Verification of Performance

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Verification of Performance Power Metrics International Sensor Perfect 1000 (Model A) Power Factor Correction System KCE-140315 Engineering Report, August 2014 Tom Spinelli & Hamid Pishdadian Power Metrics International, Inc. 1961 Richmond Terrance Staten Island, New York 10302 United States KCE Engineering Project Manager P. Keebler KCE Engineering, LLC 3202 Tazewell Pike; Knoxville, Tennessee 37918 USA 865-660-9915 [email protected]

Transcript of Verification of Performance

Page 1: Verification of Performance

Verification of Performance

Power Metrics International — Sensor Perfect 1000 (Model A) Power Factor Correction System

KCE-140315

Engineering Report, August 2014

Tom Spinelli & Hamid Pishdadian Power Metrics International, Inc. 1961 Richmond Terrance

Staten Island, New York 10302 United States

KCE Engineering Project Manager P. Keebler

KCE Engineering, LLC 3202 Tazewell Pike; Knoxville, Tennessee 37918 USA 865-660-9915

[email protected]

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DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF WORK SPONSORED BY GREEN ENERGY MANAGEMENT, INC., AMERICAN ENERGY SOLUTIONS, INC. AND KCE ENGINEERING, ANY SUBCONTRACTOR, THE ORGANIZATION(S) BELOW, NOR ANY PERSON ACTING ON BEHALF OF ANY OF THEM:

(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I) WITH RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, OR (II) THAT SUCH USE DOES NOT INFRINGE ON OR INTERFERE WITH PRIVATELY OWNED RIGHTS, INCLUDING ANY PARTY'S INTELLECTUAL PROPERTY, OR (III) THAT THIS DOCUMENT IS SUITABLE TO ANY PARTICULAR USER'S CIRCUMSTANCE; OR

(B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER (INCLUDING ANY CONSEQUENTIAL DAMAGES, EVEN IF KCE OR ANY KCE REPRESENTATIVE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES) RESULTING FROM YOUR SELECTION OR USE OF THIS DOCUMENT OR ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT.

ORGANIZATION(S) THAT PREPARED THIS DOCUMENT

KCE Engineering, LLC

NOTE

For further information about KCE Engineering, please call 865-660-9915 or email [email protected].

KCE Engineering LLC and IMPROVING OUR WORLD ... ONE TECHNOLOGY AT A TIME are pending registered service marks of the KCE Engineering, LLC.

Copyright © 2014 KCE Engineering, LLC. All rights reserved.

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CITATIONS

This report was prepared by

KCE Engineering, LLC

3202 Tazewell Pike

Knoxville, Tennessee 37918

Principal Investigator

P. Keebler

This report describes the results of a photometric site analysis sponsored by Power Metrics

International, Inc., and conducted by KCE Engineering, LLC.

This publication is a corporate document that should be cited in the literature in the following

manner:

Verification of Performance: Power Metrics International — Sensor Perfect 1000 (Model A).

Green Energy Management, Inc., Fort Lee, NJ: 2014. KCE-140315.

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CONTENTS

1 INTRODUCTION ........................................................................................................................... 1-1

2 TEST LOADS FOR THE LOAD BANK ............................................................................................ 2-1

3 NOMINAL VOLTAGE TESTS ..................................................................................................... 3-1

4 OTHER TEST RESULTS ............................................................................................................. 4-1

5 CONCLUSION .............................................................................................................................. 5-1

A BIBLIOGRAPHY ........................................................................................................................... A-1

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LIST OF FIGURES

Figure 1-1 The PMI SP1000 Model A Test System ............................................................................ 1-2

Figure 2-1 Multi-Channel Linear and Non-Linear Load Bank ............................................................ 2-2

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1 INTRODUCTION

The continued growth of electrical/electronic products in customer facilities is improving

peoples’ lives but increasing grid load at tremendous rates. Many of today’s products are aimed

at increasing energy efficiency and intelligent use of electronic loads. The purpose of these two

activities is to counterbalance load growth and postpone the construction of power plants.

Modern electrical/electronic products have non-linear load (NLL) characteristics which place a

strain on building electrical systems and the grid. NLLs range from a few watts (e.g., your cell

phone charger) to thousands of watts (e.g., a power supply for a large server) and are specialized

electronic circuits that convert AC grid energy to energy (AC or DC) to power modern electronic

devices.

