ENERGY SAVINGS THROUGH POWER CONDITIONING WITH THE PowerGUARD SYSTEM
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1 ENERGY SAVINGS THROUGH POWER CONDITIONING WITH THE PowerGUARD SYSTEM Abstract Efficient operation of the electrical system of any facility is essential to controlling operational costs while maximizing the performance of motors and electronic equipment and minimizing equipment downtime. Poor power factor and high levels of total harmonic distortion in the current and voltage of an electrical circuit result in wasted power as the result of motor and transformer inefficiencies, copper losses and heat. Poor power quality also affects the reliability of electrical equipment, resulting in higher maintenance and repair costs. Utility providers are increasingly charging penalties for poor power quality which, together with steadily rising energy rates, result in higher operating costs. The PowerGUARD System provides a new and innovative approach to electrical circuit protection, power factor correction and the reduction of harmonic power on the circuit. The PowerGUARD system improves overall power quality in three principal ways, each accomplished through coupling of the three phases of power: 1. It provides effective spike and surge protection, including protection against lightning strikes, ground faults and transients. It does this in a superior fashion to conventional Transient Voltage Surge Suppression (TVSS) systems by shunting the electrical disturbance to all three phases and absorbing the disturbance through magnetic chokes. 2. It corrects Power Factor in a fundamentally different way than Power Factor Correcting Capacitors by using transformers to generate current which is fed to the opposite phases in a way which cancels out reactive power. The PowerGUARD system does not create dangerous resonance, making it a much more advantageous power factor correction system than capacitors. 3. It reduces the total harmonic content of the circuit by taking some power off the circuit to generate an equal amount of new power through the transformers. The power delivered by the POWERGUARD system is free of harmonics because the power is delivered through band-pass filters which filter the power to 60 hertz. As a result of these actions, each PowerGUARD 480 volt unit will reduce the demand for electricity by between 13,140 and 26,280 kilowatt-hours (kwh) per year while reducing reactive power by approximately 22 KVAR. Additionally, amperage is reduced and voltage is increased on each phase. One PowerGUARD 480 volt unit is specified for each 30,000 kwh/month or for each 85 amps (see sizing chart below). Typical facility installations require multiple units. This unique system combines the benefits of power factor correction with harmonic filtering and superior surge and spike protection, all in one compact power conditioning system. There is no other technology on the market that corrects power factor, filters harmonics or absorbs spikes and surges in a similar manner as this system. Because of this, the PowerGUARD system results in the reduction of the demand and consumption of real power on the circuit which goes beyond that which is possible with power factor correcting capacitors alone.
2 PowerGUARD Power Factor Correction With the POWERGUARD system, capacitive reactive power is not generated by capacitors but is the product of transformer action inherent in the design of the PowerGUARD device. The system couples the three phases of power supply using transformers coupled to 60Hz band-pass filters. The transformers develop current in phase with one phase, and deliver the current simultaneously to the second and third phases. The delivered current assumes the properties of capacitive reactive power and cancels out an equal amount of inductive reactive power. The amount of capacitive reactive power generated by the PowerGUARD product is dependent on the circuit voltage and model specified. Because the PowerGUARD system does not rely on the design of capacitors to generate its capacitive reactive current, problems associated with resonance are avoided. PG Current generated in phase with Phase #1. is delivered simultaneously to Phase #2. and to Phase #3, thus canceling out Reactive Power. PowerGUARD Harmonic Filtering By coupling the transformers with 60Hz band-pass filters, the PowerGUARD system supplies inductive reactive current which reduces the harmful effects of harmonics. In a properly sized system application, over thirty percent of the current on the circuit will be free of harmonics, reducing the total harmonic current and total harmonic voltage on the circuit. The reduction of harmonics results in added efficiency of motors and transformers while minimizing the harmful effects of harmonic distortion. PowerGUARD Spike & Surge Protection The PowerGUARD system incorporates Metal Oxide Varistors (MOVs) and other electronics to protect the electrical circuit against electrical spikes and surges, transients, ground faults and lightning strikes. By shunting these disturbances from one phase to all three, and then channeling them through the transformers and band-pass filters, these disturbances are absorbed by the device and circuit protection is accomplished without shunting power to neutral. Unlike TVSS systems which 2
