1. Background.

PT. Aneka Tambang Tbk, ("ANTAM") is currently building a new smelter, in Buli, East
Halmahera. This smelter has special characteristics with the Electric Furnace which is a
resistive load and contributes as a load up to 80% of the total load. Active power
fluctuations can occur at any time in the Eelectric Furnace including current imbalances,
which occur over a period of seconds to minutes.

The additional load with a total capacity of 13.5 MW is supplied with a 22 MVA transformer
while the smelter's own load capacity is 60 MW which is supplied with an on load multitap
transformer with a capacity of 75 MVA. Therefore it is necessary to use stabilizer equipment
to avoid trip on power plant.

2. Project Description.
PT ANTAM had built a Feni Haltim smelter, which is located at East Halmahera, This smelter
is a kind of electric arc furnace that having one production line. It is used to manufacture
ferronickel products from ferroalloy ore. The construction of smelter is finished but not
operated yet because there’s no electricity supply as the plant is isolated from the national
power grid.

a. Smelter load profile.

Electric Smelter Furnace (ESF) load profile curve for FeNi Haltim ESF , referred to
POMALA ESF.

Figure 1. Smelter Load profile during metal Bath.

 Figure 2 Load Profile curve

b. Load Modeling for ESF.

In this smelter modeling, it is assumed that the maximum swing of the smelter load is 50%
and for the worst scenario, that is a smelter with a ramp-rate of 2 MW/s with a smelter trip.
The shape of the smelter load profile curve is shown in the following figure.

Figure 3 Load profile of the smelter refers to the Poomala smelter

 Figure 4 Load profile of a 60 MW smelter with a maximum ramp-rate of 2 MW/s

Figure 5 Load profile of a 60 MW smelter with a maximum ramp-rate of 2 MW/s with a

smelter trip scenario

Such big & sudden load decrease will influence the isolated grid’s normal operation.
As there is no other big load, the active power cannot be consumed in the network,
then power generators must act rapidly to adapt to this load rejection, otherwise it
may run into overspeed condition which is very dangerous.

It will be even worse if load was tripped during internal failure; it may introduce
even bigger active power decrease.

c. System modeling.
The model of the Haltim FeNi Power Plant (HFPP) electricity network is as follows.
 Gambar 1 Single Line Diagram Pemodelan Sistem Tenaga Listrik

With these load profile, stabilize equipment needed to avoid trip of power plant.
The ramp rate of load is estimated at 2 MW/s.

d. Stabilize Modeling
Stabilize technology which is used for this project is SWC (Static watt Compensator)
and SVC (Static VAR Compensator).

SWC.
Static watt compensator (SWC) is an active power stabilization equipment which is
modeled as a variable shunt resistor. This Equipment is able to increase active power
consumption when the furnace suddenly reduces consumption.
Modeling of the SWC is as follows.

Figure 7 Static Watt Compensator Model

The control implemented in the SWC aims to compensate for fluctuations and
balance the active power felt by the power plant. This means that the SWC will
adjust the active power load it consumes according to the setpoint of the total
active power (from the furnace and SWC) given. This control model is valid for both
load balanced and unbalanced furnaces. For unbalanced load simulation, setpoint
and active power measurements are given per phase.
The control model is given in Figure 8 below.

Figure 8 Model of Static Watt Compensator Control.

Note :
Qmeas = Measured active power through the line connecting the generator
and the furnace
Pset = Active power setpoint
Pout = Target active power from SWC (Inversely proportional to
resistance)

SVC
Static VAR compensator (SVC) is a reactive power stabilization equipment which is
modeled as an inductor and a variable shunt capacitor. This equipment is able to
increase and reduce reactive power injection.
Modeling of the SVC is as follows.

Figure 9 Static VAR Compensator Model

 The control implemented in the SVC aims to compensate for fluctuations and
balance the reactive power felt by the power plant. That is, SVC will adjust the
injected reactive power according to the setpoint. This control model is valid for
both load balanced and unbalanced furnaces. For unbalanced load simulation,
setpoint and reactive power measurements are given per phase.
The control model is given in Figure 10 below.

