Recycling Power Through a Wye-Wye Transformer

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Ingenieur

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...we have developed a plan to recycle the 208V power in a very unconventional way

custom transformer ... with 480V primary and 480V secondary
as well as 208V taps on both the primary and secondary windings


What we plan on doing for our 208V tests is having 480V power initially enter with relatively high current into the transformer.

It would then be transformed into 208V, 100A, and pass through our test unit

Once it has passed through all of these, it returns to the input side of the transformer enters the primary winding via the 208V tap.


kVA: 75
Qty: 7
Primary: 480V Wye
Secondary: 480V Wye
Taps: 208V Wye on both primary and secondary
Material: Aluminum
Temp Rise: 150

The main issue that we have is that no one is willing to make it for us.
We have tried many custom transformer companies, and received answers ranging from, "it's not safe," ....

his post edited for salient points
His words put into a diagram
the op agreed the diagram is accurate (it was previously posted) with minor comments
see post 4
 
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Besoeker

Senior Member
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UK

The transformer has a fixed turn ratio and there is no guarantee that the service taps and load-influenced changes will be compatible.
Basically the 480 and 240 need to be on different transformers. The converter can bridge from one to the other, but a direct grid connection may not make a suitable load for all tests. You still need a resistive or motor/brake load at some point.

mobile
For the 900kW system I describe a few posts back the input and returned power had no isolation between them other than the Ddyn11 required for 12-pulse operation.
 

Ingenieur

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For the 900kW system I describe a few posts back the input and returned power had no isolation between them other than the Ddyn11 required for 12-pulse operation.
Interesting project but there are several points of isolation
rectification to dc
elec-mech with the flywheel, replaced by dc-ac inversion
but the last step of isolation/transformation is not required in this case because the v is the original bus voltage, not a different v tied into the main bus xfmr primary

he would be better served by this method than his proposed
 

Besoeker

Senior Member
Location
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Interesting project but there are several points of isolation
rectification to dc
elec-mech with the flywheel, replaced by dc-ac inversion
but the last step of isolation/transformation is not required in this case because the v is the original bus voltage, not a different v tied into the main bus xfmr primary

he would be better served by this method than his proposed
Rectification does not usually use or require isolation.
The flywheel drive motor acts a generator back into same common DC bus.
The mains commutated inverter dc to ac doesn't provide electrical isolation.

I hope that answers your points but I'd be happy to expand on any of them.
 

Ingenieur

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Rectification does not usually use or require isolation.
The flywheel drive motor acts a generator back into same common DC bus.
The mains commutated inverter dc to ac doesn't provide electrical isolation.

I hope that answers your points but I'd be happy to expand on any of them.

all imo all are forms of isolation
rectification negates any freq/phase or voltage discrepency, fresh slate when inverting back
the flywheel is major isolation elec-mech-elec
the field can be manipulated for control
gen windings act as isolation, basically a rotating xfmr
and you had a load: the motor/flywheel/load bank
then the motor/flywheel supplying the inverterh
he has no load, or energy storage
he is feeding 480 bus with 208, power can't flow (at least in the desired direction)

but the main point is that you put 400 vac synch'ed into a 400 bus
no need for a final isolation step
not 208 into a 480 xfmr via a common primary winding tap
 
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Besoeker

Senior Member
Location
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all imo all are forms of isolation
rectification negates any freq/phase or voltage discrepency,
Not electrical isolation as a rule.

the flywheel is major isolation elec-mech-elec
the field can be manipulated for control
The flywheels are powered by inverter fed SCIMs. There is no seperate field to adjust. They are fed from the common 600Vdc link. These run in two quadrants. Motoring to run the flywheels up and generation to feed stored energy back into that same dc link. No isolatiion there.

but the main point is that you put 400 vac synch'ed into a 400 bus
not 208 into a 480 xfmr via a common primary winding tap
A mains (line) commutated inverter actually ties it to line frequency. Even if it varies.

I hope that helps.

But I'd be happy to expand on any of the points.
 

Ingenieur

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Not electrical isolation as a rule.

The flywheels are powered by inverter fed SCIMs. There is no seperate field to adjust. They are fed from the common 600Vdc link. These run in two quadrants. Motoring to run the flywheels up and generation to feed stored energy back into that same dc link. No isolatiion there.

A mains (line) commutated inverter actually ties it to line frequency. Even if it varies.

I hope that helps.

