Penelec / EPRI / Tom Ridge Environmental Center
Power Quality and Efficiency Solutions
Keeping Industrial & Manufacturing Facilities
Competitive & Productive
M. Edward Brandau III
Manager, Customer Support
Pennsylvania Electric Company
Mark Stephens, PE, CEM, CP EnMS
EPRI Principal Project Manager
Industrial Energy Efficiency & Power Quality Services
Justin M. Price
FirstEnergy Engineer IV
Distribution Planning & Protection
Penelec / EPRI / Tom Ridge Environmental Center
May 5, 2016
Penelec / FirstEnergy / EPRI Power Quality Workshop *
Keeping Industrial & Manufacturing Facilities Competitive & Productive
Penelec / FirstEnergy, the Electric Power Research Institute (EPRI), and the Tom Ridge Environmental Center are
sponsoring the following workshop for industrial & manufacturing facility managers.
* NOTE: For those needing continuing education certification, this workshop qualifies for three (3) Professional
Development Hour (PDH) credits.
THURSDAY, May 5, 2016 (9:00 AM - 12:30 PM) Course Registration at 8:30 am
Location: The Tom Ridge Environmental Center
301 Peninsula Dr. #1, Erie, PA 16505
KEEPING INDUSTRIAL FACILITIES COMPETITIVE AND PRODUCTIVE WITH POWER
QUALITY AND EFFICIENCY SOLUTIONS
Course Description: This workshop will help industrial and manufacturing facilities improve their
competitiveness through low-cost power quality (PQ) solutions and efficiency applications.
Industrial technology has evolved from traditional labor-intensive mechanical processes to a
sophisticated IT-based additive manufacturing process. These new advanced manufacturing
systems employ state-of-the-art control and automation systems including sensors, robotics,
motors/drives and 3D printing equipment. This course provides an overview of power quality
principles, and addresses the PQ impacts for industrial facilities with traditional and advanced
manufacturing equipment. This training will also review energy efficiency technologies, and lowcost solutions to mitigate equipment susceptibility, keeping industrial facilities competitive and
productive.
Instructors:
•
•
Mark Stephens, EPRI Principal Project Manager, Industrial PQ/EE, PE, CEM, CPEnMS - Industrial
Justin M. Price, FirstEnergy Engineer IV, Distribution Planning & Protection
Course Abstract:
This course reviews how PQ events can impact the traditional and advanced manufacturing
industry and facility efficiency applications, providing:
1. An overview of power quality principles and tools for industrial engineers and technical
personnel, to better understand their impacts on facility equipment.
2. A review of facility efficiency applications and technologies to improve industrial or
manufacturing productivity.
3. An understanding of this new generation of advanced manufacturing equipment,
EPRI/DOE initiatives in this area, and low-cost solutions for industry to mitigate the
susceptibility of these systems to PQ events, keeping them competitive and productive.
Following the training, EPRI’s industrial PQ/EE expert will be available to review facility or sitespecific questions in these areas.
Page 1|3
Penelec / FirstEnergy / EPRI Power Quality Workshop *
Keeping Industrial & Manufacturing Facilities Competitive & Productive
Thursday, May 5, 2016, 9:00 a.m. – 12:30 p.m.
1. Energy Efficiency Overview
2. Improving Power Quality (PQ) through low-cost solutions
• The Electrical Environment: Common Levels of PQ
• The PQ Electrical Environment and Utility Distribution Design
• Effects of Voltage Sags on Industrial equipment including demonstrations
• Embedded Solution Approaches through Equipment Design Strategy (w/ demos)
• Embedded Solutions through Targeted Power Conditioning (w/ demos)
• Relevant Case Studies
• Economics of Downtime – Cost/Payback / Net Present Value of PQ Solutions
3. Advanced Manufacturing – The Future of How Things are Made
• Technology Overview
• Power Quality, Energy Intensity & Performance Characterization of Advanced
Manufacturing Equipment
Meet EPRI’s Expert immediately following this workshop to discuss facility or
site-specific questions in the Power Quality or Energy Efficiency areas (12:301:30 pm)
* NOTE: For those needing continuing education certification, this workshop qualifies for three
(3) Professional Development Hour (PDH) credits.
