You are on page 1of 7

i

IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 29, NO. 2, MARCWAPRIL 1993 391

Voltage Sags in Industrial Systems


Mark F. McGranaghan, Member, IEEE, David R. Mueller, Member, IEEE, and Marek J. Samotyj, Member, IEEE

Abstract-This paper describes the causes of voltage sags in


industrial plants, their impacts on equipment operation, and pos- 2
sible solutions. The definition proposed focuses on system faults
as the major cause of voltage sags. The sensitivity of different
types of industrial equipment, including adjustable speed drive 2’
controls, programmable logic controllers, and motor contactors,
is analyzed. Available methods of power conditioning for this
sensitive equipment are also described. io
> -1
I. INTRODUCTION
-0

A VOLTAGE SAG is a momentary (i.e., 0.5-30 cycles)


decrease in the rms voltage magnitude, usually caused
by a remote fault somewhere on the power system (Fig.
1). Voltage sags are the most important power quality prob- Fig. 1. Voltage sag waveform caused by a remote fault condition (six cycles).
lem facing many industrial customers. Equipment used in
modem industrial plants (process controllers, programmable
logic controllers, adjustable speed drives, robotics) is actually Substatlon
becoming more sensitive to voltage sags as the complexity of
the equipment increases. Even relays and contactors in motor
starters can be sensitive to voltage sags, resulting in shutdown
of a process when they drop out.
It is important to understand the difference between an
interruption (complete loss of voltage) and a voltage sag.
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 sags occur
during the period of a fault for faults over a wide part of Fig. 2. Typical distribution system one line diagram illustrating types of
protection devices.
the power system. Faults on parallel feeder circuits or on the
transmission system will cause voltage sags but will not result
in actual interruptions. Therefore, voltage sags are much more starting can also result in undervoltages, but these are typically
frequent than interruptions. If equipment is sensitive to these longer in duration than 30 cycles and the associated voltage
voltage sags, the frequency of problems will be much greater magnitudes are not as low. Motor starting voltage variations
than if the equipment were only sensitive to interruptions. are often referred to as “voltage flicker,” especially if the motor
This paper describes the voltage sag characteristics and the starting can occur frequently.
sensitivity of equipment. With this information, the range of Faults resulting in voltage sags can occur within the plant
fault locations on the power system that can cause problems or on the utility system. The voltage sag condition lasts until
can be estimated (area of vulnerability). Options for improving the fault is cleared by a protective device. In the plant, this
equipment performance in the presence of voltage sags include will typically be a fuse or a plant feeder breaker. On the
power conditioning or equipment design modifications. Both utility system, the fault could be cleared by a branch fuse
of these options are described. or a substation breaker. If reclosing is used by the utility, the
voltage sag condition can occur multiple times.
11. CAUSES OF VOLTAGE SAGS Utility system faults can occur on the distribution system
or on the transmission system. Fig. 2 illustrates a typical
Voltage sags are typically caused by fault conditions. Motor
distribution system configuration with a number of feeders
Paper ICPSD 91-51, approved by the Power Systems Protection Committee supplied from a common bus. A fault on Feeder F1 will cause
of the IEEE Industry Applications Society for presentation at the 1991
Industrial and Commercial Power Systems Department Technical Conference, an interruption which will affect the customers on that feeder.
Memphis, TN, May 6 9 . Manuscript released for publication April 29, 1992. However, all of the customers on the three parallel feeders
M. McGranaghan and D. Mueller are with Electrotek Concepts, Inc., will experience a voltage sag while the fault is actually on
Knoxville, TN 37932.
M. Samotyj is with Electric Power Research Institute, Palo Alto, CA 94303. the system. With the reclosing breakers at the substation, the
IEEE Log Number 9207100. customers on parallel feeders can experience as many as four
0093-9994/93$03.00 0 1993 IEEE
I
398 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 29, NO. 2, MARCWAPRIL 1993

\Recloser Operalinq Sequenceb

I Conlocls Closed

\ I I
Reclosing Intervals (Contacts Open)

Fig. 3. Typical recloser operating sequence.