Today’s modern electronic loads are called NLLs because they utilize a series of switching

power transistors that simply act as switches to control the flow of current from the facility (grid)

to charge a series of capacitors. These capacitors act as energy “tanks” to provide energy to the

microelectronic circuits that make up our electronic loads.

Economic sustainability for any customer today is largely a function of reducing the cost of

operating their facilities. Customers demand lower energy and maintenance costs and increased

productivity, therefore improving the bottom line to sustain profits. Currently, the largest growth

in non-linear loads is seen in energy-efficient technologies—electronic lighting, variable speed

drives (VFDs, also called adjustable speed drives), and smart appliances to name a few. Rapid

growth in consumer electronic equipment (e.g., LED, plasma and LCD televisions) also

continues to rapidly increase non-linear grid load. Load research indicates that facility loads are

nearly all non-linear. Moreover, the linear loads that are still in use today are being transformed

into essentially non-linear loads by adding power electronics on the front end to increase

efficiency.

Aside from increased use of energy-efficient technologies and consumer electronics is the

increased use of renewable energy resources (RER), also called distributed energy resources

(DER) or distributed generation resources (DGR) systems. These resources include wind

turbines, microturbines, photovoltaic (PV) solar systems and fuel cells among others. While the

primary purpose of these systems is to convert mechanical, thermal or solar power to electrical

power at large power levels (i.e., high power energy conversion system), they also utilize power

to carry out the energy conversion process. Power electronic systems (e.g., converters, inverters,

etc.) change the energy they capture and inject it back into the grid. This process generates

steady-state and transient electrical disturbances including harmonic currents which flow back

into the grid and into the customer facility. The tremendous growth in the use of these resources

is causing a rapid increase in harmonics and distortion in the quality of voltage and current. Any

electrical system that produces harmonic currents also affects the quality of the voltage which

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Introduction

adds harmonics to the voltage. Increases in harmonic voltage distortion add reactive power

demand to a customers’ electrical system.

An additional concern is the growing need for petroleum-free vehicles which is spawning the

growth in development, manufacture and use of electric vehicles (EV). EVs require charging of

their batteries, both at the place where the vehicle is typically parked (e.g., a residence or

business) at the end of a driving period and at vehicle stopping points. EV charging systems,

whether they are part of the on-board electrical system inside the vehicle or stand-alone charging

stations, also use inverters that change AC power to DC power to charge the batteries. If a utility

dispatches the need for energy stored in EV batteries in parked vehicles, energy is again inverted

and injected back into the grid. This process also generates harmonics and distortion which can

easily combine with other harmonics on the grid and in a facility.

What is a Sensor Perfect (SP) 1000?

The Sensor Perfect (SP) 1000 system is an intelligent electronic system developed and

manufactured by Power Metrics International (PMI) in Staten Island, New York. This system

electronically senses several electrical power quality conditions and specific characteristics of a

facility electrical system at its point-of-installation. Each SP 1000 product utilizes a set of

microprocessors to sense these conditions and characteristics and make specific decisions to

provide dynamic control of one or more sets of internal capacitor banks available at each phase

(A, B, and C).

Figure 1-1

The PMI SP1000 Model A Test System

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The SP1000A Specifications

The current specifications for the SP1000A units tested are shown in Table 1-1. The SP1000A

is a three-phase system designed for 208Y/120V facility electrical systems. Each unit contains 180

microfarads per phase which can be switched into and out of each phase in increments. Each unit

can provide as little as 0.05 kVARs of power factor correction or as much as 3 kVARs of

correction per phase. Each unit contains immunity protection against voltage surges on each

phase. (Evaluation of surge protection was not included in this project.) Because the SP1000A

(and the other SP 1000 products) contains multiple micro-electronic components including three

microprocessors, high-performance surge protection of the SP1000A electronics is critical to its

proper operation and life. For these and other safety reasons, the performance of its surge

protection should be evaluated by a third-party engineering firm. The SP1000A requires over-

current protection at 30 amps per phase.

Table 1-1

SP1000A Technical Specifications

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Introduction

The above specifications indicate that the losses (i.e., power to operate the SP1000A) are 1.2

watts per kVAR. Thus, for correction at 3 kVAR, the maximum losses should be 3.6 watts. The

power consumption with the SP1000A in its quiescent state (i.e., with no correction taking place)

was measured and is reported in Chapter 3 — Nominal Voltage Tests.

Spider Software Used during Testing

The Spider software used during the testing was Version 5.4.

