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In a under designed power system network, an unbalanced load at the distribution end
can cause unbalanced voltage conditions. If a synchronous generator is connected to
an unbalanced voltage, then the stator current which due to that voltage will be
unbalanced. The unbalanced current give rise to negative sequence currents which
cause hot spots (heating) on the stator as well as rotor winding. This heating may
increase the winding temperature, which degrades the insulation of the winding and
increasing losses eventually decreasing the life expectancy of the winding.
Mechanical stress on the shaft is also increased in result of pulsating torque caused by
unbalanced currents thus effecting prime mover as well.
In Pakistan where grid is partially stable and losses are in abundance, it is also
observed that the heavy loads are not intelligently distributed thus causing load
unbalance among all the three phases more over generating harmonics and negative
sequence currents.
In our work, we observe the behavior of a power plant unbalance voltage and current
conditions which eventually effects the alternator windings, in some cases causes
burning up of insulations. Our work indicates the percentage difference between
balance and unbalanced system. More over analyzing the adverse effects of voltage
unbalance on alternator’s stator & rotor and devising the solutions to minimize the
effects through Analysis based analysis.
Our work contributes to the solutions that electrical system can be balanced through
several techniques e.g. changing the system configuration through manual and
automatic switching operations to transfer load among networks. Reconfiguration can
be performed to reduce loss and to balance loading across network. Un-allocating
certain type of load especially inductive from the network can also reduce negative
sequence currents. More over increasing the core size of alternator cables and
crimping joints can increase the capability of alternator winding to with stand the
immense voltage unbalance to a certain extent.
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Contents
1.1 Introduction
1. Prime Movers:
1.3 Types of Alternators & Motors
1.7 Methodology:
2.1 Introduction
a) Positive Sequence
b) Negative Sequence
c) Zero Sequence
b) Non-Linear Load
C) Malfunctioning Equipment
b) Effects on Transformer
2.6 Conclusion
3.1 Analysis of a balanced system:
3.1.2.3 Generators:
4.1 Introduction
4.5.4 Transposition
4.6 Conclusion
2.7 References
Figures:
Figure 16: Image of winding showing heating effects due to voltage unbalance
Figure 18: Image 3 of winding showing heating effects due to voltage unbalance
Figure 19: Image 4 of winding showing heating effects due to voltage unbalance
Tables:
ABSTRACT
In a under designed power system network, an unbalanced load at the distribution end
can cause unbalanced voltage conditions. If a synchronous generator is connected to
an unbalanced voltage, then the stator current which due to that voltage will be
unbalanced. The unbalanced current give rise to negative sequence currents which
cause hot spots (heating) on the stator as well as rotor winding. This heating may
increase the winding temperature, which degrades the insulation of the winding and
increasing losses eventually decreasing the life expectancy of the winding.
Mechanical stress on the shaft is also increased in result of pulsating torque caused by
unbalanced currents thus effecting prime mover as well.
In Pakistan where grid is partially stable and losses are in abundance, it is also
observed that the heavy loads are not intelligently distributed thus causing load
unbalance among all the three phases more over generating harmonics and negative
sequence currents.
In our work, we observe the behavior of a power plant unbalance voltage and current
conditions which eventually effects the alternator windings, in some cases causes
burning up of insulations. Our work indicates the percentage difference between
balance and unbalanced system. More over analyzing the adverse effects of voltage
unbalance on alternator’s stator & rotor and devising the solutions to minimize the
effects through Analysis based analysis.
Our work contributes to the solutions that electrical system can be balanced through
several techniques e.g. changing the system configuration through manual and
automatic switching operations to transfer load among networks. Reconfiguration can
be performed to reduce loss and to balance loading across network. Un-allocating
certain type of load especially inductive from the network can also reduce negative
sequence currents. More over increasing the core size of alternator cables and
crimping joints can increase the capability of alternator winding to with stand the
immense voltage unbalance to a certain extent.
INTRODUCTION
A bird’s eye view of the Network:
The below mentioned figure shows the single line diagram of the network,
In this chapter
1.1 Introduction
This chapter deals with the introduction and review on the technology of combined
cycle thermal power plants installed in Pakistan. Due to shortage of electricity in
Pakistan several HFO based thermal combine cycle power plants were installed to
meet the peak as well as base Load demand of the country.
