POWER QUALITY REPORT

1
1.1

MEASUREMENTS AND RECOMMENDATIONS

GENERAL
Issues regarding quality of energy have increased in the last decade. Power electronic equipment
(drives, UPS, electronic ballasts, convertors, etc) affect the pure 60Hz sinusoidal power
waveform, inducing harmonics for multiples other frequencies (multiples of 60Hz).
The most damageable are the third (180Hz), 5th (300Hz) and 7th (420Hz), as they are usually of
greater amplitudes. Sometimes superior harmonics order (11th, 13th) and inter-harmonics could
also cause electrical quality problems.
The measurements were done for a week when were assumed the company was working at a full
capacity and all the electrical loads susceptible have negative influences over the electrical
network.
The scope of work had as objective to find out the issues generated by poor quality energy onto
the electrical network of the site, as the customer has concerned about the failure of the electrical
equipment.
The transformer supplying power to the site is a 1MVA transformer, with 5.69% impedance,
converting the incoming line from 44kV to 600V.
A Power Quality Analyzer was installed at the main incoming 1600A breaker. The apparatus was
a portable HIOKI 3196, S/N 100432626.
The power quality monitoring was done for a week, between 9 June and 16 June 2014.

1.2

MEASUREMENTS RESULTS
1.2.1 Measurements Analyze
Recordings are presented in manufacturer report for voltage, current, apparent, reactive and
reactive power, power factor and harmonics.
The 1000 kVA main transformer was finding to have, for short periods of time an overload state
for 1018kVA ( 101.8% from the nominal power). Even the equipment has the capability to sustain
the overload, it generates a winding temperature increase with more concerns within harmonic
presence.
Temperature increase is one of the prime factors that affect a transformer's life.
Power quality monitoring has revealed three mains issues:
a) Power factor issues and energy consumption in terms of components (apparent, active and
reactive)
b) Harmonic pollution.
c) Voltage disturbances.

1.2.2 Power Factor issues and energy consumption

Electrical network use by the network is composed by active, reactive and the apparent energy.
The active is the real power consumption, billed by the utility and expressed in kW.
Reactive power could be seen as necessary losses, as do not serve to produce work, but is
inherent to equipment (transformer, motors and so), it is expressed in kVARs. Decreasing its
consumption means better energy utilization.
Apparent power is the total (complex addition of active and reactive power) and gives the level of
loading of the distribution network. Is apparent power that is used to calculate the current through
transformer coil as the direct measure of the heating.
The power factor is a measure of the losses occurs as increase reactive power demand.
The electricity companies will apply penalties for a low power factor (high reactive energy
consumption).
On the site the measurements revealed a low power factor with certain implications on the
electricity bill.
A maximum demand in terms of real power recorded was 713.07kW, but with the low power
factor records (around 0.7) the transformer is at its full capacity.
The poor power factor (usually under 0.9) is generally subject of penalties from utility company
with increase of electricity bill for unjustified energy consumption.
From the recorded data, it could be seen that an improvement should be done to increase the
power factor with two main benefits: reduce the transformer load and electricity costs.

1.2.3 Harmonic distortion

Power electronics used to control the electrical equipment inject harmonics in electrical network.
The electrical waveform is not anymore a pure sinusoid and motors, transformers, cables and
others are polluted with electrical disturbances. Equipment as VFDs, power convertors, control
panels, UPS and PLC, battery chargers are some that could generate harmonics.
The result is the increase the load of the distribution network, overheat the motors transformers
and other equipment and generate the power quality problems.
In general, the problems are generating by the 3d, the 5th and the 7th harmonics, but
investigations could go also to 11 and 13th. Further increase the order, less amplitude, so less
influences to the electrical network.
Total harmonic distortion is a measurement of the content of harmonics comparing with the
fundamentals, the only that produce real power and make equipment working.
A high level of harmonic distortion is also penalized by the utility and different standards offer
recommendations to improve the waveform quality. As general accepted industry standard is IEEE
519, Recommended Practice for Harmonics in Electrical Power System.
The data recordings between 9 and 16 June on site reveal some harmonic issues, especially for
currents, but network could still cope with that level.
The total harmonic distortion for voltage is THDv=3.2%, slowly over the recommended values, but
only at some instants, so not of a main concern.
The currents harmonic distortion is exceeding recommended limits referred in IEEE519,
Recommended Practice for Harmonic Control. Measurements show a THD for the current over 4%,
the limit by the table