Non-Linear Loads (NLLs), Harmonic Currents and Reactive Power

Operation of NLLs on any facility electrical system today produces dynamic power quality

problems which result in waste of electrical energy. The dynamic power quality problems that

occur in these systems occur because

· NLLs draw irregularly sine-wave shaped (or distorted) current on each phase,

· NLLs draw unbalanced distorted current on each phase,

· Facility electrical systems were not designed to support NLLs very well (e.g., losses and

heating result from harmonic currents flowing in conductors and transformers),

· Harmonic currents produced by NLLs cause harmonic voltages to develop in

transformers (facility and utility).

Electrical energy waste occurs and cost the customer money because

· Harmonic currents drawn by NLLs must flow through the facility electrical system (i.e.,

conductors and transformers). This flow of unwanted current causes I2R heating in

conductors and transformers which consumes power and results in the drop and distortion

of voltage at the end of the system where the loads are connected.

· Harmonic currents flowing in a facility electrical system combine in an upstream fashion

with the highest harmonic currents being at the main service entrance where the utility

revenue meter is located. Some harmonic current cancellation occurs within the facility

electrical system, but the overall result is that some amount (typically large) of reactive

power must be provided to the NLLs. This results in a demand for reactive power that the

utility must provide to ensure the system operates correctly according to the laws of

physics. The utility cannot provide reactive power to a facility for no cost. Utilities have

different policies and rules for measuring how much reactive power is required and how

to bill customers for it.

· Harmonic currents (individually and summed) can be higher than the usable 60-hertz

current that performs work (i.e., turns motors and lights lamps). The 60-hertz current is

the only current that performs work for the customer. Harmonic currents perform no

work and only add to the cost of operating a facility. High harmonic currents equate to

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Introduction

high reactive power demands. When harmonic currents are high, power cables and

transformers experience higher temperatures. Higher temperatures not only reduce the

life of cables and transformers, but also add to the building heat load which air-

conditioning systems must work against.

NLLs require reactive power to operate, and they do not care where it comes from. Providing

reactive power to NLLs via the utility power grid can be costly and results in a higher usage of

power to cover the losses that reactive power flow imposes on facility electrical systems.

Providing a reactive power source (i.e., the SP1000) closer to the NLL is a much more cost

effective approach that providing it from the utility or from fixed capacitor banks staged out

across a facility electrical system.

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2 TEST LOADS FOR THE LOAD BANK

The loads in commercial and industrial facilities are made up of a complex arrangement of loads.

Some of the loads are linear and some non-linear. The ratio of linear to non-linear loads depends

on a number of factors related to the type of business the customer is carrying out in their

facility. Most of today’s loads are non-linear. Non-linear loads draw non-linear current and

reactive power from the utility power system. Drawing non-linear current causes harmonic

currents to flow from the utility which also circulate in the facility electrical system. Allowing

non-linear current to enter a facility and circulate in a facility electrical system causes energy

losses both in the utility power system and in the customer’s facility electrical system.

Designing and implementing a controlled electrical environment is a requirement when testing

any electrical or electronic system or device in a laboratory testing environment. When testing a

system designed to provide reactive power to a customer’s facility electrical system, laboratory

control over the load is required. Loads in customer facilities vary too much to determine or

verify any electrical-related performance of the SP1000A.

The SP1000A is designed to monitor electrical conditions on a circuit, determine when injection

of reactive power is required on that circuit and switch banks of capacitors in and out of the

circuit. The switching of the capacitors inside the SP1000A is under microprocessor control and

occurs very frequently when an SP1000A is installed inside an actual facility. Real linear and

non-linear loads are used in the CLB. Although the power drawn by any load will drift, using

fewer loads in a test load bank subjects the SP1000A to a much lesser degree of drift. This

enables the investigator to more precisely determine the performance of the SP1000A.

The Load Bank

Figure 2-1 illustrates the multi-channel load bank custom-designed for the SP1000A testing

project. This load bank is operated at 208 volts and is comprised of linear and non-linear loads.

The power chain shown illustrates the flow of power from the voltage source to the load bank.

The voltage source is a standard 50-kVA multi-tap transformer which is the most common dry-

type transformer used in commercial and industrial facilities. The voltage derived from the

transformer is fed to a 5.5-kVA power amplifier. The power amplifier maintains the integrity of

the voltage during the testing. (The amplifier is kept in idle mode (i.e., direct power pass-

through) during Test 1 – Nominal Voltage Tests.) The purpose of the amplifier is to inject

voltage distortion into the voltage waveform when necessary during Test 4 – Voltage Distortion

Tests.