will not reinitiate after they have been cleared and the line
2oov , 7 is reclosed.
The probability of a flashover during a lightning stroke
can be reduced by applying surge arresters to divert the
lightning current to ground. The probability of backflashes
can be reduced by minimizing footing resistances. Some
utilities are considering the application of arresters along
transmission lines to reduce the incidence of lightning-induced
faults on transmission systems. Regardless of the measures
ov taken, lightning-induced faults cannot be eliminated com-
20 0 V/div verticol 2 sec/div horiz pletely. There will still be lightning strokes with high current
Fig. 4. Voltage sag at customer location with one recloser operation. magnitudes and rates-of-rise which will cause flashovers.
Therefore, it is important for customers to make sure that
critical equipment sensitive to voltage sags is adequately
voltage sags in succession, lasting for durations ranging from a protected.
couple of cycles to more than ten cycles (see typical reclosing
sequence in Fig. 3). The voltage characteristic at the customer
location on a parallel feeder will look something like the plot 111. RANT
VOLTAGEDURINGSINGLE
in Fig. 4 (one reclosing operation). FAULTSON THE UTILITY SYSTEM
LINE-TO-GROUND
Faults on the transmission system can affect even more Single line-to-ground faults (SLGF’s) on the utility system
customers. Customers hundreds of miles from the fault loca- are the most common cause of voltage sags in an industrial
tion can still experience a voltage sag resulting in equipment plant. The voltage on the faulted phase goes to zero at the fault
misoperation when the fault is on the transmission system. location. The voltage at the substation and on parallel feeders
The large majority of faults on a utility system are single will depend on the distance of the fault from the substation.
line-to-ground faults (SLGF). Three phase faults are more On transmission systems, the faulted phase voltage at a remote
severe, but much less common. SLGF’s often result from location depends on the overall network impedances.
weather conditions such as lightning, wind, and ice. Contam- The important quantities for equipment sensitivity are the
ination of insulators, animal contact, and accidents involving voltages at the customer bus. These voltages will depend on the
construction or transportation activities also cause faults. Al- transformer connections between the faulted system and the
though utilities go to great lengths to prevent faults on the customer bus. For a distribution system fault, the worst case
system, they cannot be eliminated completely. occurs when the fault is close to the substation bus. Effectively,
Lightning is the most common cause of faults on overhead this is the same as a fault near the customer transformer
transmission and distribution lines. Lightning can cause a fault primary (Fig. 5). The voltages on the customer bus will then
by directly striking a phase conductor (direct strike) or by be a function of the customer transformer connections, as
striking a grounded object, such as a shield wire or tower indicated in Table I.
(backflash). In either case, the voltage developed across the The relationships in Table I are very important. One might
phase conductor insulators close to the stroke location can think that an SLGF on the primary of a wye groundeddelta
cause a flashover which then results in the flow of fault current. transformer could result in zero voltage across one of the
Usually, these faults are temporary, which means that they secondary windings. Instead, circulating fault current in the
I
MCGRANAGHAN: VOLTAGE SAGS IN INDUSTRIAL SYSTEMS 399

480 Vok
C

U t i l i t y Co.
Source Transformer
Connection lighls. solenoids

J Motor-Acmss Ute
unc Conbol
Adjuotablc Spccd
Fig. 5. Single line-to-ground fault near substation. Drlvc

TABLE I Fig. 6 . Typical single-phase and three-phase loads.


TRANSFORMERSECONDARY WITH AN SLGF ON THE PRIMARY
VOLTAGES
Phase to Phase
Vab Vbc Vca Jab vbc Vca

