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Power Factor & Harmonics:
StacoSine: Technical
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
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 specifierā€™s state that ā€œsolving 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
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‚Ÿ Environmental problems affecting grid
reliability -- e.g., lightning, weather extremes,
animal intrusion, resulting in:
ļƒ¼Electrical outages, disruptions
ļƒ¼Voltage sags and surges
ļƒ¼Transients and overvoltages
ļƒ¼Frequency or Harmonic problems
ļ‚Ÿ Operational Issues, including de-regulation,
affecting grid reliability:
ļƒ¼Reduction in Maintenance
ļƒ¼Aging Transmission System
ļƒ¼Demand / Supply (e.g. Calif..)
ļƒ¼Consolidations / Mergers
ļƒ¼Financial Concerns
From within the Facility:
ļ‚Ÿ Aging building infrastructure or
equipment
ļ‚Ÿ Building not designed for electronic
loads
ļ‚Ÿ New equipment and processes do
not include mitigation solutions
ļ‚Ÿ Improper wiring and grounding
ļ‚Ÿ Outdated electrical system
ļ‚Ÿ Equipment failures
ļ‚Ÿ Improper maintenance
ļ‚Ÿ Overloaded circuits
ļ‚Ÿ Non-coordinated circuit protection
and/or electrical loads
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
$/kVA The P.Q. Pyramid: Start with Grounding; add
other mitigating products where required
Outages (UPS; ATS; Flywheel; Gen)
Harmonic Distortion (Active/Passive
Filters; K-Factor, Phase Shifting)
Voltage Variations (Tap Changer,
Sag Correction, Ferroā€™s, DVR)
TVSS/PFC (AC,DC,Dataline)
Grounding/Bonding (ground rods,
fittings, lightning system)
P.Q. SOLUTIONS ARE OFTEN CUSTOM:
COST VARY LOCATION AND/OR
INDUSTRY
o UPS Alone
o UPS & MBPS
ļ‚§ 2 Piece Shipping Split
o Ambidextrous Side Car
o Standard Kick Plates
o Easy Transport & Installation
o Single Hole or NEMA 2 Hole Landing
o Standard UVR For Battery Cabinet
ļ‚§ Can Be Configured For Shunt Trip
Manufacturing Facility (Medium Sized 480 V, 1000A)
(eg. Plastics, Automation, or Higher Tech Assembly)
Capital ($ 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
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.
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).
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
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.
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
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.
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
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
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
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!
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.
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
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?
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.
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?
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.
HARMONIC DISTORTION
oHarmonic problems are
becoming more
apparent because more
equipment
that produce harmonics
are being
applied
to power
systems Harmonic
Solutions
SOURCES
General categories of nonlinear loads are:
o Power Electronic Equipment
o Arcing Devices
o Iron Saturating Devices
o Rotating Machines
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
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 ā€œde-tuneā€ to below a
certain order, balancing the capacitive
requirement
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
HARMONICS APPLICATION
REVIEW
oNote equipment most vulnerable to
harmonics
oAny critical loads and process requiring
ā€œpremium powerā€, outage concerns?
oReview downtime, scrap, maintenance,
equipment replacement costs, loss of
production, profits
oIsolated solution, long term PQ strategy
HARMONIC BASICS
Where Harmonics Exist
oWater treatment, glass making, steel
processing, packaging, data centers,
printing/publishing, paper processing,
plastics, chemicals, automotive, to
name few
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
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 ā€œfixesā€, lack to review total PQ
situationā€¦ā€¦..monies lost
HARMONIC BASICS
Suggestions
oKeep a record of problems and
associated costs
oActions taken to review and ā€œfixā€
problem(s), associated costs
oPotential need to monitor (collect data)
on facility loads, to help with evaluation
oDiscuss problem with a ā€œsolutions
drivenā€ equipment manufacturer
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 ā€œsinkā€ 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.
HARMONIC DISTORTION
480 V
Xs
M
XT
G
HARMONIC DISTORTION
480 V
Xs
M
XT
UPS
Electronic Ballast
+ -M
Blocking
Filter
G
Welder
HARMONICS
100%, 60 Hz
2%, 780 Hz
20%, 180 Hz
12%, 300 Hz
4%, 420 Hz
2%, 660 Hz
%100
...
