Voltage Sags

Reduction in the ac voltage, at the power frequency, for

durations from a half-cycle to a few seconds.
Magnitude between 90% and 10%
Voltage Sag is Characterized by two parameters Magnitude
and Duration
Power Electronics Loads are Sensitive to Voltage Sags
Impacts Industrial Customers 7 to 8 Times More Likely Than
Outages

Power Quality Problems

Voltage Sag

What Causes Voltage Sags?

Short Circuit Faults
Motor starting
Transformer Energization

Power System Network

What Causes Voltage Sags?

Short Circuit Faults
Motor starting
Transformer Energization

Lightning

Equipment Failure

Animals

Voltage Sag due to Motor Starting

220

215

RMS voltage in V

210

205

200

195

190
0

5
6
Time in Cycles

10

11

Voltage Sag due to Transformer

Energization
11
10.9
10.8

RMS voltage in kV

10.7
10.6
10.5
10.4
10.3
10.2
10.1
10
0

10

15
Time in Cycles

20

25

DOE Study
Voltage Sags
$377,000 per year / large industrial customer.
National Cost: $114 B

Interruptions
$132, 000 per year / large industrial customer
National cost: $39 B

21

Duke Power Study

198 Industrial and Commercial
Customers
voltage sag results in 37% work
stoppage, costs $7,700
Mom. outage: 57% work stoppage,
$11,000
Total Annual Cost: $4.4 B
22

Effect of Voltage Sags on

Adjustable Speed Drives
(ASDs)

What is in a Name?
Adjustable Speed Drive (ASD)
Variable Speed Drive (VSD)
Inverter
Voltage Source Inverter
Variable Frequency Drive (VFD)

24

Why Use ASDs

Energy Savings
Process Improvement
Improved Quality
Reduced Noise
Saves Space

25

Voltage Sags Drive Response

Reset Manual Restart

Reset Auto Restart
Non-synchronous Restart
Non-synchronous Time Delay Restart
Non-synchronous Ride-Thru with Flying
restart

ASD Performance Improvement

Processes that require precise speed/
torque will not benefit from ASD
Programming
Other Alternatives
Add DC Bus Capacitors
Boost Converters
Add High Speed Fly Wheel

Effect of Voltage Sags on

Programmable Logic Controllers
(PLCs)

What is PLC?
Programmable Logic Controller, PLC, or
Programmable Controller
small computer used for automation of
real-world processes, such as control of
machinery on factory assembly lines
The main difference from other computers
are the special input/output arrangements
Digital or Analog Signals

What is PLC?

Voltage Sag Sensitivity of Common Relays and

Contactors

BIG

Voltage Sag Mitigation

Equipment
Traditional UPS (Uninterruptible Power Supply)?
Dynamic Voltage Restorers
Medium Voltage Dynamic UPS
Superconducting Magnetic Energy Storage
Static Transfer Switches
Battery and Batteryless UPS
Dynamic Sag Corrector
Dip Proof Inverters
Coil Hold-In Devices

SMALL

Off - Line Technology UPS

Input Power Present
Xfer Switch

Input

Filter

Output

Charger

Battery

Inverter

Off - Line Technology

Input Power Fail
Xfer Switch

Input

Filter

Output

Charger

Battery

Inverter

On - Line Technology UPS

System Operation
INPUT

EMI / RFI
TVSS

OUTPUT

DC / DC
Converter

Charger

Battery

Facility Voltage Present

On - Line Technology Battery

Operation
INPUT

EMI / RFI
TVSS

OUTPUT

DC / DC
Converter

Charger

Battery

No Facility Voltage Present

Dynamic Voltage Restorer

Energy storage - DC capacitors
Rectifier changes the voltage to DC
Inverter changes the DC back to AC
AC output waveform is controllable
Adds its output to the utility waveform through the use
of a series transformer
1 to 4 ms response time
Practical boost to about 50%
Manufacturers:

S&C Electric ($ 2M/5 MVA)

ABB

D is trib u tio n
S u b s ta tio n

P rim a ry F e e d e rs

Line Voltag e
With Sag

T ra n s m is s io n
S y s te m S w itc h in g
o r F a u lt C le a rin g

-1

R estored
Voltag e

C ompensating
Voltag e

PU
+1
0

F a u lt o c c u rin g o n
a d ja c e n t fe e d

PU
+1

PU
+1

0
-1

0
-1

D Y N A M IC
V O LTAG E
RE S TO RE R

P ro te c te d
S e n s itiv e L o a d

DVR Application in a Feeder

(Courtesy: Westinghouse)

54

DVR Container

Dynamic Voltage Restorer

Limitations
Do not address interruptions
Limit to boost capability - amplitude and
duration
Boost effectiveness may depend on load
power factor

Dynamic UPS (ABB)

Pure Wave UPS (S&C)

Energy storage is a high energy cranking battery.