The three-phase power meter measures the power parameters during the testing. This

measurement documents the performance of the SP1000A during testing as the load in the load

bank is varied. The power from the meter flows into the Load Switching Network (LSN). The

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Test Loads for the Load Bank

LSN is designed to switch a number of linear and non-linear loads into and out of the circuit

which varies the load detected by the SP1000A (when it is connected to the circuit). The

SP1000A can also be switched into and out of the load bank circuit. This is the approach used to

determine the performance of the SP1000A. The LSN can accommodate up to five SP1000A

units so they can be operated in parallel.

Figure 2-1 Multi-Channel Linear and Non-Linear Load Bank

Loads in the Load Bank

The most common loads in any facility are lighting loads, computer loads, mechanical (e.g.,

motors), purely resistive heater loads and miscellaneous non-linear loads. Lighting loads are

quickly becoming non-linear loads. The majority of fluorescent lighting fixtures use electronic

ballasts which contain switch-mode power supplies. High-intensity discharge (HID) lighting

fixtures still primarily use magnetic (i.e., inductive) ballasts—transformers that draw non-linear

current shifted from the voltage. Electronic ballasts are frequently used in HID lighting to

improve efficiency and reduce energy consumption but have still not captured the market share.

Induction lighting fixtures, a form of fluorescent lighting, all use electronic ballasts because re-

entry point into the market came when it was not practical to use magnetic ballasts. Light-

emitting diode (LED) fixtures also all use electronic ballasts (frequently called electronic drivers)

to power their LEDs. With lighting becoming all electronic, the increase in reactive power

requirements from the utility grid and the degradation of power factor will continue. This will

increase the need for the SP1000 technologies. For these reasons, the load bank incorporates

three metal halide lamps driven by magnetic ballasts rated at 1,000 watts each and three 400-watt

induction lamps driven by electronic ballasts.

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Test Loads for the Load Bank

All computer loads are non-linear loads as all computers contain a switch-mode power supply

(SMPS). Computers are no longer operated by transformer-based power supplies. The load bank

incorporates six SMPS-based computer power supplies rated at 650 watts each.

The load bank also incorporates two forms of mechanical loads—pure electric motor load rated

at three horsepower powered directly from the AC line and a 15 horsepower motor powered by

an adjustable-speed drive (ASD) rated for this motor.

The load bank also contains three high-power rheostats to increase the ratio of linear to non-

linear load.

Power Parameters Measured

In the area of energy and power quality performance, a number of power parameters can be

measured. Two of the most important parameters are real power and true power factor. Real

power is measured in watts and is what consumers pay for at the end of the day. In commercial

and industrial facilities, commercial and industrial customers sometimes pay for exceeding a

utility-prescribed limit on either true power factor, reactive power or apparent power or any

combination of these parameters.

In this testing project, the following parameters were measured for each phase (A, B and C)

· Real power (in watts)

· True power factor (no units)

· Line voltage (in volts)

· Line current (in amps)

· Voltage distortion (in percent)

Reactive power and apparent power can be calculated from knowing the real power and true

power factor. If the SP1000A provides reactive power to the load (as it is designed to do) instead

of allowing it to be supplied from the utility, the power meter should show a reduction in real

power and an increase in power factor. (If reactive power is reduced, true power factor will

increase and real power will decrease; thus resulting in energy savings over time.)

Potential purchasers of SP1000 technologies will be looking to see if their energy bills can be

reduced by installation of these technologies at the correct locations within their electrical

systems. Performance of the SP1000A can be verified in a mixed (or any load environment

containing non-linear loads) load environment by examining the real power and true power

factor at the SP 1 000A installation point.

Power Factor

Generally speaking, power factor is a unit less measurement. It defines how the ratio between the

three power parameters: real power (in watts), reactive power (in VARs) and apparent power (in

volt-amperes). Non-linear loads cannot operate without reactive power—a source of reactive

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Test Loads for the Load Bank

power must exist in any power system. However, the source of reactive power does not have to

be the utility. There are two types of power factor: true power factor and displacement power

factor. Displacement power factor is a measure of the shift between the voltage and current. (The

voltage and current are in phase (i.e., shift in time is equal to zero) if the load is purely linear

(i.e., contains no electronic components). However, in all of today’s facilities—residential,

commercial and industrial—no pure linear load exists. The majority, if not all, of the load is non-

linear.

