Three level

STATCOM

Solution for a 4

Based Power Quality MW Induction Furnace

Unnikrishnan A.K, Senior Member, IEEE, Aby Joseph, and Subhash Joshi T.G., Member, IEEE

Abstract-- The paper explains the power quality study conducted in a 4MW mini steel plant, having fault level of 250MVA, to investigate the critical electrical problems caused by the harmonics and the development of a STATCOM as a solution for harmonic mitigation. A 500Kvar STATCOM is realized with a current controlled three level voltage source converter (VSC). The hardware configuration and the control strategy have been dealt in detail. Site installation and experimental results verifying STATCOM's performance are also presented.

II. TUE TEST SITE The plant selected for study is located in northern Kerala, India. The plant consists of a rolling mill and a casting unit. I. INTRODUCTION There is an 11kV under ground cables from the utility subAS technology advances, the electrical loads are station and connected to High Voltage Distribution Board multiplying in numbers and complexity. This throws (HVDB). Two feeders are taken out from HVDB. One feeder tremendous challenge to the quality of power supply system. is connected to induction furnace installation via 11kV/850Power electronic converters are examples of such types of 850V,A/A-Y, 5MVA transformer with a fault level of loads. Steel mills, which employ induction furnaces for 250MVA.The induction furnace installation consists of a 12 melting scrap iron is one of the industrial areas where the use pulse controlled rectifier, dc reactor followed by a singleof such power converters is inevitable. The tuned filters or phase medium frequency inverter feeding the furnace coil. passive compensators are the traditional solution for Second feeder is connected to the auxiliary loads, which harmonics issues. Since they are tuned for a fixed frequency includes cooling pump motors, cranes, welding machines, they are not affective for varying harmonics spectrum. The lightings etc. The furnace load has power factor correction induction furnace is a typical example of load, which capacitors also. The single-line diagram showing main power generates harmonics in different spectrum based on the distribution of the plant is shown in Fig. 1. configuration of the controlled rectifier i.e., 12-pulse for heating mode or 6-pulse for sintering mode. Passive filters are also susceptible to sinking the harmonics injected by other I lkV BUS l loads in the grid. To overcome these shortcomings of passive filters various active power filter configurations have been reported [1]. Among these configurations, shunt active filters with two-level or multilevel converter have been recognized as one of the viable solutions for harmonic compensation. The
This project is funded by Department of Information Technology, Govt. of India, under administrative approval No. 28(5) 099 -IAD, dated 24-08-01. Unnikrishnan A.K. is with Centre for Development of Advanced Computing (C-DAC), Trivandrum, Kerala, India. Phone: + 91 471 2723333, Fax: + 91 471 2723456, (e-mail: unnikrishnan ocdactvm.in) Aby Joseph is with Centre for Development of Advanced Computing (CDAC), Trivandrum, Kerala, India (e-mail: abypj ocdactvm.in) Subhash Joshi T.G. is with Centre for Development of Advanced Computing (C-DAC), Trivandrum, India (e-mail: subhash ocdactvm.in)
5MVA

Index Terms-- Digital Signal Processor (DSP), IEEE 519-1992 Std., induction furnace, Power Quality (PQ), Pulse Width Modulation (PWM), STATCOM, Total Demand Distortion (TDD), Three level converter, Unit vector, Voltage Source Converter (VSC).

use of two-level converter is limited to medium voltage levels due to higher voltage stress on switching devices and the effective switching frequency. But multilevel converters [2] can be used in higher voltage and power applications to obtain better performance for the given switching frequency and lower voltage stress on switching devices. This paper explains the power quality study conducted in a mini steel plant to investigate the critical problems caused by the harmonics current drawn by induction furnace and development of 500kVAR three-level STATCOM as a solution for harmonic mitigation.

D/D6-Ynl I

11kV/850-850V

kV 433V I DYnl I

|FURNACE|

|CONVERTER|
Fig. 1. Single-line diagram of main power distribution at the steel plant.
\IDCTION \NDUCTACEN/7TO \F AC!/

AUXILIARY
LOADS

0-7803-9772-X/06/$20.00 (2006 IEEE

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The plant has three induction furnaces, one of 9-ton and other two of 4-ton capacity each. Reports regarding the failure of the protection and relaying equipments and over heating of the distribution transformers supplying for the steel plant in substation premises was the inspiration for the field study. Continuous monitoring and data logging of different signals were carried out and a harmonics database was prepared. The measuring point used for data logging is shown in Fig. 2.
in

I lkV BUS i. BOC

k

A500kVA I 80V /83

| BOC

The STATCOM is rated for 500kVAR and having DC bus voltage of 1700V. For constructional simplicity, each phase leg of the converter module is integrated as a stack, which contains IGBT modules and their gate drivers mounted on a heat sink, fans for forced air cooling, thermistors mounted on the heatsink near the device for temperature monitoring and protection. In order to minimize the stray inductance of the converter circuit a sandwiched multi-layer bus bar architecture is used. The system consists of 300A, 1400V IGBT modules as switching devices, three-phase series inductor of 0.44mH and a DC capacitor bank of effective capacitance 7050 [iF. The inductance of series inductor take care the leakage of transformer also. The power stack assembly of one of the phase is shown in Fig. 3.

