2. PF CORRECTION AND
HARMONICS
o Introduction
o Power Quality In
General
o Power Factor Correction
o Harmonics
o Related Standards
o Symptoms and
Equipment Tolerances
o Staco Energy Solutions
o Monitoring Harmonics
3. THE IMPACT OF POWER
PROBLEMS
o UPS Alone
o UPS & MBPS
ļ§ 2 Piece Shipping Split
o Ambidextrous Side Car
o Standard Kick Plates
o Easy Transport & Installation
o Single Hole or NEMA 2 Hole Landing
o Standard UVR For Battery Cabinet
ļ§ Can Be Configured For Shunt Trip
o $120-$180 Billion/yr. = cost of power outages and
disturbances in U.S. economy 1
o 8 hrs, 45 minutes/yr. = typical utility grid
downtime (99.9% reliability) in U.S.1
o $41,000/hour = cost of downtime, cellular communications 2
o $100,000/minute = lost sales, datacom/networking end user 3
o $8,000 = cost of voltage sag event -- average for all business 5
o $11,000 = cost of momentary outage event -- average for all
business 5
o 30% of equipment insurance claims are due to electrical
problems 6
o 68% of plant engineers and specifierās state that āsolving P.Q.
issues is a very important challengeā 7
1 - EPRI -- Primen Study: The cost of Power Disturbances to Industrial and Digital
Economy Companies
2 - 2001 U.S. DOE Distributed Energy Resource Program and Strategic Plan
3- Venture Development Corporation Survey
4 - Energy Conservation News
5 - 1996 Duke Power Survey
6 - Hartford Steam Boiler
7 - EC&M Survey
4. THE CAUSES OF POWER
PROBLEMS
o UPS Alone
o UPS & MBPS
ļ§ 2 Piece Shipping Split
o Ambidextrous Side Car
o Standard Kick Plates
o Easy Transport & Installation
o Single Hole or NEMA 2 Hole Landing
o Standard UVR For Battery Cabinet
ļ§ Can Be Configured For Shunt Trip
From Outside the Facility:
ļ Environmental problems affecting grid
reliability -- e.g., lightning, weather extremes,
animal intrusion, resulting in:
ļ¼Electrical outages, disruptions
ļ¼Voltage sags and surges
ļ¼Transients and overvoltages
ļ¼Frequency or Harmonic problems
ļ Operational Issues, including de-regulation,
affecting grid reliability:
ļ¼Reduction in Maintenance
ļ¼Aging Transmission System
ļ¼Demand / Supply (e.g. Calif..)
ļ¼Consolidations / Mergers
ļ¼Financial Concerns
From within the Facility:
ļ Aging building infrastructure or
equipment
ļ Building not designed for electronic
loads
ļ New equipment and processes do
not include mitigation solutions
ļ Improper wiring and grounding
ļ Outdated electrical system
ļ Equipment failures
ļ Improper maintenance
ļ Overloaded circuits
ļ Non-coordinated circuit protection
and/or electrical loads
5. POWER QUALITY
PYRAMIDā¢
o UPS Alone
o UPS & MBPS
ļ§ 2 Piece Shipping Split
o Ambidextrous Side Car
o Standard Kick Plates
o Easy Transport & Installation
o Single Hole or NEMA 2 Hole Landing
o Standard UVR For Battery Cabinet
ļ§ Can Be Configured For Shunt Trip
Relative
Cost
High $/kVA
Low
$/kVA The P.Q. Pyramid: Start with Grounding; add
other mitigating products where required
Outages (UPS; ATS; Flywheel; Gen)
Harmonic Distortion (Active/Passive
Filters; K-Factor, Phase Shifting)
Voltage Variations (Tap Changer,
Sag Correction, Ferroās, DVR)
TVSS/PFC (AC,DC,Dataline)
Grounding/Bonding (ground rods,
fittings, lightning system)
6. P.Q. SOLUTIONS ARE OFTEN CUSTOM:
COST VARY LOCATION AND/OR
INDUSTRY
o UPS Alone
o UPS & MBPS
ļ§ 2 Piece Shipping Split
o Ambidextrous Side Car
o Standard Kick Plates