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3 NOMINAL VOLTAGE TESTS

Utility grids do not deliver nominal steady-state voltage to any customer load. The old adage

with respect to voltage and current states, “The voltage belongs to the utility, and the current

belongs to the customer.” In electrical engineering, students are taught that voltage is the

stimulus (i.e., like water pressure) and current is the response (i.e., like water flow). Without

loads, there would be no current, and the utility line voltage could be set to provide the exact

voltage needed which would never change, meaning that the voltage at any receptacle would be

the same at the substation. Zero current in a power cables means that the voltage at the end of the

cable is the same as that at the beginning of the cable. If no current flows in a power cable, no

voltage is dropped along that cable.

The utility power system employs a series of subsystems to monitor the voltage and adjust it up

and down as the load on the grid varies. Around 5:00 pm, utility customers are returning home to

cook dinner. Everyone is using a series of appliances everywhere. The load on the grid rises as

more current flows. More NLLs are operated resulting in a high demand for reactive power.

Utilities must provide a source of reactive power, typically at a substation or part of the service

entrance to a facility where power factor correction (PFC) correctors are used.

Two principle methods of providing voltage control originate from the operation of tap-changing

transformers located in substations and capacitor banks located at carefully selected points along

the power distribution system. Tap-changing transformers can step the voltage up and down in

present increments. Utilities carefully set up the operation of these transformers in efforts to

automatically control the voltage. Capacitor banks are typically switched on or off the grid

through automated (i.e., timed) switches. In many cases, capacitors in today’s system are

switched manually by a utility employee. Switching a bank of capacitors into a power

distribution line in a utility grid provides voltage support to the power system which is a source

of reactive power.

Characterization of the energy and power quality parameters under nominal voltage conditions

must be accomplished in order to provide useful and realistic comparison data when applying

real-world steady-state voltages to the SP1000A under real-world load conditions. Within Test 1,

KCE Engineering applied nominal steady-state voltage to a Custom Load Bank (CLB). The Load

Switching Network (LSN) was designed to accompany two SP1000A units. Power quality

parameters were measured at the input to the CLB at each loading point characteristic of the

loads found in various commercial and industrial facilities. Selected power quality parameters

were measured at the SP1000A interface point downstream of the voltage source (transformer)

upstream of the LSN and CLB. The nominal voltage for these tests was 208 volts.

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Nominal Voltage Tests

Single-Load Tests

A single-load test is defined as a test where the power parameters are measured with a single

load type turned on with the SP1000A disconnected from the load bank and then the SP1000A

connected to the load bank. No multiple load configurations are included in this test set.

Lighting Load — Magnetically-Ballasted Metal Halide Lamps

Three 1,000-watt magnetically-ballasted metal halide lamps are the single load for this lighting

load test. Each ballast has a power loss of about 100 watts. From the results in the table, one can

see that the measured reduction in real power was about 14 % and measured improvement in true

power factor was about 40 %.

Table 3-1

Single-Load Tests — Magnetically-Ballasted 1,000-Watt Lamps

SP1000A Line Voltage

(volts)

Line Current

(amps)

Real Power

(watts)

True Power

Factor (no units)

1 — Off 120 29.1

3,495 0.57

1 – On 120 25.3

3,041 0.78

Savings (%) - - 12.9 36.8

2 — Off 120 29.1

3,495 0.57

2 – On 120 24.6

2,953 0.84

Savings - - 15.5 47.4

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Nominal Voltage Tests

Lighting Load — Electronically-Ballasted Induction Lamps

Three 400-watt electronically-ballasted induction lamps are the single load for this lighting load

test. Each ballast has a power loss of about 20 watts. From the results in the table, one can see

that the measured reduction in real power was about 12 % and measured improvement in true

power factor was about 4%.

Table 3-2

Single-Load Tests — Electronically-Ballasted Induction Lamps

SP1000A Line Voltage

(volts)

Line Current

(amps)

Real Power

(watts)

True Power

Factor (no

units)

1 – Off 120 10.5 1,260 0.96

1 – On 120 9.5 1,140 0.99

Savings - - 9.5 3.1

2 — Off 120 10.5 1,260 0.96

2 – On 120 9.1 1,090 1

Savings - - 13.5 4.2

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Nominal Voltage Tests

Lighting Load — Magnetically-Ballasted Metal Halide Lamps and Electronically-Ballasted Induction Lamps

Three 1,000-watt magnetically-ballasted metal halide lamps and the 400-watt electronically-

ballasted induction lamps are the single load for this lighting load test. From the results in the

table, one can see that the measured reduction in real power was about 12 % and measured

improvement in true power factor was about 14 %.