Mitigates sags and outages, providing 100% voltage
compensation
During a sag or outage the system disconnects from
the utility.
Standby system
4 ms response or less
Manufacturers:
S&C Electric
ABB

S&C Purewave UPS

380 V to 34.5 kV voltage applications
313 kVA to 20 MVA per system
4 ms response
More than 98% efficient
30 second protection at
100% load
Maintenance free high
performance lead-acid
cranking battery
S&C Purewave UPS at ST Microelectronics Fab in Phoenix, AZ
12.5 MVA @12.47kV

DVR & DUPS Differences

DVR
Capacitors
Series injection
Voltage Sags only

DUPS
Batteries
Shunt Device
Static Transfer Switch
sags and mom. interruptions

SVR Principle of Operation (ABB)

Utility

1. Booster converter

2. Charger converter
3. DC link

4. Charger transformer

Load

Low Voltage (480 V) Application

0.5 8 MVA load

ABB Series Voltage Restorer (480 V, 3 ph, 1.5 MVA)

11 ft

MV Static Transfer Switches

Solid State thyristor or GTO (Gate Turn-off thyristor)
switches transfer between independent distribution
sources
Transfers to a good source if one is available
Transfer time as quick as 2 ms
Numerous manufacturers, including, among others:
ABB
Cyberex
Silicon Power
S&C Electric

PowerDigm Sub Cycle Transfer Switch

Addresses interruptions
and sags
4 ms response
Up to 38 kV, 600 A
No energy storage
Only as good as sources
Electronics require cooling
~ $350k to $700k each

Dynamic Sag Corrector

Soft Switching Technologies: Dr. Deepak Divan

9 kVA ProDySC

1.0 MW DySC

Provides tool (process) or fab-level protection (0.25

kVA to 3,000 kVA) Soft Switching Technologies
Corrects for voltage sags down to 50% for to 2-3
seconds
Corrects for momentary interruptions up to 12 cycles
4 ms response
Proven track record

DySC Operation
Normally static switch is closed
During a sag, the switch is opened and the inverter is
energized, inserting a PWM signal in series with the
voltage sag
No stored energy is used for sags down to 50%.
Electrolytic capacitors are discharged for voltage
sags below 50% (12 cycles max)

Voltage Dip Proofing Inverter (DPI)

Voltage Dip Proofing Inverter
Static
Switch

From
100-120 Vac
or
200-230Vac
voltage source

Bridge
Inverter

=
Storage
Capacitor

To
Load

Off-line Device.
Sub-cycle switching time in the event of a sag
Disconnects the normal supply and serves the load
from the internal stored energy for up to 3 seconds.
The energy storage is a set of DC capacitors.

Protects against voltage sags and

momentary outages.

Coil Hold-In Devices

Designed to Prop Up individual relays and
contactors
Holds in relay/contactor down to 25% of nominal
voltage.
Small Size
Less than $120
Size Based on Voltage and Coil Resistance
Voltage rectification produces an average DC
waveform on device secondary

Coil Hold-In Devices

Ideal for Motor Control Center and Emergency
Power Off Applications.

Manufacturers: Square D, Coil-Lock, KnowTrip

Whats the Problem?

EMO circuit drops

critical equipment

The Fix Coil Hold-In Device

Support EMO circuit with

coil hold-in device

Whats the Problem?

Desktop computers
crashing

The Remedy Offline UPS

Offline UPS

Whats the Problem?

Data Center Downtime

The Remedy On-Line UPS

UPS
System

Whats the Problem?

Manufacturing Downtime

The Fix Dynamic Voltage Restorer

Dynamic Voltage
Restorer

Power Quality
Solutions for MOS 12
Pros & Cons

ABB DVR

S&C Purewave UPS

Soft Switching DySC

77

DVR
Pros

PQ solution for the entire site

Doesnt encroach on valuable fab space
On-line within months
Will cover most recorded events
Proven technology

Cons
Not all events covered
Caps need time to re-charge (Breaker re-closing could be
a problem)
Expensive
Requires lots of space near substation
Substation reconfiguration required
Maintenance contract required

Medium Voltage UPS

Pros

One system to solve the PQ problem for the entire site

Doesnt encroach on valuable fab space
All recorded events covered
Proven technology
Will handle breaker re-closing events