Page 2|3
76 South Main St.
Akron, OH 44308
www.firstenergycorp.com
M. Edward Brandau III
Manager, Customer Support
Pennsylvania Electric Company
M. Ed Brandau is manager of Customer Support for the
Pennsylvania Electric Company (Penelec), an electric utility
operating company of Akron, Ohio-based FirstEnergy Corp. His
group includes eight professionals who manage the interaction with
approximately 850 major customers.
He has been with FirstEnergy for 30 years in various departments
including Customer Service, Engineering, Power Team ValueAdded Jobbing and Contracting, Marketing, Transmission Planning
and Analysis, and System Economy/Power Supply. In addition, Mr.
Brandau has served as the company representative on several
PJM Power Pool committees, and has testified as an expert
witness for the company in cases before the Pennsylvania Public
Utility Commission.
Mr. Brandau has a Bachelor of Science in Electrical Engineering
Technology from the University of Pittsburgh at Johnstown and a
Master of Science in Engineering Management from Robert Morris
University. In addition, he has completed six Master’s level
Electrical Engineering/Power courses from Drexel, and has
completed a two year 19.5 CEU course of study in Electric Power
Systems Engineering from Power Technologies Inc. (PTI).
Mr. Brandau is a Licensed Professional Engineer in the state of
Pennsylvania, a Certified Energy Manager, a Certified Power
Quality Professional, a Certified Business Energy Professional,
Certified Green Building Engineer, and a Certified Sustainable
Development Professional.
He has worked with the community on many fronts, including
serving as a member of the University of Pittsburgh at Johnstown
Engineering Industrial Advisory Board, Chairman, Secretary,
Treasurer, and Director of the Johnstown Section Institute of
Electrical and Electronics Engineers, Johnstown Area Regional
Industries Advisory Board and Workforce Development Committee,
as executive board member, Chairman of fundraiser golf outing,
and fundraiser dinner committee member for the Penn’s Woods
Council, Boy Scouts of America, a United Way Loaned Executive,
and the Transportation and Leadership Alumni Committees for the
Greater Johnstown/Cambria County Chamber of Commerce.
rev. 06-10
Mark Stephens manages research and services work
related to Industrial Power Quality and Energy
Efficiency as well as Retrofit Energy Savings Devices
(RESDs) at EPRI. He is a Senior Member of the
Association of Energy Engineers, and several power
quality standards working groups in IEEE and CIGRE.
With over 27 years of professional experience, he has
a solid background in all aspects of industrial plant
systems including control systems, power quality,
energy efficiency and energy management systems.
Mark W. Stephens, PE, CEM,CP EnMS
Principal Project Manager
Industrial Energy Efficiency Power Quality
Services
Power Delivery and Utilization
Stephens joined EPRI in 1997 as an employee of the
former Power Electronics Application Center (PEAC).
His most visible projects include extensive research
and management of the seminal EPRI System
Compatibility Task 24 research program which led to
the development of the SEMI F47 power quality
standard. Since then, he was worked to characterize
and improve power quality and energy efficiency
issues in all manufacturing sectors by leading testing
and site audits at customer locations in the worldwide.
Working extensively to resolve industrial power quality
and energy efficiency issues at the equipment level
and process level, Stephens has taught over 60
industrial related courses and is commonly asked to
lecture on the subject at conferences worldwide. He
has written over 20 conference papers on the subject
matter as well.
Stephens received a Bachelor Science degree in
electrical engineering from the University of
Tennessee in 1988 and has been a registered
professional engineer in the state of Tennessee since
1995, a certified energy manager since 2010 and an
ISO 50001 certified practitioner of energy
management systems since 2012.
76 South Main St.
Akron, OH 44308
www.firstenergycorp.com
Justin M. Price
Engineer IV, Distribution Planning and Protection
FirstEnergy Service Company
Justin Price is an Engineer IV in the Energy Delivery Distribution
Planning and Protection group at FirstEnergy.
He is responsible for corporate technical support and guidance for
distribution circuit protection, power quality, var support, volt-var
control, and distributed generation.
