Power Quality and Energy Saving Solutions - What Is Real?
Power Quality and Energy Saving Solutions - What Is Real?
Presented by:
Dan Carnovale, P.E.
danieljcarnovale@eaton.com
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Overview
• Need – Everyone wants to save energy!
• People want to believe that there is a simple
  solution
• Electric bills can be confusing
• Misleading sales methods by unknowing
  salespeople
• What claims are real?
• What claims are false?
• What should YOU do?
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Understanding Your Utility Bill
             Energy
             (kWh)
             Demand
             (kW)
PF Charges
+ Taxes
                                  4
                                      4
   Is the Glass Half Empty or Half Full?
Wasted
Capacity
                               Full
                             Capacity
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EPRI Said It Best….
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PQ Solutions that “Claim” to Save Energy
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Energy Savers
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It Happens to the Best of Us….
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It Happens to the Best of Us….
                                                     kW savings over   Cost savings over
          kWh        kW     Excess rKVA    Cost       previous year      previous year
  N-07   346,811    664.3      198.5    $28,856.55         4.3%              4.1%
Oct-07   329,366    628.5      150.1    $27,351.46         3.9%              3.2%
  S-07   297,597     571       106.5    $24,879.59        13.1%              11.5%
Aug-07   312,736   605.02       22.8    $26,120.39        15.9%              15.4%
  J-07   331,227   637.56       64.1    $27,100.99        10.5%              10.4%
Jun-07   308,103    616.8      467.4    $26,607.99        12.2%               9.2%
  M-07   319,200     630       529.7    $26,920.13         6.3%              5.6%
Apr-07   369,870     643       439.5    $28,231.73        16.6%               9.5%
  M-07   354,678     664       510.1    $28,663.34        -4.5%              -4.5%
Feb-07   400,302   704.4       506.2    $30,757.42        16.2%              11.7%
  J-07   395,049    708.7      533.6    $30,808.96       -18.0%             -21.5%
Dec-06   357,737    718.6      564.6    $30,444.10
  N-06   384,850    693.9      546.7    $30,099.75
Oct-06   354,128    653.9      455.7    $28,255.68
  S-06   339,933   656.9        560     $28,109.33
Aug-06   382,376    719.2      579.4    $30,869.79
  J-06   361,292    712.5      558.4    $30,259.63
Jun-06   345,645   702.44      508.4    $29,315.43
  M-06   352,918     672       493.8    $28,505.66
Apr-06   337,043    771.2      534.1    $31,194.23
  M-06   347,956    635.3      468.1    $27,432.08
Feb-06   387,728   840.9       527.1    $34,813.36
  J-06   289,015    600.7      458.5    $25,364.67
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Year-over-year Data Should NOT be Used
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PQ Solutions that “Save” Energy
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But they showed me how it works…
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But they showed me how it works…
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But they showed me how it works…
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Typical Claims
• Correct PF
• Provide Surge Protection
• Save Energy
• Commercial, Institutional and Residential
  Targets
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Authors’ Viewpoint
• We have done the calculations
• We have done the measurements
• We have talked to the vendors
• We simply do not believe the excessive claims
• Can you save significant money with PF
  correction? Yes, IF there is a penalty
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PQ Solutions that “Save” Energy
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PF Correction and Energy Savings
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PF Correction and Energy Savings
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Capacitor Placement – Physical Location
Utility Penalty – If needed for PF penalty
 • Typical savings is 5-30% of bill
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Power Factor Penalties
• Not possible to cover all penalties
  • Table 3 (Blooming/Carnovale paper) shows some
    typical methods
• User should determine which type of penalty
  (if any) the utility is using
  • Then investigate further
  • Sometimes utility uses multiple penalty methods
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         Power Factor Penalties
       Table I (partial) from “Capacitor Application Issues” paper
       http://www.eaton.com/EatonCom/Markets/Electrical/ServicesSupport/Experience/index.htm
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  PF Correction – Loss Reduction
                                                                   Resistive
                 R1                                                 Load
                                          R2
                                                                     Motor
                                                                     Load
                                                             Motor
         R1                        R2                        Load
                                                            Resistive
                                     I2                      Load
          I1
Delivery Losses
                                                            25
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Savings Depends on Location
                                                              Motor
           R1                       R2                        Load
                                                             Resistive
                                      I2                      Load
            I1
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Savings Depends on Location
                                                             Motor
           R1                       R2                       Load
                                                            Resistive
                                      I2                     Load
             I1
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   Example – PF Correction Savings
                         12.47/0.48
                            %R=1
 12.47 kV   2 mi, 336 MCM             300 ft, 1000    500 kW
              Overhead                MCM Cable       PF=.88
                                                      500 kW