Table 10. Extract from 519 IEEE

THDi (total harmonic distortion for current) gives indication about the harmonic pollution, but not
always the best criteria. The loading level (power withdrawn from the main transformer in our case)
has a crucial signification for the system. A 50% loaded system with 75% THD will have much less
harmful (or not at all) as a 100% loaded transformer with 10% harmonic current distortion. The
negative effects of the harmonics rise exponentially with transformer loading.
A better indication of the states of entire electrical system (and in our case also of the 1MVA main
transformer) is the total demand distortion (TDD factor). It express harmonics in terms of load
current and in our case is over the limit, so mitigation will bring a major correction.
Calculated values are between 5 and 7% for some portion of the recordings, so over the 5% we
can see on the TDD column of table 10.3 of 519 IEEE standard.
A higher level was recorded for the 5th harmonic.
The measurements are relevant for the Point of Common Coupling (PCC) at the main bus, were
the recording was done.
If after the overload release of the power transformer, heating or other power quality persist, some
investigation should be done to identify and eliminate the harmonic generation hotspots.

1.2.4 Voltage unbalances and transients

Unbalance voltages were not significant during recording periods and only some transients events
appeared.
Voltage transients are short delays when under or overvoltage occur on one point of the network
and could have as effects weakness of dielectric strength of isolation or even loss of power of the
equipment.
Transients could be generates from the external phenomena (utility power switching, lightening,
etc) or internally, from owner equipment. Both have negative consequences, sometimes with big
financial implications.
Control panels are loads with high sensitivity to electrical transients and could affect their
functionality.
In an harmonics environment, transients effects could be amplified, as well as their negative
consequences.
The measurements recorded some isolated transients as two sags and lightly over voltages. As
recordings are not eloquent for this kind of events (statics for longer laps of time give a better
understanding of the environment), we appreciate the recommendation to install SPD could be a
good investment.

Even rare, the damages could be significant, particularly in a pharmaceutical company where high
cost equipment should be protected.

1.3

MANUFACTURER PROPOSAL
1.3.1 Detuned automatic capacitor bank
Chapter D of Schneider report issue the recommendations based on the power quality data records
with the goal of improving the performance, reliability and efficiency of the electrical distribution.
The first recommendation, for installing a de-tuned capacitor bank could be an optimal choice for
reducing the electricity bill and decreasing the load of the transformer.
A detuned automatic capacitor will mainly improve the power factor, but bring also some small
amelioration to harmonic contents.
It is a cost effective solution, but in case of further power quality issues, supplementary harmonic
mitigations could be necessary.
1.3.2 Surge Protection Devices (SPD)
The second recommendation is regarding the protection of equipment and electrical network
against the transients, by placing a surge protection device (SPD) at the incoming 600V bus, at the
PCC were the measurements were done.
As transients could come from internal network too, it is a good practice to install SPD on the
electrical panels servicing the most sensitive loads. It is worth, especially for expensive process
equipment. The average price is 5k$ per unit and could be installed near the panels supplying
power to process equipment.

2
2.1

POWER QUALITY MITIGATIONS AND BUDGETING

POWER FACTOR CORRECTIONS
The network has a poor power factor and improvement from 0.7 to 0.95 is very necessary.
Because the network has harmonic disturbances, a regular power factor correction couldnt be
installed as a resonance could occurs getting worse conditions.
A detuned automatic capacitor banks will avoid the case and improve the power factor. The main
transformer will be less loaded, decreasing the operation temperature and giving spare power for
future loads.
Improving the power factor will bring cost savings for the electricity bill for the amount between
400$-700$ monthly (number is a rough estimation for budgeting propose, for better approximation
the last year bills and Hydro-One penalties are necessary).
The cost for the automatic power factor capacitor could achieve 30k$ excluding the work for
installation and some additional equipment (breaker if needed, disconnect switch, cables, etc).
If no other harmonic mitigation equipment will be installed, a detuned capacitor bank will improve
the network conditions by decreasing the load of the transformer and the losses in cables.
However, the harmonics contents will still remain downward in the electrical network with
associated losses and premature aging of the equipment.
Capacity of the transformer could be also increase with a minimal investment (under 5k$) by
installing cooling fans on the transformer, as its configuration allow it.
It should be also mentioned that harmonic mitigations could also improve the power factor