o Easy Transport & Installation
o Single Hole or NEMA 2 Hole Landing
o Standard UVR For Battery Cabinet
ļ§ Can Be Configured For Shunt Trip
Manufacturing Facility (Medium Sized 480 V, 1000A)
(eg. Plastics, Automation, or Higher Tech Assembly)
Capital ($ 000's)
Possible P.Q. Solution
Simple
Solution
Med Complex
Solution
P.Q. Survey = $0 $2 $15
Grounding equipment = $0 $1 $5
Lightning System = $0 $0 $20
Surge Protection (hardwire, datacom) = $0 $5 $20
Surge Strips = $1 $1 $2
Voltage Regulation/Sag Correction = $0 $0 $60
UPS (servers, telcom system, other
small boxes) =
$4 $8 $12
Harmonics (reactors, capacitors, )= $0 $1 $20
Ferroresonant or other power
conditioners =
$2 $4 $6
Power Quality Monitor = $0 $1 $10
Total $6.8 $21.4 $170.0
Does not include installation or ongoing maintenance
Other potential equipment: PDU, shielded isolation transformers,
parallel gear, generators, ATS
7. WHAT IS POWER FACTOR?
"Power factor" involves a
relationship between two types
of power: Working or Real
Power and Reactive Power.
o Working Power, which
performs the actual
work of creating heat,
light, motion, etc.
o Reactive Power, which
sustains the
electromagnetic field.
8. WHAT IS POWER FACTOR?
oWorking Power
ā¢ Normally measured in kilowatts (kW). It does the "work"
for the system--providing the motion, heat, or
whatever else is required.
oReactive Power
ā¢ Normally measured in kilovolt-amperes-reactive (kVAR),
doesn't do useful "work." It simply sustains the
electromagnetic field.
oWorking Power and Reactive Power together make up
Apparent Power.
ā¢ Apparent Power is normally measured in kilovolt-amperes
(kVA).
9. WHAT IS POWER FACTOR?
oPower Factor is the ratio of Working Power to
Apparent Power, or kW/kVA.
oPower Factor = Working Power / Apparent
Power
PF = Cos Ī = kW / kVA
Ī
kW
kVA
10. APPARENT &
DISPLACEMENT PF
oCalculation of
displacement
power factor:
ā¢ PF displacement =
WATT/
[WATT2
+ VAR2
].
ā¢ Only the 60 Hz
components are
measured.
ā¢ For use in power
factor correction
calculations.
oCalculation of
apparent power
factor:
ā¢ PF apparent =
WATT/VA.
ā¢ This includes all
measured
harmonics.
11. WHAT DOES POWER
FACTOR MEASURE?
o Power factor measures how effectively electrical power is
being used.
ā¢ A power factor reading close to 1.0 means that electrical power is
being utilized effectively, while a low power factor indicates poor
utilization of electrical power.
o Example:
ā¢ If you had a paper mill that was operating at 100 kW and the
Apparent Power consumed was 125 kVA, what is the Power Factor?
ā¢ This represents a fairly normal Power Factor.
PF = 100 kW / 125 kVA
PF = 0.80
12. IS LOW POWER FACTOR A
PROBLEM?
oLow power factor means you're not fully utilizing
the electrical power you're paying for.
oIn the earlier example, with a Power Factor of 0.80
or 80%, your paper mill would be utilizing only 80%
of the energy supplied by the utility. That means
only 80% of the incoming current is being used to
produce useful work.
13. POWER FACTOR BASICS
Utility and Energy Firms Billing
Practices
oVaries by company due to type user,
contract, mergers, deregulation
oMay include Kva, Kwh, demand, penalty
or surcharge
oDiscuss billing components with service
provider for better understanding
14. TYPICAL ENERGY BILL
Customer:Customer: AnyAny Payment To:Payment To: Large Power Co.Large Power Co.