                                                       PF=1
                  1076 kW
                                                     Source:
                                                      28     EPRI   28
  Example, Capacitor at Main Incoming
                         12.47/0.48
                           %R=1
12.47 kV   2 mi, 336 MCM              300 ft, 1000          500 kW
             Overhead                 MCM Cable             PF=.88
                                                           Source:
                                                            29     EPRI        29
  Example, Capacitor at Load
                         12.47/0.48
                                                     (250 kvar)
                           %R=1
12.47 kV   2 mi, 336 MCM              300 ft, 1000            500 kW
             Overhead                 MCM Cable               PF=.88
                                                                  500 kW
                                                                   PF=1
                 1065 kW
                                                             Source:
                                                              30     EPRI   30
       Computer Simulation – High Rise Building
 PF       kW     kvar    kvar added       % kW Savings
0.58      615     870         0               0.0%
0.62     612.8    771        100              0.4%
0.67     610.9    671        200              0.7%
0.73     609.2   568.8       300              0.9%
0.79     607.7    466        400              1.2%
0.86     606.6    361        500              1.4%
0.92     605.7    255        600              1.5%
0.97     605.1    147        700              1.6%
1.00     604.8    38        800               1.7%
0.99     604.9    -72       900               1.6%
0.96     605.3   -184       1000              1.6%
                                                        % Loss Improvement
                              1.8%
                              1.6%
                              1.4%
                              1.2%
                              1.0%
                              0.8%
                              0.6%
                              0.4%
                              0.2%
                              0.0%
                                      0     100   200    300   400   500   600   700   800   900 1000
                                                                           31
                                                        Losses vs. kvar Added                           31
Computer Simulation – High Rise Building
                                                      Utility
                                                      615.0 kW
                                                      870.3 kVAR
1000 kVA @ 0.6 PF
                                                                    0.19 % VD
                                                      Utility Bus   LF Voltage 12446.51 V
                                                                    LF Voltage(%) 99.81 %
                    Utility Feeder
                           615.0 kW
                           870.3 kVAR
                           LF kW Loss 0.00 kW
                                                                    0.19 % VD
                                                      Transf Pri    LF Voltage 12446.47 V
                                                                    LF Voltage(%) 99.81 %
                       615.0 kW
                       870.3 kVAR                     1000 kVA
                       LF kW Loss 11.40 kW
                                                      Secondary Bus
                                                      5.71 % VD
                                                      LF Voltage 452.61 V
                                                      LF Voltage(%) 94.29 %
                       603.6 kW
                       805.8 kVAR                     480 V Cable
                       LF kW Loss 3.64 kW
                                                           Load Bus
                                                                                            6.34 % VD
                                                                                            LF Voltage 449.56 V
                                                                                            LF Voltage(%) 93.66 %
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                Field Tests
              600                                         1.000
                                                          0.900
              550
                                                          0.800
              500                                         0.700
                                                                                 Trend Data During Test
kW, Current
                                                          0.600        kW
              450
                                                                  PF
                                                          0.500        Current
              400                                                      PF
                                                          0.400
              350                                         0.300
                                                          0.200
              300
                                                          0.100
              250                                         0.000
                    1                                   600                                        1.000
                                                        550                                        0.900
                                                                                                   0.800
                                                        500
                                                                                                   0.700
                                                        450
                                          kW, Current
0.600 kW
                                                                                                           PF
                                                        400                                        0.500        Current
                        Trend Data Zoom                                                            0.400        PF
                                                        350
                                                                                                   0.300
                                                        300