Justin joined FirstEnergy in 2006. He spent his first 2 years with the
company as a rotational engineering spending six months at a time in
different engineering departments within Energy Delivery. After that,
he worked on the operations side as engineering support within the
Toledo Edison Distribution Control Center for two years. Then Justin
was a Distribution Planning Engineer and Lead Power Quality
Engineer for Toledo Edison for two years. Following that, he
transitioned into his current role.
Justin holds a BS in Electrical Engineering from Purdue University
and a MBA from the University of Toledo, received in 2006 and 2011
respectively. He is a registered professional engineer in the state of
Ohio.
rev. 06-10
Power Quality Seminar
Ed Brandau
Manager, Customer Support/PQ Engineer
May 5, 2016
Copyright M. Ed Brandau III, 2008
EPRI / Penelec PQ-EE Workshop
Power Quality Seminar
Ed Brandau
Manager, Customer Support/PQ Engineer
May 5, 2016
Copyright M. Ed Brandau III, 2008
Overall Agenda




Welcome!
Introductions
CE credits
Penelec protection scheme overview
–
–

EPRI Power Quality short course
–
–
–
–

Why does my power go off multiple times?
Why did my lights flicker and my machines shut down?
PQ defined
Causes
Wiring and grounding
Mitigation techniques
Energy Efficiency overview
– What is the EE charge?
– What is eligible for a rebate?
– Where can I get more information?
Penelec Intro & EE Program Oveview
Ed Brandau, Erie, PA, May 5, 2016
1
EPRI / Penelec PQ-EE Workshop
Who is Penelec? We Keep The Lights On!

Top 10 or so most dangerous job
Transmission & Distribution Company
Penelec Intro & EE Program Oveview
Ed Brandau, Erie, PA, May 5, 2016
2
EPRI / Penelec PQ-EE Workshop
Penelec is Central – Key Transmission Corridor
Penelec Intro & EE Program Oveview
Ed Brandau, Erie, PA, May 5, 2016
3
EPRI / Penelec PQ-EE Workshop
Key Investment Period

Largest transmission investment since inception

New transmission subsidiary

Distribution improvements ramping up

$10 million plus on tree trimming
Up Next…

EPRI Power Quality (PQ) overview (Mark Stephens)

Penelec / FirstEnergy protection schemes (Justin Price)

PQ demonstrations of industrial susceptibility & low
cost mitigation solutions (Mark Stephens)
Penelec Intro & EE Program Oveview
Ed Brandau, Erie, PA, May 5, 2016
4
Power Quality & Energy
Efficiency Seminar
M. Edward Brandau III
PE, CEM, CPQ, BEP, GBE, CSDP, MSEM
Manager, Customer Support, Penelec
Mark Stephens, PE, CEM, CP EnMS
Principal Project Manager, EPRI
Justin Price, PE
Distribution Planning & Protection, FirstEnergy
© 2015 Electric Power Research Institute, Inc. All rights reserved.
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Power Quality & Energy
Efficiency Seminar
M. Edward Brandau III
PE, CEM, CPQ, BEP, GBE, CSDP, MSEM
Manager, Customer Support, Penelec
Mark Stephens, PE, CEM, CP EnMS
Principal Project Manager, EPRI
Justin Price, PE
Distribution Planning & Protection, FirstEnergy
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Seminar Outline
 8:30 AM - Welcome and Introductions
 8:40 – 9:10 Energy Efficiency Overview
 9:10 AM - Improving Power Quality (PQ) through Low-Cost Solutions
– The Electrical Environment: Common Levels of Power Quality (PQ)
– Effects of Voltage Sags on Industrial equipment including demonstrations
– Embedded Solution Approaches through equipment design strategy with
demos
– Embedded Solutions through targeted power conditioning with demos
– Machine and Panel Level Solutions
– Relevant Case Studies
– Economics of Downtime
 12:00 PM Electrification Technologies
– Non-Road Electric Transportation – Electric Forklifts
– Electrotechnologies for Industrial Process Heating
 Lunch 12:15
2
© 2015 Electric Power Research Institute, Inc. All rights reserved.
1
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Who is EPRI?