2.2

HARMONIC MITIGATIONS
Data recordings show harmonics content sometimes exceeding the recommendations values, but
not significant concerns were found out. Elimination will certainly improve electrical distribution,
motors and transformers will be less stressed and live expectancy will be increased.
In certain conditions it could ameliorate the power factor too.
A detuned reactor will eliminate harmonics at the point of common coupling (PCC), but some
disturbances could still exist in the downward electrical distribution network. A detailed load analyze
to identify nonlinear loads concentration could impose local harmonic mitigations, as harmonics
could still overheat the motors and transformers from the generation point to the PCC.
If disturbances will occur after decreasing main transformer overload (what is the first
recommendation), the limitation of the harmonic currents could be a point to consider.
Harmonic pollution could be eliminated by different methods and at different levels. For an optimal
choice to be done, a detailed analyze of loads distribution and configuration is necessary.
A verification of the grounding and binding, as well as neutral connections could bring out power
quality problems and correcting them will ameliorate the electrical distribution (most cases for the
3d order harmonics).
For the harmonic mitigations, if additional equipment should be considered, load configuration
could influence also the choice of harmonic mitigation techniques.

The individual loads characteristics could make as power factor could be improved after with
harmonics mitigation equipment is installed.
The less expensive is by installation passive equipment, as line reactors and isolation transformer
where non-linear loads are concentrating. They could offer a good cost effective option for
harmonics reduction near the load generating them.
As a rule of thumb, 100$ per HP power nonlinear load should be considered, detailed load
configuration will be necessary.
If the nonlinear load is scattered on site, harmonic filtering equipment could be installed at the point
th
th
of entrance (PCC). It will remove most dangerous order harmonics (5 and 7 ) but will not remove
all the high orders(those do not have a serious negative impact on the network). For a budget
estimation the value could be 35k$.
The most evaluated technique eliminating a higher spectrum is by active harmonic filtering. It could
be necessary if nonlinear loads have fast variations, as high power motors driven by VFD with
frequent starting. However the cost is elevate, for site conditions minimum 100k$ should be
considered as a budget cost estimate, if the case.

BUDGET OPTIONS

The main transformer is overloaded and the first and most economical option is to install the fans on the
transformer. With an investment less than 5k$, the new capacity will be 1.33 MVA and overheat will be
eliminate.
Detuned capacitor bank will allow to adjust the capacitor value (and the energy consumption) based on
the momentary states of electrical distribution network. This option involve around 30k$ and will bring a
payback from electricity bill. With an average of 6k$ savings by year, the investment is covered in 5 years.
This option will bring out also a light improvement in harmonic content.
Another option is to install dedicated harmonic mitigations equipment. The equipment could be with
passive filters to eliminate the most important harmonics (investments around 35k$) or active filters
(invest 100k$) for a complete monitoring of the harmonics in the network and total power quality
improvements.

Option

Load releas for

main transformer

Cooling fans on 1MVA

transformer
Detuned power factor
correction capacitor
Local reactors

Harmonics
mitigation

Passive harmonic filtering at

PCC

Estimate
value

<5000
30,000

No payback from electrical bills, no electrical

distribution improvement
Electrical distribution improvement,
payback from utility, slightly harmonics
mitigations.

25,000

Detailed network analyse, optimal only if

loads are concentrate

35,000

Harmonic mitigations ( eliminate the most

dangerous disturbances).

100,000
Active filter

Comments

Advanced harmonic mitigations, eliminating

a high spectrum of harmonics.

CONCLUSIONS
The site conditions impose urgent countermeasures against high loading of the main 1MVA
transformer, as is sometimes over its limits. This goal could be achieved with a minimum financial
effort by installing fans to increase the capacity. However, it is recommended the power factor to be
improved, solving most of the problems.
Harmonic content is also lightly over recommended limits and should be improved too, but their
elimination is not a very critical issue.
Harmonic filtering will certainly improve power quality and optimal use of the equipment, but in
financial issues cases, a power factor capacitor installation could be more concretely sensed on a
short term.
After the transformer will be brought at normal work conditions, if power quality issues still persist,
harmonic mitigations should be done.