HFO based power plants consists of engines driven by fuel and eventually driving the
alternator to produce electricity which is eventually fed to the nation grid at different
voltage levels. These plants are installed at various locations of Pakistan mainly
considering the low voltage levels of the region so that they can be maintained and
quality of electricity can be improved.
HFO based combined cycle power plants are usually equipped with prime movers as
Engines mainly (Wartsilla, MAN, CAT, Nagata etc.) which runs on heavy furnace oil
or diesel and eventually driving the alternators mainly of (ABB, Converteam,
Siemens etc.) this simple process is mainly known as the single cycle of a power
plant.
In combined cycle power plants, the exhausts of the prime movers/engines are fed to
water tube multi stage heat recovery boilers in which high temperature exhaust of the
engines heat the water in the tubes and convert it into steam. Steam produced is then
fed to the steam turbine mainly (GE, Dresser rand etc.) which eventually drives the
alternator and producing electricity.
More over the steam from the exhaust of steam turbine is then fed to the condensers
converting the steam to condensate water which can also be used again and again in
the boilers to make steam. Slight top up of water is made to the condensate water to
maintain the required levels.
In the light of above process such power plants are termed as Combined Cycle Power
Plant.
1. Prime Movers:
It is the fuel oil based engine (MAN 18V48/60B) which is coupled with alternators
rotor shaft and drives it. It is an 18 cylinder V shaped medium speed engine having a
rated power of 18.428 MW and rated speed of 500 rpm.
2. Alternators:
Alternator is the main electricity generator whose rotor shaft is coupled with prime
mover and upon rotating and excitation of field current electricity is produced in its
stator. Alternator is (ABB AMG1600). It is a synchronous generator having a rated
power of 23.035 MVA.
Steam turbine is the essential part of closed cycled system of power plant. Power
plant of our study involves the steam turbine of dresser rand HP 20/LP 8 Bar having a
rated power of 16.2 MW & rated speed of 6048 rpm. It is coupled to steam turbine’s
alternator through speed reduction system. Steam turbine alternator is a synchoronus
generator of 21 MVA rated power.
4.
HV network: 132KV switch yard has been installed with single break double bus
scheme 4 different feeders are connected to a single HV bus bar of 7500MVA rating.
While the other bus bar of same rating is idle in current scheme.
Figure 4: Converteam Alternator Name Plate
5. Transformers:
There are two types of transformers included in our study. 70 MVA, 132/15 KV
Power transformer of AREVA and 3.045 MVA, 15/0.4 KV Auxiliary Transformer of
Siemens.
2.
6. Auxiliary Equipment:
Equipment that is not involved in direct operation instead used to support he main
equipment’s operation is known as auxiliary equipment. At a power plant, there are
several types of auxiliary equipment as mentioned below:
1. Pumps
2. Motors
3. Radiator Fans
4. Oil Purifiers etc.
Some of the types of alternators and motors used in power plant are as follows:
1. Synchronous
1. Generators
2. Motors
2. Asynchronous
1. Motors
1. Synchronous Generators:
Power plant with in itself contains three different voltage levels High
Voltage(132KV), Medium Voltage(15KV) & Low Voltage(440V). Every voltage
level has its own network specifications and these networks are connected through
transformers. Below mentioned are the details on above mentioned individual voltage
networks.
Unbalanced voltages are unequal voltages on 3-phase network circuits that can exist
in a power system. Unbalanced voltages can cause problems, specifically to
alternating equipment’s e.g motors, generators & other inductive devices etc.
Complete & ideally voltage-balanced circuits are mere imagination in the real-world
due to presence of losses in the system especially in the network of Pakistan.
Normally difference of few voltages are acceptable and many manufacturers mention
the tolerance range of the equipment’s but when voltages differ excessively then
problems occur. Unbalanced voltages generally occur because of variations in the
load. Unbalanced voltages can be due to different impedances, or type and value of
loading on each phase. Fundamentally, the resulting current unbalance is caused not
only by the voltage unbalance of the system but also due to the system impedance, the
loads which cause the unbalance, and the operating load on equipment, especially
motors. Complete phase loss, is the definitive voltage unbalance condition for a three-
phase circuit. Specific values should show the impact in a more elaborative way.[1]
The aim of this report is to analyze the voltage unbalance among different lines, there
effects on alternators and plant auxiliary motors, and to provide Analysis based
comparison of the system.
