Revision of the CBEMA Curve

Equipment Performance
Control System Testing
Individual Component Sag Test Results
Photo Eye (Emergency Stop), < 1cyc X 87%

120 Vac DPDT Relay, 75%

Percent of Nominal Voltage

24 Vdc Instrument Power Supply, 70%

Programmable Logic Controller, 47%

2 cycles

9.2 cycles

37 cycles

time (cycles)
 System Compatibility
Assessment
90

20 events
80
120 Vac DPDT Relay, 75%
Percent of Nominal Voltage

70
24 Vdc Instrument Power Supply, 70%
15 events
60
5 events per
site per year

50

Programmable Logic Controller, 47%

40
10 events per
site per year
30

20

10

15 30 60 96 128 160 320 480 640 800 960 2880 4800

Duration (milliseconds)
 Semi Equipment Tolerance
Duration of Voltage Sag in Seconds
0.05 0.1 0.2 0.5 0.1
100

90
Percent of Equipment Nominal Voltage

80

70

60

50

40

30

20

10

Semiconductor Equipment Voltage Sag Ride-Through Capability Curve

Note: Equipment must continue to operate without interrupt during voltage sags above the line.
Relative Costs for PQ Solutions
Cost versus Benefit Analysis
Commonly
Used Power
Correction
Devices
 Practical Example
! Facilityexperiences dropouts each time a
thunderstorm rolls through the area
! Estimated number of events impacting production
10 to 15 per year
! Estimate cost per event 20 to 30 thousand dollars
! What systems are impacted?
! HID lighting
! Air Handling Processes
! Programmable controllers
! Miscellaneous other equipment
EPRI Portable Sag Generator
 Why Do Chillers, Motors, Pumps and Other
Processes Shut Down When the Lights Blink?

Main
Contactor Contactor
2 cycles, 2 cycles,
43% 49%

EMO Relay
EMO (next gen)
Relay 0.5 Cycles,
1 cycles, 78%
52%

EMO Relay
EMO Relay 1 Cycle
0.5 cycles, 45%
61%

Not Shown:
EMO Relay 1 Cycle, 38%
Emergency Off (EMO) Circuit
(Simplified)

Q1. What happens if the EMO relay or Main

Contactor are extremely vulnerable to voltage
sags?
Q2. What if the plant voltage is low?
Q3. What if the transformer rated output voltage
does not match the relay and contactor?
Contactor Hold-in Circuit
TYPICAL SAG AND INTERRUPTION RIDE THROUGH PERFORMANCE CURVE
30

Coilock holds contacts closed for sags above the line

25

Percent of Nominal Voltage

20

Coilock allows the coil to de-energize in this area

to insure that E-stop circuits operate as intended
15

10

0
0 5 10 15 20 25
3cy 5cy 8cy 330
sec 35

Duration
 Contactor Hold in Device
! Designed to let contactor, relay, and solenoid coils
energize and stay energized unless input voltage is
interrupted
! About the size of a small “Ice Cube” relay
! Also provides surge protection for the coil
! Designed to specifically work during voltage sag
conditions but to allow the coil to de-energize during
interruptions so that process timing and safety is not
compromised
 Impact on Lighting
PQ Issue:
! Some HID metal halide
lamp/ballast systems are
prone to blackouts due to
voltage sags from the
normal operation of large
electric loads.
! Restart times may take as
long as 10-15 minutes.
 Susceptibility of High
Pressure Sodium Lights
Sag Tolerance for HPS Ballasts vs.
Lamp Operating Voltage
Percent of Nominal Supply Voltage

80

60

40 Non-Regulating Ballast

Auto-Regulating Ballast
20
Magnetic-Regulating Ballast

0
New Lamp Old Lamp
0 6,000 12,000 18,000 24,000
HPS Lamp Age (Hours of Use)
Voltage Sag Impact on ASD
dc Link
Rectifier Induction
Inverter
Inverter Motor

dc Bus
660V Voltage

420V trip level

Drive Trips on Undervoltage

 Undervoltage Trip Point

! Typically set to 80-85% of nominal DC

Bus voltage
! DC Bus voltage during sag depends on
!Depth of voltage sag in each phase
!Loading
!Output frequency
!DC capacitor value
 Evaluation of a DC-Bus
Ride-through Module
With Ride-Through Device:
Input Voltage, Motor Current,
Motor Speed, and DC-Bus
Voltage During a 50%
Voltage Sag (100% Loading)

100
ASD Voltage-Sag Tolerance without Ride
90 Through Device
80
70
Additional ASD Voltage-Sag
60
Tolerance from Ride Through
50 Device
40
30
20
10
0
1 2 3 10 100
Time (Cycles at 60 Hz)

