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Harmonic Filter Design for Induction Furnace Load in 22 kV Distribution System

Chakphed Madtharad PEA, Bangkok, Thailand chakphed.mad@pea.co.th Abstract-- This paper illustrates a procedure to design harmonic filters for industrial applications, induction furnace load (22 kV, 27 MW, 0.84 PF, and voltage distortion 16.15% from harmonics and interharmonics). This is essential for eliminating and reducing the effects of harmonics in a power system to comply with limit of the Kingdom of Thailand (4.0% THDv for 22 kV distribution systems). Off-line steady state simulation program, DIgSILENT, is used to model loads, to study variation of the harmonics, to study the impedance versus frequency, and to evaluate the effect of harmonic filter in the system using actual recorded data. After the designed harmonic filters are placed, the voltage distortion are dramatically reduced to be 2.7%. Mark McGranaghan EPRI, Knoxville, TN, USA mmcgranaghan@epri.com II. HARMONIC FILTER The harmonic shunt filter works by short-circuiting harmonic currents as close to the source of distortion as practical. This keeps the currents out of the supply system and is the most common type of filtering applied because of economics and because it also tends to correct the load power factor as well as remove the harmonic current. The first step to design filter is computer simulation, then hypothetical harmonic filters are placed in the model and the response of the power system to the filter is examined. If unacceptable results are obtained, the location and values of the filter parameters are changed until the results are satisfactory.

III. INDUCTION FURNACE LOAD Index Terms-- Harmonics, Harmonic Filter Design, The basic characteristic of the induction furnace load Induction Furnace is described in [3]. Fig. 1 shows the network configuration of this load in PEA transmission and I. INTRODUCTION distribution system. An induction furnace immediately The increase of harmonics in the power system generated customer complaints to 115 kV customer of threatens the quality of the electricity supplied to the PEA when connected in the same transmission system. customers. Fundamentally, one needs to control Complaints included noisy capacitors, capacitor harmonics only when they become a problem. When a failures, flickering lights, UPS alarms, drive trips, and problem occurs, the basic options for controlling other problems. Transformer noise would rise and fall harmonics are in [1]. several times per second. It affected nearby industrial This paper illustrates a procedure to design customers and the PEA system. harmonic filters for 27 MW induction furnace with voltage distortion from harmonics and interharmonics IV. FILTER PARAMETER SELECTION CRITERIA (3.713.4% of THDv and 7.89.0% of Total The major criteria to design harmonic filter is to Interharmonic Distortion in voltage (TIDv)). Section select a suitable capacitor size that results in a II presents basic characteristic of harmonic filter. The reasonable PF at fundamental frequency. [4] induction furnace load characteristic is presented in section III. Section IV shows the criteria to select 1)Load Parameter parameter of harmonic filter, section V shows the Load: 27 MW (max), 22 kV, 0.84 PF (17.44 implementation results and conclusion is presented in MVAr), 13.4% THDv and 9.0 TIDv section VI. Constrained: THDv less than 4.0% to comply with limit of the Kingdom of Thailand, and PF higher than 0.95 This work was supported by the Provincial Electricity Authority (PEA),
Thailand.

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(a) Harmonic current waveform

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Fig. 1 Single line diagram

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2) Monitoring Device and Location

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Dranetz-BMI PowerXplorer PX5 Signature System has been used, 256 samples/cycle. It is located at 22 kV bus inside PEAs substation. 3) Fundamental Frequency Reactive Power Compensation

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(b) Harmonic voltage waveform The reactive power, Qcomp , to improve the PF of 27 Fig. 2 Monitoring result for designing harmonic filter. MW load from 0.84 to be 0.96 can be given by
1 1 Qcomp = 27 tan ( cos 0.84 ) tan ( cos 0.96 ) = 9.57 MVAr (1)

Qcr =

The number of filter branches can be selected based on the percentage of the harmonic components of voltage and current. It may also, be necessary to place filters elsewhere in the system to reduce resonance problems (series or parallel), if any. At the tuning frequency hr , the capacitive and inductive components of the filter become equal. That is
XC = hr X L Then hr = hr XC XL

