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港口起重机与冶金电力系统计算器

为岸桥、港口设备及电弧炉设计供电方案 — 冲击负载无功补偿（SVC/SVG）、谐波滤波及电机启动电压跌落校验，附 BOM 与单线图。

开始计算港口起重机与冶金解决方案

为什么使用此计算器

起重机和电弧炉属于极端冲击负载：快速波动会引起电压闪变，且 VFD/ 整流器驱动会注入大量谐波。本计算器按平均需求为变压器选型，校验最大驱动启动时的电压跌落，并确定动态无功补偿及失谐谐波滤波的容量。

Worked Examples

Example 1 — 4 × 500 kW Quay Cranes (Impact Load, SVC + Harmonics) · FOB $438,818

Port crane / metallurgy power system · 35kV/0.4kV

1,600 kVA transformer

S13-M-1600/35 · impact 2,600 kW · THDi 30%

Connected load

2,000 kW

Impact peak

2,600 kW

Reactive comp.

1798 kvar

Start dip

2.2%

Est. total (FOB)

POA

📦 Bill of Materials

Equipment	Model	Spec	Qty
HV incoming panel	KYN61-40.5-1250-25	1250 A / 25 kA · vacuum	1
Main transformer	S13-M-1600/35	1600 kVA · Oil-Immersed · Copper · S13	1
LV incoming panel	GGD-2500	2500 A busbar · In 2309 A	1
LV feeder panel	GGD-2500	distributes 4 circuits	1
Main feeder cable (TX→LV)	YJV 0.6/1kV 300 mm² ×5	5× 300 mm² Cu · ΔU 1.50% @ 100 m · $154.0/m	5
Feeder cable — Quay crane 1 (×4)	YJV 185 mm² ×3	3× 185 mm² Cu · 1031 A · ΔU 1.8% · $103.0/m	12
Main busbar (Cu)	Cu 125×10	125×10 · 2500 A rating · ref $147.8/m	included
Grounding electrode	Φ20mm × 2.5m rod	R₁ 39.6 Ω → 13 rod(s) ≤ 4 Ω	13
Dynamic reactive compensation (SVC/SVG)	±5 Mvar	Static Var Generator · fast response for impact loads · FOB reference	1
Detuned PFC capacitor bank	1798 kvar	automatic · 7% detuned · 0.4 kV	1
Series detuning reactor (7%)	125.9 kvar	189 Hz tuning · below 5th harmonic	1
Quay crane regenerative drive	500 kW four-quadrant	regenerative VFD (energy feedback on lowering) · per crane	4
Shore power supply (岸电)	300 kVA	50/60 Hz frequency converter + shore connection panel · IEC/ISO 80005-1 · quoted per project	1

📐 Single-line diagram

⚙️ Electrical schematic (protection & metering)

⛳ Grounding grid layout

🔌 Cable schedule & routing

🗄 Switchgear arrangement

🛡 Protection configuration

📋 Protection settings

Circuit	Protection	Setting	Time	Standard
HV incoming 35 kV	50 instantaneous	211 A	inst	IEC 60255-151 / IEEE 242
HV incoming 35 kV	51 overcurrent	32 A	0.5 s	IEC 60255-151 / IEEE 242
HV incoming 35 kV	51N earth-fault	5 A	0.5 s	IEC 60364-4-41
Transformer 1600 kVA	49 thermal overload	79% of rated	alarm 90%	IEC 60076-7 / IEEE C57.91
LV incoming 0.4 kV	50 instantaneous	18475 A	inst	IEC 60947-2
LV incoming 0.4 kV	51 overcurrent	2771 A	0.3 s	IEC 60947-2 / IEC 60255
LV incoming 0.4 kV	51N earth-fault	462 A	0.3 s	IEC 60364-4-41
Quay crane 1	50/51/51N (MCCB)	Ir 1134 A - Im 8248 A - Ig 206 A	0.1 s (grading)	IEC 60947-2 / IEC 60255
Quay crane 2	50/51/51N (MCCB)	Ir 1134 A - Im 8248 A - Ig 206 A	0.1 s (grading)	IEC 60947-2 / IEC 60255
Quay crane 3	50/51/51N (MCCB)	Ir 1134 A - Im 8248 A - Ig 206 A	0.1 s (grading)	IEC 60947-2 / IEC 60255
Quay crane 4	50/51/51N (MCCB)	Ir 1134 A - Im 8248 A - Ig 206 A	0.1 s (grading)	IEC 60947-2 / IEC 60255

Settings are illustrative starting points — confirm with a protection coordination study per IEC 60255 / IEEE 242.