But I'd be happy to expand on any of the points.

you missed the key point
208 into a 480 xfmr primary via a direct tap

thought experiment
2000 A 505 vac supply >>> than test load(?)
100 A xfmr 480-480 with +/- 5% taps
a vfd input is 505 output controlled to 455

Configure as follows
the 505 is connected to the +5% 504 vac tap (sec is 504 also)
the sec is connected to the vfd supply
the vfd out/load of 455 vac is connected to the xfmr -5% (456 vac) tap

this is very similar, but not as extreme, as the op's proposal
what is the result?
Can i flow from the vfd 455 to the xfmr? What v is on the -5% tap?
what induces the vfd to produce/allow power to flow?
 

Ingenieur

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Power can't flow from the 'device' output to the 480 bus
3 ways to control power flow bus-bus
1 sending v > receiving v
2 line Z
3 power angle, ph delta v sending - v receiving

1 not the case, receiving > sending, if anything the 480 bus will flow power TO the device
2 ignore, short cables, low voltage
3 he stated the v's were in phase, no power can flow, but regardless could not be increased enough to overcome v delta

increasing power angle would make things worse, now the v's on the xfmr prim are out of phase

Imho the op needs to rethink this and consult his plant power ee
 

Besoeker

Senior Member
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Power can't flow from the 'device' output to the 480 bus
That's what the system I designed did. At 400V 50Hz.
Four quad systems are fairly common in process industries. Call it recycling power or whatever.

It's an interesting area and one that have been involved with for a very long time.
 
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Ingenieur

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That's what the system I designed did. At 400V 50Hz.
Four quad systems are fairly common in process industries. Call it recycling power or whatever.

It's an interesting area and one that have been involved with for a very long time but can we now please draw a line under this or I will be accused yet again of bickering by you know who.............
Not bickering, but respectful discussion
Your system has nothing in common with his
that is why yours worked and his will not
yours 400-400 (or minor differences to allow power flow) to a common xfmr tap
his 208-480 with 0 power angle into 2 different taps on a common winding/core

It is better to discuss now before he expends resources and damages equipment (depending on protective device trip times) or creates a hazardous condition for personnel
 

Sahib

Senior Member
Location
India
There should be a regeneration of power to feed back into the system. I think it does not matter it should take place at the same system voltage level.
 

Besoeker

Senior Member
Location
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Not bickering, but respectful discussion
I also see it that way.

Your system has nothing in common with his
that is why yours worked and his will not
yours 400-400 (or minor differences to allow power flow) to a common xfmr tap

There are no differences. It's the exact same 400V common supply The mains commutated inverter doesn't worry about the exact voltage. Closed loop control would see to that. Ours had circuitry where the firing angle was directly compensated for voltage.


his 208-480 with 0 power angle into 2 different taps on a common winding/core

It is better to discuss now before he expends resources and damages equipment (depending on protective device trip times) or creates a hazardous condition for personnel
Essentially, like the system I've described, the output goes back into the same supply.
 
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Ingenieur

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Location
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I also see it that way.

Your system has nothing in common with his
that is why yours worked and his will not
yours 400-400 (or minor differences to allow power flow) to a common xfmr tap
There are no differences. It's the exact same 400V common supply The mains commutated inverter doesn't worry about the exact voltage. Closed loop control would see to that. Ours had circuitry where the firing angle was directly compensated for voltage.

Essentially, like the system I've described, the output goes back into the same supply.

the hugely significant difference being
yours 400-400 into a single tap xfmr
his 208-480 into a single winding/core with 2 disparate voltage taps
hence yours worked
his will not or worse

if your v magnitudes were identical then the v power angle must differ
otherwise no power transfer from your 400 vac inverter bus to the 400 vac power input bus
 
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Sahib

Senior Member
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India
the hugely significant difference being
yours 400-400 into a single tap xfmr
his 208-480 into a single winding/core with 2 disparate voltage taps
hence yours worked
his will not or worse

if your v magnitudes were identical then the v power angle must differ
otherwise no power transfer from your 400 vac inverter bus to the 400 vac power input bus

why regenerated power of OP at 208V
can't be fed back through 208V tap of 480V transformer? I think it can. During such process, the net current taken by 480V transformer would be reduced.
 
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Ingenieur

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Location
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why regenerated power of OP at 208V
can't be fed back through 208V tap of 480V transformer? I think it can. During such process, the net current taken by 480V transformer would be reduced.

Are you saying a 208 vac bus will flow power to a 480 vac bus?
if the ONLY load (or not) on the 208 bus is the 480 bus

what is the xfmr ratio?
 
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