I v . SENSITIVITY OF EQUIPMENT
TO VOLTAGE SAGS
0.58 1.00 0.58
Industrial plant power is often distributed by three-phase
480 V feeders. The loads can be categorized by type and
connection to the power system (Fig. 6):
I Motors, heating elements, and other three-phase loads can
0.58 1.00 0.58 be connected directly to the 480-V feeders.
Adjustable-speed drive and other power electronic de-
vices that use three-phase power will be connected di-
rectly to the 480-V feeders or through an isolation trans-
former.
0.33 0.88 0.88 Lighting often utilizes single-phase 277-V connections
from phase-to-neutral or may use 480- or 120-V single-
I
phase connections.
Control devices such as computers, contactors, and pro-
0.88 0.88 0.33 grammable logic controllers utilize 4801120-V single-
phase transformers for 120-V control.
The voltages experienced during a voltage sag condition
will depend on the equipment connection. Table I showed that
the individual phase voltages and phase-to-phase voltages are
delta secondary windings results in a voltage on each winding. quite different during an SLGF condition on the transformer
The magnitude of the lowest secondary voltage depends upon primary. Some single phase loads will be unaffected and other
the relationship single phase loads may drop out, even though their sensitivities
to voltage sags may be identical. Voltage unbalance is also
a concern for motor heating. However, the durations of the
unbalanced voltages during fault conditions are so short that
motor heating is not a significant concern.
where Different categories of equipment and even different
brands of equipment within a category (e.g., two different
X , transformer short circuit reactance models of adjustable speed drives) have significantly different
sensitivities to voltage sags. This makes it difficult to develop a
single standard that defines the sensitivity of industrial process
equipment.
XS source equivalent reactance. The closest document to a standard is the CBEMA curve
given in Fig. 7, which was developed by the Computer
For industrial power distribution, the ratio a will usually be Business Manufacturers Association [3]. This applies primarily
very close to unity and the relationships in Table I are for to data processing equipment. The curve shows that the load
this case. sensitivity is very dependent on the duration of the sag.
Even with an SLGF on the primary of the transformer, the Allowable sags range from 0% voltage for 1/2 cycle to only
voltage sag at the customer bus will be no lower than 33% 87% voltage for 30 cycles.
normul value. These faults account for the greater majority of While the CBEMA limits suggest a "standard" sensitivity
faults on the power system. to voltage sags, actual plant equipment has a variety of op-
I
400 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 29, NO. 2, MARCWAPRIL 1993

CBEMA
400

300

voltage
in 200
Percent

100

0
0.001 0.01 0.1 0.5 1.0 6 10 30 1000

2s
Time in Cycles (60 Hz)

ANSIIIEEE - Std 446-1987


Typical Design Goals of
Power-Conscious Computer Manufacturers
Fig. 7. CBEMA operating voltage envelope.

erational characteristics during voltage sags. A few examples


are listed here. 100
90
I) Motor Contactors and Electromechanical Relays: One VOLTAGE 80

manufacturer has provided data that indicates their line of


motor contactors will drop out at 50% voltage if the condition
(PERCENT 70
NORMAL) ::
40
lasts for longer than one cycle. This data should be expected 30
20
to vary among manufacturers, and some contactors can drop 10
0
out at 70% normal voltage or even higher [4]. 0 10 20 30
2) High-Intensity Discharge (HID) Lamps: Mercury lamps TIME (CYCLES)
are extinguished at around 80% normal voltage and require
time to restrike [ 5 ] . A voltage sag that extinguishes HID light-
Fig. 8. Range of equipment sensitivity to voltage sags.
ing is often mistaken as a longer outage by plant personnel.
3) Adjustable Speed Motor Drives (ASD’s): Some drives
are designed to ride through voltage sags. The ride through motor contactors, robotics, etc., that are all integral to the
time can be anywhere from 0.05 to 0.5 s, obviously depending plant operation. This can also make it difficult to identify
on the manufacturer and model. Some models of one the sensitive piece of equipment after the entire process shuts
manufacturer monitor the ac line and trip after a voltage sag down.
to 90% normal is detected for 50 ms.
4 ) Programmable Logic Controllers (PLC’s): This is an
important category of equipment for industrial processes v. ESTIMATING
THE PROBABILITY
because the entire process is often under the control of these OF A VOLTAGE SAG PROBLEM
devices. The sensitivity to voltage sags varies greatly but The most frequent cause of voltage sags at a large industrial
portions of an overall PLC system have been found to be plant is lightning. Lightning is weather related, and the weather
very sensitive. The remote VO units, for instance, have been can be extremely variable from one season to another, or one
found to trip for voltages as high as 90% for a few cycles [6]. year to another. But over longer periods of time, weather will
The sensitivity range for these types of equipment is shown more closely follow certain pattems.
in Fig. 8 with the durations of fault induced voltage sags Activities such as those by the National Lightning Detection
also indicated. The wide range of sensitivities underlines the Network are establishing the amount of lightning strokes a
importance of working with the manufacturer to make sure the given area will receive over longer periods of time. The
equipment can work in the environment where it will be used results of this paper report on ground flash density (Ng)
and to develop specifications based on realistic power system for all areas of the country. The ground flash density is a
conditions. measure of lightning strokes to ground per square km per
It is important to recognize that the entire process in an year. It is more accurate than the previously used isokeraunic
industrial plant can depend on the sensitivity of a single piece level in determining the expected lightning performance of
of equipment. The overall process involves controls, drives, transmission lines. Isokeraunic level is the number of days
I
MCGRANAGHAN: VOLTAGE SAGS IN INDUSTRIAL SYSTEMS 40 1