Table 3-3

Single-Load Tests — Combined Lamp Loads

SP1000A Line Voltage

(volts)

Line Current

(amps)

Real Power

(watts)

True Power

Factor (no

units)

1 – Off 120 39.6 4,755 0.76

1 – On 120 35.3 4,232 0.89

Savings - - 11.0 17.1

2 — Off 120 39.6 4,755 0.76

2 – On 120 34.6 4,157 0.83

Savings - - 12.6 9.2

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Nominal Voltage Tests

Computer Load — One Computer Power Supply

One 650-watt loaded computer power supply is the single load for this computer load test. The

computer power supply has an efficiency of about 85 percent. From the results in the table, one

can see that the measured reduction in real power was about 7 % and measured improvement in

true power factor was about 6 %.

Table 3-4

Single-Load Tests — One Loaded Computer Power Supply

SP1000A Line Voltage

(volts)

Line Current

(amps)

Real Power

(watts)

True Power

Factor (no

units)

1 – Off 120 5.3 634 0.94

1 – On 120 5.0 594 0.99

Savings - - 6.3 5.3

2 — Off 120 5.3 634 0.94

2 – On 120 4.8 581 1

Savings - - 8.4 6.4

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Nominal Voltage Tests

Computer Load — Six Computer Power Supplies

Six 650-watt loaded computer power supplies are the single load for this computer load test. The

computer power supply has an efficiency of about 85 percent. From the results in the table, one

can see that the measured reduction in real power was about 9 % and measured improvement in

true power factor was about 3 %.

Table 3-5

Single-Load Tests — Six Loaded Computer Power Supplies

SP1000A Line Voltage

(volts)

Line Current

(amps)

Real Power

(watts)

True Power

Factor (no

units)

1 – Off 120 32.3 3,874 0.95

1 — On 120 29.8 3,572 0.97

Savings - - 7.8 2.1

2 — Off 120 32.3 3,874 0.95

2 – On 120 28.9 3,471 0.99

Savings - - 10.4 4.2

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Nominal Voltage Tests

Mechanical Load — Three-Horsepower Electric Motor

One three-horsepower electric motor is the single load for this mechanical load test. The electric

motor is rated for 208-volts has an efficiency of about 70 percent. From the results in the table,

one can see that the measured reduction in real power was about 15 % and measured

improvement in true power factor was about 31 %.

Table 3-6

Single-Load Tests — Three-Horsepower Electric Motor

SP1000A Line Voltage

(volts)

Line Current

(amps)

Real Power

(watts)

True Power

Factor (no

units)

1 – Off 208 10.6 2,215 0.65

1 – On 208 9.3 1,924 0.84

Savings - - 13.1 29.2

2 — Off 208 10.6 2,215 0.65

2 – On 208 8.8 1,836 0.87

Savings - - 17.1 33.8

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Nominal Voltage Tests

Mechanical Load — Adjustable-Speed Drive-Powered 15 h.p. Electric Motor

One 15-horsepower electric motor powered by an adjustable-speed drive is the single load for

this mechanical load test. The electric motor is rated for 11-kW has an efficiency of about 88

percent. From the results in the table, one can see that the measured reduction in real power was

about 11 % and measured improvement in true power factor was about 32 %.

Table 3-7

Single-Load Tests — ASD-Powered 15 h.p. Electric Motor

SP1000A Line Voltage

(volts)

Line Current

(amps)

Real Power

(watts)

True Power

Factor (no

units)

1 – Off 208 52.7 10,953 0.61

1 – On 208 47.4 9,852 0.79

Savings - - 10.1 29.5

2 — Off 208 52.7 10,953 0.61

2 – On 208 46.2 9,618 0.82

Savings - - 12.2 34.4

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Nominal Voltage Tests

Mechanical Load — Three-Horsepower Electric Motor and Adjustable-Speed Drive- Powered 15 h.p. Electric Motor

One three-horsepower electric motor and one 15-horsepower electric motor powered by an

adjustable-speed drive are the single loads for this mechanical load test. From the results in the

table, one can see that the measured reduction in real power was about 12 % and measured

improvement in true power factor was about 32 %.

Table 3-8

Single-Load Tests — Combined Electric Motor Load Test

SP1000A Line Voltage

(volts)

Line Current

(amps)

Real Power

(watts)

True Power

Factor (no

units)

1 – Off 208 62.9 13,076 0.63

1 — On 208 57.1 11,874 0.81

Savings - - 9.2 28.6

2 — Off 208 62.9 13,076 0.63

2 – On 208 54.3 11,289 0.84

Savings - - 13.7 33.3

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Nominal Voltage Tests

Mixed-Load Tests

A mixed-load test is defined as a test where the power parameters are measured with mixed load

types turned on with the SP1000A disconnected from the load bank and then the SP1000A

connected to the load bank. No single-load configurations are included in this test set.