 Founded by and for the electricity
industry in 1973
 Independent, nonprofit center for public
interest energy and environmental
research
Collaborative
Value
 Collaborative resource for the electricity
sector
 Work with Utilities, Industry, and
Government
Thought
Leadership
 Major offices in Palo Alto, CA; Charlotte,
NC; Knoxville, TN
Industry
Expertise
3
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Mark Stephens, PE, C.E.M., CP EnMS
Principal Project Manager
Scott Bunton, C.E.M., C.P.Q.
Technical Lead
PQ Proposals & Assessments
Bill Howe, PE, C.E.M.
PQ Program Manager
Team Advisory Role
PQ & EE
On-Site
Assessment
Team
Baskar Vairamohan, PE, C.E.M.
Specialists: Project Management,
& Industrial Process Heating
Jason Johns, C.P.Q.
Technologist,
PQ Monitoring & Assessments
James Owens, C.E.M., C.P.Q.
PQ and EE Team Member
Logistics, Scheduling, Process
Alden Wright, PE, C.E.M., CP EnMS
Technical Lead, PQ & EE Assessments
4
© 2015 Electric Power Research Institute, Inc. All rights reserved.
2
EPRI / Penelec PQ/EE Workshop
May 5, 2016
EPRI’s Industrial Energy Efficiency and Power Quality
Work
 Headed up primarily from Knoxville, we specialize in solving EE & PQ Problems
In all Manufacturing Sectors
 Our Primary mission is to Focus on Reducing End Use Customer Losses by
improving process Energy Efficiency and PQ through:
– Energy Efficiency Assessments
 Traditional Areas
 Process Heating
 Energy Management
– Power Quality Assessments
 Voltage Sags
 Harmonics
 Flicker
 Wiring and Grounding
– Common Areas to PQ and EE
 Testing (lab and field)
 Consulting with OEMs
 Training
5
© 2015 Electric Power Research Institute, Inc. All rights reserved.
EPRI Industrial Site Assessments 1996-2015
Site Investigations 1996-2015
Industry
Sites
Percentage
19 Sites in 2015
Semiconductor
Plastics
Food & Beverage
Automotive
Paper/Printing
Med Fac/Med Research
Aviation/Aerospace
Machining
Fibers/Textile
PetroChem/Nat Gas
Chemical
Commercial
General
Glass
Metals/Wire
Heavy Ind
Govt
Pharma
Electronic
Power Gen
30
28
27
22
20
13
12
12
11
9
8
8
7
7
7
6
5
5
4
1
Total Sites
Average/Year
242
13
12%
12%
11%
9%
8%
5%
5%
5%
5%
4%
3%
3%
3%
3%
3%
2%
2%
2%
2%
0.4%
6
© 2015 Electric Power Research Institute, Inc. All rights reserved.
3
EPRI / Penelec PQ/EE Workshop
May 5, 2016
The Electrical
Environment:
Common Levels of
Power Quality
Justin Price, PE
Distribution Planning & Protection,
FirstEnergy
© 2015 Electric Power Research Institute, Inc. All rights reserved.
8
© 2015 Electric Power Research Institute, Inc. All rights reserved.
4
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Power Quality
 Transients
– Impulse
– Oscillatory
– Irregular
 Short Duration
Variations
– Sags/Swells
– Interruptions
 Interruptions
– Momentary/Sustained
 Waveform Distortion
– Harmonics
 Voltage Fluctuations
9
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Transients
 Impulse Transients
 Lighting
 Oscillatory Transients
 Irregular Transients
10
© 2015 Electric Power Research Institute, Inc. All rights reserved.
5
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Short Duration Variations
 Momentary Interruption
– Less than 10% of the voltage
 Protective device operation with
automatic reclosing
 Sags
 Swells
Time Period
11
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Short Duration Variations
 Momentary Interruption
 Sags
Voltage sag
– A decrease in voltage of
10% to 90% for durations
less than 1 minute
 Electrical Faults
 Large load additions
 Motor starting
 Capacitor banks turning
off
 Swells
12
© 2015 Electric Power Research Institute, Inc. All rights reserved.
