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Customers with poor power factors take up capacity on our lines. To compensate for this losswe mustincrease the size of our facilities Recently the NYS Public Service Commission directed us to revise the power factor threshold from 90% to 95%...to reduce the lost energy on oursystem
Agenda
Where are capacitors needed? What is power factor? The benefits of capacitors How to size capacitors Where to place capacitors Capacitor equipment options An introduction to harmonics Product offerings Product features and benefits
Capacitor Opportunities
Where Office Buildings Mfg Plants Apartments/Condos Shopping Centers Schools, Hotels
Why Improve Power Factor Plant Expansion Voltage Problems Specd by Engineer Consultant
Capacitors
Who Saw Mills Hospitals Motor Suppliers Panel Shops Processing Steel Mills
When New Installation Upgrading Facilities Poor Power Factor Plant Expansion
kVA
Working Power (kW) It does the "work for the system Provides the motion or heat. Reactive Power (kVAR) Sustains the electromagnetic field Doesn't do useful "work." Apparent Power (kVA) Working Power and Reactive Power together kVAR
Utility supplied
kW
= Power Factor
1921 kVA0
1200 kVAR0
Utility supplied
1921 kVA0
1581 kVA1
700 kVAR1
Customer supplied
500 kVAR0
Utility supplied
Adding 700 KVAR would save over $9000 per year resulting in a payback of as little as 2 years
Total KVA
60 A
80 A
60 A
80 A
M M
Capacitor
% Loss Reduction
A typical plant with a 1,500 KVA demand will use 500,000kwh/month Typical I2R losses can be as high as 2.0% of the kwh consumption Resulting in 120,000 kwh saved annually Transformer loss reduction can be an additional 10% in kwh reduction
The Solution Installed 4200 kvar Total installed cost $200k Raised power factor to .95
The Result Reduced fuel usage Reduced maintenance Lower cooling costs Additional transformer capacity
Benefits of Capacitors
Improved Voltage Carbon Footprint Reduction Capacitors = $ Savings + Better Plant Efficiency + a Greener Planet
Use 12 Months of Utility bills if possible Find worst KVA or kW and Power Factor, or KVAR used Determine desired Power Factor Use Charts to find kW Multiplier Motor data can be useful
Voltage, RPM, HP, Type
Main Bus Motor Feed Circuit Breaker Fixed Capacitor Bank Automatic Capacitor Bank Fused Disconnect Fixed Capacitor Contactor Fixed Capacitor Thermal Overload M
At the Motor
Advantages
Easy to install Can mount & switch with equipment No expensive switchgear Minimal transients Most line loss reduction Most accurate correction
Advantages
Disadvantages
Disadvantages
More units to install More expensive per kvar
Equipment Fixed and Automatic (at motor and incoming) Pole top Metal Enclosed Substation Stack Rack Substation Stack Rack
High Voltage
>34.5 KV
Low Voltage
Automatic banks
Low Voltage
208-600 volts Fixed or automatic 2-2400 KVAR Can put small amounts of KVAR at motors Can install a bank at the facility incoming Can be used at facilities of all sizes, indoors or outdoors Can be used in conjunction with MV or HV capacitors Easy to install
Typical dimensions 30H x 24W x 8D
Fixed bank
Fixed Capacitors
NEMA 1, 3R & 12 enclosures
For all motors in the plant Enclosures to fit every customers needs
208 to 600 volts, 2 kvar to 400 kvar With 3 Fuses and Lights
Customer knows when a fuse operates For harmonic rich environments
Heavy duty 3 phase capacitors Capacitor-rated contactors Microprocessor based controller Up to 800 kvar in a single enclosure De-tuned iron core reactors (3.78th)
Controller
NEMA 1 enclosure with top or side entry Same components as the full-sized automatic bank resulting in the same high quality
Heavy duty metalized self-healing 3 phase capacitors Capacitor-rated contactors with damping resistors Microprocessor based controller
62H x 33W x 17D
Optional circuit breaker and blown fuse lights Designed to provide the right amount of kvar at a very competitive price allowing for a shorter payback
Smaller steps for precise control Wall mounted NEMA 1 enclosure with top or side entry Same components as the full-sized automatic bank resulting in the same high quality Blown fuse lights standard Optional circuit breaker StacoVAR mini brochure updated to include these new ratings
30H x 24W x 8D
Designed to provide cost effective power factor improvement for commercial and small industrial customers
Metal Enclosed
Medium Voltage
Metal Enclosed 2.4-34.5 KV Fixed or automatic Multiple steps available De-tuned or filter banks 300-25,000 KVAR Usually used only at large industrial facilities Pad Mount banks
Blown fuse lights available Indoor or outdoor installations For installation at large motors Components stocked for short lead time Brochure available at www.stacoenergy.com
Equipment Comparison
Low Voltage Fixed Installation Expertise to Install Assembly Assembly time KVAR per step Switching Equipment Cost* Apply to small motors Easy In house maintenance staff Self Contained Hours All on at once
Use existing motor contactor
Low Voltage Automatic Install at incoming LV Electrician Self Contained 1-2 days 25-100 KVAR Inexpensive contactor $20-30/KVAR
Metal Enclosed Install at incoming MV/HV Electrician Self Contained 3 days 300-2000 KVAR Expensive contactor or switch $15-40/KVAR
Substation Stack Rack Install at incoming MV/HV Electrician & Crew Many parts to assemble 1-2 weeks 300-5000 KVAR Expensive switch $10-20/KVAR
$8-30/KVAR
Harmonic Distortion
Harmonic Solutions
An integer multiple of the fundamental frequency Continuous disturbances Additive Makes installing capacitors more expensive
5th Harmonic= 300 Hz 3rd Harmonic= 180 Hz 7th Harmonic= 420 Hz
Transformer heating Motor and generator heating, vibration and burnout Neutral heating Nuisance fuse operations Insulation deterioration Electronic control malfunctioning Inconsistent meter readings Voltage regulator miss-operations Capacitor failures Circuit breaker tripping
Wall Mounted
Free Standing
Eliminates the harmonics on the system Handles 3rd through 51st Does not have a major impact on power factor