Power Capacitors Design

ABB Capacitors
Shunt Banks & Filter
Design Features
&
Advantages
ABB PP/H/HV - Page 1
Edition 2, 2006-03
ABB
Ludvika High Voltage Products
Surge Instrument Live Tank Configurable High / Medium Voltage
Arresters Transformers Breakers Switchgear Capacitors
High Voltage Product: Focused Factories and Testing Resources

Capacitors
ABB Capacitors worldwide
Quebec City Ludvika Xian
Galindo
Bangalore
Output: 30 000 Mvar Lilydale

Number of HV factories: 6
Market share: 25 - 30%
Capacitors
ABB Capacitors in Sweden
Ludvika
Capacitors
ABB Capacitors in Sweden
One the worlds largest factories

for high voltage capacitors.
Most modern factory in the world
Export: >95%
Employees: app. 110
145 kV Filter bank in Norway Volume: 15 000 Mvar/year

Capacitors
History and policy
Lead the development of capacitor technology,
which we have done over the past 75 years:
1932 2005
Paper Dielectric All-film Dielectric
Mineral Oil Synthetic Oil
2000
The first dry DC capacitor for high voltage
2005
The first dry AC capacitor for high voltage
Supply everything from individual capacitor

units to complete projects
Market leader in the capacitor business

Capacitors
Capacitors at all voltage levels
800 - 400 kV
130 kV
40-70 kV
1 - 24 kV 400 V
Distribution
substation
Power Quality
Reactive power compensation
Active power
Many loads consume reactive power
M
Shunt capacitors generate reactive Reactive power
power and thereby
M
Improve the power factor
Reduce the network losses M
Decrease voltage drops

M
Capacitors improve the power quality

Power Quality
Harmonics in the network
All non-linear loads are
sources for harmonics:
Rectifiers
Drive systems
Electric arc furnaces
Frequency converters
Welding machines Current in typical office feeder, recorded on CT secondary
HF lamps, fluorescent tube
Electronic equipments
Harmonic currents increase the losses, which means

higher temperature in equipment and system

Harmonic voltages increase the stress on insulation in
electrical equipment
Power Quality
Reduction of harmonics
The amount of harmonics is growing, both in industrial and in
general public distribution systems.
Harmonic filters reduce: 3,5

The harmonic content in the network 3,0
V o lta g e D is to r s io n %
2,5
Disturbances in telecommunication 2,0
and computers 1,5
Misbehavior on control equipment 1,0
and relay protections 0,5

0,0
Measuring errors in metering system 1989 1992 1994 2000
Overloading of Capacitors Measurements from a Swedish city
Harmonic filters improve the power quality

Power Quality
Power Utility needs compensation
Electric energy is the commodity. Reduced cost
Focus is on: Higher capacity No need for new
Network losses lines and substations
Voltage stability Low losses Low maintenance
Transmission capacity
Higher revenues
Voltage stability Load flow control
Power quality Higher efficiency
Load increase Higher capacity
Environmental Aspects
Less power lines
Less generation of electricity
Power compensation increases capacity and gives lower costs

Power Quality
Industry needs compensation
Electric energy is a production cost. Reduced cost
Focus is on:
Higher power factor cos No
Power factor penalty tariff
Voltage stability
Voltage stability No unplanned
Power quality production stops
Lower losses Low maintenance
Power quality No disturbance
Higher revenues
No stops Higher output
Power compensation decreases costs and gives higher revenues

Capacitors
Product range, 1 800 kV
HV and MV capacitors
Shunt capacitors
Series capacitors
Systems
Shunt compensations
Filter applications
Railway applications
HVDC
Series Compensation - SC
Static VAR Compensation - SVC
A complete program with complete support

Capacitors
Harmonic Filters, 1 300 kV
Tuned or de-tuned design
Tuned filters: Suitable when source of
harmonics, and harmonic content is well
defined
De-tuned filters: Suitable when harmonics
originate from many sources, and many
harmonic frequencies are present
Band-pass, High-pass or C-type filters
Band-pass High-pass C-type
We optimise each project to get the best solution

Capacitors
Enclosed Banks, 1 24 kV
Voltage Range: 1 12/24 kV
Automatically controlled in steps
Filter solutions
Completely factory assembled
Highest safety for personnel

Technology
Capacitor unit
Al foil, Insulating paper

Dielectric
material (Internal
fuse) Stacking
Al foil Element
Canning
Painting
Impregnation
Technology
Capacitor principle
U+ Electrode area (mm2)

A = d xw
h Capacitance (F)
A
C=
h
w d
U- Reactive power (Mvar)
Q = U C
2
In order to get a large capacitance is needed:

Large electrode area A

Small electrode separation h
This will result in a high electric field strength
Technology
Design of capacitor element
Al foil Folded edge Extended foil
D D = Film
thickness
a = Radius of
Film folded edge
a
Optimal electric field strength, well Design with safety margins:
utilized insulation: Several film layers (normally three)
Air Breakdown, AC 3 kV/mm High electrical withstand
Cables, AC <15 kV/mm Folded foils at electrode edges
Cables, DC 30-40 kV/mm Low electric stress amplification
Capacitors, AC 80 kV/mm Minimized PD generation
Capacitors, DC 200 kV/mm
Reliable and well utilized capacitor elements

Technology
Insulating fluid
Capacitor units are impregnated with Benzyltoulene (Faradol)
CH3 CH3
Composed by a
CH2 CH2 CH2 mixture of mono- and
dibenzyltoluenes
Monobenzyltoluene Dibenzyltoluene
Excellent electrical properties

(especially PD)
Type of fluid Dielectric strength Permittivity
High permittivity
Works well together with Mineral oil Moderate 2.1-2.3
polypropylene film
Benzyltoulene High 2.7
Low ecotoxicity
Low bioaccumulation and rapid biodegradability
Environmentally safe insulating fluid which

also gives high capacitance per unit
Technology
Preferred fusing technology
Internal fuses cover most applications
System supplier with competence

Technology
Capacitor with internal fuses
Internal fuses act current limiting, i.e.

Internal
only a small amount of available energy
fuse
is released. The impact on adjacent
insulation components is limited.
Capacitor
element Increase of voltage over the parallel
elements is small
Discharge Enables large size units and compact
resistors bank design
Operation of one fuse has negligible influence on the capacitor unit

Good overall economy due to large capacitor units and compact bank design
Technology
Internal fuse design
Side view Location of fuses in
middle of element
package
Low risk of damage to
Capacitor element
major insulation
(insulation to can)
Pressboard cover Impact only on the own
failed element at fuse
operation
Top view Patented design
Internal fuse - twisted connection wires
- no soldered points close
to fuse wire
Fuse
Automatic production
connecting wire
Reliable fuse design with selective operation

Technology
Large units
2 x 500 kvar 1 x 1000 kvar

Same Dielectric Stress
Same Number of Elements
Same Active Material
Less Passive Material

(Bushings, Insulation etc.)
Less ground area
Less foundation
Less fence
Large units give lower total cost for the customer

Technology
Reduced noise levels
A poorly designed capacitor bank may be a source of severe acoustic noise
ABB has patented solutions for low noise

generation
Mechanical resonance in capacitor units
is eliminated
Examples of installations with stringent
demands on low acoustic noise
Sweden-Poland, HVDC, 11/13/24:th
harmonic filter
Italy-Greece, HVDC, 12/24:th
harmonic filter
Essent, Netherlands, Shunt
compensation, 8 x 48 Mvar, 180 kV
Stringent demands on low acoustic noise can be met

Technology
Bird caps
Bird caps may be used to

protect against short circuits
caused by birds, snakes,
vermin,
Combined with insulated cable
For all voltage levels
Efficient protection against accidental faults

Technology
High reliability
Detailed service experience from major installations verify

that failure rates are extremely low.
Project Application No. of units Failure rate (%/year)

Itaipu HVDC 15224 0.03
IPP HVDC 13786 0.05
Itaipu SC 5040 0.04
Rihand-Delhi HVDC 6103 0.004
Reliable Capacitors with extremely low failure rate

Technology
Controlled switching of capacitor banks
Energizing of capacitor banks and harmonic Voltage transients when
filters may cause severe inrush currents and energizing one phase of a
voltage oscillations 72 kV capacitor bank
A: Energizing close to the power
A B frequency voltage peak. A high
voltage transient is generated
B: With Switchsync relay.
Energizing close to voltage zero.
The transient is considerably
reduced
Controlled switching of the capacitor bank breaker

gives efficient reduction of the switching transients
Well proven SwitchsyncTM controllers
ABBs circuit breakers are well suited
Damping reactors are normally superfluous
Very well proven application - all equipment is available

Capacitors
Capacitor service & maintenance
A capacitor bank or filter bank is

virtually maintenance free
CB 10 is a Scheering bridge that
enables control of capacitor units
without removing the inter-connections
between the individual units in a bank
The average measurement time is 30
seconds per capacitor unit.
ABB capacitor and filter banks are virtually maintenance free

Capacitors
PCB in capacitors
Polychlorinated biphenyls ( PCB ) were formerly used as insulating

fluids due to good insulating and fire-resistant properties
PCB was used extensively by most manufacturers of HV equipment
(1963 - 1978 ABB use in capacitors)
Severe environmental effects were detected in the 1970s
Total production of PCB is estimated to 1.5 million tons
>50% is in use or storage
Get rid of capacitors containing PCB!