1.7 Methodology:
Chapter 1:
Introduction
Chapter 2:
Literature Review
Chapter 4:
It presents the in-depth details of Changes in HV switchgear scheme and its effects
and Introduction of additional phase balancing equipment into the network.
2
Literature Review
In this chapter
Literature Review
2.1 Introduction
A balanced three phase load is a one which is equally shared among all three phases.
Which eventually means that the magnitude of currents in all three phases are equal
and are displaced from each other by 120° and thus add up to zero. Hence zero neutral
current. If either or both of these conditions are not met, the system is called
unbalanced or asymmetrical.
Positive Sequence
Negative Sequence
Zero Sequence
1. Positive Sequence
It represents three equal phasors phase displaced by 120° and has phase sequence
same as original phasors. It specifies that the current is flowing through source to
load. [2]
2. Negative Sequence
It represents three phases displaced by 120° with each other and have phase sequence
opposite to that of the original phasors. It specifies that current is flowing from load to
source. [2]
3. Zero Sequence
It represents three equal and parallel phasors with zero-degree phase displacement. It
specifies current is flowing from source to ground
A balanced three phase system operating in normal condition, only positive sequence
component exists. [2]
Most of the domestic loads and industrial lighting loads are single phase. However,
these loads are fed from three phase supply. If the load divisions among different
phases are not coordinated, the phase parameters may differ from each other causing
unbalanced demand from the supply. The negative or zero sequence voltages in a
power system typically result from unbalanced loads causing negative or zero
sequence currents to flow.[3]
2. Non-Linear Load
When a sinusoidal voltage is applied to a certain type of load, the current drawn by
the load is proportional to the voltage and impedance and follows the envelope of the
voltage waveform. These loads are referred to as linear loads.
Some loads cause the current to vary disproportionately with the voltage during each
half cycle. These loads are classified as nonlinear loads, and the current and voltage
have waveforms that are no sinusoidal [2], containing distortions, whereby the 50-Hz
waveform has numerous additional waveforms superimposed upon it, creating
multiple frequencies within the normal 50-Hz sine wave.
The interaction between the positive and negative sequence magnetic fields and
currents produces oscillations of the motor shaft. The permissible limit in terms of
percentage of negative phase sequence current over positive sequence current is 1.3%
ideally but acceptable up to 2%.[4]
C) Malfunctioning Equipment
The facility housing the motor can also create unbalanced voltages even if the utility
supplied voltages are well balanced. Resistive and inductive unbalances within the
motor equipment lead to unbalanced voltages and currents. Defects in the power
circuit connections, the motor contacts, or the rotor and stator windings, can all cause
irregular impedances between phases in the motor that lead to unbalanced conditions.
[7]
This reverse rotating magnetic field rotates at synchronous speeds but in opposite
direction to the rotor of the machine. With respect to the rotor surface, this reverse
rotating magnetic fields induces double frequency currents into the rotor. This
resulting induced currents into the rotors will provide high resistance path to the
normal induced currents (generated due to synchronous rotating magnetic field)
resulting in the rapid heating. This heating effect in turn results in the loss of
mechanical integrity or insulation failures in electrical machines within seconds.
Therefore, it is undesirable to operate the machine during unbalanced condition when
negative sequence currents flow in the rotor and has to be protected. [6]
The graph below shows the relationship between voltage unbalanced and temperature
rise, which approximately increases by twice the square of the percentage of voltage
unbalance.
Current imbalance can also be caused by voltage imbalance and a temperature rise a
lot greater than the percentage of voltage imbalance. We can calculate the increased
temperature in a synchronous motor winding as a result of voltage imbalance. [5]
To calculate the system imbalance and the temperature rise in the winding, the
following formulae are used:
Figure 10: %Voltage Unbalance Example
The table in Figure 2 shows the exponential winding temperature increase compared
with the increase in voltage imbalance. An imbalance greater than 2% is unacceptable
as it results in a temperature rise in the winding that will be more than the motors
specification; the life expectancy of the motor may be decrease. NEMA limits require
no more than 5% unbalanced voltage. Studies show that the average life expectancy
of insulation becomes half with every 10° of temperature increase. The increased
operating heat also induce premature expiration of the motor, excess current is also
drawn without any additional power output, therefore over-stressing the supply cables
and reaching levels where the current overloads and the Variable Speed Drives (VSD)
over current protection will trip. [5]
2. Effects on Transformer
Transformers subject to negative sequence voltages transform them in the same way
as positive-sequence voltages. The behavior with respect to zero sequence voltages
depends on the primary and secondary connections and, more particularly, the
presence of a neutral conductor. If, for instance, one side has a three-phase four-wire
connection, neutral currents can flow. If at the other side the winding is delta
connected, the zero-sequence current is transformed into a circulating (and heat-
causing) current in the delta.[12]
Transformer offers high reactance to negative phase sequence currents and thus
reduces the level of unbalance on the other side of the system.