%
1
2
4
2
3
2
2
Ɨ
+++
=
I
III
THDI
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
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
EXPECTED HARMONICS
H = NP+/-1
i.e. 6 Pulse Drive - 5, 7, 11, 13, 17, 19,ā€¦
Source Typical Harmonics*
6 Pulse Drive/Rectifier 5, 7, 11, 13, 17, 19ā€¦
12 Pulse Drive /Rectifier 11, 13, 23, 25ā€¦
18 Pulse Drive 17, 19, 35, 37ā€¦
Switch Mode Power Supply 3, 5, 7, 9, 11, 13ā€¦
Florescent Lights 3, 5, 7, 9, 11, 13ā€¦
Arcing Devices 2, 3, 4, 5, 7...
Transformer 2, 3, 4
* Generally, magnitude decreases as harmonic order increases
VOLTAGE NOTCHING
PARALLEL RESONANCE
PARALLEL RESONANCE
CAP
SC
R
MVAR
MVA
f =
600 kVAR
1500 kVA
5.0%
480 V
Xs
200 HP
VSD
500 HP
MOTOR HEATING AND VIBRATIONS
60 Hz Rotation
5th Harmonic
Rotation
NEUTRAL HEATING
C
B
A
N
0A at 60 Hz
10A at 60 Hz
10A at 60 Hz
10A at 60 Hz
30A at 180 Hz
10A at 180 Hz
10A at 180 Hz
10A at 180 Hz
HARMONIC SOLUTIONS
ā€¢ Clean power drives (18 Pulse)
ā€¢ Clean MCCā€™s
ā€¢ Active harmonic filters
ā€¢ Passive harmonic filters
ā€¢ Blocking filters (drives)
ā€¢ Blocking filters (3rds)
ā€¢ Zero-sequence traps
ā€¢ Delta/Wye transformers
ā€¢ Harmonic cancellation (phase shifting transformers)
ā€¢ Isolation transformers
ā€¢ Commutation reactors
ā€¢ 200% neutral conductors
ā€¢ K-factor rated transformers
EFFECT OF DRIVE LINE
REACTORS (IEEE519-1992)
PHASE SHIFTING - 12 PULSE
PHASE SHIFTING - 72 PULSE
230KV
69KV
0Ā° -40Ā° -20Ā° -10Ā° 10Ā° -30Ā° 5Ā° -35Ā° -15Ā° -45Ā° -25Ā°
69KV
-5Ā°
0Ā° 0Ā°
HARMONIC CORRECTION SELECTION
FOR DRIVES IN MCCā€™S
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
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
STACOVAR SOLUTIONS
oSmall ā€œfootprintā€ with maximum
Kvar
oStand-alone, multi-unit, integrated
systems
oModular design for expansion and
upgradeability
oUL508A, complete assembly
STACOVAR SOLUTIONS
oNEMA 1, 12 and
3R enclosures
oOptional circuit
breaker, TVSS, CT
oā€œOff-the-Shelf and
application
engineered
oThree phase dry-
type capacitors
STACOVAR 100KVAR MODULE WITH
CAPACITORS, REACTORS,
CONTACTORS, FUSES
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
STACOVAR ā€œTYPICALā€ INTERNAL
STRUCTURE ARRANGEMENT
Acrobat Document
STACOVAR ā€œTYPICALā€
ENCLOSURE ASSEMBLY
Acrobat Document
STACOVAR ā€œTYPICALā€
ENCLOSURE PLAN VIEW
Acrobat Document
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 ā€“surge protection (option)
STACOVAR SOLUTIONS
Tuned Harmonic Filters
oApplication designed to trap or reduce problem harmonics
ACtive~trAC
oActive harmonic filters available early second quarter 2005
ā€œAt Loadā€ Fixed Capacitors
oAvailable second quarter 2005
ACTIVE~TRAC ACTIVE HARMONIC
FILTER
ACTIVE~TRAC
COST OF HARMONIC
CORRECTION
Description Typical $/kVA*
K-Factor 20
Reactor 3-4
Capacitors (LV) 12
Switched Capcitors (LV) 25
Single-Tuned Fixed Filter (LV) 35
Single-Tuned Switched Filter (LV) 40-50
Single-Tuned Fixed Filter (MV) 12
Single-Tuned Switched Filter (MV) 15
Blocking Filter (3rd's) 100
Blocking Filter (Drives) 100
Active Harmonic Filter 150
Phase-Shifting Transformers 50
Note that prices are generalized for comparison only but not absolute.
Some equipment must be fully rated for loads - others can be partially rated
Capacitors are shown for reference only.