3 only suppress voltage spikes above a certain clamping voltage, the PowerGUARD system absorbs both voltage and current spikes and surges, providing additional circuit protection. Typical Sizing for the PowerGUARD Shunt Efficiency System This system is sized to a specific circuit configuration to maximize its performance relative to power factor correction, energy savings potential and/or circuit protection. There are two configurations of the system for each voltage; a delta configuration and a wye configuration. The wye configuration provides additional circuit protection of the facility neutral conductor against transient voltage spikes and surges, ground faults and lightning strikes. Typically, one wye configured unit is installed for each neutral conductor. Voltage Model # Units/Amps KVAR Reduction KW Demand Reduction 208 VAC COMM-3Y 1 per 50 amps kwh/hr/unit 208 VAC COMM-3D 1 per 50amps kwh/hr/unit 480 VAC IND-3Y 1 per 85 amps kwh/hr/unit 480 VAC IND-3D 1 per 85 amps kwh/hr/unit 600 VAC IND-3Y 1 per 100 amps kwh/hr/unit 600 VAC IND-3D 1 per 100 amps kwh/hr/unit Performance Examples The PowerGUARD system produces easily measured and verifiable results. Each unit is connected through a 3-pole, 40-amp circuit breaker or equivalent fused disconnect, allowing the unit to be switched on and off at intervals of 5, 10 or 15 minutes. The following performance results were measured at Saratoga Wastewater Treatment Facility using an Amprobe DMII-Pro multi-meter and data logger. This meter is NIST-certified and collects a reading every one-second. 3
4 Graph #1 Wattage and Power Factor 7:53:30 AM 12.2 kw instantaneous reduction 7:54:00 AM 7:54:30 AM 7:55:00 AM 7:55:30 AM 7:56:00 AM W 490, , , , , , , , , , , , , , ,000 7:56:30 AM [PF] Blower Building MCC Power Factor - 3Ø ([PF]) Real Power - 3Ø (W) Graph #1 shows the effects of eight (8) PowerGUARD model IND-3D-480 volt units at the blower building. The blue line shows power factor which improves from 96% to 99% when the PowerGUARD system is switched on. The green line shows real power in watts and shows a 12,200 Watts (12.2 kw) instantaneous demand reduction when the PowerGUARD system is switched on. Graph #2 Voltage, 3-Phase V :00:00 PM 2:05:00 PM 2:10:00 PM 2:15:00 PM 2:20:00 PM 2:25:00 PM 2:30:00 PM MCB 1 RMS Voltage - VAB (V) RMS Voltage - VBC (V) RMS Voltage - VCA (V) 4
5 Graph #2 shows the effects of one (1) PowerGUARD model IND-3D-480 volt units at the same Wastewater Treatment Facility. Significant voltage fluctuations are caused by the facility s Variable Frequency Drive (VFD) control system. When the POWERGUARD system is switched on, there is an increase in voltage on each phase and a reduction in voltage fluctuations (noise) on each phase. Graph #3 Reactive and Apparent Power Reactive & Apparent Power VAR 400,000 VA 650, , , , , , , , , , , ,000 50, , ,000 9:00:00 AM 10:00:00 AM 11:00:00 AM 12:00:00 PM 1:00:00 PM A pparent Power - 3Ø (V A ) Reactiv e Power - 3Ø (V A R) Start: 8/23/2007 8:30:01 AM End: 8/23/2007 1:36:06 PM Main Switch Gear Graph #3 shows the effects of twelve (12) PowerGUARD model IND-3D-480 volt units at a wastewater treatment plant in Maine. The green line shows apparent power while the red line shows reactive power. Reactive power is reduced by 247 KVAR while apparent power is reduced by 87 KVA when the POWERGUARD system is switched on. Graph #4 Amperage, 3-Phase A :10:00 AM 11:15:00 AM 11:20:00 AM 11:25:00 AM Incinerator Bldg MCC RMS Current - IA (A) RMS Current - IB (A) RMS Current - IC (A) 5
6 Graph #4 shows the effect of seven (7) PowerGUARD model IND-3D-480 volt units at the blower MCC. Amperage on each phase is reduced by about 55 amps when the PowerGUARD system is switched on. Conclusion The PowerGUARD System presents a new, innovative way to correct several different power quality problems in one package. The system has the potential to reduce kilowatt demand beyond that which can be achieved through power factor correction alone. This is accomplished by improving power factor while reducing harmonics and increasing the circuit efficiency of the facility. The system also acts to protect the facility from the damaging effects of spikes, surges, transients, ground faults and lightning strikes. Installation at Motor Breaker Installation at MCC for multiple motors 6
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