Plant Voltage vs. Fault Location


Area of Vulnerabilib
Normal Volraoa 11W%1 for Senoithn Loads
100
90 T Area of Vulnerabilily
for Motor Contactors

p - L - t -

0 2600 6000 76W loo00 12600 16ooO

Distance From Substationto Faun (Feet)

Fig. 9. Voltage sag versus fault location.


I
I ‘ m
Miles

0 1 2 3 4 5

per year lightning is heard, and must be multiplied by a Fig. 10. Area of vulnerability to transmission system faults for a particular
proportionality factor to convert it to ground flash density. customer location.
Utilizing geometry of the transmission lines, BIL levels of
the insulators, and ground flash density, the expected number
of recovering lost production, material, product quality, and
of faults per km of line per year can be calculated [ 2 ] .
customer responsiveness must be determined. Experience by
Fortunately not every fault on the utilities’ transmission grid
the industrial plant will provide data on production losses for
will disrupt production at the industrial plant. The effect of a
a given occurrence following a voltage sag. There may even
fault on plant equipment depends on the fault clearing time and
be a record the number of disruptions due to voltage sags in
the location of the fault. Computer calculations can determine
the past calendar months or years. If the necessary data exists,
the plant voltage versus fault location on a distribution system
the cost of implementing a solution can be evaluated against
and curves similar to those in Fig. 9 can be used to illustrate
the expected cash flow of recovered production losses.
the range of fault locations that can cause problems.
Factors governing the magnitude and duration of voltage Solutions to the voltage sag problem must almost always
sags include the fault impedance and location, the configura- be implemented in the customer facility. As mentioned pre-
tion of the power network, and the system protective relay viously, it is possible for the utility to reduce the number of
design. Fig. 2 illustrates a relationship between fault location faults on the system through design practices and additional
and voltage sag magnitude, for an example distribution system equipment, but it is never possible to eliminate faults on the
(through a wye-delta transformer connection). system. The plant equipment must be designed to handle the
Fault clearing time is dependent on the utility company’s most common voltage sag conditions or be retrofitted with
system protection practices. If instantaneous fault clearing is appropriate power conditioning.
used, 4-6 cycles is a likely duration of the voltage sag. If an In the long run, the best solution to voltage sag problems
intentional time delay is used, the duration might be as long will be to purchase equipment that has the necessary ride
as 15 cycles. through capability. As manufacturers become increasingly
On transmission systems, it is more difficult to determine the aware of the need for this capability, it will become more
range of fault locations that can result in unacceptable voltage and more standard in industrial process equipment. Even now,
sags. Computer simulations can be used to determine voltages manufacturers offer new models or simple modifications that
around the system for any fault location. These calculations permit extended ride through capability.
can be used to define an “area of vulnerability” for a particular Until equipment can handle voltage sags directly, it will
customer (Fig. lo). The likelihood of a fault within this area often be necessary to apply power conditioning equipment
can then be calculated. for particular sensitive loads. Most voltage sag conditions can
be handled by ferroresonant, or constant voltage, transformers
(CVT’s). CVT’s are especially attractive for loads with rela-
SOLUTIONS TO VOLTAGE SAG PROBLEMS
VI. EVALUATING tively low power requirements and loads which are constant.
The interruption of an industrial process due to a voltage Variable loads are more of a problem for CVT’s because of
sag can result in very substantial costs to the operation. These the tuned circuit on the output.
costs include lost productivity, labor costs for clean-up and These power conditioners work similar to a transformer
restart, damaged product, reduced product quality, delays in being excited high on its saturation curve, so that the output
delivery, and reduced customer satisfaction. voltage is not significantly affected by input voltage variations.
Proper evaluation of alternatives to improve plant equipment The actual design and construction is more complicated. A
and the power distribution network requires a cost versus typical ferroresonant circuit is shown in Fig. 11.
benefit comparison. For example, once the costs of retrofitting Ferroresonant transformers output over 90% normal voltage
sensitive process equipment with some method of improv- as long as the input voltage is above a minimum value, at
ing voltage sag ride through are determined, the benefits which the output collapses to zero voltage. Table I1 shows
402 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 29, NO. 2, MARCWAPRIL 1993