Figure 10 Static VAR Compensator Control Model

The system modeling and SWC and SVC modeling will be implemented to study SWC
and SVC in Antam FeNi Haltim smelter to find the need of the stabilzation of the
plant.
The rated active power consumption capability of the SWC is 50MW at 30kV (1.0pu).
The rated reactive power capacity of the SVC is -25Mvar (inductive) to 50Mvar
(capacitive) at 30kV.

3. Design criteria.
a. Network Conditions
The SWC&SVC design is based on following system conditions:
1. Nominal System Voltage, line-to-line : 30kVrms
2. Maximum Long-term ac system voltage, line-to-line : 36kVrms
3. Lightning impulse protective level (BIL) : 185kVpeak
4. Power Frequency Withstand level (1min) : 85kVrms
5. Design 3-phase System Short Circuit Current level : 40kArms.

b. Stabilization Criteria.
SWC and SVC is provided to keep the system stabilize, and the criteria for stabilization are
c. SLD Model for Simulation :
The single line diagram to simulate the power system is describe below :

Figure 11 SLD for Antam FeNi Haltim Model

This model used for simulation in the electrical design software to find out the
characteristic of :
• Frequency.
• Voltage,
• Voltage unbalance,
• Current unbalanced
• Harmonic.

Assumption Power plant Modeling.

Power Plant
• Generator :
• 30 MW – 46 863 kVA/11.5 kV,
• H = 5s
• 17 MW – 24 000 kVA/11.5 kV
• H = 4s
• Generator Transformer:
• 40 MVA 13% – YnD1 – Rn 40 ohm
• 30 MVA 13% – YnD1 – Rn 40 ohm
• Transmission Line :
• 30 kV, 2 km, T-ACSR 680 mm2, Capacity 97 MVA/circuit

Load side:
• Transformator Smelter
• 75 MVA 30/1 kV, DYn, 7%-55%, typ 15%
• Transformator Auxiliary
• 22 MVA 30/6.6 kV, DYn5, 8%
• Load
• 3 fasa unbalanced
• SWC
• 3 fasa unbalanced, up to 50 MW
• SVC
• 3 fasa unbalanced, up to 50 MVA

In this simulation the smelter load profile still uses a 60 MW smelter load profile with the
load being assumed to be unbalanced in each phase. The power stabilizing equipment
whose performance will be reviewed is the Static Watt Compensator (SWC) and Static Var
Compensator (SVC) with a total capacity of 60 MVA. The parameters to be observed
include GI(Substation) voltage, furnace terminal voltage, current on the 30 kV line (which
is also felt by the generator).

The furnace load profile is shown in Figure 12 and Figure 13 It should be noted that phase
C trips at t = 720s.

Figure 12 Profile of Simulated Furnace Active Power per Phase

 Figure 13 Reactive Power Profile of a Simulated Furnace per Phase

With this model we applied in the simulation model SWC with the capacity of 50 MW and
the SVC with the capacity of 50 MVA.

d. Simulation result.
In the simulation we compare the voltage before and after use the compensator.
The result is as follow :

Figure 14 Voltage Profile in Unbalanced Furnace, Without SVC and SWC

Figure 22 Sequence Voltage Profile on Generator Busbar Due to Imbalance, Without SVC
and SWC

The above two figure is the voltage profile with the 60 MW ESF without using SWC and
SVC, The next figure is the voltage profile with and without using SWC and SVC in ESF 60
MW load.

Figure 23 Voltage Profile in Unbalanced Furnace, With SVC and SWC

Figure 24 Current Profile per phase on 30 kV Channel Due to Imbalance, Without SVC and
SWC

Gambar 2 Profil Arus per fasa pada Saluran 30 kV Akibat Ketidakseimbangan, Dengan SVC
dan SWC
 Figure 26 Current Profile of Positive and Negative Sequences on a 30 kV Channel Due to
Imbalance, Without SVC and SWC.

