magnitudes. In fact, pairs of dip types D&F and C&G are so similar, that their distinction and identification from the recording in actual power systems is almost impossible without further knowledge about the fault types that caused them. Some of the factors that are associated with the faults in the power system, which can make it difficult, if not impossible, to distinguish between different dip types are: unbalances in the fault resistances, load characteristics or system impedance characteristics, contributions of motors, coupling between the overhead transmission lines, changes in unfaulted voltages and phase shifts introduced by the differences in X/R ratios during the fault [5]. The main advantage of this method is that three complex phase voltages for all dip types in Table 2-3 can be reconstructed if the characteristic voltage and related dip type are known. Characteristic voltage is generally determined as the lowest of six phase-toground and phase-to-phase voltages, calculated in per-unit values and after extracting the zero-sequence component from phase-to-ground voltages. Although this classification, as given in Table 2-3, neglects the phase shifts due to the differences in X/R ratios introduced by the fault, (some values of) this parameter can be easily incorporated. This means that three per-phase values are not necessary for the full description of various dip types as defined in this method, and that only one set can be provided instead. The assumption that magnitudes, phase angles, and phase shifts of phase voltages do not change in time means that dip duration is an independent parameter. However, if the dip duration is different in different phases, individual dip duration values should be provided as additional information, and related dip types, which now change during the dip, should be determined regarding the individual dip duration intervals. It is also important to consider dip propagation and dip change phenomena when the (expected) number of dips is calculated from the known fault rate data of system components. Depending on the number and type of transformers between the fault
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locations and buses of interest, single-line faults, for example, can produce either twophase or single-phase dips. Related fault rates, expressed as the number of single-line faults per year, then should be carefully related to each dip type in order to obtain the precise number of their occurrences. Practically, this means that in this method, the fault type should also be considered as an additional parameter for characterization of various dip types. Table 2-3 Classification of Voltage Dips in Regards to Complex Phase Voltages
(depicted from [21])
Note 1: Dip types A, B, C, and E are four basic dip types, which means that they are caused by four general fault types, as they occur at the fault location. They correspond to three-phase, single-phase, two-phase, and two-phase to ground faults, respectively. Note 2: Dip type C may occur as a result of propagation of dip types B and D. Dip types D, F, and G are only the results of propagation of dips caused by single-phase and two-phase faults (for type D), or two-phase-to-ground fault (for types F and G). Only dip type A does not change in propagation. Note 3: Phase shift characterizes dip types C, D, F, and G. As given in Table II, the phase shift for dip type C is introduced either due to the nature of two-phase fault at the fault location, or due to the further propagation of dip types B (and D) through the systems transformers. The phase shift for dip types D, F, and G is introduced only in propagation through the systems transformers.
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Finally, information about the fault type can be useful in a more general context. For example, it is generally assumed that the point on wave of dip initiation is, in most faults, associated with the breaking of electrical insulation and flashovers/arcs, which are more likely to occur when voltage is near the maximum (90 or 270 in the voltage waveform), than when voltage is near zero. However, all characteristics of dips change in propagation and it may happen that at the bus of interest, point on wave values are completely random, or start to cluster around some other point on the voltage waveform. In that situation, back-tracking of the dips all of the way back to the fault locations at which the dips originate can provide explanation.
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rotor protection. Maximum voltage dip magnitude and/or duration, which the motor operation can survive, depend on the motor parameters and the torque-speed characteristic of the driven load. Motor recovering process after voltage dips is dynamically similar to motor starting process and is accompanied by large inrush currents. Depending on motor protection settings, these currents can trigger short circuit or locked rotor protection of the motor resulting in the tripping of the motor. Most of induction machine protection settings are too conservative. This leaves room for adjusting these settings without causing any threat to the motor safety. Many of the unnecessary motor tripping incidents can be avoided by simple adjustment to the motor protection settings. 2.5.3 AC Drives Adjustable-speed drives probably are the type of equipment most sensitive to voltage dips [24,25]. Not only are these drives very sensitive, it is also generally assumed that it is difficult to make them more tolerant against dips. Tripping of speed drives may occur due to several phenomena [25]: The drive controller or protection will detect the sudden change in operating conditions and trip the drive to prevent damage to the power electronic components. Tripping of the drive is mainly on dc bus undervoltage. The increased ac currents during the dip or the postdip overcurrents charging the dc capacitor will cause an overcurrent trip or blowing of fuses protecting the power electronics components. The process driven by the motor will not be able to tolerate the drop in speed or the torque variations due to the dip. The main causes of drive trips at the moment are still the control system and the protection. Some of the more modern drives restart immediately when the voltage comes back; others restart after a certain delay time or only after a manual restart. The various automatic restart options are only relevant when the process tolerates a certain level of speed and torque variations. The effect of a balanced dip on a three-phase rectifier is that the maximum ac voltage no longer exceeds the dc bus voltage. Thus the capacitor continues to discharge. This discharging continues for a number of cycles, until the capacitor voltage drops below the maximum of the ac voltage. After that a new equilibrium will be reached.