Mixed Load Test — All Non-Linear Load

A mixed load test with all non-linear loads is the mixed load for this test. This mixed load

includes the three 1,000-watt metal halide lamps, the three 400-watt induction lamps, the six

loaded computer power supplies, the three-horsepower electric motor and the ASD-powered 15-

h.p. electric motor. From the results in the table, one can see that the measured reduction in real

power was about 11 % and measured improvement in true power factor was about 7 %.

Table 3-9

Mixed-Load Tests — All Non-Linear Loads

SP1000A Line Voltage

(volts) Line Current

(amps)

Real Power

(watts)

True Power

Factor (no

units)

1 – Off 208 103.7 21,562 0.77

1 – On 208 92.6 19,264 0.81

Savings - - 10.7 5.2

2 — Off 208 103.7 21,562 0.77

2 – On 208 90.3 18,783 0.84

Savings - - 12.9 9.1

Page 29: Verification of Performance

3-11

Nominal Voltage Tests

Mixed Load Test — Primarily Non-Linear Load with Some Linear Load

A mixed load test with primarily non-linear loads and some linear load (2,000 watts) is the

mixed load for this test. This mixed load which is primarily non-linear loads includes the three

1,000-watt metal halide lamps, the three 400-watt induction lamps, the six loaded computer

power supplies, the three-horsepower electric motor and the ASD-powered 15-h.p. electric

motor. The linear part of the load is represented by a rheostat loaded on each phase. From the

results in the table and one can see that the measured reduction in real power was about 8 %,

measured improvement in true power factor was about 4 %.

Table 3-10

Mixed-Load Tests — Primarily Non-Linear Load with Some Linear Load

SP1000A Line Voltage

(volts)

Line Current

(amps)

Real Power

(watts)

True Power

Factor (no

units)

1 – Off 208 113.3 23,562 0.79

1 – On 208 104.1 21,652 0.8

Savings - - 8.1 1.3

2 — Off 208 113.3 23,562 0.79

2 – On 208 102.6 21,349 0.82

Savings - - 9.4 3.8

Page 30: Verification of Performance
Page 31: Verification of Performance

4-1

4 OTHER TEST RESULTS

The remaining three tests that were conducted on the Model SP1000A power factor correction

units were

· Long-term undervoltage test

· Long-term overvoltage test

· Voltage distortion test

Surprisingly, the test results for these three test configurations were very acceptable and are

summarized in the following Table 4-1 through 4-3. These were conducted only for the

combined mixed load test with all non-linear loads active in the load bank.

Table 4-1

Summary of Three Remaining Tests — Long-Term Undervoltage Test

SP1000A Line Voltage

(volts) Line Current

(amps)

Real Power

(watts)

True Power

Factor (no

units)

1 – Off 187.2 116.1 21,732 0.78

1 — On 187.2 103.2 19,327 0.82

Savings - - 11.1 5.1

2 — Off 187.2 116.1 21,732 0.78

2 – On 187.2 101.5 18,993 0.84

Savings - - 12.6 7.7

Page 32: Verification of Performance

4-2

Other Test Results

Table 4-2

Summary of Three Remaining Tests — Long-Term Overvoltage Test

SP1000A Line Voltage

(volts)

Line Current

(amps)

Real Power

(watts)

True Power

Factor (no

units)

1 – Off 228.8 91.6

20,963 0.75

1 – On 228.8 85.3

19,522 0.81

Savings - - 6.9 8.0

2 – Off 228.8 91.6

20,963 0.75

2 – On 228.8 84.5

19,329 0.83

Savings - - 7.8 10.7

Table 4-3 Summary of Three Remaining Tests — Voltage Distortion Test

SP1000A Line Voltage

(volts) Line Current

(amps)

Real Power

(watts)

True Power

Factor (no

units)

1 – Off 208 109.3

22,734 0.71

1 – On 208 95.5

19,873 0.82

Savings - - 12.6 15.5

2 – Off 208 109.3

22,734 0.71

2 – On 208 94.9

19,732 0.84

Savings - - 13.2 18.3

Page 33: Verification of Performance

5-1

5 CONCLUSION

The SP 1000 Model A system is a power factor correction (PFC) system. Its purpose is to sense

the degree of non-linearity in the voltage and current waveforms produced by the operation of

non-linear loads and apply a dynamic correction to a customer’s facility electrical system. Given

the nature of non-linear operation and the operation of these loads in today’s facility electrical

systems, integration of the SP 1000 technologies overlaid onto an electrical system, energy

savings ranging from a few percent up to as much as 20 to 25 % can be realized in real customer

environments.