Figure 27 Current Profile of Positive and Negative Sequences on a 30 kV Channel Due to

Imbalance, With SVC and SWC

According to the ANSI C84.1 standard, it is recommended that the largest voltage
unbalance is 3%. The NEMA standard requires that the voltage unbalance be at 1%. The
standard also estimates that a voltage unbalance of 1% can result in a current unbalance
of 6-10%. Imbalance is defined as the magnitude of the negative sequence divided by the
positive sequence.
Meanwhile, according to EN-50160 and IEC 1000-3 standards, the voltage unbalance
should be a maximum of 2%, with the highest instantaneous value of 4%. From the figure
above, when SWC and SVC are not used, the voltage imbalance at the generator busbars
can reach 2% which occurs when tripping a single-phase smelter load.
Meanwhile, the current imbalance can reach 15%, and when tripping a single-phase
smelter load can reach 46%. Meanwhile, if SWC and SVC are used, the voltage unbalance
and current unbalance can be kept close to 0%. This will minimize generator tripping
caused by current and voltage imbalances. It is proven that when SWC and SVC are used
together, the system can maintain current and voltage balance and is able to maintain
fluctuations in frequency and voltage so that the generator feels a relatively non-
fluctuating load so it can operate stably.

Figure 28 SWC Active Power Profile to compensate for fluctuations and Load Unbalance

Figure 29 SVC Reactive Power Profile to compensate for fluctuations and Load Unbalance
4. SWC & SVC Basic design

From the study we found that :

40 MW SWC is sufficient to maintain the system frequency at a level of around 52 Hz when a
3-phase smelter trip occurs.
Taking into account a safety factor of 20%, SWC 50 MW is sufficient to keep the system
frequency below 52 Hz.
MVAR SVC needs to maintain current and voltage balance :
13 MVAR capacitive per phase and
7 inductive MVAR per phase.
By taking a safety factor of 15-20%, the following requirements are obtained:
15 MVAR/capacitive phase (total 3 phase 45 MVAR)
8.33 MVAR/inductive phase (total 3 phase 25 MVAR)

The SWC&SVC project based on the specified system requirements and shows the approach
of the Final Design.
The SWC&SVC will efficiently regulate and consume the active and reactive power at the
point of connection, The rated active power capacity of the SWC&SVC is 50 MW at 30kV
(1.0pu), and the output range of reactive power is 25Mvar inductive to 50 Mvar capacitive,
according to requirement.

Figure 4 capacity curve of integrated compensator

a. Integrated Stabilization Equipment Design.

The Integrated Stabilization equipment concict of A total 5branches were designed

in this project. The branches are :
SWC branch capacity is 50MW.
The TCR branch is 75Mvar Inductive reactive power,
Three Branches for Filter capacitive FC3 ; FC5 and FC7 branches for a total of
50Mvar capacitive reactive power.
Overall, the integrated power balancing system can achieve an active power in 0 to
50MW range and reactive power in 25 Mvar inductive to 50Mvar capacitive range.
A typical SLD of integrated power balancing is shown in the figure below.
 Figure 3. Single line diagram compensator.

b. SWC
The SWC uses power electronic devices (generally thyristors) as control components
to control the current flowing over power resistors through phase control, and then
control the active power consumed by the entire branch.
Figure 3 shows a single-phase schematic of the SWC. At the appropriate moment,
change the current flowing through the resistor by changing the trigger angle of the
thyristor.

Figure 3: Single-phase schematic of the electronic load

The SWC is connected to the system by delta connection. The delta connection
method can suppress third and third integer multiple harmonics. Due to the
interruption of the current during operation, 6n±1 harmonics will be generated, and
the higher the number of harmonics, the smaller the harmonic content.
Therefore, in engineering applications, in order to prevent harmonic interference,
5th and 7th filters need to be configured to absorb harmonics. In addition, the SWC
is coordinated with the fixed load, and the fixed load can be attached to the low-
 voltage side of the same bus line as the integrated power balancing according to the
situation, and can also be directly connected to the high-voltage side with a closer
electrical distance, which can achieve continuous adjustment in a wider range.
Formula for power and Current :

Delta Connection of SWC

Figure 4 SWC connection diagram

c. Power resistor design.

