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Mitigating Short Voltage

Sags with Cogeneration


Improving Power Quality & Reliability

Power Quality 2000


Conference - Boston, MA

5 Oct 2000

Dan Smith, P.E.


Section Manager
Site Electrical & Mechanical Engineering
Who is AMD?
• AMD is global supplier of integrated circuits for the
Power Quality 2000 - Boston, MA

personal & network computer & communication markets


• Founded in 1969, currently 14,000 employees world-wide
• 24x7 operations, 365 days per year
• 100% utility uptime requirement
• Newest factory located in Dresden, Germany
– 875,000 ft2 w/ 90,000 ft2 Clean Room
– Milestones:
• Construction - Apr 97
• First Silicon - Dec 98
• Today it produces AMD’s fastest microprocessors

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Power Quality 2000 - Boston, MA AMD Fab 30 in Dresden, Germany

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Impact of Utility Problems
• Cost of an Outage is relatively well defined
Power Quality 2000 - Boston, MA

– AMD has experienced (2) ~2 minute interruptions over


the past 5 years resulting in multi-million $ losses
• Cost of a short sag is more difficult to quantify
– Although disruptive, they pale compared to losses
resulting from outages
– Sags vary in duration, magnitude, and number of
phases involved affecting losses
– Usually does not equal our insurance deductible
– Losses are considered confidential
• One of our competitors has reported ~$500k in losses/sag

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Impact of Utility Problems (cont.)
• Dr. Rinn Cleavelin w/ TI stated in a recent EPRI
Power Quality 2000 - Boston, MA

conference “… a voltage sag can shut down equipment and


control systems used in the production of semiconductor
devices. … the company’s real financial loss is typically
in the range of $500k to $2M per event …”
• Impact will likely be more significant as high opportunity
and down time costs increase due to:
– Larger wafer sizes (300mm)
– Smaller feature geometry's (approaching the
wavelength of light)
– Copper
– Other factory enhancements
AMD requires solutions that address both reliability
(outage protection) protection 5
protection and quality (sags protection)
AMD Germany’s Playing Field
• Utility Reliability & Quality Problems
Power Quality 2000 - Boston, MA

− Significant power problems at Siemens’ (now


Infineon’s) semiconductor fab located in Dresden
– Power Monitoring data from AMD temporary office
– Local newspaper accounts about other industrial users
– The proposed Utility design (long underground cables
& shared transformers)
• High cost of electricity in Germany
• Reliable and inexpensive supply of natural gas
• Significant cold and hot water requirements of
semiconductor manufacturing factories

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Generation
What are the Solutions? •Fuel Cells
•Turbines
Storage
Reactive & Static •Gas Gen Sets
•Flywheels
•Tap Changers •Cogen
•SMES
•DVR •Batteries D-Statcom
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Filters •Statcom •Capacitors


•Passive •Fast Fuses + SSCB +
•Active Storage
Power Quality (Sags)
D-Statcom Statcom
•Arrestors + Generation
•TVSS + SSCB
DVR + Storage
DVR + STS
Condition + Storage
DVR +STS
Power + Generation
Filters + Storage
Supply (CPS)

TVSS Solid State UPS


CB (SSCB)
Generation
& Static Xfer
Switch (STS)

Power Reliability (Outages)


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*Adapted from EPS&T Presentation
Interdependence Between Utility-
Electrical System-Process Equipment
Power Quality 2000 - Boston, MA

Tools

Operations

Utility
Facilities

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Centralized versus Distributed Solutions
• Centralized is preferred due to:
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– Avoids iterative approach for connecting critical load


– Protects critical facilities systems as well as process
– Reduces amount of distributed stored energy systems
required (capital, maintenance, space, …)
– Increases flexibility
– Cost effective for large loads (~20-30MW)
• However, it does not address internal plant problems

Industry has been pushing for centralized (site-wide)


solutions
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Options Considered
• Utility’s Proposed Distribution Solution
Power Quality 2000 - Boston, MA

• Dedicated Utility Transmission Substation


• Static Transfer Switch
• Extensive Internal UPS & MG Installations
• Large scale Voltage Support Systems
• Distributed Generation
• Cogeneration w/ Voltage/Frequency Support

Ultimately AMD chose to implement Cogeneration w/


voltage/frequency support based on the ability to address
both sags and outages
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AMD Germany Cogeneration Plant
Cogeneration
Power Quality 2000 - Boston, MA

Electrical Utility
(Back-up & Export)
Gas Supply
(Energy Source)

Electricity
Chilled Water Hot Water
20kV +/-8%
5oC +/-0.5oC 32oC +/-1oC
50Hz +/-1%
11oC +/-1oC 80oC +3/-1oC
Sagless and
Uninterrupted

AMD Fab 30
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Commercial Considerations
• Ownership - third party power supplier
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– Capital Costs (~$50M)


– Shifted Liability
– Schedule Constraints
– AMD is not in the Power Generation Business
• Business/Economics
– Energy savings to AMD over the conventional system
– Reduction in base building capital costs
– Liabilities shifted to the supplier
• Contractual Guarantee
– In case of excursions & out-of-tolerance events
– Ability to recover direct and indirect damages
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Technical Considerations
• Energy Efficiency
Power Quality 2000 - Boston, MA

– Waste heat produced by the generation of electricity is


recoverable to generate other forms of energy such as
hot and cold water
– Overall Efficiency: ~70-80%
• Utility Back-up
– Ability to import/export electricity
– Avoids need for generation flywheels
– Improved black start capabilities
– Limited island only plants
• Emergency Power Requirements