100 % X L Vcr Qcomp 100 Vs

(4)

where Vs is bus voltage of filter, and Vcr is critical or rated voltage of capacitor. The next step is to decide if how many harmonic filter banks should be used. In this step the impedance versus frequency analysis (frequency scan) and harmonic load pattern have to be considered. The three-phase power converter of induction furnace in this case is a 12-pulse current-source. The monitoring results and harmonic spectrum in Fig. 2 shows that the characteristic harmonics in the ac-side line currents are the 11th, 13th, 23th, 25th, etc with some non characteristic 2nd, 5th and 7th and also interharmonic. Since the magnitude of harmonic and interharmonic currents decreases as the harmonic order increases, a damped or high pass filter is recommended to screen out a broad range of higher order harmonics. The parameters of these filters can be obtained similar to the single tuned filter except the value of the resistance which can be obtained as where quality factor ( QF ) has a low value. [4]

(2)

To design harmonic filter, X L was normally defined in term of percentage of X C . That is

hr = 100 100 Then % X L = 2 % XL hr

(3)

The parameters X C and X L are the fundamental frequency capacitive and inductive components of a single tuned filter, respectively. If Qcomp is the total reactive power generated by the filter, the critical or rated reactive power ( Qcr ) at fundamental frequency can be given by

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DIgSILENT

80.00

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With Filter 11 and 13 4.984 59.180 Ohm With Filter 5,11 and 13

X C 50 Hz () =

2 Vcr Qcr

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5.048 29.460 Ohm

106 C ( F ) = 2 fX C 50 Hz

(5)

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0.00

The value of inductive reactance can then be calculated using equation (6).
X L Tuned () = X C Tuned () =
[-] 30.20

5.048 10.298 Ohm

X C 50 Hz hr

-20.00 0.20

10.20 20.20 CSI 22 kV: Network Impedance, Line-Ground A in Ohm CSI 22 kV: Network Impedance, Line-Ground A in Ohm CSI 22 kV: Network Impedance, Line-Ground A in Ohm

L (mH ) =

X L Tuned 10 2 f

(6)

Then X L 50 Hz () = 2 fL

Fig. 3 Frequency scans at 22 kV bus in customer side. Fig. 3 shows frequency scans at 22 kV bus in customer side, the black line shows frequency scan in existing case (without harmonic filter). While the blue line represents frequency scan in case of using harmonic high pass filter just only in significant characteristic harmonic orders (11th and 13th). The blue line in Fig. 3 show parallel resonance at harmonic order 5th, harmonic order at parallel resonance frequency would be magnified about 6 times of normal value. As a result, harmonic high pass filter order 5 has to be added to shift the resonance frequency and/or lower the impedance at resonance frequency (red dotted line). 4)Capacitor, Inductor, and Resistor of each banks

The value of parallel resistance can then be calculated using equation (7).
R() = hr X L 50 Hz QF

(7)

where QF is the quality factor of the filter. 5)Evaluate filter duty requirements Evaluation of filter duty requirements typically involves capacitor bank and also inductor/resistor duties. These duties include peak voltage, current, kVAr produced, and rms voltage. Ref. [6-7] is used as the limiting standard to evaluate these duties. Table 1 summarizes the parameter of each harmonic high pass filter banks. Table 1 Summarize the parameter of harmonic filter.

Harmonic filter order Items 5th 11th 13th To decide if how much reactive power in each banks hr 4.5 10.9 12.8 should be used, harmonic pattern have to be taken into th th QF 4.0 4.0 4.0 account. The harmonic orders 11 and 13 are th %X 4.94 0.84 0.61 dominant harmonic components and filter order 5 is L Qcomp mainly used to shift the resonance frequency. Then 2.0 4.0 4.0 reactive power for harmonic high pass filter order 11th Vs 22.0 22.0 22.0 and 13th are 4.0 MVAr, and 2.0 MVAr for order 5th. Vcr 32.32 38.80 32.49 The design of the filter bank may result in an iterative Qcr 4.317 12.435 8.723 process to optimize the capacitor bank size and filter X C 50 Hz ( ) 254.5289 122.0827 121.7518 the unwanted harmonics [5]. C ( F ) 12.5058 26.0733 26.1442 For any banks of harmonic high pass filter, Qcr can X L Tuned ( ) 56.5620 11.2003 9.5119 be calculated using equation (4). For filter bank order th L ( mH ) 40.0094 3.2708 2.3654 5 , if Vs is 22 kV, Vcr is 32.32 kV, and Qcomp is 2.0 then X L 50 Hz ( ) 12.5693 1.0275 0.7431 Qcr would be 4.317 MVAr. In the same manner, if the R ( ) 226.2480 44.8010 38.0474 tuning frequency hr is 10.9 and Vcr is 38.80 kV then Qcr would be 12.435 MVAr. V. IMPLEMENTATION RESULTS If the value of reactive power to be supplied by the Table 2 shows monitoring result comparing with filter ( Qcr ) is known, the capacitive component of simulation result which the values are not far away wye-connection can be given by from each others.