Billing Period From:Billing Period From: 9/1/01 12:00:01 AM9/1/01 12:00:01 AM To:To: 9/30/01 12 Midnight9/30/01 12 Midnight
Demand (Power)Demand (Power)
Rate PeriodRate Period Peak atPeak at kVAkVA $/kVA$/kVA ChargeCharge
Off PeakOff Peak 10:35 PM10:35 PM 1,4871,487 3.253.25 $4,832.75$4,832.75
On PeakOn Peak 1:05 PM1:05 PM 2,4962,496 16.7516.75 $41,808.00$41,808.00
EnergyEnergy kW hrkW hr $ / kW$ / kW.hrhr
Off PeakOff Peak 224,600224,600 0.03690.0369 $8,287.74$8,287.74
On PeakOn Peak 458,800458,800 0.0520.052 $23,857.60$23,857.60
Other ChargesOther Charges
Connection ChargeConnection Charge $500.00$500.00
Power Factor Adj.Power Factor Adj. $390.00$390.00
State Energy ChargeState Energy Charge 683,400683,400 -0.009-0.009 -$615.06-$615.06
Taxes & Special ChargesTaxes & Special Charges $3,178.04$3,178.04
Total DueTotal Due $82,239.07$82,239.07
15. ENERGY MANAGEMENT
okW Hour (Usage - 1Ā¢ - 15Ā¢/kWH)
okW Demand (15 Minute - $5 - $300/kW)
oRatio of Usage to Demand
okVAR (Power Factor) Penalties
Example
Power Factor Penalty
0.699 or lower Not permitted ā 25%
0.700 to 0.749 3%
0.750 to 0.799 2%
0.800 to 0.849 1%
0.850 to 1.000 No penalty
16. WHAT CAN BE DONE?
oThe easiest solution which can improve power factor is to
add power factor correction capacitors to your electrical
distribution system.
oCapacitors act as reactive current generators. By
providing the reactive current, reactive current is no
longer drawn from the utility.
oCurrent that is drawn from the voltage source is then only
used to do real work (kW) and not to create a magnetic
field (kVAR). The source current is then minimized!
17. WHY CONSIDER PF
CORRECTION?
o PF capacitors provide many benefits:
1. Reduced electric utility bills (a typical payback period is less than one year)
2. Increased system capacity
3. Improved voltage regulation
4. Reduced heat losses in transformers & cables
o Applications that typically exhibit low Power Factors use
motors and include:
ā¢ air compressors
ā¢ plastics extruders
ā¢ machine tools
ā¢ stamping
ā¢ and others.
18. TYPICAL UNCORRECTED POWER
FACTOR
By Industry Percent
Power Factor
By Operation Percent
Power Factor
Auto parts 75-80 Air compressor:
Brewery 76-80 External motors 75-80
Cement 80-85 Hermetic motors 50-80
Chemical 65-75 Metal working:
Coal mine 65-80 Arc welding 35-60
Clothing 35-60 Arc welding with
standard
capacitors
40-60
Electroplating 65-70 Resistance welding 40-60
Foundry 75-80 Machining 40-65
Forge 70-80 Melting:
Hospital 75-80 Arc furnace 75-90
Machine manufacturing 60-65 Inductance furnace
60Hz
100
Metalworking 65-70 Stamping:
Office building 80-90 Standard speed 60-70
Oil-field pumping 40-60 High speed 45-60
Paint manufacturing 55-65 Spraying 60-65
Plastic 75-80 Weaving:
Stamping 60-70 Individual drive 60
Steelworks 65-80 Multiple drive 70
Textile 65-75 Brind 70-75
Tool, die, jig 60-65
19. APPLYING PF CAPACITORS
oSome factors that should be considered
when applying PF capacitors:
ā¢ Where to apply?
