MV Capacitor Banks

 

Introduction 
This is a stand-alone complete system designed for easy installation
It incorporates an earthing switch to disconnect feeder and earth capacitors
It includes iron-core / air-core harmonic filter reactors or air-core inrush current limiting reactors
Optional high pass low inductance resistors are available
The system also features vacuum contactors for switching capacitors and includes capacitor fuses
An automatic power factor correction controller is included for efficient operation. Over-voltage relay, over-current relay, current transformers (Cts), and voltage transformers (Vts) are also part of the package
Touch protections are integrated for enhanced safety
Optional double star connection for unbalanced protection
The system operates within the range of 2.4 kV to 36 kV at 50-60 Hz, with a BIL (Basic Insulation Level) of 200 kV
Smoke detector
The modular structure is suitable for indoor or outdoor installation, providing flexibility and expandability as needed

 

Capacitor Bank Tests

  • Coating Thickness Measurement
  • Capacitance Measurement
  • Power Frequency Withstand Test
  • Insulation Resistance Measurement
  • Full Capacity Loading Test
  • Consult Factory for Other Tests

 

Areas of Use

  • Power Factor Correction
  • Harmonic Filtering
  • Over-Voltage Protection
  • Loss Mitigation

 

Surge Capacitor

 

Introduction

Electrical surges from various sources are common in power systems, such as lightning strikes, equipment failures, switching surges which have a high dv/dt ratio.

 

Hilkar Surge Capacitors are designed to prevent damage to the winding insulations of equipment such as generators, motors, reactors and transformers, where significant losses may occur if the necessary protection measures are not taken. Surge Capacitors are used to reduce or eliminate the effect of over-voltages on these devices, are frequently preferred as a cost-effective and versatile solution.

 

Surge Capacitors absorb energy from electrical surges and protect equipment. Therefore, implementation of Surge Capacitors as surge protection devices, significantly reduces the direct and indirect costs related to equipment repair and cessation of business activity. Surge Capacitors help to eliminate switching transients that can occur as a result of switchgear operation as well as significantly reduce the steep wave-front surges seen at load terminals. Also, Surge Capacitors are manufactured as wire-wrapped to have minimum inductance.

 

Advantages

• Save on costs, via reduced downtime and repair costs

• Improve operational performances, as a result of reduction in production downtime

• Superior protection against interturn insulation failures

• More effective protection against rapidly increasing voltages as the response time is shorter than surge arresters

• Extends lifetime of motors/transformers

• Reduce the likelihood of pre-strike, re-strike, and re-ignition observed at circuit breakers

• Ease of installation

• Low loss dielectric

• Long lifetime

 

Application Areas

• Power Generation

• Pulp and Paper Industry

• Petrochemical Industry

• Chemical Factories

• Surface and Underground Mining

• Water and Oil Pumping Stations

• Railway Applications

• Large Motors

• Arc furnaces

• and many other facilities using any kind of motors and/or transformers

 

Protections Provided

• Protection against all practical surge peaks and rise-times

• Withstands all the motor impulse voltage levels recommended by both CIGRE and IEEE

• Elimination and damping of multiple pre/re-strike transients that occur during switchgear operation

• Surge Capacitors are recommended to be used with surge arrester for more comprehensive protection

 

Product Range

• Operating Voltage: Up to 36kV

• Impulse Withstand Voltage: Up to 200 kV BIL

• Variety of surge capacitance ratings depending on the site requirements and application type (ie, 0.1-0.5 µF)

• Fully assembled, tested, and ready for interconnection

 

General Technical Specifications

  • Type: Single Phase / Three Phase
  • Rated Voltage kV: 1-36
  • Rated Frequency Hz: 50/60
  • Capacitance Range uF: 0.1 - 0.5
  • Capacitance Tolerance: -5 / +10%
  • Incoming Terminal (IEC 60137): Top
  • Enclosure Protection Degree (IEC 60529): IP00    
  • Max Ambient Temperature °C: ≤ 55
  • Cooling: Air Natural
  • Dielectric System: All-film
  • Painting: Red (Consult to our factory for other colors)
  • Lightning Arrester: Optional

 

RC Snubber Filters

 

Advantages

  • Enhance operational performances through decreased production downtime
  • Enhanced protection against internal insulation failures
  • Prolongs the lifespan of motors / transformers / generators / reactors
  • Decrease the probability of pre-strike, re- strike, and re-ignition observed in circuit breakers
  • Decrease the magnitude and rate of rise of voltage (RRRV) transients
  • Ease of installation

 

 

Iron Core Harmonic Filter Reactors

 

Nonlinear loads such as power electronics-based equipment and electric furnaces are sources of harmonic currents that can lead to harmonic distortion. This is one of the most important parameters for defining the power quality. Most commercial and industrial loads (ex. personal computers, photocopy machines, power supplies, compact fluorescent lamps, AC and DC motor drives), inject harmonic currents into the networks they are connected to.