The results of the tests conducted in this study revealed that savings ranging from about 5 to 17

% were realized when the SP 1000 Model A was applied to a load bank of real non-linear loads.

A slightly smaller amount of energy savings were realized using this exact same test

configuration when real-world electrical conditions were applied to the load bank with SP 1000

Model A technologies actively providing power factor correction.

The SPIDER software was also evaluated during these tests. This evaluation was centered

around functionality of the SP1000 Model A not as an energy-savings measurement system. The

SPIDER software is designed to verify that the SP 1000 technology is functioning correctly when

installed in a facility as a ground of PFC systems. If energy savings verification is needed for an

individual SP 1000 installation (i.e., one unit installed in a facility even if the facility contains 100

units), then that should be done using a calibrated laboratory-grade instrument specifically

designed for energy savings measurements.

Lastly, the SP 1000 Model A technology is by far the most advanced and dynamic PFC system

designed to invoke energy savings in a customer’s facility electrical system when operating non-

linear loads such as computers, electronic or magnetic lighting, electric motors and variable

frequency drives to name a few.

Page 34: Verification of Performance
Page 35: Verification of Performance

A

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with the New Digital Control System. EPRI, Palo Alto, CA: 2009.

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98. Keebler, Philip F., New Test Methods to Determine the Shielding Effectiveness of Small Enclosures

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Page 42: Verification of Performance

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100. Keebler, Philip F. (EPRI) and Kermit O. Phipps (AMS Technology Center), Equipping

Instrumentation & Control Engineers with the Right Knowledge to Address EMI Problems in Their

Plants, Eighth American Nuclear Society International Topical Meeting on Nuclear Plant

Instrumentation, Control and Human-Machine Interface Technologies (NPIC&HMIT) 2010, San

Diego, CA., July 22-26, 2012, on CD-ROM, American Nuclear Society, LaGrange Park, IL (2012).

101. Keebler, Philip F. (EPRI) and Frank D. Sharp (EPRI), Eliminating the Need for Exclusion Zones in

Nuclear Power Plants: What are the New Boundaries?, Eighth American Nuclear Society

International Topical Meeting on Nuclear Plant Instrumentation, Control and Human-Machine

Interface Technologies (NPIC&HMIT) 2010, San Diego, CA., July 22-26, 2012, on CD-ROM,

American Nuclear Society, LaGrange Park, IL (2012).

102. Keebler, Philip F. (EPRI) and H. Stephen Berger (TEM Consulting), Wireless: Its Advantages and

Disadvantages – Future Connectivity in Nuclear Power Plants, Eighth American Nuclear Society

International Topical Meeting on Nuclear Plant Instrumentation, Control and Human-Machine

Interface Technologies (NPIC&HMIT) 2010, San Diego, CA., July 22-26, 2012, on CD-ROM,

American Nuclear Society, LaGrange Park, IL (2012).

103. Keebler, Philip F. (EPRI) and H. Stephen Berger (TEM Consulting), Interconnecting the Elements of

an Effective EMC Management Program for Nuclear Power Plants, Eighth American Nuclear Society

International Topical Meeting on Nuclear Plant Instrumentation, Control and Human-Machine

Interface Technologies (NPIC&HMIT) 2010, San Diego, CA., July 22-26, 2012, on CD-ROM,

American Nuclear Society, LaGrange Park, IL (2012).

104. Keebler, Philip F., D. Michael Evans and Nathan A. Reid, Practical Reasons for Shifting to the

Application of Dielectric-Independent EMI Filters with Integral Surge Protection in Product Designs,

ITEM Design Guide, October 2012.

105. Keebler, Philip F. D. Michael Evans and Nathan A Reid, Induction Lighting – Nikola Tesla’s Initial

Path to a Promising Light Source, Electrical, Construction & Maintenance (EC&M) magazine,

February 2013.

106. Keebler, Philip F. D. Michael Evans and Nathan A Reid, Dropping the Ball, or Dropping the Lights,

Electrical, Construction & Maintenance (EC&M) magazine, March 2013.