Fuseco Provides AHF Solution to Wallumbilla Gas Hub

Fuseco Provides AHF Solution to Wallumbilla Gas Hub

Located in remote central Queensland, the Wallumbilla Gas Hub is a major part of the Australian natural gas infrastructure network. The function of this facility is to compress the natural gas that is extracted from the ground in that area and pipe it to Brisbane and Rockhampton. To comply with the requirements, Fuseco supplied a Sinexcel 200A Active Harmonic Filter in an IP54 cabinet due to its exceptional performance, small footprint and flexibility.



The Challenge


Part of the design specification was a defined electrical harmonic level for the site. The majority of the load comprises of VSD’s and the Engineering team decided to use an Active Harmonic Filter to mitigate the harmonics at the main switchboard and comply with the requirements. The electricity supply to the site consists of the local grid and two generators. When running at full load all three of these supplies are required to power the site.



The Solution


Fuseco selected the Sinexcel 200A Active Harmonic Filter (AHF) due to its exceptional performance, small footprint and flexibility. In this case an IP54 version was installed to comply with the customer’s requirements. One of the challenges of this site was that the incoming supply was soft and unpredictable which necessitated the use of two large generators on-site. It was deemed important for the AHF to be able to operate efficiently in such an environment that often had three independent synchronised power supplies.



VIEW THE RANGE


The Outcome


The results were immediate and the performance of the AHF was above and beyond the requirements of the specification, the Supply Authority and the manufacturer of the two generators.

If we refer to the screen shot from the AHF’s touch screen post installation, we can note the following points:

1. The harmonic content of the load is 32%, which is quite typical of VSD loads (top left).
2. The Sinexcel AHF mitigated the load harmonics down to approx. 3% (bottom right).
3. As a result of the compensation by the AHF the corresponding grid voltage harmonics is approx. 2% (bottom left).



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In simple terms, harmonics are extra frequencies that when present in an electrical circuit, distort the AC sine wave. A harmonic of a wave is a component frequency of the signal that is an integer multiple of the fundamental frequency. For example, if the fundamental frequency is f, the harmonics have frequencies 2f, 3f, 4f... etc. 


Harmonic frequencies are equally spaced by the width of the fundamental frequency and can be found by repeatedly adding that frequency. In the case of the Australian electricity supply, the fundamental frequency is 50Hz. The frequencies of the harmonics are 100Hz, 150Hz, 200Hz, 250Hz, 300Hz, 350Hz and so on.


Learn more

For electrical systems to function in their intended manner without significant loss of performance or life, they require a supply of electricity that is of good quality. Good quality electrical power has the following characteristics: 

  • It must have a continuity of service (not be interrupted). 
  • It must have a very low Harmonic content. 
  • It must have a very low variation in the voltage magnitude. 
  • It must have very low transient voltages and currents. 

The term 'clean power' is used to describe electricity that is considered to be of good quality (see above) with particular reference to a very low harmonic content. Therefore, the term 'dirty power' is used to describe electricity that is considered to be of low quality (opposite to the above) with particular reference to a very high harmonic content. 


In Australia, our electricity is supplied in alternating current at a frequency of 50Hz. In alternating current (AC) the movement of electric charge periodically reverses direction. In direct current (DC), the flow of electric charge is only in one direction. 50Hz means that the AC has a frequency of 50 cycles per second. This is also known as the 'fundamental' frequency. AC is the form in which electricity is delivered to businesses and residences. Most electrical devices (such as motors) need clean electricity to function properly. This means that the electrical supply needs to be a clear sinusoidal wave.


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If you occasionally experience some unexplained occurrences such as flickering lights, alarms going off, or MCB's, MCCB's, RCD's and Earth Leakage devices tripping for no apparent reason, you are most likely experiencing harmonics in your electrical environment. Other signs are cables running hot, hot switchboards or overheating motors. If you are replacing your motor's bearings & insulation often, that's a strong indication of the presence of harmonics.

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Harmonics are very harmful within an electrical system and can have serious consequences. For example, the presence of harmonics reduces the life of equipment. It is possible that the investment that you made in your motors & drives will not be realised if they are damaged and need replacing before their expected life span. This can be very expensive. Harmonics cause things to run hot, which cause stress on the cables and equipment.


In the long term, this degrades an electrical system. The presence of harmonics will also mean that although you will get billed for the power that you are supplied, a large percentage of that power may be unusable. Harmonic mitigation is taking action to minimise the presence of harmonics in your electrical system and can achieve great cost savings.


Variable Speed Drives (also known as Variable Frequency Drives) are prolific creators of harmonics in electrical systems and as a result, most of the harmonic mitigation effort focuses on the input side and output side of a VFD.


Learn more

Depending on the specific situation, there are a variety of products that are used to mitigate harmonics. Fuseco's Power Quality Consultants can assist by conducting a site analysis or simply providing advice based on the details of the particular electrical system. Here is a brief summary of the product groups:


Line (input) side of the VSD

Device Features:

  • Line Reactors Simple & cost-effective method to reduce harmonics. Available in 3% & 5% versions.
  • Passive Harmonic Filters Significantly reduces harmonics from the VSD back out to the system and also improves true power factor.
  • Meets the IEEE519 Standard.
  • Active Harmonic Filters Active filters inject a 180 degree inverse current to nullify the harmonic content going back out to the system. They mitigate harmonics, compensate for voltage dips & can handle multiple VSD's relative to the reactive power required. Meets the IEEE519 Standard.

Load (output) side of the VSD

Device Features:

  • Load Reactors Simple & cost-effective method to reduce harmonics. Available in 3% & 5% versions.
  • dV/dT Filters dV/dT filters have been designed to limit peak voltage and increase voltage rise time. In addition to mitigating harmonics, the dV/dT filter also clips voltage spikes.
  • Sinewave Filters The ultimate load side harmonic mitigation product. Filters all harmonics, including reflective currents, eddy currents, common mode currents. Can be used for long cable runs (many kms). Stops the heating of cables. Great for the longevity of motors.

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Located in remote central Queensland, the Wallumbilla Gas Hub is a major part of the Australian natural gas infrastructure network. The function of this facility is to compress the natural gas that is extracted from the ground in that area and pipe it to Brisbane and Rockhampton. To comply with the requirements, Fuseco supplied a Sinexcel 200A Active Harmonic Filter in an IP54 cabinet due to its exceptional performance, small footprint and flexibility.
Sinexcel takes a monumental stride forward with 40 - 90kHz switching frequencies in their “Ultra” generation of Active Harmonic Filter (AHF) with SiC Mosfet technology – the epitome of groundbreaking advancements in power electronics engineering.
Early focus on the various Power Quality topologies when putting together power engineering designs can have a huge impact on project performance, capital expenses and ongoing operational costs for the end users.
While common mode over voltage cannot be eliminated, it can be reduced.
In recent times, the use of high-power Low Harmonic Drives (LHD’s) has increased. However, do their benefits outweigh their cost and space demands? Or do more cost-effective solutions exist? With our experience in the field, we believe that Active Harmonic Filters are still the preferred choice in many applications.
Exploring truly engineered harmonic mitigation solutions early in the design process, can make a huge positive impact to the overall project capital costs and ongoing operational efficiencies.
We are excited to announce the release of the new Sinexcel 200kVAr Static Var Generator (SVG) module!

From the moment the AHF and SVG units were turned on our power factor issues were a thing of the past. At both sites our PF is now 0.99 on all phases all the time, the units react instantaneously to our fluctuating load and power factor and the result has been an excellent return on investment.

Brad Kilner

OPERATIONS MANAGER AT KILNER'S ENGINEERING

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