Why Your Facility Needs Harmonic-Dampening Distribution Solutions
The electrical installations of today have little to compare with the ones as a couple of decades ago. Increase in variable frequency drives, LED lighting, UPS systems, battery chargers and other power electronics have changed the electrical load profile. Although these devices offer efficiency and control advantages, they also introduce harmonic currents into the system of distribution-distorting the voltage waveforms, over heating equipment, and lowering the overall system reliability. Harmonics is now an issue of concern and a day-to-day operational issue to facility managers and plant engineers. Harmonic-dampening distribution solutions are developed on the basis of innovative transformer technologies and offer the mitigation of equipment and the minimization of losses, as well as the preservation of the quality of power. Jiangsu Ryan Electric is providing these solutions to plants in over 80 countries and this has ensured that the modern loads are operating without jeopardizing the integrity of the distribution systems.
Harmonics create costs, which accrue in all areas of the facility operations, and tend to reveal themselves when it is too late. The short-term effect is the thermal one - the harmonic currents add to the total currents, yet do not add to useful work and lead to higher temperatures in transformers, cables, and switchgear. In case of transformers, this translates to faster aging of the insulation with every increase in temperature by 6°C to 10°C doubling of the remaining life. In the case of cables, it implies lower ampacity and the possibility of insulation damage. In the case of motors, it implies extra heating and torque pulsations which put pressure on mechanical systems.
In addition to thermal effects, harmonics lead to nuisance tripping over protective devices, annoyance of sensitive electronics, and decreased power factor, which attract utility penalties. The cost in monetary terms is cumulative, wasted energy due to heat, wasted equipment due to premature replacement, downtime in production due to unexpected failures, and monthly utility bills due to poor power factor. The harmonic-dampening solutions of Ryan Electric deal with those costs at their origin to minimize the total harmonic distortion (THD), and guard the facility assets against the non-obvious harm produced by harmonics.
Normal distribution transformer is used in sinusoidal currents and linear loads. They are subjected to the high losses of eddy current in windings, stray flux heating of structural components and overheating of neutral conductors in three-phase systems when subjected to the harmonic rich currents of modern facilities. The answer is harmonic specially designed transformers.
Transformers produced by Ryan Electric are K-factor rated to be able to deal with non-linear loads. To support both triplen harmonic currents and electrostatic shielding, our designs use neutral conductors larger than those used for AC currents of similar frequency, and winding configurations optimized to reduce eddy current losses at harmonic frequencies. Cores and coils are designed with higher cooling capacity whereby the temperature of the hot spots is kept within a limit even when the load on it becomes very harmful. K-factor transformers are rated by their capability to provide rated non-linear loads without excessive temperature rise- K-4 moderate harmonics, K-13 major harmonics and K- 20 worst case. These special transformers can offer the high-quality operation standard units cannot afford to deliver due to their high concentration of VFDs, UPS systems, or data center loads.
Whereas K-factor transformers survive harmonics, phase-shifting transformers remove them actively. These transformers generate preferred harmonics that are canceled magnetically before spreading out into the distribution system by adding controlled phase differences between multiple secondary windings.
Multi-pulse transformers at Ryan Electric Ryan Electric has the basis of passive harmonic mitigation on large loads at rectifiers: the multi-pulse transformer, offered in 12-pulse, 18-pulse, 24-pulse and beyond. Two six-pulse rectifiers fed by 30 degrees phase-shifted secondaries of the transformer result in the cancellation of the 5th and 7th harmonic. In 18-pulse and 24-pulse systems, other harmonics are rejected, leaving the primary current that is almost sinusoidal. In large variable frequency drive facilities or DC power supplies, as well as electrolytic loads, these transformers act as DC current harmonic filters and the system has a high efficiency in total. Our phase-shifting designs are tailored to the harmonic content of a specific application and provide maximum cancellation and minimum residual distortion. Supported by our extensive testing solutions, such as harmonic performance testing in our CNAS-certified laboratories, Ryan Electric provides phase-shifting solutions that convert harmonic generators into load-friendly loads.
Harmonious management is not just limited to single transformers but that of the whole distribution system. The solutions to harmonic-dampening proposed by Ryan Electric involve built-in solutions that integrate various mitigation solutions to ensure a complete enhancement of power quality.
K-factor transformers with provision of passive filters can be installed in our unit substations, and they are tuned to the harmonic frequencies of the facility. To support applications which need harmonic reduction and also voltage regulation, we provide designs of phase-shifting transformer plus on-load tap changer. In the case of renewable energy and energy storage installations, our transformers have some additional features to mitigate the harmonic peculiarities of inverters and battery chargers. Each solution is tailored to be easily integrated with downstream switchgear, upstream protection and facility monitoring systems so as to offer a comprehensive power quality management solution.
The value is not limited to the protection of the equipment but operational and financial advantages. High power factor will eliminate or mitigate utility penalties. Less harmonic currents leave more room on the distribution to add loads. Reduced operating temperatures increase equipment life and lessen the maintenance needs. Green power enhances the consistency of the processes and minimizes quality problems in delicate manufacturing processes. To facility managers with the challenges of modern loads, the harmonic-damping distribution solutions of Ryan Electric provide trustworthy, efficient power, and quality of power, which are experienced in more than 50 countries and are relied upon by clients in Microsoft data centers to industrial facilities throughout the world.
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