Power resistor is a key component of SWC, bearing the consumption of active

power. The main principle is to convert electrical energy into heat energy
consumption dissipation. In this project, the metal resistance is selected as the load
power resistance.

The resistance calculated as follows:

The is much smaller than R, and according to the experience, λ = (1.05 ~ 1.10)
 So, the resistance of the power resistor is set as 50Ω. And according to the (4-1), the
current shall be calculated as:

Considering the accuracy of the trigger angle and the effect of the current
transformer measurement error, the actual fundamental current is considered as an
increase of 1%, that is 577*1.01=583A.

d. Series reactor design

The series reactor is installed inside the delt connection of the SWC branch and
connected in series with the power resistor and thyristor valve group. The series
reactor is not necessary to be installed, but after installation, the power quality of
the entire electronic load system can be greatly improved. The main functions of
series reactors are as follows:
1) Reduce current harmonic content, and reduce the size and capacity of the
filters.
2) Reduce the current change rate di/dt when the thyristor is turned on/off
to extend the service life.
3) In case of short circuit or fault, limit the short circuit current and protect
the valve group.
Generally speaking, the larger the inductance value of the series reactor, the more
obvious the role mentioned above, but it will correspondingly increase the capacity
and cost of the series reactor, so the selection of the series reactor needs to be
considered according to the actual grid conditions and combined with economic
indicators.
According to empirical design experience, the reactor impedance shall meet the
following condition.

e. Valve bank design.

The rated current of the SWC valve shall be equal to the power resistor (583A), and
the detail design process please refer detail engineering design.

f. Design of TCR branch

 TCR is connected in delta, reactor and thyristor valve bank are series connected in
each phase. Phased controlled reactor is a type of dry type air core that shows a
double split structure.
The characteristic of phased controlled reactor is inductive continuous regulation,
the reactive power calculation formula is:

Where α is thyristor control angle (electric angle), U is phase-to-phase voltage, LTCR

is inductance of phase-controlled reactor.

Figure 7 TCR connection type

g. Phased Controlled Reactor design

According to the chapter 3, assuming the trig angle of TCR at full inductive reactive
power (-75Mvar) is 110 degree, so the LTCR can be obtained according to formula
(4-4) and (4-5).

So according to formula (4-6):

 if production error is positive, actual value will be larger than calculated value and
output capacity will be smaller than designed value.
In order to prevent this situation, -3% decrease of LTCR is applied.
So the actual split value of the reactor is 2×32.84mH.
Rated base current is calculated as below:

Based on above calculation, parameters of phase controlled reactor is shown in the

table below:

Table 4-1 Parameters of Phased Controlled Reactor

No Parameter Unit Value

1 Actual inductance LS mH 65,68
2 Split inductance Lf mH 2×32.84
3 Rated current of reactor A 833,33
4 Maximum continuous current A 1.1 times

h. Valve bank design

The rated current of the TCR valve shall be equal to the phase-controlled reactor,
and the detail design process please refer to Detail engineering design.

i. Design of FC branches
A reactor needs to be added when a capacitor is tuned into a harmonic frequency or
a capacitor is designed to filter a frequency of harmonic wave. Under the condition
of tuning, the following formula is satisfied.
Usually filter rating and steady state is the main factors considered in design process
of filter. When primary design is done, proper verification such as simulation is used
to verify the filter performance and transient analysis. In this document only primary
filter design is submitted. Refer to other technical documents for filter performance
and transient analysis.