ā¢ Low voltage or medium voltage?
ā¢ Fixed vs. Switched?
20. APPLYING PF CAPACITORS
oWhere to apply?
ā¢ When applied close to the load (i.e. motor)
transformer and cable losses are reduced.
ā¢ Lower installation cost when applied in a
central location.
ā¢ Commonly applied at the utility metering
point.
21. APPLYING PF CAPACITORS
oLow voltage or medium voltage?
ā¢ When applied on the 480V side of a substation
transformer and cable losses are reduced.
ā¢ This may required multiple banks.
ā¢ When utility feed is medium voltage a single bank at
PCC is often lowest cost.
ā¢ Must first determine all the reasons for installing PF
capacitors:
ā¢ Only to reduce utility bill?
ā¢ Reduce load on cables and transformers?
22. APPLYING PF CAPACITORS
oFixed vs. Switched?
ā¢ Fixed banks are simplest and lowest cost but can cause
problems:
ā¢ Leading PF - some utilities charge
ā¢ Overvoltage conditions when load drops
ā¢ If the plant load is fairly constant a fixed bank may work.
ā¢ Usually a combination of some amount of fixed capacitance
and switched steps works best.
ā¢ Also need to consider # of steps.
23. HARMONIC DISTORTION
oHarmonic problems are
becoming more
apparent because more
equipment
that produce harmonics
are being
applied
to power
systems Harmonic
Solutions
24. SOURCES
General categories of nonlinear loads are:
o Power Electronic Equipment
o Arcing Devices
o Iron Saturating Devices
o Rotating Machines
25. SYMPTOMS
oTransformer heating
oMotor and generator heating
and vibrations
oNeutral heating
oNuisance fuse operations
oInsulation deterioration
oElectronic control malfunctioning
oInconsistent meter readings
oVoltage regulator misoperations
26. HARMONICS BASICS
Harmonics and PFC
oCapacitors do not create harmonics
oConcern for resonance ā currents
amplified, voltage distortion, potential
damage to capacitors
oReactors help to āde-tuneā to below a
certain order, balancing the capacitive
requirement
27. HARMONICS APPLICATION
REVIEW
oFacility walk-through ā installed
equipment, systems and processes
oReview plant electrical documents
oNote plans for new equipment,
expansion
oAnalyze 6-12 months of electric bills
oReview past electrical system studies,
may require a PQ survey, energy audit
28. HARMONICS APPLICATION
REVIEW
oNote equipment most vulnerable to
harmonics
oAny critical loads and process requiring
āpremium powerā, outage concerns?
oReview downtime, scrap, maintenance,
equipment replacement costs, loss of
production, profits
oIsolated solution, long term PQ strategy
29. HARMONIC BASICS
Where Harmonics Exist
oWater treatment, glass making, steel
processing, packaging, data centers,
printing/publishing, paper processing,
plastics, chemicals, automotive, to
name few
30. HARMONIC BASICS
Economic Considerations
o Harmonics can create nuisance
problems (rebooting a PC, restarting
equipment) to serious concerns
(product quality issues), through
catastrophic events (production halted)
ā¦ā¦.monies lost
31. HARMONIC BASICS
oNew and replacement
equipment/controls and devices
typically are electronic, which may
exacerbate a border-line harmonic
condition, immediately creating a new
set of problems, which ultimately affect
businessā¦ā¦.monies lost
oPartial āfixesā, lack to review total PQ
situationā¦ā¦..monies lost
32. HARMONIC BASICS
Suggestions
oKeep a record of problems and
associated costs
oActions taken to review and āfixā
problem(s), associated costs
oPotential need to monitor (collect data)
on facility loads, to help with evaluation
oDiscuss problem with a āsolutions
drivenā equipment manufacturer
33. HARMONICS & CAPACITORS
oCapacitors not only supply reactive power to the loads in
an electrical distribution system they also
change the resonance frequency of the system.
oCapacitors are also a āsinkā for harmonic currents
present in a system.
oWhen the resonance frequency of a system with PF
correction capacitors is close to the frequency of a
harmonic current generating load parallel
resonance can occur.