6
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Short Duration Variations
 Momentary Interruption
 Sags
 Swells
Voltage swell
– An increase in voltage to
more than 110% for
durations less than 1
minute
 Electrical Faults
 Large load shedding
 Capacitor banks turning
on
13
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Long Duration Variations
 Overvoltage
– Sustained voltages, longer than
1 minute, outside range A.
 Load variations
 Temporary switching
conditions
 Voltage regulating equipment
 Under voltage
 Sustained Interruptions
14
© 2015 Electric Power Research Institute, Inc. All rights reserved.
7
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Long Duration Variations
 Overvoltage
 Under voltage
– Sustained voltages, longer than
1 minute, outside range A.
 Overloaded equipment
 Load variations
 Temporary switching
conditions
 Voltage regulating equipment
faults
 Sustained Interruptions
15
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Long Duration Variations

Overvoltage

Under voltage

Sustained Interruptions
– Decreases in supply voltage,
to less than 90% of nominal
voltage for more than 1
minute.
– Protective Device Operation
– Faults
16
© 2015 Electric Power Research Institute, Inc. All rights reserved.
8
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Momentary and Sustained Interruptions
 PA PUC Definitions:
– Momentary - A momentary interruption means an interruption of
electric service to one or more customers of duration limited to the
period required to restore service by an interrupting device.
A single operation of an interrupting device that results in a voltage
zero. Such switching operations must be completed within a specified
time of 5 min or less.
– Sustained - the interruption of service to a customer for more than
five minutes.
17
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Fuse Save vs. Fuse Sacrifice Protection
Strategy
Customer
Customer
®
®
Fuse Save
18.6 mi of
Exposure
Fuse Sacrifice
2.1 mi of
Exposure
18
© 2015 Electric Power Research Institute, Inc. All rights reserved.
9
EPRI / Penelec PQ/EE Workshop
May 5, 2016
 Fuse Save: Allows automatic devices, like relays and reclosers
to clear temporary faults without damaging the fuse.
 Reduces overall outage duration (SAIDI)
 Increases “blinks” or momentaries (MAIFI)
 Fuse Blow: The fuse clears the fault before relays or reclosers
operate.
 Often used to protect underground systems – UG faults are
generally permanent.
 Used in commercial/industrial areas where customers
complain most about momentaries.
 Some utilities block the instantaneous trip on the relay to
ensure that the fuse will clear
19
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Fuse Sacrifice (Fuse Blow)
• The fuse-sacrifice strategy delays the initial operation(s) of the recloser, giving
downstream fuses time to sense faults and operates.
• i.e., For any fault down-stream of tap-fuse A, the recloser is delayed enough to
allow tap-fuse A time to operate before the recloser operates.
20
© 2015 Electric Power Research Institute, Inc. All rights reserved.
10
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Fuse Save
 In a fuse-saving strategy, reclosers are set to operate one or more times on a
“fast” time-current characteristic, more quickly than downstream fuses can
operate, then and subsequently one or more times on a “slow” characteristic
which provides ample time for downstream fuses to sense and operate.
 i.e., For a fault downstream of tap-fuse A, the station recloser operates one or
more times more quickly than the tap fuse will operate.
21
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Advantages of each Strategy
 Fuse Sacrifice
 Fuse Saving
– The number of temporary outages
to all customers on the circuit is
minimized
– Permanent faults on lateral taps
are cleared in one operation (the
fuse blowing), minimizing faultduty.
– The number of recloser operations
is minimized.
– Temporary faults on fused lateral taps
can be cleared and restored by fastoperating reclosers, minimizing
permanent outages.
– Quicker clearing of temporary faults
by the recloser can minimized
though-fault duty.
– Lower total fault energy (I2T) for
permanent main-line faults
– Lateral temporary faults result in
outages to small zones, reducing
the area to be investigated for
temporary outage causes.
22
© 2015 Electric Power Research Institute, Inc. All rights reserved.
11
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Disadvantages of each Strategy
 Fuse Sacrifice
 Fuse Saving
– Temporary faults on fused-lateral
taps will result in sustained outages
to the customers on that tap,
necessitating the dispatching of
line/trouble personnel to investigate
and repair the fuse that operated.