j. Design principle

Based on the harmonic generation, an initial estimate of the harmonic filter tuning is
made. The tuning is usually designed to reduce harmonic voltage and current
distortion to meet specified harmonic performance criteria. To meet this objective,
the harmonic filter will typically be tuned to the lowest frequency of the most
significant harmonics.
For example, if the highest harmonic current levels were 5th and 7th harmonics, a
single filter tuned near the 5th harmonic may be sufficient to control the distortion.
On later evaluations with harmonic analysis program may determine that other
harmonic filters are also required.
Harmonic filters are not usually tuned to correct harmonic frequencies. Tuning
directly to the harmonic frequency may have two undesirable consequences:

a) The low impedance at resonance can result in nearly all harmonic current
at that frequency being absorbed by the harmonic filter. The harmonic
filter is required to be larger and more expensive than is needed to
achieve the required harmonic performance.

b) The harmonic filter interaction with the system impedances results in a

parallel resonance at a frequency just lower than the tuned frequency. If
a harmonic filter is designed exactly at the harmonic frequency, a
variation in the impedance values of the actual equipment from the
design values could retune the harmonic filter and place the parallel
resonant frequency very close to the harmonic.

Instead of low impedance, the combined harmonic filter system impedance

becomes resonant at the harmonic frequency, distortion levels become
unacceptable, and damaging voltage amplification may result in severe cases.
Changes in the system supply can shift the parallel resonance also.
The most common mechanisms that cause a shift in the resonance are as
follows:

1) Harmonic filter capacitor unit/element failure.

Externally and internally fused banks have fuses that operate when a unit
or element shorts. The fuse operation, which reduces the total
capacitance, increases the resonant frequency of the harmonic filter. On
the other hand, shorted
elements in a fuseless harmonic filter capacitor bank (or in an externally
fused harmonic filter capacitor bank prior to fuse operation) are not
removed from the circuit. The capacitance rises and the resonant
frequency decreases.

2) Tolerances.
Manufacturing tolerances in both the harmonic filter reactors and the
harmonic filter capacitors, and capacitance change due to temperature
variations in the capacitors.

3) System variations.
Power system configurations are not static.
- The loss of one of two parallel transformers or of one of two supply
feeders can weaken the source and shift the parallel resonance to a
lower frequency
- Routine maintenance can often result in a weakening of the source
supplying the harmonicproducing load.
- Portions of overhead circuits may be replaced with underground lines,
and lines may be relocated.
 These changes will impact the impedance between the source and the load. It is
often advantageous to tune the harmonic filter below the desired frequency. This
tuning will provide for sufficient harmonic filtering, yet will also provide allowance
for the detuning of the harmonic filter.
The reactance of the harmonic filter capacitor is determined by the var size of the
harmonic filter. The inductive reactance is selected to create a series resonance with
the harmonic filter capacitor at the tuned frequency.
The series resonance provides a low impedance path to neutral for the harmonics of
the system.
A simple equation to calculate the capacitive reactance (for a filter tuned to the h
harmonic) at power frequency is Equation (4-8).

5.

6. Single Line diagram (SLD).

a. Equipment SLD
The SWC and SVC integrated compensator SLD described as the SLD Below.:

Figure 3. Single line diagram compensator.

The SWC&SVC consist of five branches, the active power capacity of the SWC branch is
50MW, its output range is 0~50MW.

The reactive power capacity of the TCR is -75Mvar (inductive, output range -75Mvar to 0).
The total capacity of three FC branches is 50Mvar (capacitive, fixed capacity).

Capacity curve of the compensator :

Figure 4 capacity curve of integrated compensator.

b. Overall SLD
SLD For compensator placement on Antam's 30 KV network, it can be seen in the
following figure.
 Figure 5 Overall compensation SLD
The Power source comes from the existing Cubicle 30 KV, through the cable line
3x(3x240mm2) which is in the trench.
From the calculations, it is found that for a 3 x cable (3x240 mm2) it is sufficient for
the compensator current requirements. However, to increase reliability, it is
necessary to add another 1 cable so that it becomes 4x( 3x240mm2).

Likewise, from the existing conditions, the cable line to the smelter only consists of
one line, with 3 cables. To increase the reliability of distributing electric power to
the smelter, another 1 cable should be added so that the cable line to the smelter
are 4-fold.