performance of transmission and distribution overhead lines

Windinn
1 can predict the frequency of lightning induced faults, or be
compared to existing performance.
3) A single line-to-ground fault on the primary side of a
distribution transformer will result in a voltage sag to no lower
than 33% of normal voltage on any phase-to-phase connection.
Ncutrrlizing
4) The sensitivity of industrial equipment to voltage sags
Winding varies greatly. The more sensitive equipment widens a plant’s
I area of vulnerability to disruptive voltage sags.
5 ) Constant Voltage Transformers can be applied economi-
cally at constant loads to handle the great majority of voltage
sag conditions. If needed, increased protection for voltage sags
Fig. 1 1. Typical circuit for a ferroresonant transformer. or actual interruptions can be provided in the form of UPS
systems.
TABLE I1
ALLOWABLE
VOLTAGE SAG VERSUS TRANSFORMER REFERENCES
LOADING
FOR FERRORESONANT TRANSFORMERS
[ I ] L. Tang and M. McGranaghan, “Power quality definitions and standard
~~ ~

Amount of Load Minimum Input Voltage”


terms development,” EPRI, Res. Project RP3098- 1, June 1990.
1/4 of rating 36 V (30%’of 120 V) [2] J. G. Anderson, “Lightning performance in transmission lines,” in EPRI
1/2 of rating 55 V (46% of 120 V) Transmission Line Reference Book, pp. 545-597.
131 Recommended Practice for Emergency and Standby Power for Industrial
Full loaded 85 V (71% of 120 V) and Commercial Applications, IEEE Standard 446-1987.
Voltage collapses, even at full [4] D. M. Sauter, “Voltage fluctuations on power systems,” in Westinghouse
150% of rating (overloaded)* Electric Utili@ Engineering Reference Book, Distribution Systems, 1965,
input p. 362.
aIf the input voltage is above the minimum input voltage, the output [ 5 ] Recommended Practice for Electric Power Distribution for Industrial
voltage will remain in the range of +3 to -6% of normal value. These Plants, ANSI-IEEE Standard 141-1986.
[6] V. E. Wagner, A. A. Andreshak, and J. P. Staniak, “Power quality and
transformers are also available with 480-V input. factory automation,” IAS Annu. Meeting, vol. 35, no. 6, pp. 1391-1396.
bInrush current greater than 150% rating will cause the voltage to
collapse. Inductive loads such as contactors require special consideration
to ensure that the transformer has adequate capacity to handle current
inrush rwuirements.

