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6 stable loads, is shown below. Although this fairly efficient process had pre-existing power factor levels averaging .91 prior to modifications, the resulting
impact on the power quality characteristics is easily apparent. The current
load demands were reduced by about 12 percent, active power demands (k W)
were reduced by approximately six percent, and apparent power demands
(kVa) were reduced by approximately 12 percent.
Dynamic power quality enhancement systems – these systems can
measure, calculate and correct voltage imbalance at a speed of less
than 1 cycle (1/60 second).
Baseline Analysis Chart
Post-Treatment Analysis Chart
For the highly dynamic processes,
the impact was even greater. The
sawmill saw k W demand reductions
of over 26 percent prior to production
adjustments and over 11. 5 percent
with production adjustments made
during the analysis. Additionally,
areas where modifications were
not financially justified also saw
improvements. Due to the voltage
stabilization and reduction of transference of power quality characteristics between electrical circuits, a
three percent savings in active power
was also observed on the untreated
systems after production adjustments
were accounted for.
More significant was the secondary
impact on the operations. By stabiliz-ing the voltage to a tight bandwidth,
all previous drive issues, motor breaker trips, and phantom alerts observed
were significantly reduced or eliminated after implementation. This
significantly improved the operation’s
production time and considerably
reduced the unplanned downtime associated with these issues, which were
previously not associated with power
quality concerns. Although the energy
savings and capacity improvements
were considerable, the MRO cost savings observed far exceeded the monthly savings from utility electrical costs
including power factor penalties.
For this customer, because of their
ability to measure, calculate and correct voltage imbalance at a speed of
less than one cycle, a dynamic power
quality solution was the right choice.
What is right for your facility?
Whether it's capacitor banks, static or
dynamic conditioning units, the best
place to start is by engaging a qualified electrical power quality provider
that will take long-term measurements to validate your facility's needs
and provide the right power quality
solution.
Mike Nagy is Motion Industries’
Director of Cost Savings Management, and has led the Motion
Industries Energy Services Team for
seven years.