Cons
Most expensive
Requires lots of space near substation, more than the
DVRs
Substation reconfiguration required
Maintenance contracts required

DySC (tool level)

Pros
Proven track record (DySC installations at MOS 12)
Protected for all but one event (7/1/03)
Can be implemented in phases

Cons
Must be located closely to the tool in valuable fab space
Not enough space in some congested areas
Numerous devices located throughout the factory

DySC (load center)

Pros
Locate in electrical rooms to protect a group of sensitive
equipment
Can be implemented in phases
May not be necessary to install on all load centers

Cons
Space limitations in the electrical rooms
Will not cover all events

Embedded Solutions
Pros
Most cost effective
Can be implemented in phases

Cons

Engineering challenge to find all PQ problems

Most time consuming option, an ongoing effort
PQ problem wont immediately be solved
Collaboration with facilities and production is crucial

Other
Of all the options requires the highest degree of in-house
power quality knowledge

The Embedded Solution Challenge

From a PQ perspective
tool support systems are
as critical as the process
equipment
If the PCW loop looses
pressure due to a voltage
sag the tool may
shutdown
Challenging task to find
all of these PQ sensitive
devices

Scrubber Fan

Fume Scrubber
Scrubber Exhaust Distribution
CDA Motor &
Compressor
Fab Power
Distribution

Wafer Processing
Tool
Clean Dry Air Distribution
Process Vacuum
Distribution
Tool High
Vacuum Pump

Process Vacuum
Pump & Motor

Power Source

DC

Tool Closed
Loop Chiller

Tool RF
Generator

PCW Pump
Power

Process Mechanical

Process Cooling Water

Distribution

Hybrid Solution
Combination of embedded solutions &
DySCs for concentrations of loads
Pros
Possibly more cost effective than a solely embedded
solution approach
Reduce schedule

Cons
Space limitations in the electrical rooms
Will not cover all events

Closer Look at Sags below

SEMI F47
Sag details & coverage comparisons

For most events not covered by the DVR

and the DySC, the voltage sag will be
improved, but not corrected 100%

Overview
Option

Largest Detractor

Biggest Plus

DVR

Very expensive
investment that doesnt
cover all sags

Single solution for

entire site correcting
most sags

UPS

Most expensive

Single solution for

entire site correcting all
sags

DySC (tool level)

Space in sub-fab

Will cover most events

Cost & Space

Will cover most sags

Engineering challenge
to find and fix all PQ
sensitive devices

Most cost effective

DySC (load centers)

Embedded

Considerations
The options provide varying degrees of PQ
protection.
Whats the best technical option?
Whats the best business option?
Systems for large scale power quality
protection, such as DVRs and Medium Voltage
UPSs, require a large capital expenditure.
Does the cost/benefit analysis warrant the
expenditure?
If not what is the most cost effective option?

Case Study - I
Dynamic Voltage Restorer (DVR) at a
Semiconductor Chip Manufacturing Plant in
Chandler, Arizona
Worlds Largest DVR

Commissioned July 1998 Two 6 MVA inverters

each

Dynamic Voltage Restorer (DVR)

Worlds largest DVR installation
(Chandler, AZ)
Two sets of twin 5- or 6-MVA
DVR systems
Substation dedicated to two major
semiconductor fab plants
69/12.5-kV substation fed by
three 69-kV overhead lines; five
50-MVA transformers
Both projects completed in record
time (8 and 11 months)
First twin system break even was
estimated < 4 years (actual was
< 6 months in first year of service)
Both units saved plant from
production losses within days after
startup

DVR South
WEST
East

DVR North
Chip Fab 12 Site

DVR Performance for three-phase voltage sag 7/31/98

Waveshape Disturbance 7/31/98 @ 11:05 South Bus

15000
System Phase A
System Phase B
System Phase C

10000

3295

3417

3539

3426

3563

3173

3289

3051

2929

2807

2685

2563

2441

2319

2197

2075

1953

1831

1709

1587

1465

1343

1221

977

1099

855

733

611

489

367

245

123

Volts

5000

-5000

-10000

-15000

DVR Output Voltage

Waveshape Disturbance
Cycles

15000
Plant Phase A
Plant Phase B
Plant Phase C
10000

-5000

-10000

-15000
Cycles

3152

3015

2878

2741

2604

2467

2330

2193

2056

1919

1782

1645

1508

1371

1234

1097

960

823

686

549

412

275

138

Volts

5000

Cost of Voltage Sags to Customer

DVR Problems
11 months after installation, one DVR caught fire
in May 1999
Bypass MOD switch failed to close had burnt
close coil which was undetected
Harmonic Instability in control caused very high
voltage and current distortion
Switching in the plant initiated the event

