2012 Interational Conference on Computing, Electronics and Electrical Technologies [ICCEET]

Modeling and Simulation of 6-Pulse Rectifer Drives with

Impacts to Input Current Harmonics
D.Maheswaran
Electrical Department,
TNPL, Karur, India.
e-mail:mwaran78@gmail.com
Abstract- This paper describes the measurements and
simulations of harmonics from six pulse adjustable speed
drives in Pulp and paper Industry. Harmonic analysis of
the distribution system is essential to study the behavior of
equipments connected in the non-sinusoidal system
environment for designing and optimal location of flters.
The simulations are done in Mat lab by sim-link circuit
simulator. Validation of the load models is done by
performing case study for an Tamil Nadu Newsprint and
Papers Ltd (TNPL) supply system and comparing the
THDs obtained from simulation using MA TLAB package
with the THD values obtained by measurement. Due to a
very close match, the simulators are used further to
analyze diferent harmonic mitigation solutions. The best
solution found by simulations, for the given plant, is an
advanced harmonic flter dedicated for adjustable Speed
Drives.
Index Ters-Harmonics, Pulse Width Modulation, Six Pulse
Drive, Filter.
I. INTRODUCTION
The application of cost effective power converter
circuits which enhance the overall performance, eficiency,
and reliability of industrial processes is common in all
industry. The industrial applications of ACIDC and DC/AC
power conversion have increased gradually since the advent of
silicon controlled rectifiers (SCR) in 1957. However, the wide
use of single and three phase diode/thyristor rectifers, for DC
power supplies, Adjustable Speed Drives (ASD) in industrial
appliances. With an estimated 65% of industrial electrical
energy used by electric motors, the major users in industry
increasingly see energy reduction as a key to improve their
profitability and competitiveness.
Because variable speed drives reduce energy
consumption (20-30% savings) and decrease pollutant
emission levels to environment while increasing productivity,
their proliferation is inevitable. For variable speed
applications, ASDs are widely employed in driving induction
and permanent magnet motors due to the high static and
dynamic performance obtained in such systems. High energy
efficiency and high motion quality, low starting torque, etc.
are the positive attributes of the ASDs.
978-1-4673-0210-4112/$31.00 20 12 IEEE 477
Dr.N.Rajasekar
Electrical Engineering Department,
VIT, Vellore, India.
e-mail: drrajasekar@gmail.com
Line
Impedance
L
s
II. SIX PULSE DRIVES
J
+
J
Rectifer Voltage Somce hlVener

ASD System
Fig.l. Six pulse AC Drive Power Structure
ASDs, consists of ACIDC converter connected to
DC/ AC inverter. Of all the modem power electronics
converters, the Voltage Source Inverter (VSI) is perhaps the
most widely utilized DC/ AC conversion device with
commonly used Pulse Width Modulation (PWM) methods.
The PWM-VSI consists of three basic stages the frst stage of
the drive must convert three-phase AC to DC. The first stage
is known as the converter section. In an AC drive, the
converter stage consists of a three phase, full wave diode
bridge, though SCRs (Silicon controlled rectifiers) are
sometimes used in place of diodes.
A flter is required to smooth out the ripple on the DC
bus in order to run the IGBT inverter. Therefore, a second or
"filter" stage is required. Primarily, this consists of a large
capacitor bank and an inductor or "link choke" may be added.
The choke, when used, helps bufer the capacitor bank from
the AC line and serves to reduce harmonics.
The third stage is the inverter section. This section uses
high-speed transistors or IGBTs as switches to apply a "Pulse
Width Modulated" or PWM waveform to the motor. Taking
advantage of the fact that a motor is basically a large inductor,
and that current does not change very fast in an inductor, the
DC bus voltage can be applied in pulses of varying width in
order to achieve current in the motor that approximates a sine
wave.
2012 Interational Conference on Computing, Electronics and Electrical Technologies [ICCEET]
III.SIMULATON MODAL AND SIMULATION RESULS
Fig. 2.Simulation model of the Six Pulse Drive
The single line diagram of the system is simulated using
MATLAB/SIMULINK-platform to study the distortions in the
voltage and current waveform due to the presence of a
nonlinear load in the system. The actual system can be
modeled with a high degree of accuracy in this package. It
provides the user interactive platform and a wide variety of
numerical algorithms. Fig.2 shows the system modeled in
SIMULINK. The system consists of six pulse rectifier model
with dc link choke and PWM inverter. The same system is
simulated with line reactor and without line reactors.