1 IkV/850-850V D/D6-Ynl I _

kV/433V

DYnl 1

FURNACE ~~CONVERTER

I l t~ ~ ~ ~ (

From the harmonic measurements, it was found that 4MW 12-pulse converter which feeds 9-ton furnace in casting plant draws a current from grid with Total Demand Distortion (TDD) of 8.6%, which exceeds the IEEE 519-1992 recommendations. The harmonic spectrum shows that 11th and 13th harmonics, having TDD of 6.4% and 4.5/0 respectively, are predominant in the line current while the furnace is under Fig. 3. Power stack assembly of one phase. operation. To bring down the TDD within recommended . CONTROLSTRATEGY level, STATCOM is identified as the appropriate solution [3]. Synchronous d-q reference frame based control strategy [4] III. TUE HARDWARE CONFIGURATION is adopted to control the STATCOM, which requires sensing STATCOM detailed in this paper is realized with a voltage of grid voltage and generation of unit vectors for the source converter (VSC) connected to the 3- Phase grid of orientation. But the presence of harmonics in the grid voltage 830V, 50Hz, through a series inductor, as shown in Fig. 2. and noise in voltage sensor restricts its direct use. To reduce IGBT based three-level neutral-point clamped converter [2] the effect of harmonics and noise in the unit vector, simple and efficient method is adopted [5]. topology, is used for realizing VSC.
Low Pass Filter

TO AUXILIARY LOADS Fig. 2. Single-line diagram of STATCOM connection to the main power distribution at the steel plant.

STATCOM

INDUCTION FURNACE /

voltage

Grid

Unit Vectors

Low Pass Filter

Fig. 4. Block diagram of unit vector generation.

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The method used for the construction of unit vector is shown in Fig. 4. The sensed grid voltages are filtered using a first order digital low pass filter whose corner frequency is C)O In the present work, C2) is chosen to be equal to the nominal grid frequency (50Hz). So, after filtering, the percentage of hth order harmonics of the sensed grid voltage is reduced by a factor of
h2

1 (assuming fundamental

voltage is always 100%). It is clear that 5th and higher order harmonics, which can normally be present in the line-to-line grid voltages, are reduced considerably using this low pass filter. High frequency noise gets eliminated almost completely. Finally, dividing the filter output signals with their magnitude generates the required unit vectors. However, this low pass filter introduces a phase lag to the unit vector generation. For nominal grid frequency (50Hz), this phase lag is 450 and can be easily compensated. The block diagram of the control strategy is shown in Fig. 5. Converter and load currents are oriented along the grid voltage using the unit vectors. After orientation, the fundamental components of d-axis and q-axis load currents are extracted using low pass filters. Knowing the fundamental d and q components of the load currents, the harmonics component is estimated by subtracting the fundamental component from the total d and q load currents. The estimated harmonic components of the load current are used to generate the references for the d and q axis current controllers. A PI controller is used to regulate the dc bus voltage at a constant level. The output of this controller generates the reference daxis current required to keep a steady dc bus. This reference current added with the d-axis component of the harmonics in the load current to generate the total reference for the d-axis current controller. The reference to the q-axis current controller is the q-axis harmonic component of the load current.

After extracting the harmonics from the load current it is passed through a lead lag compensator. The lead lag compensator will compensate the phase lag incurred in the sensor, ADCs etc. The sensed converter current is transformed into synchronous d-q reference frame. The d and q axis converter current is then compared with the d and q references to get the error, which is fed to the PI-controller. The remaining terms of the control equations "(1) and (2)," are added at the output of the PI-controller to get the voltage references of d and q axis. These references are then transferred back into 30 stationary frames and fed to a PWM modulator to control the operation of the VSC. Space vector modulation technique is used for switching the IGBT [6][7][8]. The control algorithm is implemented on a digital signal processor, TMS 320F240, based controller. The control law along the d-q axis is given below.
- oLi +V V =i R+L (1) d d q g dt di V =i R+L q+Li (2) q d q dt where, Vd and Vq are d and q axis voltage command. L and R are the inductance and resistance of the coupling inductor. id and iq are the d and q axis current of the converter. V. RESULTS

did

Fig. 6 shows the fully assembled STATCOM installed at the mini steel plant. Field trial had been carried out to validate the performance of both the hardware and the control strategy. It was observed that the source current TDD is brought down to 4.10% from 8.6% at full load of the furnace after the installation. The 11th and 13th harmonics are brought down from 6.4% to 2.8% and 4.5/0 to 2% respectively.

q axis voltage references

d axis voltage reference

Fig. 5. Synchronous D-Q reference frame based control strategy.