Load side (Channel 2) Voltage, ph B, 3/8, 10:10:04.22

20000

15000

Voltage (volts)

10000

5000

0
0

0.05

0.1

0.15

-5000

-10000

-15000

-20000
Time (seconds)

0.2

0.25

Load side ph B (Channel 2) Voltage, 04.83

15000
14220 V
10000

Volts

5000

0
0

0.05

0.1

0.15

0.2

0.25

-5000

-10000

14,363 V

-15000
Time (sec)

South DVR, Load side, Ph B, I harmonics

180%
160%

% of Fundamental

140%
120%
5th I (% F)

100%

6th I (% F)
80%

7th C (% F)

60%
40%
20%
0%
0

10

15

20

25
Cycles

30

35

40

45

SouthDVR, Load side, Ph B, V, I rm s plot

7600

1000
900

7500

800
7400
700

Volts (rms)

7300

I rm s

600

7200

500
400

7100

300
7000
200
6900

100

6800

0
0

10

15

20

25
Cycles

30

35

40

45

Sout hDVRLoadPhB,VIplt

Fund V rms
Fund I rms

South DVR Phase B injection voltage

3500

3000

Volts, rms

2500

2000

Vrms,total
Fund V rms

1500

1000

500

0
0

10

15

20

25
Cycles

30

35

40

45

South DVR injection volt B, beginning of event, 3/8/1999, 10:10:04.22

3000
2716v
begin event

2000

volts

1000

0
0

0.05

0.1

0.15

0.2

0.25

-1000

-2000
2718V
-3000
Tim e (seconds)

Ph B inj v

6000

4000

2000

0
0
-2000

-4000

-6000

-8000

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

Ph B inj v

South DVR Ph A injection voltage

4000

3000

2000

volts

1000
Ph A inj v
0

-1000
begin

Middle

-2000

-3000
0

0.1

0.2

0.3

0.4
Time (seconds)

0.5

0.6

0.7

0.8

Case Study - II
PureWave UPS, 15,000 KVA @ 12.47 KV
Installed at ST Micro Electronics Plant
in Phoenix, Arizona

Dynamic UPS (ABB)

Pure Wave UPS (S&C)

Energy storage is a high energy cranking battery.

Mitigates sags and outages, providing 100% voltage
compensation
During a sag or outage the system disconnects from
the utility.
Standby system
4 ms response or less
Manufacturers:
S&C Electric
ABB

Semiconductor Wafer FAB - Phoenix, AZ

Semiconductor Wafer FAB, Phoenix, AZ

15,000 KVA, @ 12.47 KV
S&C Electric PureWave UPS

Why use a Wide Area (Whole Plant)

Solution?
Large site with connection to utility network
Not cost-effective to isolate sensitive loads
High percentage of sensitive load
Congested plant areas where numerous smaller
devices wouldnt fit
Cost effectiveness vs. multiple small systems
More efficient, reduced maintenance effort
Highly specific to targeted problem
Transfer maintenance and operations to supplier

IEEE PE Review July 2001

While most utilities can quote
reliability numbers ..; they cannot
provide a measure of performance for
the quality of power supply
Don Volzka, PES President

Tracking Power Quality

Reliability Indices, SAIDI, SAIFI, CAIDI,
CAIFI
Voltage Sag Indices, similar to Reliability
Indices
SARFIX Index
Voltage Sag Energy Index
Voltage Sag Severity Index

Reliability Indices
Power Outage voltage goes to zero
Frequency and Duration

SAIFI System Average Interruption

Frequency Index
SAIDI System Average Interruption
Duration Index
CAIDI Customer Average Interruption
Duration Index

Voltage Sag
0

20

40

60

80

100

120

140

Decrease in Voltage
Magnitude varies during the event
Sag different in Three Phases
Impact of sag event is function of both voltage
magnitude and duration
Impact on equipment is exponential relationship
to voltage
Single Index based on integral of voltage
squared and duration

Voltage Sag Energy, EVS

VS [1

Vt

2
nom

dt ] x 100

Sag Energy Index

For a given location and period

E
VS _ i
i

System Average Sag Energy Index

SEI

Voltage Sag Index Definitions

SEI Sag Energy Index
Analogous to SAIDI, takes into account voltage sag
frequency, magnitude, and duration.

SCI Sag Count Index

Analogous to SAIFI, takes into account voltage sag
frequency.

