Experience with Custom Power Applications for Critical Manufacturing Facilities

September 2003

Medium Voltage UPS Systems

Systems commonly at 5, 15 25 & 34.5 kV Ratings up to 20,000 kVA / 16,000 kW

PureWave Medium Voltage UPS Configurations For 5,000 kVA and Larger

PES Available Ratings: 600 and 1200 amps Available Voltages: 4.16, 6.6, 11.0, 13.8 and 22 kV

Building Block - 250 kW Power Module

Merck Pharmaceutical Puerto Rico

Typical Medium Voltage System Layout 4,000 kVA @ 4160V

Rating: 5000 kVA/ 4000 kW at 12.47 kV

Power Electronic Switch Modules stacked in series

Three modules per pole for 15 kV Three poles per switch N+1 design for reliability

Medium Voltage System Power Electronic Switch

Rating: 600 amps @ 5 or 15 kV

Medium Voltage Source Transfer System (STS)

Mechanical and Electro-Mechanical systems
Less than 3 seconds Less than 2 cycles

Solid State Electronic systems

2-4 milliseconds (1/4 cycle)

Electronic Source Transfer System

Seamlessly transfers in 1/4 cycle Maintains load within CBEMA/ITIC curve Protects entire load from distribution system disturbances

Semiconductor Fab
Albuquerque, NM Rating: 2 x 10,000 kVA UPS @12.47 kV With Source Transfer and Generators

Semiconductor Fab
Albuquerque, NM Rating: 2 x 10,000 kVA UPS @12.47 kV With Source Transfer and Generators

Dynamic Voltage Restorer (Sag Correction System)

Dynamic Voltage Restorers (DVRs) are being applied up to protect loads up to 100 MVA Capacitor energy storage provide voltage boost up to 50% for up to 1 second on all three phases. Most economical solution for voltage sags and swells for large loads Ideal when only one source is available or with two sources when sags/swells are transmission related

DVR Performance

Distribution Substation

Primary Feeders

Fault occuring on adjacent feed

Line Voltage With Sag

Compensating Voltage

Restored Voltage

Transmission System Switching or Fault Clearing

PU +1 0 -1

PU +1

PU +1

0 -1

0 -1

DYNAMIC VOLTAGE RESTORER

Protected Sensitive Load

Dynamic Voltage Restorer (DVR) Semiconductor Fab Chandler, AZ

Worlds largest DVR installation Two sets of twin 5- or 6-MVA DVR systems Substation dedicated to two major semiconductor fab plants 12.5-kV substation fed by three 69-kV overhead lines; five 50-MVA transformers

Typical DVR Performance

Dynamic Voltage Restorer (DVR)

Large Paper Mill Critical Load Bus Protection
Continuous process coated paper production 47MVA total plant load; 8.3MVA critical 23 synchronized motor drives Largest 1300 hp DVR provides critical load bus protection for orderly shutdown to avoid costly web damage.

UPM

Low Voltage PureWave UPS System Single Line Diagram w/ Generator

Precision Manufacturer
Newark, NJ 2,500 kVA UPS @ 480Vwith backup generator

Medical Clinic
Southeastern US 313 kVA UPS @ 480V