 

Harmonic distortion in a network causes:

  • Equipment heating
  • Insulation failure due to overheating and higher voltage peaks than rated fundamental voltage (50Hz or 60Hz) sinusoidal signal
  • Equipment malfunction (false zero cross detection on power electronic devices)
  • Communication interference
  • Fuse and breaker mis-operation

 

Passive harmonic filters are the most commonly used devices for reducing harmonic distortion in a network. They are built from passive RLC components, i.e. resistors, inductors and capacitors.

 

At low voltage level, iron core reactors are typically used as harmonic filter inductors. They may be also used at medium voltage level in some applications.

 

Together with the capacitors existing in the harmonic filter, the reactors in these filters serve to provide a resonance path. By appropriately tuning the resonance frequency of a harmonic filter, the unwanted harmonic currents injected by the nonlinear loads can be prevented from entering the electrical grid.

 

Features

  • Designed and tested to applicable IEC and IEEE standards
  • Excellent voltage withstanding
  • High quality factor (Q)
  • High thermal capacity
  • High mechanical strength to withstand high short-circuit forces
  • Laminated core, low core losses
  • Low tolerance of inductance value
  • Off-load tapping on demand
  • Compact design, dimensions can be adjusted according to customer's specific needs
  • Single phase or three phase design
  • Pulsed power compatibility for filter energization and transformer inrush scenarios
  • Corrosion and heat resistant electrostatic paint
  • Insulators with high creepage distance on demand for polluted areas and high altitudes
  • Maintenance-free design
  • Aluminum, hot dip galvanized steel or concrete support stands are available

 

Technical Specification

  • Voltage: Up to 1000 V
  • Fundamental Current: I1(50 Hz / 60 Hz)
  • Harmonic Current: Ih=0.3I1
  • Overload Current: Ith=1.2I1
  • Magnetic Saturation Current: Im=1.8In
  • Maximum Current: Imax=2I1 for 60 seconds
  • Type: Dry, iron core
  • Frequency (harmonic order): Up to 2.5 kHz (50th harmonic for 50 Hz systems)
  • Altitude: Up to 1000m*
  • Installation: Indoor
  • Insulation Class: F (155°C)
  • Winding Material: Aluminium or copper
  • Protection Degree: IP00 (indoor)
  • Temperature Range: -40°C to 55°C
  • Cooling: Air Natural (AN)
  • Options: Taps with DIN or NEMA terminal configuration

Iron Core Shunt Reactors

 

Iron core Shunt Reactors act as an absorber of reactive power so as to increase the energy efficiency of power systems.

 

Shunt Reactors compensate the capacitive reactive power generated by long and lightly loaded transmission lines as well as underground cables, thus allowing the flow of more active power through the system and avoiding over-voltages. Shunt Reactors can be directly connected to the power line or to a tertiary winding of a three-winding power or distribution transformer.

 

Typical Applications

  • Mainly used for reactive power compensation of long or lightly loaded transmission lines as well as underground cables used in the following applications:
  • Wind Farms
  • Subways (Metro)
  • Urban Distribution Systems
  • Industrial Zones
  • University Campuses
  • Substations

 

Technical Specification

  • Voltage: Up to 1000 V
  • Power: Up to 500 kVAr *
  • Frequency: 50 Hz / 60 Hz
  • Winding: Aluminium or copper winding
  • Temperature: -40°C to 55°C
  • Insulation class: F class or custom specific design
  • Cooling: ONAN, ONAF
  • Standards: IEC 60076-6, IEC 61558
  • Options: Taps, Enclosure, Complete solution with CBs, snubber circuit and protection relay

*Consult factory for higher values.

 

Iron Core Motor Starting Reactors

 

Motor starting reactors are used to reduce the voltage during starting up of large 3 phase motors while at the same time limiting inrush currents.

 

Large motors generally draw 6-8 times more current than their nominal current from the grid. They are typically started with 70% of voltage and the rest of the voltage, while the other 30%, is dispersed across the motor starting reactor. After 15 - 20 seconds, the reactor is bypassed by contactors in the system.

 

Advantages

  • Perfect mechanical strength to withstand high short-circuit forces
  • Limited temperature rise enables longer lifespan
  • Maintenance-free design

 

Technical Specification

  • Voltage: Up to 1000 V
  • Power: Up to 1 MVAr* motors
  • Frequency: 50 Hz / 60 Hz
  • Winding: Aluminium or copper winding
  • Temperature: -30°C to 55°C
  • Insulation class: F class or custom
  • Cooling: AN (air-natural) cooling
  • Standards: IEC 60076-6, IEC 61558
  • Options: Taps, Enclosure, DIN or NEMA terminal configuration

*Consult factory for higher values.