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Voltage/Frequency Support
Considerations
• Required to address utility faults when inter-tied and
Power Quality 2000 - Boston, MA

generation/load variations
• Quick disconnect
• Batteries
• SMES
• Capacitors/DVR
• Automatic Tap Changers
• Motor Generators
• Flywheels

Decision to implement flywheels w/ MG based on high


MTBF, ability to import & export, commercial viability.
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So called Power Conditioning Device (PCD)
Power Quality 2000 - Boston, MA Cogeneration

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Power Quality 2000 - Boston, MA Cogeneration

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Simplified Cogeneration Plant Schematic
110kV Utility Network
Power Quality 2000 - Boston, MA

Natural
Gas Supply

EG 20kV Grid Quality Bus

Control Open

Choke
System
PCD

Bypass
20kV High Quality Bus
AMD

Overall Availability = 99.9998% available

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PCD Block Diagram
20 kV Grid Quality Bus
Power Quality 2000 - Boston, MA

Flywheel
= DC ~
G ~ M/G

0.6 kV Bus
Bus
=

Choke
Flywheel

= DC ~
G M/G
~ Bus
=
Transformer
Flywheel

= DC ~
G ~ Bus M/G
=
Generator Bi- Motor
Directional Generator 20 kV High Quality Bus
Converter

Total Stored Energy = 3 x 1.67 or 5 MVA for 5 sec


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Theory of Operation - Normal Mode
• N+1 Engine-Generators on-line
Power Quality 2000 - Boston, MA

• PCD on-line with no transfer of energy (except for


negligible losses & system charging)
• Generation is synchronized
to the Utility by PCD
• AMD supplied by Generators
on “High” Quality Bus 110kV Transmission Network

• Co-generation auxiliaries
supplied by both the Utility

“Grid” & “High” Quality EG EVC 20kV Grid Quality Bus

(N+1)
Buses Open

CHOKE
~20MW

~1MW
PCD

BYPASS
20kV High Quality Bus

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AMD
Fault on the Utility System
• N+1 Engine Generators on-line
• Stored energy from PCD is transferred to the Utility &
Power Quality 2000 - Boston, MA

Generation Bus
• Transfer occurs within 10ms
• Disconnect from Utility w/in 80ms
• 80 to 120 ms the fault is
cleared by Utility Protection
110kV Transmission Network

• Co-generation operates in
island mode until fault clears

~5MW
Utility
• Co-generation reconnects EG EVC 20kV Grid Quality Bus

to the Utility (N+1)


Open

CHOKE
~20MW
Mutual
Inductance PCD

BYPASS
20kV High Quality Bus
Voltage and Frequency
remain w/in specification AMD
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Loss of Generation or Sudden Load
Increase
Power Quality 2000 - Boston, MA

• N Engine Generators on-line


• Stored energy from PCD transferred to supply bus
• Engine control system adjusts the output of the on-line
generators (within 2s)
• Additional generation is 110kV Transmission Network

added within 2-5 minutes

Utility
EG EVC 20kV Grid Quality Bus

(N+1)
Open

CHOKE
~20MW
PCD

BYPASS
Voltage and Frequency 20kV High Quality Bus Up to 5MW

remain w/in specification


AMD 21
Sudden Loss of Load
• N+1 Engine Generators on-line
Power Quality 2000 - Boston, MA

• Excess generation is transferred into the PCD


• Engine control system adjusts the output of the on-line
generators (within 2s)
• Generation is adjusted
to match actual load 110kV Transmission Network

Utility
EG EVC 20kV Grid Quality Bus

(N+1)
Open

CHOKE
~20MW
Voltage and Frequency PCD

BYPASS
Up to 5MW
remain w/in specification 20kV High Quality Bus

AMD

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Loss of 2 or More Generators
• Low gas alarm signals (engines will operate for a few
minutes on the residual) or the engine control system
Power Quality 2000 - Boston, MA

initiates:
– Stop the transfer to electricity between the Utility via
the PCD
– Close tie breaker between “high” quality and the “grid”
quality busses
– Open the PCD circuit 110kV Transmission Network

~20MW
No reduction of EG
Utility
EVC 20kV Grid Quality Bus

electrical quality (N+1)


Closed

CHOKE
~0MW
PCD

BYPASS
However, thermal capacity 20kV High Quality Bus

is reduced AMD 23
Actual System Performance
• 5 Feb 99 thunder storms caused 3 disturbances ~22% for
Power Quality 2000 - Boston, MA

80ms
• 17 Feb 99 heavy snow & winds caused 18 disturbances
(Max. Sag of 41% for 100ms)
• Last month, a maintenance crew error at a nearby utility
substation resulted in a 3 phase, 80% for 100ms sag
• Frequent engine trips (MTBT ~ 2 months)

In all cases AMD was unaffected & continued to operate


normally

However, the plant did experience one start-up problem


interrupting power to AMD 24
Power Quality 2000 - Boston, MA

L1-L2 Feeder from 41% Sag on L1-L2


Co-generation to Utility Connection
AMD Unaffected to Co-generation
Disturbances
Wave Forms from 17 Feb 99

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Conclusions
• Semiconductor Manufacturers require immunity to voltage
sags (power quality) and interruptions (outages)
Power Quality 2000 - Boston, MA

• Cogeneration utilizing stored energy


– Mitigates short voltage sags and interruptions
– Reduces production and business interruptions
• The concept and plant has been proven based on actual
performance data
• Dependent upon utility reliability and availability,
environmental, and economic conditions, this type of
solution is a viable & attractive options for semiconductor
& other sensitive loads
• A degraded deregulated utility market coupled with
increased opportunity costs further support this type of
approach to mitigating power problems 26

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