that the minimum input voltage is a function of the load. It is


noteworthy that at 1/4 load, the ferroresonant transformer will
output the necessary voltage even during voltage sags to as
Mark F. McGranaghan (M’78) received the
low as 30%. This is important since it is virtually impossible B.S.E.E. and M.S.E.E. degrees from the University
for an SLGF condition on the utility system to cause a voltage of Toledo in 1977 and 1978, respectively, and the
sag below 30% at the customer bus when the customer is M.B.A. degree from the University of Pittsburgh in
supplied through a delta-wye or wye-delta transformer. 1985.
He is responsible for development and marketing
CVT’s will handle the majority of voltage sag conditions. of power systems products at Electrotek Concepts
Voltage sags which are too severe for CVT’s, such as due Inc., Knoxville, TN. These products include
hardware and software for power quality analysis,
to a three phase fault close to the customer location, or harmonic analysis, and transient analysis on power
actual interruptions, could still cause process disruptions. systems. In addition, he manages and performs
Protection for extremely critical loads, such as life safety studies in the areas of market assessment and power quality analysis. He
systems and critical data processing equipment, should in- has been involved in a wide range of activities dealing with concems for
power quality and the integration of power electronic equipment on the
clude UPS systems or the equivalent for complete backup power system. He has developed and taught harmonics, transients, and power
capability. quality seminars during the past 10 years, and has been actively involved in
rewriting the IEEE Harmonics Standard (5 19.1981). Before joining Electrotek,
he worked in the Systems Engineering Group at McGraw-Edison. There, he
VII. CONCLUSIONS directed work on engineering studies employing both the Transient Network
Analyzer (TNA) and digital computer programs. He has directed studies
1) Voltage sags are becoming an increasing concern of for utilities and consultants throughout the United States and in many
industrial plants due to increasing automation. Automated foreign countries. His primary study areas were transient analysis, insulation
facilities are more difficult to restart, and the electronic con- coordination, harmonic analysis, series capacitor protection, shunt capacitor
switching, SVS applications, flicker analysis, and equipment failure studies.
trollers used are sometimes more sensitive to voltage sags than Mr. McGranaghan is a member of the IEEE Power Engineering Society
other loads. and is actively involved in a number of IEEE and CIGRE committees. He
2) Single line-to-ground faults on the utility distribution has been chairman of the Switching Surge Working Group and is Chairman
of ANSI-C92 on Insulation Coordination. Currently he is working on revising
or transmission system are often the cause of voltage sags. IEEE 519-1981 (Harmonic Standard) and is a liaison to the EEI Working
Lighming is a frequent cause. Evaluation of the lightning Group on Power Quality.
I
MCGRANAGHAN: VOLTAGE SAGS IN INDUSTRIAL SYSTEMS 403

David R. Mueller (M’91) received the B.S.E.E. Marek J. Samotyj (M’88) received the B.S. and
degree from the University of Cincinnati in 1982 M.S. degrees in electrical engineering from Silesian
and the M.Eng. degree in electric power engineering Polytechnical University, Gliwice, Poland, in 1969
from Rensselaer Polytechnic Institute in 1990. and 1971, respectively, and the M.S. degree in
He is employed with Electrotek Concepts, engineering-economic systems from Stanford Uni-
Knoxville, TN, as a Senior Power Systems versity in 1985.
Engineer. He has primarily been responsible for He is Manager of Power Electronics End-Use
power quality investigations at industrial plants. Systems in the Power Electronics and Controls
He has been responsible for studies to identify Program, of the Customer Systems Division at the
the causes of power system equipment failure, or Electric Power Research Institute (EPRI) in Palo
the misoperation of process controls due to power Alto. CA. During 1984. he was a Consultant for
disturbances. He has also conducted several studies involving power factor Power Electronic Systems at EPRI; he joined the Institute in 1985. He is
correction and harmonic filtering. He has taught several power quality responsible for the applications and field testing of adjustable speed drives,
seminars. Prior to joining Electrotek, he was employed for eight years with and conducts research in the areas of power quality and end-use magnetic
Delco Products Division of General Motors. During his employment with GM, fields management. Before coming to EPRI, he was a Research Assistant for
his assignments included the design and troubleshooting of machine controls, the Energy Modeling Forum at Stanford University (1982-1985). From 1980
maintenance, and upgrade of the plant power distribution system, and energy to 1981, he was a Consulting Member of the Scientific Board of the Future
conservation activities. Research Center at Technical University in Wroclaw, Poland, and a Consultant
Mr. Mueller is a member of the IEEE Industry Applications Society and for R&D planning strategy with the Commission on the National Economic
is a Registered Professional Engineer. Reform in Warsaw, Poland. From 1971 to 1975, he was a Consulting Staff
Engineer and Project Manager for the Polish Ministry of Mining and Energy.
Mr. Samotyj is a member of CIGRE, which is the International Conference
on Large High-Voltage Electric Systems. Currently he is a secretary of the
IEEE Power Quality Standards Coordinating Committee 22. He also actively
participates in C E R E Working Groups on adjustable-speed drives and on
power quality. From 1981 to 1982, he was a Fulbright Senior Scholar and the
Fellow of the Professional Journalism Program at Stanford University.

You might also like