                                                                                                   0.200
                                                        250                                        0.100
                                                        200                               33       0.000
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                                                              1
                               Field Tests
                          12                 1.000
                                             0.900
                          10
                                             0.800
Harmonic Distortion (%)
                                             0.700
                           8
                                             0.600        VTHD
                                                     PF
                           6                 0.500        ITHD
                                                          PF
                                                                 Harmonic Trend Data During Test
                                             0.400
                           4
                                             0.300
                                             0.200
                           2
                                             0.100
                           0                 0.000
                               1
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                          Field Tests
                250                                              1               kW
                                                                                 kvar
                                                                 0.9
                                                                                 kVA
                200                                              0.8
                                                                                 PF
                                                                 0.7
kW, kvar, kVA
150 0.6
                                                                       PF
                                                                 0.5                       Load with Cycling Air Compressor
                100                                              0.4
0.3
50 0.2
0.1
0 0
                      1                       1001                                                                            1
                                                                                                                                          kW
                                                                                 160
                                                                                                                              0.9         PF
140 0.8
                                                                                                                              0.7
                                                                                 120
                                                                            kW
                                                                                                                                    PF
                                                                                                                              0.6
                                                                                 100
                          Zoom of Load with Cycling Air Compressor
                                                                                                                              0.5
                                                                                 80
                                                                                                                              0.4
                                                                                 60                                           0.3
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Confusion Created by Sales
 Hard Savings                        Soft Savings
 Reduced kWh                         Lengthens equipment life
 Reduced kW                          Protects sensitive electronic
                                     equipment
 Improved PF                         Reduces maintenance
Space savings
Improves safety
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Confusion Created by Sales
• Expert/Third party testimonials and/or “Technical sign-off”
  (usually engineer signs off then the sales person goes to the
  controller or finance person with the paper)
• Unknowing/Non-technical or passionate salesmen (he
  believes and so should you!)
• Patented technology
• Only the inventor truly understands the “technology”
• Hard to prove/disprove guarantees (buy our stuff and then
  show us you didn’t save…)
• Sell to unknowing residential and commercial customers with
  little or no knowledge of kW vs. kVA (current is reduced so
  “power is reduced”)
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Confusion Created by Sales
Confusing Percentages
  • Transformer 97% Efficient
  • New Transformer 97.8% Efficient
  • Either 0.8% Improvement or 27% Reduction in Losses
Faulty/Questionable M&V
  • Inferences/overgeneralizations from “similar” measurements
  • Comparison to customer with PF penalty
  • Revenue grade metering
  • CT inaccuracies/phase shifts
  • Lack of practical demonstration method
  • Too long/short measurement length
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Interesting Quotes
What genuinely makes this product different and thus sets it apart from most other
devices on the market is built in line noise filtering, “LNF”. This LNF circuit helps to
balance out the distortion in the wave cycle which causes KVAR’s in the harmonic
balance associate with inductive loads.
(Interpretation: Can you say “flux capacitor”?)
Achieved savings derived from using both MOV, TVSS and line filter capacitance
together in one unit maximizes the energy savings feature in real time operations,
with results showing anywhere from 5% - 20% or more in monthly electrical
savings possible.
(Interpretation: I can almost guarantee it might work….)
Highly sophisticated band-pass filter….blocks out harmonics, power spikes and
surges….clean up your power…increase your power factor, reduces KVAR, amp
draw and most importantly kWH usage…remember, you are billed for
kWH….reducing your kWH reduces your electric bills.
(Interpretation: Does everything but wash your car)
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Interesting Quotes
Utility companies hate our product because it takes money out of their pockets.