37. HARMONIC DISTORTION
STANDARDS
Harmonic Voltage Distortion Limits
IEEE Standard 519 ā 1992
Maximum Voltage Distortion in % at PCC*
Below 69kV 69-138kV >138kV
Maximum
for Individual
Harmonic 3.0 1.5 1.0
Total Harmonic
Distortion (THD) 5.0 2.5 1.5
* % of Nominal Fundamental Frequency Voltage
38. HARMONIC DISTORTION
STANDARDS
Harmonic Order (Odd Harmonics)
Isc/IL <11 11<h<17 17<h<23 23<h<35 35<h %TDD
Maximum Harmonic Current Distortion
IEEE Standard 519 ā 1992
In Percent of Fundamental
<20* 4.0 2.0 1.5 0.6 0.3 5.0
20-50 7.0 3.5 2.5 1.0 0.5 8.0
50-100 10.0 4.5 4.0 1.5 0.7 12.0
100-1000 12.0 5.5 5.0 2.0 1.0 15.0
>1000 15.0 7.0 6.0 2.5 1.4 20.0
49. HARMONIC CORRECTION SELECTION
FOR DRIVES IN MCCāS
Drive Quantity
5 10 15 20
10 Hp
50 Hp
125 Hp
and up
Parallel / Passive
Filter
(10-20% Distortion)
Series
Passive Filter
(8-12% Distortion*)
Active Correction
(5-20% Distortion)
18 Pulse Drive
(5% Distortion*)
30 Hp
* per Drive
Recommendation based on
price and MCC integration
50. STACOVAR SOLUTIONS
o Power Factor and
Harmonic Correction
o Low Voltage Class,
240-600vac
o Automatically
switched and fixed
o Virtually unlimited
Kvar
o Optimum standard
sizes of switched
steps
51. STACOVAR SOLUTIONS
oSmall āfootprintā with maximum
Kvar
oStand-alone, multi-unit, integrated
systems
oModular design for expansion and
upgradeability
oUL508A, complete assembly
52. STACOVAR SOLUTIONS
oNEMA 1, 12 and
3R enclosures
oOptional circuit
breaker, TVSS, CT
oāOff-the-Shelf and
application
engineered
oThree phase dry-
type capacitors
54. STACOVAR ZX AND ZXR
APPLICATIONS
oPower systems with frequent load
changes, voltage sags and surges
oWelding, flicker problems
oSaw mills, elevators, cranes
oRolling mills, arc furnaces
oEngine-generators, wind power
58. ā¢ STACO CATALOG NUMBERING SYSTEM
ā¢ To assist in the understanding of the Staco catalog numbering system, a brief explanation follows:
ā¢ Part Number Example
ā¢ P A - 0 0 7 5 ā 0 1 A 0 1 B ā N 4 8 6 W 1 ā C B T
ā¢ ļ£°___ļ£» ļ£°______ļ£» ļ£°____________ļ£» ļ£ŗ ļ£°__ļ£» ļ£ŗ ļ£°__ļ£» ļ£ŗ ļ£ŗ ļ£ŗ
ā¢ 1 2 3 4 5 6 7 8 9 10
ā¢ 1 PA= StacoVar Automatic Power Factor Correction
ā¢ 2 0075= 75kvar
ā¢ 3 01A= (1), 25kvar step 01B= (1), 50kvar step
ā¢ 4 N= No reactors
ā¢ 5 48= 480vac
ā¢ 6 6= 60hz
ā¢ 7 W1= Wall Mounted NEMA 1
ā¢ 8 C= Split Core CT- current transformer (option)
ā¢ 9 B= Molded Case Circuit Breaker (option)
ā¢ 10 T= TVSS āsurge protection (option)
59.