Iron Core Smoothing Reactors

 

Smoothing Reactors are serially connected reactors inserted into DC systems. They reduce harmonic current and transient over-currents and/or current ripples in DC systems.

They are necessary in order to smooth the direct current wave shape, reduce losses and improve system performance.

 

Smoothing Reactors also reduce the occurance of alternation failure in inverters caused by dips in AC voltage at the converter bus. Consequent communication failures are prevented by reducing the rate of rise of direct current in the bridge when the direct voltage of another series connected bridge collapse.

 

Smoothing Reactors even out ripples in the direct current in order to prevent it from becoming discontinous for light loads. They decrease harmonic voltages and currents in DC lines and limit the crest currents in the rectifier due to a short circuit on the DC line.

 

Advantages

Perfect mechanical strength to withstand high short-circuit forces

Limited temperature rise enables longer lifespan

Maintenance-free design

 

Technical Specification

  • Voltage: Up to 1000 V
  • Type: Iron core, dry-type
  • Frequency: 50 Hz / 60 Hz
  • Installation: Indoor
  • Winding: Aluminium or copper winding
  • Temperature: -40°C to 55°C
  • Insulation class: F class or custom
  • Cooling: AN (air-natural) cooling method>
  • Options: Taps, Enclosure available on demand, Available designs as per IEEE, IEC and others, DIN or NEMA terminal configuration

*Consult factory for higher values.

 

 

Iron Core Line & Load Reactors

 

Line and load reactors are generally serial-connected to the input and/or output terminals of three phase equipment such as motor speed controllers, inverters and UPS systems. This equipment makes use of semiconductor switches such as IGBTs, thyristors, and diodes and thus creates harmonic distortion and high switching over-voltages (dv/dt). Use of such equipment has become more widespread as the technology advances. However, the negative effects of these types of equipment should not be overlooked.

 

By using line and load reactors, the adverse effects of using such equipment can be decreased in the following ways:

  • Limited starting current
  • Reduced motor noise
  • Reduced harmonic distortion
  • Reduced motor heating
  • Reduced switching over-voltages
  • Easier selection of fuses as per nominal motor current

 

These reactors are designed to provide a 4% voltage drop. Different voltage drop values can be provided on demand.

 

All line & load reactors are custom designed for diverse applications to provide the most efficient design at the most economical prices. Consideration of the voltage, current, inductance, type of application, harmonics, interharmonics, size, transient events such as switchings, and required loss characteristics are always taken into account. All routine tests are performed in accordance with IEC 60076-6 or other standards depending on customer request. Type test reports are available on request and all results are submitted to customer. Basic testing programs include some or all of the following:

  • Routine Tests (Inductance, Resistance, One Minute AC Insulation Voltage Withstand Test and Impulse Voltage Withstand Test)
  • Short Circuit Withstand Test
  • Temperature Rise Test
  • Sound Level Test
  • Seismic Test

 

Features

  • Designed and tested according to applicable IEC and IEEE standards
  • High quality factor (Q)
  • High thermal capacity
  • High mechanical strength to withstand high short-circuit forces
  • Compact design, dimensions can be adjusted according to customer's specific needs
  • Maintenance-free design
  • Aluminum, hot dip galvanized steel or concrete support stands on demand
  • Elevation stands on demand
  • Enclosures on demand

 

Technical Specification

  • Voltage: 208-690V
  • Rated Current: In, 50-60 Hz*
  • Overload Ratings: Imax = 2I1 for 12s, 1.5I1 for 60s, 1.1In continuous
  • Linear Current: Ilin = 1.6I1
  • Impedance Levels (Z): 1.5%, 2%, 3%, 4%, and 5%
  • Type: Iron Core
  • Altitude: Up to 1000m*
  • Installation: Indoor
  • Insulation Class: F (155°C)
  • Winding Material: Aluminum or Copper
  • Protection degree: IP00 (indoor)
  • Temperature range: -40°C to 55°C
  • Thermostat: 125°C
  • Insulation Level: 3kV AC for 1 min
  • Cooling: Air Natural (AN)
  • Options: Taps with DIN or NEMA terminal configuration

*Consult factory for higher values.

 

 

LCL Filters

 

LCL Type Harmonic Filter Modules are used to filter out the input current harmonics of Motor Drives that have six-pulse diode/thyristor rectifiers, and where harmonic current distortion exceeds the standard defined limits.