Fig. 3. Simulation waveforms for voltage and current on II
kV/4I5V side of the transformer. (a) 3-phase Voltages, (b).
Line current, Iabe
Fig. 3 and 4 shows simulation results of voltage and current on
11 kV side and 3-phase Voltages and Line current, Iabe on
4I5V side of the transformer and Simulation waveforms for
voltage and current on Load side. (a) V
d
e (b)Vinv (c) Vab (d)
Iab( e )Modulation Index.
478
Fig. 4. Simulation waveforms for voltage and current on Load
side. (a) V
d
e (b),Vinv (c) Vab (d) lab (e)Modulation Index.
Fig. 5. Simulation waveforms for Phase current Ia without Line
Reactor
The Fig.5 shows simulation results of Phase current Ia and
fg.6 shows the Real Time measured waveforms for Phase
voltage Va and Phase current Ia without Line Reactor. The line
reactors are commonly used in two types one is AC side three
phase line reactor and another one is DC side line reactor. The
simplest and most economical passive harmonic reduction
technique involves the use of AC line reactors (Lac) in front of
the ASD's. The series inductance flter or in-line reactance is a
well established method. Typically 1 % to 5% Lac inductors
are used. In the USA 3% and in Europe 4% values are
commonly utilized. The effective impedance value in % is
based on the actual loading as given by
2*
.
*r*
I
*L*[ ]d
Zell =
X 100
vu,
|4)
The AC inductor's reactance increases proportional to the
system fequency. Therefore, the inductance smoothens the
line current drawn by the converter. Hereby, a signifcantly
2012 Interational Conference on Computing, Electronics and Electrical Technologies [ICCEET]
lower current harmonic distortion can be achieved down to 30-
35 % THDI range compared to the basic ASD THDI. This
THDI range can be improved when a DC link inductance is
combined with the AC line reactors. Unlike the AC line
reactors, the DC link inductance does not cause any reactive
voltage drop while contributing to shaping the current
waveforms. It is known that the efective impedance of the DC
link inductance, when referred to the AC side, is approximate
the half of its numerical value. DC link inductor size between
3% and 5% is typically built into some of the commercial
ASD systems
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Fig. 6. Real Time measured waveforms for Phase voltage Va
and Phase current Ia without Line Reactor
I I I I
Fig. 7.Simulation FFT Result for Line current lab
Figure 7 shows the supply current waveform and its FFT
components with respect to phase voltage Vab. It is clear from
this fgure that the supply current has very high THD mostly
of 5
th
and 7
th
harmonics.lt is clear from this figure that the
supply current becomes to non sin-wave with 38.93%THD.
IV.CASE STUDY
Tamil Nadu Newsprint and Papers Limited (TNPL) was
established by the Government of Tami Nadu during early
eighties to produce Newsprint and Printing & Writing Paper
using bagasse, a sugarcane residue, as primary raw material.
The Company commenced production in the year 1984 with a
479
initial capacity of 90,000 tonnes per annum (tpa). Over the
years, the production capacity has been increased to 2,45,000
tpa and the Company has emerged as the largest bagasse based
Paper Mill in the world consuming about one million tonnes of
bagasse every year. The Company completed a Mill
Expansion Plan during December 2010 to increase the mill
capacity to 4,00,000 tpa. The mill consists of the following
sections:
I. Paper Machine-1
2. Paper Machine-2
3. Paper Machine-3
4. Finishing House
5. Pulp Mill
6. Soda Recovery Plant (SRP)
7. Power and Steam generation Plant
8. Water Treatment Plant (WTP)
9. Efuents Treatment Plant (ETP)
10. Coal Handing Unit
The harmonic study conducted in TNPL and results of a
harmonic study are presented in table I. The effects of
harmonic distortion on the operation of electric drives are
discussed. To provide detailed analysis of the system, one of
the 132 KW PA fan six pulse drive were investigated in
Recovery Boiler and simulated using Matlab/Simulink in
presence of harmonics and the results comparison are
presented in table II. The three phase line voltage and current
wave form measured by using power quality analyzer and its
harmonic spectrum are shown in figure-8 and 9 .A six pulse
converter would generate harmonic current of the order 5
th
, 7
th
, 11
th
, 13
th
, 17
th
, 19
th
23
r
d
,25
th
,etc.