Ideally any distribution transformer gives best performance at 50% loading and every
electrical distribution system is designed for it. But in case of unbalance the loading
goes over 50% as the equipment’s draw more current.
For a distribution transformer of 200KVA rating, the eddy currents accounts for
200W but in case of 5% voltage unbalance they can rise up to 720W [12].
For motors, an unbalance of 5% will result in capacity reduction by 25%. That means,
the motor current will increase to match the equipment’s torque needs which will
result in proportional copper losses in motor. The voltage unbalance of 3% increase
the heating by 20% for an induction motor.
The resistance for negative sequence current is 1/6th of the positive sequence
current which means a small unbalance in voltage waveform will give more current
and thus losses.
1. The first and most basic solution is to rearrange or redistribute the loads in such a
way that the system becomes more balanced.
2. Reducing the harmonics also reduces the unbalance, which can be done by installing
reactive or active filters. These filters reduce the negative phase sequence currents
by injecting a compensating current wave.
3. In case the disturbing loads cannot be replaced or repaired, connect them with high
voltage side this reduces the effects in terms of percentage and even controlled
disturbance in low voltage side.
4. Motors with unbalanced phase reactance should be replaced and re-winded.
5. Another type of mitigation technique is the use of special transformers, such as
Scott- and Steinmetz transformers:
2.6 Conclusion
After a deep study of previous literature, it was concluded that the occurrence of
unbalanced phase voltages will give rise to negative sequence currents which will
cause heating and deuteriation of alternating & induction machines. Thus, to
minimize the phase unbalance effects network to be optimized so that it can handle
the phase unbalance issue more over cable sizes along with crimp connections to be
upgraded with large core size cables and crimps.
3
In this chapter
Analysis based on values of balanced power system.
Analysis based on values of unbalanced power system.
Difference and its effecting parameters.
Settings placed in for the equipment’s are as follows in the form of snapshots of
ETAP 12.0
3.1.2.3 Generators:
Figure 14: Setting and parameters of Generators on ETAP
As according to balanced system summary report the load is balanced on every phase
of an individual bus. While the system overall voltage has a difference as follows
Bus Amp
1 2324.9
6 2263.1
8 2293.1
10 2257.5
Bus 1 & 6 3%
Bus 1 & 8 1%
Bus 1 & 10 3%
Bus 6 & 8 1%
Bus 6 & 10 0%
Bus 8 & 10 2%
thus, as per Voltage unbalance and temperature rise formula as discussed in chapter #
2 we can say that the temperature rise is zero due to zero % voltage unbalance while if
we see at MV bus bars they all have a minor load difference due to system losses as
well as difference in load demand on different lines.
In this section the Bus ratings along with their type and their capacity is mentioned.
In this section the transformers ratings along with their type, capacity and tap settings
are mentioned.
3. Branch connections
In this section the loading schemes of buses are mentioned along with their individual
resistance, reactance & impedance.
Load flow report depicts the load flow on every bus along with their flow to and from
other buses, load flow reports plays a very vital role in our study it helps us to analyze
loading rates among the busses and eventually the findings from load flow report
helps in calculating % imbalance of voltage among different phases of generators or
buses.
Network design of the unbalanced system is the same as that of balanced system
design mentioned in figure 11.
3.2.2 System settings:
System setting for the unbalanced system are also same as mentioned in figure 12,
figure 13, & figure 14 .Real-time data has been used for accurate analysis.
Real-time data has been taken form the differential protection relays (MICOM P422
Differential Protection Relay, MICOM P122 Over Current Relay) installed at every
outgoing line. Data has been taken on different date, time and load demands for all
four lines.