 

Advantages

  • Meets IEEE Std.519-2014
  • Eliminates Low Order Harmonics
  • Improves System Efficiency and Reliability
  • Increases the Overall System Power Factor
  • Extends Equipment Life
  • Low-Loss Design
  • Easy-to-Install
  • Resonance-Free Operation with Line Side
  • Suitable for Multiple Motor Drive Operations
  • Cost Effective Solution

 

Typical Applications

  • Oil & Gas Industry
  • Water and Waste Water
  • HVAC
  • Textiles
  • Commercial Facilities
  • Data Centers
  • Pulp & Paper
  • Metal Fabrication
  • Electroplating
  • Elevators and Escalators
  • Industrial Rectifiers
  • Induction Furnaces

 

Technical Specifications

  • Motor drive input power ratings: 0.3-630 kW (parallel operation for higher power ratings)
  • Operation voltages: Standard voltages up to 690V
  • Operating frequencies: 50Hz - 60 Hz
  • Rated currents: 1A - 4250A
  • Input current distortion: < 8% @ full load
  • Voltage regulation: < 5% (from no-load to full-load)
  • Efficiency: >99% @ rated load
  • Overload capability: 1.6 x rated current (1 min/hour)
  • Protection degree: IP20 (upper protection degrees are upon request)
  • Ambient temperature: -30°C to +50°C
  • Altitude: < 1000m
  • Application standards: IEC 60076 for reactors, IEC 60871 for capacitors, IEEE std.519-2014 for harmonics

Sine Filters

 

Sine Wave Output Filter Modules provide a smoother sinusoidal waveform with low residual ripple, for example as is often observed in square waveforms with high voltage spikes, present at the output of motor drives.

 

These filter modules eliminate the challenge of using motor drives with long cable applications, and make it possible to utilize low voltage motor drives with medium voltage motors by deploying them in front of the step-up transformers.

 

Advantages

  • Nearly perfect sinusoidal output voltage
  • Protection of motors against high voltage spikes
  • Elimination of acoustic noise in the motor
  • Reduction of motor bearing currents
  • Extension of equipment lifespan
  • Compliance with the standards of general purpose motors
  • Usage of unshielded cable
  • Suitable for multiple motor operations

 

Typical Applications

  • Motor Drives with long motor cables
  • Motor Drives with the existing motors
  • Motor Drives with a step-up transformer
  • Compressors
  • HVAC
  • Cranes
  • Conveyors
  • Elevators and Escalators
  • Pumps

 

Technical Specifications

  • Motor drive input power ratings: 0.3-630kW (parallel operation for higher power ratings)
  • Operation voltages: Standard voltages up to 690V
  • Operating frequencies: 50Hz - 60 Hz (without derating)
  • Rated currents: 1A - 1200A
  • Minimum switching frequency: 1.5kHz - 4kHz (depending upon filter rating)
  • Maximum switching frequency: 8kHz
  • Overload capability: 1.6 x rated current (1 min/hour)
  • Protection degree: IP20 (upper protection degrees are upon request)
  • Ambient temperature: -30°C to +50°C
  • Altitude: < 1000m

 

dv/dt Filters

 

Since the rise time of IGBTs are in the range of a few tens of nanoseconds (between 50ns-200ns), even short cables between PWM motor drives and motors can cause voltage doubling at the motor terminals due to Travelling Wave Phenomenon such as in transmission lines. If sufficient precautions are not taken, the insulation of motor windings are prone to failure due to high voltage spikes.

 

dV/dT Output Filter Modules effectively protect motors against these high voltage spikes due to the use of motor cables between IGBT-based motor drives and motors.

 

Advantages

  • Reduction of dv/dt stress on the motor windings
  • Extension of equipment lifespan
  • Compliance with standards of general purpose motors up to 100 m cable length
  • Economic and compact solution for short cable applications
  • Reduction of EMI on surrounding equipment

 

Typical Applications

  • Motor Drives with short motor cables
  • Motor Drives with existing motors
  • Process Industry
  • Oil & Gas
  • HVAC
  • Water and Waste Water
  • Irrigation

 

Technical Specifications

  • Motor drive input power ratings: 0.3-630 kW (parallel operation for higher power ratings)
  • Operation voltages: Standard voltages up to 690V
  • Operating frequencies: 50Hz - 60 Hz (without derating)
  • Rated currents: 1A - 1200A
  • Minimum switching frequency: 1.5kHz - 4kHz (depending upon filter rating)
  • Maximum switching frequency: 8kHz
  • Overload capability: 1.6 x rated current (1 min/hour)
  • Protection degree: IP20 (upper protection degrees upon request)
  • Ambient temperature: -30°C to +50°C
  • Altitude: < 1000m

 

 

Motor Termination Units

 

Since the rise time of IGBTs are in the range of a few tens of nanoseconds (between 50ns-200ns), even short cables between PWM motor drives and motors can cause voltage doubling at the motor terminals, due to Travelling Wave Phenomenon as in transmission lines.

 

If necessary precautions are not sufficiently taken, the insulation of motor windings are prone to failure due to high voltage spikes. RC Type Output Filter Modules reduce these high voltage spikes and protect motors by connecting to stator terminals