They don’t like when customers save money on their bills.
(Actually: yes, they do and they would love to pay you to save them from building
new gen plants)
How do you get 30% savings on a typical power system – well, if you save 2% on
every motor and you have 15 motors, there you go….
(Must be that “new math” – I guess I really don’t understand per unit math after
all….)
The inventor will call you to talk to you about the product
(I’m still waiting by the phone….)
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Interesting Quotes
“Power Factor” improvement is recognized by the US Department of Energy and all
Electric Power Companies as a method to reduce kWH on your electric bill.
(Actually: yes, PF correction is recognized but not, generally speaking to reduce
kWH)
Our product is certified by ANSI/UL STD 810 FOLDER which means it is a POWER
FACTOR improver.
(Regarding surge protection) – Every time you type on your keyboard, you create
micro-transients. These transients travel through the power system and waste
energy. Installing our surge protection will clean up your system and save you
XXX% on your energy bill.
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Interesting Quotes
You have to install our product – it works over time. You can’t just turn it on and
off and expect it to show a difference.
These capacitors are “different” – they aren’t just regular capacitors…. (opened the
box and what do you know….)
Q: How does 18 AWG wire in a demo box translate up to 500 MCM in a plant?
A: It just does….
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Interesting Reference Quotes
Our KWH was reduced by approximately 15-18%....Amperage was reduced by 22%
and the KWH was reduced by about the same….I’m not an electrician, so cannot
explain exactly how they work, but testing has shown us they do.
This also gave (us) the opportunity to participate in something that is positive for
the environment and good for the country we live in.
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My Favorite HELP Line Calls
  “I just started working for a company that makes
  energy saving devices…sometimes our product
  saves energy and sometimes it doesn’t – can you
  help me explain to our customers why that is the
  case????”
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My Favorite Redemption Line
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Other PQ Solutions that “Save” Energy
Products that Reduce Negative
Sequence Currents in Motors
  • Description: Voltage unbalance or
    negative sequence voltage harmonics
    make motor resist 60 Hz rotation
  • Claim: > 10% savings?
                                                   5th Harmonic
  • Reality: MG-1 describes      60 Hz Rotation
                                                   Rotation
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Other PQ Solutions that “Save” Energy
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Other PQ Solutions that “Save” Energy
Surge Suppressors
   • Description: TVSS/SPD typical equipment
   • Claim: Transients waste energy and surge
     protection equipment removes transients
   • Reality: Impossible and unbelievable! FTC
     warning = 0.00000%
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Other PQ Solutions that “Save” Energy
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Other PQ Solutions that “Save” Energy
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Other PQ Solutions that “Save” Energy
Soft Starter
   • Description: Power electronic motor starter
   • Claim: Reduce kW demand
   • Reality: 2-10 seconds of starting current will
     not significantly reduce 15 min billing demand.
     In addition, inrush current is primarily reactive
     (kvar, not kW). Savings = 0%.
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 Other PQ Solutions that “Save” Energy
Conservation Voltage Reduction (CVR)
  • Description: Reduce voltage to loads by 5-10%
  • Claim: Reduce kW demand, usage up to 13%
  • Reality: Depends on load mix – constant
    impedance loads will reduce kW but could
    increase load cycles (heating loads, for example).
    Constant HP (motor) loads could increase current
    and increase I2R losses. Typical <2% for
    aggregate systems could be more for specific
    individual loads.
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Voltage Reduction and Incandescent Light Bulbs
     You save energy but you get less light: why not change to a more efficient lighting
                                   technology instead?