60. STACOVAR SOLUTIONS
Tuned Harmonic Filters
oApplication designed to trap or reduce problem harmonics
ACtive~trAC
oActive harmonic filters available early second quarter 2005
āAt Loadā Fixed Capacitors
oAvailable second quarter 2005
67. EXAMPLES OF PQ SITE SURVEYS
Oil Platform - Gulf of Mexico
ā¢ The āBad Noiseā and the āEvil Noiseā
Specialty Steel Tubing ā Cleveland, OH
ā¢ Newly installed PF Correction Capacitors Parallel
Resonant at 11th and 13th Harmonics
ā¢ Converted Capacitors to Filters
Nuclear Power Plant - Ohio
ā¢ High Harmonic Distortion with Inverter
ā¢ Single Phase Harmonic Filters
68. EXAMPLES OF PQ SITE SURVEYS
Steel Mill - Pittsburgh, PA
ā¢ Harmonic Resonance - Filter Failure
Data Center ā Cleveland, OH
ā¢ Harmonics Causing Nuisance Trips of Peak
Sensing Equipment
Video Reproduction Facility - Michigan
ā¢ Transformer Overheating
ā¢ Extremely High Harmonic Currents
69. CASE STUDY - HOSPITAL PF
CORRECTION
Problem:
Hospital was Penalized for Power Factor by Utility Company
ā¢ $2,300/month Penalty
ā¢ Consultant Already Specified Required Capacitance
ā¢ Drive Loads on Air Handling System - Harmonics
ā¢ Potential for Dangerous Harmonic Resonance
ā¢ Equipment (New Capacitors, Service Transformers and Other Loads) at
Risk
Solution:
Power Study and Implementation
ā¢ Re-Designed and Implemented Harmonic Filters with Same Required PF
Correction Compensation
ā¢ Annual Cost of PF Penalty - $27,600
ā¢ Cost of Analysis and Harmonic Filters - $45,000 (Installed)
ā¢ Payback - Less than 2 Years
Avoided Costly and Dangerous Situation for Equipment and Kept Payback
Within Hospital Constraints
70. CASE STUDY - PHASE SHIFTING
Solar Crystal R&D
Problem: Harmonics from Multiple 15 kW DC Power
Supplies
Harmonic Solution: New Facility Design with Phase Shifting
(āHarmonic Cancellationā)
4160V
8x15KW
FCE
480V 480V
etc.
12470V
480V480V
71. EXAMPLE - COMPUTER LOADS
Office Building
o Problem: Cubicle Furniture āSmokingā as a Result of
Overheated Neutral (High 3rd Harmonics from
Computer Loads)
o Solution: Run Separate Neutrals and Install K-Rated
Transformers (āLive with Harmonicsā)
72. CASE STUDY - NOTCHING
Automotive Assembly
ā¢ Problem: Large DC drives on Stamping Presses Caused
Voltage Notching on 4 kV Bus - Resulted in Incorrect
Welding Timing - Recall on āBad Weldsā
ļ§ Solution: Reduce or Eliminate Notching with Reactors/Filters
or Phase Shifting Transformers
480V480V
12470V
4160V
Stamping
Presses
Welders
73. EXAMPLE - PQ SITE SURVEY
AF
National Lab - Linear Accelerator
ā¢ Problem: Operation of Linear Accelerator Causes
Voltage Flicker and Significant Harmonics
Solution: Measurements and Specifications for Active Harmonic Filter
Compensation
2MVA 2MVA 1.5MVA 1.5MVA
13.8KV
480V480V
AF
74. MONITORING HARMONICS
Snapshot - Continuous Loading
Long Term - Suspected Resonance or Significantly Varying
Loads
Conditions
o All normal and contingent circuit configurations
o Each capacitor switching step if applicable
o For all characteristic representations of the speed
or percent loading of the harmonic producing
source(s)