Special
Considerations
for Generators
NOTCHING AND GENERATORS
Generator Source
may result in
larger
commutation
notches and
transients
HARMONICS AND GENERATORS
Utility
Source
2.3% THD
Generator Source
5.7% THD
EXAMPLES OF PQ SITE SURVEYS
Oil Platform - Gulf of Mexico
ā€¢ The ā€œBad Noiseā€ and the ā€œEvil 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
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
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
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
(ā€œHarmonic Cancellationā€)
4160V
8x15KW
FCE
480V 480V
etc.
12470V
480V480V
EXAMPLE - COMPUTER LOADS
Office Building
o Problem: Cubicle Furniture ā€œSmokingā€ as a Result of
Overheated Neutral (High 3rd Harmonics from
Computer Loads)
o Solution: Run Separate Neutrals and Install K-Rated
Transformers (ā€œLive with Harmonicsā€)
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 ā€œBad Weldsā€
ļ‚§ Solution: Reduce or Eliminate Notching with Reactors/Filters
or Phase Shifting Transformers
480V480V
12470V
4160V
Stamping
Presses
Welders
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
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)
THANK YOU
Toll Free: 866.261.1191 | sales@stacoenergy.com | www.stacoenergy.com

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Product: Power Factor & Harmonics: StacoSine: Technical

  • 1. Power Factor & Harmonics: StacoSine: Technical
  • 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 specifierā€™s state that ā€œsolving 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‚Ÿ Environmental problems affecting grid reliability -- e.g., lightning, weather extremes, animal intrusion, resulting in: ļƒ¼Electrical outages, disruptions ļƒ¼Voltage sags and surges ļƒ¼Transients and overvoltages ļƒ¼Frequency or Harmonic problems ļ‚Ÿ Operational Issues, including de-regulation, affecting grid reliability: ļƒ¼Reduction in Maintenance ļƒ¼Aging Transmission System ļƒ¼Demand / Supply (e.g. Calif..) ļƒ¼Consolidations / Mergers ļƒ¼Financial Concerns From within the Facility: ļ‚Ÿ Aging building infrastructure or equipment ļ‚Ÿ Building not designed for electronic loads ļ‚Ÿ New equipment and processes do not include mitigation solutions ļ‚Ÿ Improper wiring and grounding ļ‚Ÿ Outdated electrical system ļ‚Ÿ Equipment failures ļ‚Ÿ Improper maintenance ļ‚Ÿ Overloaded circuits ļ‚Ÿ 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 $/kVA The P.Q. Pyramid: Start with Grounding; add other mitigating products where required Outages (UPS; ATS; Flywheel; Gen) Harmonic Distortion (Active/Passive Filters; K-Factor, Phase Shifting) Voltage Variations (Tap Changer, Sag Correction, Ferroā€™s, DVR) TVSS/PFC (AC,DC,Dataline) Grounding/Bonding (ground rods, fittings, lightning system)
  • 6. P.Q. SOLUTIONS ARE OFTEN CUSTOM: COST VARY LOCATION AND/OR INDUSTRY o UPS Alone o UPS & MBPS ļ‚§ 2 Piece Shipping Split o Ambidextrous Side Car o Standard Kick Plates o Easy Transport & Installation o Single Hole or NEMA 2 Hole Landing o Standard UVR For Battery Cabinet ļ‚§ Can Be Configured For Shunt Trip Manufacturing Facility (Medium Sized 480 V, 1000A) (eg. Plastics, Automation, or Higher Tech Assembly) Capital ($ 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 ā€œde-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 ā€œpremium 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 ā€œfixesā€, 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 ā€œfixā€ problem(s), associated costs oPotential need to monitor (collect data) on facility loads, to help with evaluation oDiscuss problem with a ā€œsolutions 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 ā€œsinkā€ 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.