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It is important to realise that the discharging of the capacitor is only determined by the load connected to the dc bus, not by the ac voltage. Thus all dips will cause the same initial decay in dc voltage. But the duration of the decay is determined by the magnitude of the dip. The deeper the dip the longer it takes before the capacitor has discharged enough to enable charging from the supply. As long as the absolute value of the ac voltage is less than the dc bus voltage, all electrical energy for the load comes from the energy stored in the capacitor. The adjustable-speed drive will trip either due to an active intervention by the undervoltage protection (which is the most common situation), or by a maloperation of the inverter or the controller. In both cases the trip will occur when the dc bus voltage reaches a certain value Vmin. As long as the ac voltage does not drop below this value the drive will not trip. For a three-phase unbalanced dip of type C or type D, different phases have different voltage drops. Some phase voltages also show a jump in phase angle. The behaviour of the dc bus voltage, and thus of the drive, is completely different from the behaviour for a balanced dip. Most ac adjustable-speed drives trip on dc bus undervoltage. After the tripping of the drive, the induction motor will simply continue to slow down until its speed gets out of the range acceptable for the process. In case the electrical part of the drive is able to tolerate the dip, the drop in system voltage will cause a drop in voltage at -the motor terminals. For balanced dips all three phase voltages drop the same amount. Assume that the voltages at the motor terminals are equal to the supply voltages (in p.u.), thus that the dip at the motor terminals is exactly the same as the dip at the rectifier terminals. The dc bus capacitor will somewhat delay the drop in voltage at the dc bus and thus at the motor terminals, but saw that this effect is relatively small. The voltage drop at the motor terminals causes a drop in torque and thus a drop in speed. This drop in speed can disrupt the production process requiring an intervention by the process control. The speed of a motor is governed by the energy balance equation. The main conclusion from the above that it is difficult to make the current design of ac adjustable speed drives immune to voltage dips due to three-phase faults. This would require a much larger amount of energy storage or serious improvements in the power electronics inverter or rectifier. However, even for three-phase balanced dips, the effect of the dip on the motor speed is limited. Keeping the drive on-line would be the best way
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of mitigating the effect of a dip on the mechanical load. To make the drives immune against voltage dips due to single-phase and phase-to-phase faults, only requires a moderate amount of capacitance. The dc bus voltage, even for the most severe unbalanced dip, does not drop below 80% of its nominal value. If the drive remains online the effect on the load is minor. A reported problem with ac drives is that they trip on the current unbalance due to a three-phase unbalanced dip. This effect already occurs for shallow dips and even for unbalanced during normal operation. Mitigating this requires rating of the diodes to 200% of nominal and a time delay in any unbalance or missing pulse detection. 2.5.4 DC Drives [26] Direct-Current (DC) motors are used extensively in industrial variable-speed drive applications. DC motors can provide a high starting torque and offer easy speed control over a wide range. DC motor drives are particularly susceptible to dips since they normally have no energy storage capacitors. In fact, many drives will trip if the voltage magnitude of one, two, or all of the supply phases dips below 90%. Since the majority of the voltage dips have a magnitude of around 80-90% and a duration of few cycles, nuisance tripping is common in most industrial plants where AC/DC dives are utilized. Since DC drives do not have extra energy storage other than the motors own inertia, whenever a voltage dip occurs the DC motor slows down due to undervoltage or unbalance (phase loss), tripping the drive. However, AC drives may ride-through short duration voltage dips. AC drives have energy storage in the DC link capacitance (and inductance to some extent) which helps the motor ride-through short duration voltage dips. With proper precautions, this capacitance can be increased to improve the ridethrough capability. In general, the drive manufacturers try to minimize the capacitance so that cost and packaging space is minimized. Unfortunately, electrical energy storage is not available for most DC drives. One cannot arbitrarily place large capacitors in parallel with the DC motor to improve its ride-through capability for the following reasons: When each thyristor is fired, the partially discharged parallel capacitor causes the DC drive to draw a huge amount of charging and load current. This surge may cause damage to thyristors or blow fuses unless careful counter measures have been taken.
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