Capacitors
Reason to replace capacitors with PCB
Legal deadlines for PCB disposal
2010 in EU, 2025 in the rest of the world
Risks to employees
Risk to get bad reputation in case of an incident
Units with PCB are old and inefficient, and require more
maintenance than modern types
Capacitors
Well proven innovation DryQ
An entirely new dry concept that

fulfils the demands of the future
today
Modular concept for 40 170 kV,

Shunt Capacitor banks
Technology
Capacitors
Well-proven innovation
The dry technique has been

used for several years in ABB.
For LVAC capacitors since 1970s

For HVDC capacitors since 2000
For HVAC since 2005
Technique
Capacitors
Well-proven innovation Compact design
Polymer housing
Environmental friendly
Long term reliability
No porcelain bushings for connections
Silicone cover with sheds
Long term hydrophobic
Long creepage distance
Small footprint
Easy installation
Technique
Capacitors
Well-proven innovation - Safe operation
Self healing dielectrics

Weak spots will be locally
disconnected
Stable capacitance throughout
the product life cycle
Crosslinked silicone inside
Eliminates leaks
No Fuses
No Oil
Capacitors
DryQ Well-proven innovation - Cost efficient
DryQ is small and light
Easy handling during transport and
installation
Compact and flexible capacitor
banks
Reduced sound level
No sound-absorbing equipment
needed
No oil
No absorbing material under the
bank is needed
Compact design without risk for leakages

Capacitors
Well proven innovation DryQ
Compact design:
Polymer housing
Silicone cover with sheds
Safe operation:
Self healing dielectrics
Crosslinked silicone inside
Cost efficient:
Small footprint
Reduced sound level
World class quality

Low environmental impact
Shunt bank, 40 170 kV

Certified acc to ISO
Compact design without risk for leakages

Capacitors
References
ESKOM, South Africa
TNB, Malaysia
KEPCO, Korea
EGAT, Thailand
Vattenfall, Sweden
Statnett, Norway
Electrabel, Belgium
PG&E, USA
Furnas, Brazil
Transener, Argentina
CPG, China
RTE, France
ABBs capacitors are used all over the world

Capacitors
Example of filter projects
France
13 pcs. 30 Mvar filter banks for 10 stations
9 pcs. 63 kV filter in 6 stations
4 pcs. 90 kV filter in 4 stations
5 - 7 month delivery for all 13 filter banks
We take care of everything from system studies to commissioning

Capacitors
Production facilities - World class quality
We know that to be able to

produce world class products,
the personnel and machinery of
production have to meet the
same high standards
Our workshop has the most
modern machinery and
processes.
The capacitors are often tailor
made in order to satisfy the high
demands of our customers.
Capacitors
Focus on environmental aspects
Optimized design to save material and
transport
Great majority of materials are recyclable
LCA continually used in the R&D process for

environmental evaluation
We are certified according to:

ISO 9001
ISO 14001
Use of capacitors saves energy!


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Power Capacitors Design

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ABB Capacitors

Shunt Banks & Filter

High Voltage Product: Focused Factories and Testing Resources

Output: 30 000 Mvar Lilydale

One the worlds largest factories

Most modern factory in the world

Employees: app. 110

145 kV Filter bank in Norway Volume: 15 000 Mvar/year

Supply everything from individual capacitor

Market leader in the capacitor business

Decrease voltage drops

Capacitors improve the power quality

Harmonic currents increase the losses, which means

higher temperature in equipment and system

Harmonic filters reduce: 3,5

and relay protections 0,5

Harmonic filters improve the power quality

Less generation of electricity

Power compensation increases capacity and gives lower costs

Power compensation decreases costs and gives higher revenues

Static VAR Compensation - SVC

A complete program with complete support

Band-pass High-pass C-type

We optimise each project to get the best solution

Highest safety for personnel

Al foil, Insulating paper

U+ Electrode area (mm2)

In order to get a large capacitance is needed:

Capacitors, DC 200 kV/mm

Reliable and well utilized capacitor elements

Excellent electrical properties

Environmentally safe insulating fluid which

System supplier with competence

Internal fuses act current limiting, i.e.

Operation of one fuse has negligible influence on the capacitor unit

Reliable fuse design with selective operation

2 x 500 kvar 1 x 1000 kvar

Less Passive Material

Large units give lower total cost for the customer

A poorly designed capacitor bank may be a source of severe acoustic noise

ABB has patented solutions for low noise

compensation, 8 x 48 Mvar, 180 kV

Stringent demands on low acoustic noise can be met

Bird caps may be used to

Efficient protection against accidental faults

Detailed service experience from major installations verify

Project Application No. of units Failure rate (%/year)

Reliable Capacitors with extremely low failure rate

Controlled switching of the capacitor bank breaker

Damping reactors are normally superfluous

Very well proven application - all equipment is available

A capacitor bank or filter bank is

ABB capacitor and filter banks are virtually maintenance free

Polychlorinated biphenyls ( PCB ) were formerly used as insulating

Get rid of capacitors containing PCB!

An entirely new dry concept that

Modular concept for 40 170 kV,

The dry technique has been

For LVAC capacitors since 1970s

Self healing dielectrics

Compact design without risk for leakages

World class quality

Shunt bank, 40 170 kV

Compact design without risk for leakages