  • 35. HARMONIC DISTORTION 480 V Xs M XT UPS Electronic Ballast + -M Blocking Filter G Welder
  • 36. HARMONICS 100%, 60 Hz 2%, 780 Hz 20%, 180 Hz 12%, 300 Hz 4%, 420 Hz 2%, 660 Hz %100 ... % 1 2 4 2 3 2 2 Ɨ +++ = I III THDI
  • 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
  • 39. EXPECTED HARMONICS H = NP+/-1 i.e. 6 Pulse Drive - 5, 7, 11, 13, 17, 19,ā€¦ Source Typical Harmonics* 6 Pulse Drive/Rectifier 5, 7, 11, 13, 17, 19ā€¦ 12 Pulse Drive /Rectifier 11, 13, 23, 25ā€¦ 18 Pulse Drive 17, 19, 35, 37ā€¦ Switch Mode Power Supply 3, 5, 7, 9, 11, 13ā€¦ Florescent Lights 3, 5, 7, 9, 11, 13ā€¦ Arcing Devices 2, 3, 4, 5, 7... Transformer 2, 3, 4 * Generally, magnitude decreases as harmonic order increases
  • 42. PARALLEL RESONANCE CAP SC R MVAR MVA f = 600 kVAR 1500 kVA 5.0% 480 V Xs 200 HP VSD 500 HP
  • 43. MOTOR HEATING AND VIBRATIONS 60 Hz Rotation 5th Harmonic Rotation
  • 44. NEUTRAL HEATING C B A N 0A at 60 Hz 10A at 60 Hz 10A at 60 Hz 10A at 60 Hz 30A at 180 Hz 10A at 180 Hz 10A at 180 Hz 10A at 180 Hz
  • 45. HARMONIC SOLUTIONS ā€¢ Clean power drives (18 Pulse) ā€¢ Clean MCCā€™s ā€¢ Active harmonic filters ā€¢ Passive harmonic filters ā€¢ Blocking filters (drives) ā€¢ Blocking filters (3rds) ā€¢ Zero-sequence traps ā€¢ Delta/Wye transformers ā€¢ Harmonic cancellation (phase shifting transformers) ā€¢ Isolation transformers ā€¢ Commutation reactors ā€¢ 200% neutral conductors ā€¢ K-factor rated transformers
  • 46. EFFECT OF DRIVE LINE REACTORS (IEEE519-1992)
  • 47. PHASE SHIFTING - 12 PULSE
  • 48. PHASE SHIFTING - 72 PULSE 230KV 69KV 0Ā° -40Ā° -20Ā° -10Ā° 10Ā° -30Ā° 5Ā° -35Ā° -15Ā° -45Ā° -25Ā° 69KV -5Ā° 0Ā° 0Ā°
  • 49. HARMONIC CORRECTION SELECTION FOR DRIVES IN MCCā€™S 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 ā€œfootprintā€ 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 oā€œOff-the-Shelf and application engineered oThree phase dry- type capacitors
  • 53. STACOVAR 100KVAR MODULE WITH CAPACITORS, REACTORS, CONTACTORS, FUSES
  • 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
  • 55. STACOVAR ā€œTYPICALā€ INTERNAL STRUCTURE ARRANGEMENT Acrobat Document
  • 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 ā€“surge 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 ā€œAt Loadā€ Fixed Capacitors oAvailable second quarter 2005
  • 63. COST OF HARMONIC CORRECTION Description Typical $/kVA* K-Factor 20 Reactor 3-4 Capacitors (LV) 12 Switched Capcitors (LV) 25 Single-Tuned Fixed Filter (LV) 35 Single-Tuned Switched Filter (LV) 40-50 Single-Tuned Fixed Filter (MV) 12 Single-Tuned Switched Filter (MV) 15 Blocking Filter (3rd's) 100 Blocking Filter (Drives) 100 Active Harmonic Filter 150 Phase-Shifting Transformers 50 Note that prices are generalized for comparison only but not absolute. Some equipment must be fully rated for loads - others can be partially rated Capacitors are shown for reference only.
  • 65. NOTCHING AND GENERATORS Generator Source may result in larger commutation notches and transients
  • 66. HARMONICS AND GENERATORS Utility Source 2.3% THD Generator Source 5.7% THD
  • 67. EXAMPLES OF PQ SITE SURVEYS Oil Platform - Gulf of Mexico ā€¢ The ā€œBad Noiseā€ and the ā€œEvil 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 (ā€œHarmonic Cancellationā€) 4160V 8x15KW FCE 480V 480V etc. 12470V 480V480V
  • 71. EXAMPLE - COMPUTER LOADS Office Building o Problem: Cubicle Furniture ā€œSmokingā€ as a Result of Overheated Neutral (High 3rd Harmonics from Computer Loads) o Solution: Run Separate Neutrals and Install K-Rated Transformers (ā€œLive 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 ā€œBad 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)
  • 75. THANK YOU Toll Free: 866.261.1191 | sales@stacoenergy.com | www.stacoenergy.com