Fig.8. Line Voltage and Current Waveform
Figure 10 and 11 shows the phase current waveform and its
FFT components with respect to phase voltage Vab. It is clear
from this fgure that the supply current has very high THD
mostly of 5
th
and 7
th
harmonics.lt is clear from this figure that
the supply current becomes to non sin-wave with
33.87%THD.
2012 Interational Conference on Computing, Electronics and Electrical Technologies [ICCEET]
Yolugu
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Fig.9. Line Voltage and Current Harmonic spectrum
Figure 10 and 11 shows the phase current waveform and its
FFT components with respect to phase voltage Vab, the same
is compared with simulated wave form in fgure 7. The
simulation and real time measurement comparison results
were presented in table II.
50.0
45.0
40.0
35.0
30.0
25.0
20.0
15.0
10.0
5.0
0
0
Fig. 10. Phase Current Waveform
Current Ph1 (7)
thd
Fig.Il. Phase Current Harmonic spectrum
Figure 12 shows the average current and 3
r
d
,5
th
,7
th
, 11
@
and
13
th
order harmonics current with respect to varying load
current. It is clear from the fgure 3
r
d
order harmonic current is
480
not presented and very high THD 5
th
and 7
th
harmonics
current.
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Flg.I2. Average current and 3 ,5 , 7 ,11 and 13
harmonics current.
Ih
Figure 13 shows a simplified single line diagram for the six
pulse drive installation of the following Plants:
1. Power Boiler.
2. Paper Machine-I.
3. Paper Machine-2.
4. Chlorine Plant.
Fow8|BoII8| F8p8|M80hIn6-1
Fig.13. power Distribution and Drives Installation.
Consider the Industrial plant under study shown in Fig-l3. The
industrial plant is supplied from 24 and 20 MW T.G through
Distribution transformers 4.4, 8.3, 8.4 of 2 MV A, Dyn II, and
II kV/415V and II of 8 MVA II KV1170.2V star, 170.2V
star. The loads consist of 6-pulse converters. By studying the
equivalent impedance of the system at Distribution panel
(PCC) 1 , the table I presents the line voltage at bus and its
harmonics % THD V and the line current through main
transformer and its harmonics %THD I. From the results we
can see Distribution panel-l harmonic currents exceed the
standard limits of the IEEE Std. 519.
2012 Interational Conference on Computing, Electronics and Electrical Technologies [ICCEET]
Fig.14. Photo view of the measuring equipments installed at
PCe.
TABLE-I
Harmonic Measurement Table at PCC
S.No Tran Voltage Capacity Actual Actual P.F VTHD hHD
s. Ratio in KVA Load in Load in (cos q
) |)
No KVA KW
I 4.4 11I.433KV 2000 405.6 291 0.72 0.5 38.8
2 8.3 11I.433KV 2000 1080 796.9 0.74 I 31.2
3 8.4 11I.433KV 2000 703 535.3 0.77 1.1 24.3
4 II 11I.170KV 8000 6267 4453 0.71 1.3 23.6
Fig.14. Photo view of the harmonic measuring equipments
Installed at Drive.
481
TABLE-II
Result Comparison Table for Simulation and Experiment
Harmonic Simulation Experiment
order Results Result
Phase % distortion Phase %
Current Current distortion
1
117.45 100 116.41 100
5
34.33 29.23 36.45 31.31
7
9.86 8.40 11.62 9.98
11
7.50 6.38 7.33 6.30
13
4.16 3.54 3.72 3.19
17
2.87 2.45 2.88 2.48
19
2.30 1.96 2.01 1.72
%THD
MY M MY M
%
1.60 33.93 1.83 33.87
V.CONCLUSION
Harmonic analysis of power system is performed to study the
system behavior under harmonics IEEE 519 norms. This paper
presents the simulation modeling of six pulses converters in
industrial applications. Case study of harmonic analysis is
performed for Power Boiler, Chlorine Plant and Paper
machines distribution system at TNPL, Tamilnadu, India.
THD is used as the harmonic index and harmonic spectrum is
presented for six pulse drives and for the industrial distribution
system. The simulation results of THD were acceptable with
the practical measurement values. These models can hence be
employed for harmonic analysis of a practical system and to
design a suitable filter to mitigate harmonics in the distribution
system.
ACKNOWLEDGEMENT
The authors would like to acknowledge the Electrical
Department of Tamilnadu Newsprint and Papers Ltd (TNPL),
Karur, Tamilnadu, India for providing the electrical supply
distribution scheme to carry out the work.
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