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It is observed that the STATCOM under operation brought down TDD and individual harmonic levels of the source current well within the limit stipulated by IEEE-519-1992 standards.-The summary data given in Table 1 clearly show the performance of the STATCOM. Source current and the source voltage waveforms are shown in Fig. 7 and Fig. 8 respectively.

Fig. 6. STATCOM assembly.

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_,,,,,,,,,,,,,,,,,,,,,,

_r.

Fig. 7. Compensated (1) and Un-compensated (2) grid current.

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Fig. 8. 1 1kV incomer voltage measured at secondary (1 10V side) of PT, with compensation (1) and without compensation (2).

VI. REFERENCES
[1] [2] [3]
W.M. Grady, M.J. Samotyj and A.H. Noyola, "Survey of active power line conditioning methodologies", in IEEE Trans. Power Delivery, vol. 5, pp. 1536-1542, July 1990. A. Nabae, I. Takahashi, and H. Akagi, "A new neutral-point-clamped PWM inverter," IEEE Trans. on Industrial Applicatiosn, vol. IA-17, no.5, pp. 518-523, Sep./Oct. 1981. H. Akagi et al., "Instantaneous Reactive Power Compensators Comprising Switching Devices Without Energy Storage Components," IEEE Trans. on Industry Applications, Vol.IA-20, No.3, pp. 625-630, May/June, 1984. K.R.Padiyar V.Ramanarayanan, P.S Sensarma "A Statcom for composite power line conditioning ," IEEE International Conference on Industrial Technology, ICIT, held at Goa, India in January 2000. T.G. Subhash Joshi, Aby Joseph,Gautam Poddar, "Active Power Factor Correction for Highly Fluctuating Industrial Load", in Proc. of NPEC2003, held at IIT, Bombay. J. H. Seo, C. H. Choi and D. S. Hyun, "A new simplified space-vector PWM method for three-level inverters," IEEE Trans. Power Electronics, Vol. 16(4), pp. 545-550, July 2001. F. Wang, "Sine-triangle versus space-vector modulation for three-level PWM voltage-source inverters," IEEE Trans. Industry Application, Vol. 38(2), pp 500-506, March/April 2002. T.G Subhash Joshi, A.S Haneesh, G.Narayanan, V.T Ranganathan, "A Computationally Efficient PWM Algorithm for Multilevel Inverters", in Proc. OfNPEC- 2003, held at IIT, Bombay.

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VII. BIOGRAPHIES
Unnikrishnan A. K. (M'90-SM'99) received the B.Sc. degree in electrical engineering from Regional Engineering College, Calicut, India, in 1978, and Mthe M.Tech. degree in electrical engineering .........................with specialization in control guidance and
instrumentation from the Indian
in

-. wr _ 2D,aveso9S,, .- s-r,. -V ,X,^

..

CURRENT HARMONICS AS % OF F.L FUNDAMENTAL (TDD) STATCOM STATCOM

OFF ON

Institute

of

Technology, Madras, India,

1979

1991.

During
State

Fundamental Harmonic 5 Harmonic 7

100.00 0.29 0.35 6.40 0.75 8.60

100.00 0.19 0.21

1986,

he

was

with

Kerala

Electronics Development Corporation, Trivandrum, India, in various capacities in the

Industrial Electronics

Projects

Division.

Since

Harmonic 1 1

2.80

Harmonic 13

4.50

2.00

Harmonic 17 Total (I TDD)

0.12 4.10

1986, he has been with the Power Electronics Group, Electronics Research and Development Centre of India (ER&DCI), Trivandrum, India, which is currently C-DAC, working on various development projects. Currently, he is Additional Director of the Power Electronics Group, C-DAC, Trivandrum. Mr. Unnikrishnan served the IEEE Kerala Section as Secretary during 1999-2001, vice Chair during 2005 and Chair during 2006.

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Aby Joseph received the B.Tech degree from Mahatma Gandhi University, Kerala, India, in 1994, and the M.Tech degree from the University of Kerala, Kerala, India, in 1997. He is currently working as Deputy Director in the Power Electronics Group, C-DAC, Trivandrum, India.

Subhash Joshi T.G. (M'06) received the B.Tech. degree in electrical engineering from Government College of Engineering, Cannanore, India, in 1998, and the M.Tech. degree in electrical engineering with specialization in Power Electronics from Regional Engineering College, Calicut, India, in 2002. He is currently working as Scientist-B in the Power Electronics Group, C-DAC, Trivandrum, India.

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