📚 Calculation book

CALCULATION BOOK

1600 kVA - 35kV/0.4kV - single - illustrative

1. Load calculation

Standard: IEC 60076 - IEC 60364-5-52

Parameter	Formula	Value
Connected load	P = sum(kW)	2,000 kW
Demand factor	Kd	0.6
Demand power	Pd = P x Kd	1,200 kW
Power factor	cos(phi) before -> after	0.70 -> 0.95
Design apparent power	Sd = Pd / cos(phi)	1,263 kVA
Transformer loading	Sd / Srated	79%

2. Short-circuit calculation

Standard: IEC 60909

Parameter	Formula	Value
System impedance (pu)	Zs = S / Ssc	0.32% (on 1600 kVA base)
Transformer impedance	Zt = Z%	4%
Total impedance	Z = Zt + Zs	4.32%
LV prospective Isc	Isc = In / Z	53.5 kA
HV prospective Isc	Isc = Ssc / (sqrt(3) x V)	8.2 kA
Breaking check	Icu >= Isc	LV 65 kA (1.2x margin) PASS

3. Voltage drop

Standard: IEC 60364-5-52 Annex G

Parameter	Formula	Value
Main feeder	dU = sqrt(3) x I x L x R / V	300 mm2 - dU 1.50% @ 100 m
Limit	max 3%	within limit
Transformer volt. reg.	dU ~ loading x Z% x sin(phi)	1.0% at full load

4. Reactive power / harmonics

Standard: IEC 61921 (PFC) - IEEE 519 (harmonics)

Parameter	Formula	Value
Required compensation	Qc = Pd x (tan1 - tan2)	0 kvar
PFC bank	standard step	0 kvar
Detuned reactor	p = 6%	n/a

5. Grounding

Standard: IEC 60364-5-54 earthing arrangements and protective conductors LV earthing target 10 ohm (TN systems); 4 ohm used as a conservative design target - target 4 ohm

Parameter	Formula	Value
Single rod resistance	R1 = rho/(2 x pi x L) x ln(4L/d)	39.6 ohm
Rods required	n = R1 / (target x 0.8)	13 rod(s) <= 4 ohm
Rod spec	dia x length	20 mm x 2.5 m

This calculation book is illustrative it consolidates the computed values with the referenced standards. A licensed engineer must verify and seal final design documents for construction.

🔧 Secondary schematic (control & signal)

🔩 Terminal strip (typical)

⚙️ Impact load & motor starting

Parameter	Value
Impact peak	2,600 kW (factor 1.3×)
Largest drive	500 kW · VFD (1.3× In)
Start voltage dip	2.2% vs limit 10% — OK ✓

🌀 Reactive & harmonic compensation

Parameter	Value
Reactive compensation	1798 kvar SVC/SVG + detuned bank (7% reactor)
Harmonic current	THDi 30% → Ih 1,608 A
Resonance	f_res 189 Hz below 5th harmonic → detuned (safe ✓)

📏 Standard basis (依据标准)

Topic	Standard
Standard basis	IEC · IEC 60364-5-52
Conductor ampacity	IEC 60364-5-52 Table B.52.2–B.52.5 (copper, 3 loaded conductors, 30°C ambient, PVC) — typical/rounded values, conservative (±3%)
Voltage-drop limit	IEC 60364-5-52 Annex G · max drop 3%
Winding temp rise	IEC 60076-2 — winding temp rise 65 K (Class A insulation, ONAN)
kVA ratings	IEC 60076-1 R10 preferred numbers
Breaker frames	IEC 60947-2 frame sizes (In)
Grounding target	IEC 60364-5-54 earthing arrangements and protective conductors — LV earthing target ≤ 10 Ω (TN systems); 4 Ω used as a conservative design target · target 4 Ω
Voltage fluctuation & flicker	GB/T 12326 — voltage fluctuation and flicker limits (impact loads)
Harmonics	GB/T 14549 · IEC 61000-3-2 · IEC 61642 — harmonic limits & detuned filters
Rotating machines	IEC 60034 — rotating electrical machines
Power supply design	GB 50052 — code for design of electric power supply systems

🧮 How it was calculated

1. Quay cranes: 4 × 500 kW = 2,000 kW

2. Impact peak = 2,000 × 1.3 = 2,600 kW (short-time)

3. Largest drive start (motor-starting): 500 kW × 1.3 → dip 2.2% vs limit 10%

4. Reactive compensation: Qc = 2,600 × (tanφ₁ − tanφ₂) = 1,798 kvar (SVC/SVG + detuned bank)

5. Harmonics: THDi 30% → Ih = 1,608 A · 7% detuned reactor (f_res 189 Hz)

6. Loads: P=2,000 kW, PF 0.70, 4 circuits

7. Demand: 2,000 × 0.6 = 1,200 kW

8. Transformer: S = 1,200 ÷ 0.95 = 1263.2 kVA → 1,600 kVA standard

9. Loading: 1,263 ÷ 1,600 = 79% (good range)

10. Voltage regulation: 79% × 4% × sinφ ≈ 1.0% at full load

11. HV: In 26.4 A, Isc 8.2 kA → KYN61-40.5-1250-25

12. LV: In 2309 A, Isc 53.5 kA (Xfmr Z 4% + system 0.3%) → GGD-2500, 1 feeder panel(s)

13. Grounding: R₁ 39.6 Ω → 13 rod(s)

14. Main feeder: 5× 300 mm² · ΔU 1.50% — OK

Summary
Estimated total (FOB Qingdao, EXW) — priced equipment				$438,818

📋 Design notes

Pricing basis: FOB Qingdao (EXW) equipment price. Freight, duty and installation are not included — add for landed economics.