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Other PQ Solutions that “Save” Energy
Energy Saver (green) Plug
  • Description: “The Green Plug was invented by my thesis
    adviser…it’s really a Modulated Switched Dynamic Filter Capacitor
    Compensator (did he mean to say “flux capacitor?”), a device
    designed to make existing power systems more powerful and energy
    efficient by reducing the amount of reactive energy and harmonic
    currents that are generated by electrical residential and commercial
    loads”
  • Claim: “…the actual savings available through the green plug are
    difficult to measure…but he estimated that power producers could
    expect to experience a drop of 10-20% in power if the green plug is
    used extensively”
• Reality: No comment ☺
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Table 2 – Summary Table
Description
Primary PQ Benefit
Stated EM Savings or Other Benefit(s)
Realistic EM Savings
Reasons for Discrepancies
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      Energy Management Cost Saving Solutions
                   Save money through rate structure
Management
Supply Side
                                                                                                                                      FACTOR
Enterprise
                                                                                                                                              GENERATOR
                   money by controlling loads
                                                                                                                                                 G
                                                                                                M                                     M
                       •Peak shaving          •Distributed generation
                       •Load control          •Time-of-use programs
                                                                                     LV SUBSTATION WITH                     PEAK SHAVING
                       •Meters                •Operational savings                   LOAD CONTROL                           LOAD CONTROL & ATS
                                                                                             ENERGY EFFICIENT
                                                                                                                              HARMONIC MITIGATING
                                                                                             TRANSFORMER
                                                                                                                              TRANSFORMERS
Energy Efficient
                                                                                        M           M                M            M
                       •Drives                •Power factor correction
                       •Transformers          •Harmonic Solutions
                       •Lighting control                                           LIGHTING
                                                                                                           MCC WITH PF
                                                                                                           & HARMONIC
                                                                                                                               HARMONIC
                                                                                                                               FILTER
                                                                                                                                               DRIVES
                                                                                   CONTROL
                                                                                   PANELBOARD            57CORRECTION
                                                                                                                                          M    - Meters
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            Potential Savings of Solutions
Table 2 (partial) from “Power Quality and Energy Management Solutions” paper
http://www.eaton.com/experience
ription Primary PQ Benefit Stated EM Savings and Other Benefits Realistic EM Savings Reason for
 ucts to address    Negative Sequence        • Eliminates “reverse” rotation action on   • kW and kWh savings (usually      • Hard to m
 tive sequence      Current reduction          motors yielding higher efficiency           < 2 %)                             stated cla
 ents                                        • kW and kWh savings (usually > 10%)                                           • Easier to
                                             • Reduces heating                                                                “some” s
                                             • Prevents premature damage
 ucts to address    Negative Sequence        • Eliminates “reverse” rotation action on   • kW and kWh savings (usually      • Hard to m
  lanced voltages   Current reduction          motors yielding higher efficiency           < 2 %)                             stated cla
 uding zig-zag                               • kW and kWh savings (usually > 10%)                                           • Easier to
  ors)                                       • Reduces heating                                                                “some” s
                                             • Prevents premature damage
  e protection      Elimination of voltage   • kW and kWh savings (usually > 20%)        • 0.000 %                          • Uneduca
                    transients               • Prevents damage
                                             • Reduces need for maintenance
                                             • Improves performance of equipment
  orrection         Reduce kvar flows on     •   kW and kWh savings (usually > 20%)      • 0.5-2% typical (excluding        • Easy to s
                    power system             •   Prevents damage                           harmonics)                         based on
                                             •   Reduces need for maintenance            • If electric utility charges PF     may purp
                                             •   Improves performance of equipment         penalty, PF charges may            and kvar
                                                                                           actually save up to 10% or so    • NOTE:
                                                                                           (not kW or kWh savings)            as kW or
                                                                                                                              though a
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Summary
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Wrap-up and Questions
Reference Papers and Presentations:
   1.   Carnovale/Mueller, “Power Quality Solutions and Energy Savings” (PQ
        Conference – 2005)
   2.   Blooming/Carnovale – “Capacitor Application Issues” (IEEE IAS – 2006)
   3.   EPRI – “Energy Savings: You Can Only Save Energy That Is Wasted”
   4.   EPRI – “Strategies for Evaluating Black Box Technologies”
                        Questions?
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