SSI Sag Severity Index

Analogous to CAIDI, takes into account voltage sag
magnitude and duration.

SEI = SCI x SSI =

month,monitor,etc

SE

Sag Event Frequency Index

At a particular location and period (month
or year)
= Number of qualified sag events at that
location and period

System Sag Event Frequency Index

Total Number of Qualified voltage Sag events

SEFI = -----------------------------------------------------Number of monitor locations

Calculation for a sag event

Voltage

EVS
600
400
200
0
-200 0
-400
-600

20

Four cycle, 75%, voltage sag

= [1- 0.752 ] x 100 x 0.0667 = 2.92

40

60

80

Time (milli seconds)

100

120

140

Sag Energy (SE) for this event: 20.75

Time Stamp
04/21/2001 03:15:41PM
Duration
0.166 seconds
Minimum V1
Energy V1

59%
40

Minimum V2
Energy V2

55%
37

Minimum V3
99%
Energy V3
98
Sag Event Energy = (((100-40) +(100- 37) +(100- 98)) x 0.166 = 20.75

Qualifying Events

Voltage Must be < 90%

Aggregation Time: 10 minutes
Event Duration limited to 15 cycles
Energy > 100, = 100
Outages not included

Data for 1999 and 2000

1999

25 Monitors (PML 7700-ION)

Recorded 924 sag events
609 events after eliminating shallow sags (> 0.9 pu)
408 events after aggregation

2000

36 Monitors
1233 Events Recorded
926 events after eliminating shallow sags (>0.9 pu)
687 events after aggregation

Data for 1999 - 2002

1999 2000 2001 2002

No. of Monitors
25
36
43
57
Sag Events (<0.9)
609 926 747 1831
Events after aggregation 408 687 603 1233

Sag Event Frequency Index

Comparison, 2000 and 1999

SRP Power Quality

Monitoring System, 2002

Sag Energy Index (SEI)

SEI > 35+
25 < SEI < 34
20 < SEI < 24
12 < SEI < 19
SEI < 11

PG
SEI = 31.8

VA (3)
SEI = 29.4

BS (3)

CA
SEI = 44.0

SEI = 9.2

PV (3) [115kV]

PIO (2)

SEI = 9.8

HE (3)

FW (2)

SEI = 10.8

SEI = 39.1

EV (2)
SEI = 14.8

STR
SEI = 6.7

SEI = 13.0

NO (2)

SEI = 7.0

CEM (2)
SEI = 8.3

MIP (2)
SEI = 10.1

WER (2)
SEI = 7.9

MC (2)

PK (3)

SEI = 9.5

CLS

GR

SEI = 8.8

TVH

SR (3)

SEI = 17.3

SEI = 10.3

RO (2)
SEI = 10.2

SEI = 5.7

GL (3)
SEI = 12.8

SEI = 17.0

Includes 3 monitors at PV sub in the Eastern Mining Area

Dashed areas indicate 69kV islands

SEI = 8.2

LE
SEI = 23.7

SS
SEI = 23.0

BL

WA (2)
MEY

SEI = 8.4

SEI = 6.7

SYY (4)

Installed PQ Monitors (57) *

Future PQ Monitors, FY2002/03 (1)

CE

SEI = 10.3

GEN (2)
SEI = 7.7

Average SEI (CY2000)

Dedicated industrial substation = 12.9

Residential 69kV substation = 18.9

Correlation to C & I Customer Complaints

Sag Energy - FAQs

Where do you get sag energy data for
events?
What if PML Monitors are not used?
Product of average sag voltage squared times
duration is a good approximation for integration.
Error < 2 to 3%

Variation of number of monitor locations ?

Data is normalized

Aggregation time ? 1 min or 10 min

SRP LIC Satisfaction Index ?

X
Results using Vavg^2/Vnom^2 rather than phase Energy
Results are within +/- 10% towards the low end of the sag energy scale
Maximum deviation at the upper end (longer, more severe events)

Correlation to C & I Customer Complaints

Conclusions
SRP installed monitors at selected
locations for benchmarking and quantify
power quality
Power Quality Index based on voltage sag
energy developed
Indices have good correlation with
customers PQ concerns
Results available for two and half years

Conclusions
Voltage Sags are significant Power Quality Problem
for Industrial and Commercial Customers
Ride-thru Equipment Available, Watts to Megawatts
Embedded solutions are the most cost effective but
in many cases not practical to apply
Wide Area systems may be most appropriate when
numerous weak links exist
Carefully identify the problem and apply the most
cost effective solution.

149