– Intermittent recloser operations
(temporary faults) downstream of
lateral fuses, make identifying
location difficult.
– Coordination with tap fuses can be
restrictive with regards to lateral tap
fuse sizing.
– Coordination may involve fuses
beyond the first lateral fuse.
– All customers downstream of
recloser see temporary outages,
even for permanent faults on fused
laterals.
– Increased recloser
operations/maintenance.
23
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Why Voltage Sags Occur...
• LG/LL Faults Occur on the Utility System
due to: Weather/Trees/Public Interference
• Internally induced plant events
(starting of large high inrush load)
• Although the utility can reduce the number of events (tree trimming, root
cause analysis) it is impossible to eliminate all voltage Sags.
24
© 2015 Electric Power Research Institute, Inc. All rights reserved.
12
EPRI / Penelec PQ/EE Workshop
May 5, 2016
How Common are Sags and Interruptions?
Results of EPRI TPQ-DPQ III Study
Key results:
•For every interruption, you may experience 8 to 20 voltage sags
depending on what voltage level that you are fed from by the utility.
•The number of events that will be seen at your site is dependent on
what type of connection you have from the utility.
25
© 2015 Electric Power Research Institute, Inc. All rights reserved.
How many phases “sag”?
Ref: EPRI TPQ-DPQ III Study, June 2014
26
© 2015 Electric Power Research Institute, Inc. All rights reserved.
13
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Outage or Sag ?
27
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Example “Recloser” Operation (Ref: IEEE 1668)
28
© 2015 Electric Power Research Institute, Inc. All rights reserved.
14
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Targeting by Cause
Northwest US
Florida
EPRI Fault Study
Lightning
Tree contact
Equipment failure
Animal
Wind
Dig−in
Vehicle accident
Ice/snow
Vandalism
Construction activity
Other
0
5
10
15
20
25
Percent of faults by cause
FIGURE 7.1
Tom Short, Electric Power Distribution Handbook, CRC Press, 2004
29
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Who’s “Fault” is it?
30
© 2015 Electric Power Research Institute, Inc. All rights reserved.
15
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Important Realization
 Utilities Share Responsibility
– Tree Trimming, Lighting Arrestors, Grounding, Maintenance,
Provide PQ information to industrials, etc
– Circuit patrols, Reviewing customer complaints and device
operations, INST/QT setting reviews.
 Industrials Share Responsibility
– Understanding Equipment Vulnerability, PQ Specifications, Power
Conditioning, Proper Wiring/Grounding, etc
 Most effective solutions are reached when both sides
work together to see what can be done
31
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Effects of Voltage Sags
on Industrial Equipment
Mark Stephens, PE, CEM, CP EnMS
Principal Project Manager, EPRI
© 2015 Electric Power Research Institute, Inc. All rights reserved.
16
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Effects of Voltage Sags
(MagDur)
Duration (4 Cycle)
1
0.5
0
0
1
2
3
4
5
6
7
8
-0.5
Magnitude (50% of nominal)
-1
 Lights may or may not flicker
 Equipment shutdown or malfunction
 Can result in production downtime an/or
product loss
For every 1 momentary interruption a customer will see 8 to 20
voltage sags (EPRI TPQ-DPQ III Study)
33
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Interrelated Processes
Is Power
Present?
NO
YES
Process
Exhaust
Is Compressed
Air Present?
NO
YES
Automated
Process
Air Compressor
CONTINUALLY
REPEATED
Is Process
Cooling Water
Present?
NO
Stop
Automated
Process
YES
NO
Power
Source
Interlocked
Automated
Process
Are the Exahaust
Systems Running?
YES
PCW
Pump
Power
Is Interlocked
Process Running?
Process
Mechanical
NO
YES
Ok to Run
Automated
Process
34
© 2015 Electric Power Research Institute, Inc. All rights reserved.
17
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Why is PQ Important - Impacts
 What happens to a manufacturing process when a power
quality problem occurs?
 Who is to blame?
 How do we work together to fix the problems?