ASD Voltage Sag Tolerance for 100% Loading

CVT Output (Sag to 50% Vnom)
MRD Output
 Drive Programming Parameter

Solutions to drive problems:

! Drives can be programmed to ‘restart’ after a
momentary voltage sag
! Restart after motor coasts down to stop
(available in most of the drives)
! Restart into a spinning motor
! Non-synchronous restart (motor slows down significantly)
! Synchronous restart ( inverter picks up as soon as voltage
recovers - very promising technology; very few manufacturers
provide this option)
 Case Study Conclusions
! Site was experiencing over 300 thousand dollars
per year in losses just on air handling processes
! Applying power conditioning on the ASD control
transformers and in the PLC control cabinets was
estimated to cost less than 75 thousand dollars
complete
! Simple cost payback analysis approximately three
months (300 K per year / 75K invested = 0.25
years)
 “Sound” Power Quality
Advice
! Integrityof wiring and grounding is first
! Provide nominal or “better” voltage
! Don’t mix and match voltage ratings
! Write PQ immune PLC programs
! Understand programmable features
! Maintain an upset log at every process line
! Specify ride through and voltage regulation
for new and retrofit equipment
Voltage Support and
Regulation Concepts
 Ultracapacitor Energy Storage
! Ultracapacitors are receiving increased attention as
a temporary power source for many applications.
! Traditionally considered for only low power
applications, ultracapacitors are now being
considered for use in higher-power applications.
! The shift in focus has been made possible through
the asymmetrical ultracapacitor design.
What is a Standard Capacitor?

! Capacitance is directly related to the plate area and

dielectric constant, but inversely related to the plate
separation.
! Energy is stored in the dielectric through polarization.
What is an Ultracapacitor?

Energy is stored electrostatically at the

electrode/electrolyte surface.
The large value of capacitance is due to the tremendous
amount of surface area.
 What is an Ultracapacitor?
Ultracapacitors are
configured into arrays using
various-sized cells to fit the
power and energy
requirements for a specific
application.
 Features of Ultracapacitors
Advantages:
! Highest capacitance of any capacitor technology
! Lowest cost per Farad
! Reliable, long life
! High cycle-life
! Maintenance-free operation
! Environmentally safe
! High power density
What is an Asymmetrical Ultracapacitor?

! The asymmetrical ultracapacitor is

constructed using two different types of
electrodes

Cp Cm
Symmetrical Asymmetrical

Cp = Cm = C Cp>>Cm
Ctotal = ½ C Ctotal = 2C
Voltage of C = 0.8 V = V Operation at ~1.6 V = 2 V
Es = ½ CV2 Ea = ½ (2C)(2V)2
= ½( ½ C)V2 = 4CV2
= ¼ CV2
Therefore, Ea = 16 * Es!
 Do They Work?
! In 1999 EPRI PEAC tested
several asymmetrical
ultracapacitors. The results
confirmed the claims of the
manufacturer
! Materials:
! Activated Carbon, the main
ingredient in Odor Eaters!
! Potassium Hydroxide
(KOH), the main ingredient
in drain cleaner!

Voltage window: 16-8 V

Stored Energy: 1 MJ
Weight: 75 lbs (34 kg)
 Advantages of Ultracapacitors
! State of charge is easily determined by measuring
the terminal voltage
! Self-discharge rate is very low
! Excellent low temperature performance and wide
range of operating temperature
! Relatively inexpensive and environmentally
friendly materials (nickel, carbon, KOH)
! Recharge efficiencies approaching 99 percent
 Where Can Ultracapacitors
Be Used?
! High pulse power applications
! Supplement to a battery
! Direct replacement for lead-acid in some
short discharge applications
! Regeneration applications
! Opportunity charging applications
! Hybrid vehicle applications
 Demonstration

! EPRI PEAC has

installed and
demonstrated an
ultracapacitor-based
system.
! 100 kW for 10
seconds (1 MJ).
 Demonstration Fuel Cell System with
Integrated Ultracapacitor

!3 kW fuel cell system designed for fast response

 Demonstration
! To demonstrate the
incredible energy
density of
asymmetrical
ultracapacitors,
EPRI PEAC
integrated the caps
into a
demonstration
fork-truck.
 Transportation Applications

Capacitor Powered Cart

Capacitor Powered Bus

Comparison of Technologies
 Research and Application
Opportunities
! Research:
! Electrode Material
! Electrolyte Material
! Manufacturing Methods (Cost reduction)
! Applications:
! Proof of concept for fast charging
! Demonstrations of fork trucks and other
vehicles