Table 2 Monitoring & simulation results at 22 kV bus

Items Monitoring results (before/after) A 5.25/ 1.51 7.47/ 4.77 9.37/ 5.00 8.91/ 0.60 11.81 /2.49 14.79 /2.57 B 5.33/ 1.48 8.17/ 6.56 9.87/ 6.73 9.03/ 0.61 13.39 /2.68 16.15 /2.75
11.000 26.052 A 11.000 3.363 A 4.000 6.977 A 20.00 4.000 19.639 A

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Simulation results (before/after)

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TIDi THDi Current Distortion TIDv THDv Voltage Distortion

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C A B C 5.28/ 1.33 7.50/ 4.61 9.21/ 9.44/ 9.94/ 9.27/ 4.80 6.90 6.54 6.27 8.73/ 0.62 12.20 /2.25 15.00 14.52/ 15.06/ 13.90/ /2.33 2.45 2.49 2.36
13.000 26.497 A 13.000 2.557 A
DIgSILENT

15

10

0 THD H10 H20 A IHarm H30 H40 H50

Total RMS: 462.54 A DC Level: -1.60 A Fundamental(H1) RMS: 498.76 A Total Harmonic Distortion THD: 23.84 A (Even: 10.54 A, Odd: 21.39 A)

(c) Harmonic current spectrum (Fig.5 cont.) From simulation (Fig. 4) and monitoring (Fig. 5) results we have found that, designed harmonic filter can dramatically improve voltage distortion. VI. CONCLUSION The procedure to design harmonic filters for induction furnace load using actual recorded data has been presented. The results of harmonic high pass filters are dramatically reduced voltage distortion on the 22 kV bus; 3.713.4% to be 1.02.7% of THDv and 7.89.0% to be 0.22.0% of TIDv. In addition the filters also reduced flickering (1.8 to be 0.6 of Pst) and improved plant PF (0.84 lagging to be 0.99). VII. REFERENCES
[1] R.C. Dugan, M. McGranaghan, S. Santoso, and H.W. Beaty, "Electrical Power System Quality, Second Edition," McGraw-Hill [2] J. C. Das, "Passive FiltersPotentialities and Limitations," IEEE Trans. Industry Applications, VOL. 40, pp.232-241, Jan/Feb 2004. 126821 [3] R.C. Dugan, Sr. Conrad, and L.E., Sr., "Impact of Induction Furnace Interharmonics on Distribution Systems," The IEEE Transmission and Distribution Conference, New Orleans, LA, USA, Apr. 1999. 756150 [4] Elham B. Makram, E. V. Subramaniam,, Adly A. Girgis, and Ray Catoe, "Harmonic Filter Design Using Actual Recorded Data," IEEE Trans. Industrial Application, vol. 29, pp. 11761183, Nov. 1993. 259730 [5] D. Andrews, M.T. Bishop, and J.F. Witte, "Harmonic Measurements, Analysis, and Power Factor Correction in a Modern Steel Manufacturing Facility," IEEE Trans. Industrial Application, vol. 32, pp. 617-624, May/June 1996. 502174 [6] IEEE Standard 18-1992, IEEE Standard for Shunt Power Capacitors. [7] IEEE Standard 1531TM-2003, IEEE Guide for Application and Specification of Harmonic Filters.

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1.0 3.0 5.0 7.0 9.0 11. 13. 15. Induction Furnace: Phase Current A in A 115/22 kV: Phase Current A/LV-Side in A

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21.

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25.[-] [-]

Fig. 4 Harmonic current spectrum of before (red line) and after (green line) the filters are placed.
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(a) Harmonic current waveform

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(b) Harmonic voltage waveform Fig. 5 Monitoring result after the filter are placed.