Line 1:
Line 2:
Table 5 132KV Line 2 Real time Values
Line 3:
Line 4:
According to the unbalanced system voltage analysis it has been seen that there exists
difference among the load of all three phases of 400V, 15 KV & 132KV bus. As our
major concern is with the voltage unbalance on the 15 KV bus thus the analysis of
unbalanced voltages on it is analyzed in the sheet below along with percentage
heating caused due to it.
%
Actual Voltage Heating
Phase %
BUS # Imbalance Amp MW MVAR MVA KV
% Voltage PF
above 8% Above
Difference
Imbalance
8%
A to B 9.7375 1.74 6 2219 17.9 7.1 19.3 93 15.48
As per ABB the voltage unbalance allowed is 8% or in other words ABB Alternator
with has the capacity to with stand the heating of 8% voltage unbalance.
3.2.4 Effects of Unbalanced voltage system on alternators:
As proved above that due to voltage unbalance 2% to 6% heating increases above the
bearable capacity of the alternator. Below mentioned are some of the figures showing
actual heating effect on the alternator winding.
Figure 16: Image of winding showing heating effects due to voltage unbalance
As shown in above pictures the adverse effects of heating on the health of alternator’s
winding and its insulation, voltage unbalance majorly contributes to create such
heating.
In order to resolve such issues Voltage Unbalance shall be reduced and efforts to be
made to make system balanced as maximum as possible.
Some of the solutions are proposed based on the literature review, industrial practice
and experience are mentioned in Chapter 4.
4 Network based solutions
In this chapter
4.1 Introduction
Voltage unbalance which is a common and global phenomenon is found to be very
effective in deteriorating the operation and performance of electrical apparatus.
Voltage unbalance is the deviation of individual phase voltage magnitudes from the
normal or rated values, with the individual phase voltage being not equal to each other
either in magnitude and/or in phase displacement.
OVU is a condition when the three phase voltages are not equal to each other, in
addition positive sequence component is greater than the rated value while UVU is a
condition where the three phase voltages are not equal to each other, and in addition
the positive-sequence component is lesser than the rated value.[3]
1. NEMA Definition
The voltage unbalance percentage (VUP) at the terminal of a machine as given by the
National Electrical Manufacturer Association Motor and Generator Standard (NEMA
MGI) used in most studies is[11]
VUF %= VnVp×100
In the Power Plant the Voltage Unbalance is surly due to Unbalanced Load. If
unbalance occur due to Non- Uniform Air Gap, Winding Short Circuit the Protection
should detect this.[7]
There are various Method available for both Generation Side and
Substation/Distribution side to keep the voltages in allowable limits.
The generator bus voltage can be regulated to maintain a fixed voltage for changes in
load and reactive requirements. The generator field current can be varied to match the
changes in load current. The voltage can be increased or decreased as the load
increases or decreases.
LTC transformers are often referred to as tap-changing under load. Load tap changers
are applied to power transformers at the substation. They are used to control the
voltage on the LV or secondary side to a fixed value with a variable primary voltage
input. Also, LTCs may be used to control reactive power flow by shifting the phase
angle of the transformer secondary voltages. [12]
4.5.4 Transposition
The voltage unbalance may exist because the transmission lines are not fully
transposed to balance the line impedance. The voltage unbalance can be reduced if
transposition is done properly. [8]
Figure 21: Transposition
4.6 Conclusion
This thesis presents a comparative analysis between balanced & unbalanced voltage
system based on real time values of a power plant installed in Pakistan. In the
comparison the issue of % voltage unbalance and heating effects due to it was shown.
More over the actual demonstration of the effected alternators and its parts was also
included. It has been proven that % Voltage Unbalance not only effects the machinery
at distributed end but also on the generation end.
This could cause alternators a notice able drop in their life expectancy.
More over a short-term solution based on the industrial practice has also been shared
through which the capacity of an alternator to withstand heating effects more than its
designed limit increases but this is only short term solution and a lot more future work
is required to present a long term viable solution to the problem of % Voltage
Unbalance.
In Future, further extension of this work can be carried out in order to reduce %
Voltage Imbalance through network optimization and also an improvement can be
made by improving grid and load distribution schemes so that the life expectancy of
such expensive and important machines can be increased.
2.7 References
1. Effect of Unbalanced Voltage on Operation of Induction Motors and Its Detection
APA
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Harvard
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Wikipedia
OSCOLA
Essays, UK. (November 2018). Voltage Unbalance on Alternators, its Effects & Solution, at Pow er Plants in Pakistan. Retrieved from https:
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