35
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Typical Reported Per Event Cost of PQ Disturbance
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Process
Semiconductor
Semiconductor
Semiconductor
Metal Casting
Chemical Plant
Pulp and Paper Mill
Aerospace Engine Machining
Food and Beverage
Chemical Plant
Chemical Plant
Electronic Components
Crystal Growth
Chemical Plant
Wiring Manufacturing
Chemical Plant
Fibers Plant
Paper and Packaging
Plastic Bag Manufacturing
Plastics
Stainless Steel Manufacturing
Reported
Cost
$1,500,000
$1,400,000
$ 700,000
$ 200,000
$ 160,000
$ 110,000
$ 100,000
$ 87,000
$ 75,000
$ 75,000
$ 75,000
$ 60,000
$ 46,175
$ 34,000
$ 18,000
$ 15,000
$ 10,000
$ 10,000
$ 7,500
$ 5,500
Service Voltage
69 kV
161 kV
12.5 kV
13.8 kV
12.5 kV
161kV
13.8kV
12.5 kV
66kV
66kV
12.5 kV
12.5 kV
66kV
12.5 kV
12.5 kV
12.5 kV
12.5 kV
480V
12.5 kV
12.5 kV
Load
25 MW
30 MW
10 MW
16 MW
5 MW
100 MW
10 MW
5 MW
3 MW
5 MW
5 MW
1 MW
30 MW
2 MW
2 MW
1 MW
4 MW
4 MW
4 MW
2 MW
Automotive
Reported as high
as $700,000.
36
© 2015 Electric Power Research Institute, Inc. All rights reserved.
18
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Goal – Extending the Operating Envelope
“Extending the operating envelope” of equipment means that we have
to reduce the area of equipment malfunctions by enabling the
equipment to ride through deeper and longer voltage sags.
37
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Sag Generator
38
© 2015 Electric Power Research Institute, Inc. All rights reserved.
19
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Voltage Tolerance Curve:
Ice Cube Relay
How many potential shutdown events would be caused by the
relays?
3
39
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Voltage Tolerance Curve:
Small Contactor
What happens during
a voltage sag down to
50% of nominal for 5
cycles ?
40
© 2015 Electric Power Research Institute, Inc. All rights reserved.
20
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Voltage Tolerance Curve of Motor Starters
Which motor starters are the
most susceptible to voltage sags?
41
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Emergency Off (EMO) Circuit
Q1. What happens if the EMO relay or Main
Contactor are extremely vulnerable to voltage sags?
Q2. What if the plant voltage is low?
Q3. What if the transformer rated output voltage does
not match the relay and contactor?
42
© 2015 Electric Power Research Institute, Inc. All rights reserved.
21
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Master Control Relay Example
What happens if
1CRM1 is a
sensitive relay?
What happens
when an
operator hits the
E-Stop?
43
© 2015 Electric Power Research Institute, Inc. All rights reserved.
DC Power Supplies
 DC Power supplies range from single-phase
linear to switch-mode designs and are used to
power user interface PCs, tool controllers, and
instrument I/O applications.
 The voltage sag ride-through of most power
supplies designed for PC, tool controllers, and
instrument I/O applications is directly related to
the amount of stored energy and power and/or
topology.
 PQ Performance Varies based on topology and
loading
 An example is 120 volts to 24Vdc. The
"secondary" voltage is a lower, control level
voltage.
44
© 2015 Electric Power Research Institute, Inc. All rights reserved.
22
EPRI / Penelec PQ/EE Workshop
May 5, 2016
DC Power Supply Susceptibility Example 1: Single-Phase
120Vac Input Switch Mode
 Heavily Loaded Power Supplies will typically have less
immunity to voltage sags than lightly loaded supplies.
Astrodyne SCN-600-12
Voltage Sag Ride Through Curve
Voltage (% of Nominal)
48% Load
70%
65%
60%
55%
50%
45%
40%
35%
30%
0.000
0.200
72% Load
0.400
94% Load
0.600
0.800
1.000
Duration (in seconds)
Input:120Vac
45
© 2015 Electric Power Research Institute, Inc. All rights reserved.