Transformer loading: 79% at design demand — good range.

Short-circuit check: HV 8.2 kA vs 25 kA (3.0× margin) · LV 53.5 kA vs 65 kA (1.2× margin).

Voltage regulation: ≈ 1.0% at full load (typical limit 5%).

Copper price linkage: Copper-wound transformer price tracks LME copper (current $14,115/t · 2026-09-14 · LME Copper (Sina hf_CAD)).

Parallel conductors: Single-cable ampacity exceeded — parallel conductors specified: main feeder 5× 300 mm², Quay crane 1 3× 185 mm², Quay crane 2 3× 185 mm², Quay crane 3 3× 185 mm², Quay crane 4 3× 185 mm² (per IEC 60364-5-52 / GB 50054).

Cable & grounding pricing: Cable conductors and grounding are priced from the confirmed cables-trays-grounding price reference (per-metre copper YJV; aluminium remains POA). The main copper busbar is POA — its length is project-specific.

Busway (high-current feeders): For LV feeders above ~2500 A, a busway (母线槽) trunking system is recommended instead of parallel cables.

Impact load: Impact factor 1.3× — rapid load swings from cranes/arc furnaces cause voltage flicker; dynamic SVC/SVG compensation is required.

Starting: Largest 500 kW drive started via VFD draws a 2.2% bus dip (within the 10% limit).

Harmonics: 30% THDi from VFD/rectifier loads — a 7% detuned filter keeps the branch inductive below the 5th harmonic.

SVC/SVG pricing: Dynamic reactive compensation is priced at $183,000/unit (±5 Mvar, FOB reference).

Crane regenerative drive: Quay cranes use four-quadrant (regenerative) VFDs that feed lowering energy back to the bus — this reduces energy consumption and DC-bus overvoltage, quoted per project.

Shore power (岸电): A shore power supply converts the port grid to the vessel’s voltage/frequency (IEC/ISO 80005-1) so berthed ships shut down their auxiliary engines — quoted per project.

计算过程说明

选型计算方式

冲击峰值 = 连接负载 × 冲击系数。无功补偿 Qc = P × (tanφ₁ − tanφ₂) 用于校正较低的自然功率因数，采用快速 SVC/SVG 抑制闪变，并配置失谐滤波组抑制谐波。最大驱动启动 kVA 需对照电压跌落限值进行校验（对闪变敏感母线通常为 10%）。

适用标准

选型参考 GB/T 12326（电压波动与闪变）、GB/T 14549 和 IEC 61000-3-2（谐波）、IEC 61642（失谐滤波器）、IEC 60034（旋转电机）及 GB 50052（供电设计）。

常见问题

冲击负荷如何影响港口的电能质量？

岸桥和绞车带来快速、大幅的负荷波动（冲击负荷），引起电压闪变。冲击系数 = 峰值/平均负荷，常为 1.3-1.5。当闪变超出 GB/T 12326 限值时，需加装响应 5-20 ms 的动态无功补偿（SVC/SVG）。计算器按冲击系数配置补偿容量。

电弧炉为什么需要 SVC 或 SVG 补偿？

电弧炉电流剧烈波动，闪变与谐波严重，熔化期功率因数低至 0.6-0.7。容量为炉子 30-50% 的 SVC/SVG 可恢复功率因数并抑制闪变，满足 GB/T 12326 与 IEEE 519。50 MW 电炉典型需 15-25 Mvar 动态补偿。

港口岸桥系统用多大电压供电？

大型岸桥（每台 500 kW-1.5 MW）以 10 kV 或 35 kV 供电，在泊位附近降压到 0.4/0.69 kV 供传动。沿码头布置 10 kV 环网（环网柜/开关柜）是标准做法。计算器默认 35 kV 模拟多泊位岸桥群，小港用 10 kV。

岸桥的谐波如何治理？

岸桥传动以变频为主，注入 5、7、11 次谐波，未治理时 THDi 常达 30%。采用有源前端（AFE）或去谐无源滤波 + APF 可将公共连接点 THD 控制在 IEEE 519 的 5-8% 限值内。计算器在 THDi 超阈值时配置谐波滤波。

岸桥供电选型用多大的典型工作制？

岸桥属断续工作制（起升/下降/行走），即便繁忙期平均需求也只有装机功率的 40-60%。供电变压器按最大同时需求加最大起升启动冲击选型，而非铭牌功率简单相加。计算器套用冲击系数与同时系数避免超配。

港口开关柜要耐受多大短路水平？

港口 35 kV 开关柜通常 25-31.5 kA，10 kV 柜 25-31.5 kA，低压柜 50-65 kA。额定值须大于各母线计算故障电流（IEC 60909）。岸桥传动也贡献故障电流，50 MVA 电源的 35 kV 母线至少需 25 kA。计算器校核柜体额定与故障水平。

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