DC Power Supply Susceptibility Example 2: Universal
Input Types
Idec PS5R-A12, 7.5W
%V nom ina l
40
30
Vin=208Vac
20
Vin=120Vac
10
0
0
10
20
30
40
50
60
CM50 (208 Volts)
Cycles
Voltage (% of Nominal)
100% Load
SEMI F47
100%
80%
60%
40%
20%
0%
0
0.2
0.4
0.6
0.8
1
1.2
Duration (in seconds)
46
© 2015 Electric Power Research Institute, Inc. All rights reserved.
23
EPRI / Penelec PQ/EE Workshop
May 5, 2016
PLC Based Control Systems
47
© 2015 Electric Power Research Institute, Inc. All rights reserved.
PLC System Wiring (Typical)
E-Stop
48
© 2015 Electric Power Research Institute, Inc. All rights reserved.
24
EPRI / Penelec PQ/EE Workshop
May 5, 2016
AC Powered PLC Power Supply
From Typical PLC Literature:
What that means to you:
- Oversensitive Power Supply
- Process Shutdown due to voltage Sags
What can be done about this?
49
© 2015 Electric Power Research Institute, Inc. All rights reserved.
PLC Voltage Sag Response Demo!
 AB PLC-5
 AC I/O
– AC output Card drives AC Relay
– Relay contact drives AC fan and
feeds back to PLC AC Input Card
 DC I/O
– DC output Card Drives DC Relay
– Relay contact drives DC fan and
feeds back to PLC DC Input Card
50
© 2015 Electric Power Research Institute, Inc. All rights reserved.
25
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Discrete Inputs (DI)
24 VOLTS AC/DC
48 VOLTS AC/DC
120 VOLTS AC/DC
230 VOLTS AC/DC
TTL LEVEL
PROXIMITY SWITCHES
NON-VOLTAGE
PUSH BUTTON/SELECTOR
ISOLATED INPUT
SWITCHES
5-50 VOLTS DC (SINK/SOURCE)
LIMIT SWITCHES
MOTOR STARTER AUX. CONTACTS
RELAY CONTACTS
PRESSURE SWITCHES
ZERO SPEED SWITCHES
FLOW SWITCHES
AC Input ON to OFF detection time is ~11ms!
DRY CONTACT OUTPUT CARD OF ANOTHER PLC
51
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Discrete Outputs (DO)
12-48 VOLTS AC
120 VOLTS AC
230 VOLTS AC
12-48 VOLTS DC
120 VOLTS DC
MOTOR STARTERS
230 VOLTS DC
DISCRETE ON/OFF VALVES
CONTACT (RELAY)
SOLENOIDS
ISOLATED OUTPUT
RELAYS
TTL LEVEL
5-50 VOLTS DC
(SINK/SOURCE)
PILOT LIGHTS
BINARY CODED DECIMAL (BCD)
DISPLAYS
ALARMS HORNS/BUZZERS
INPUT CARD OR ANOTHER PLC
Output Devices Can be Susceptible to
Voltage Sags.
52
© 2015 Electric Power Research Institute, Inc. All rights reserved.
26
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Adjustable Speed Drives
53
© 2015 Electric Power Research Institute, Inc. All rights reserved.
AC PWM Drive
INPUT
SECTION
ENERGY
STORAGE
SECTION
Rectifier
Diode Bridge
DC Bus
Capacitor
800
OUTPUT
SECTION
IGBT
Inverter
800
700
600
600
600
400
200
0
-200
-400
-600
-800
Voltage (V)
Voltage (V)
400
Voltage (V)
AC
MOTOR
500
400
300
65
70
75
80
Time (mS)
Source Voltage
85
0
200
-400
100
-600
-800
0
60
200
-200
60
65
70
75
80
85
Time (mS)
DC Bus Voltage
60
65
70
75
80
85
Time (mS)
Motor Input Voltage
54
© 2015 Electric Power Research Institute, Inc. All rights reserved.
27
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Voltage Sag Impact on ASD
dc Link
Rectifier
Inverter
660V
420V
Induction
Motor
dc Bus
Voltage
trip level
Drive Trips on Undervoltage
55
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Example Drive Response
56
© 2015 Electric Power Research Institute, Inc. All rights reserved.
28
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Why Do ASDs Sometimes Trip During Minor Voltage
Sags?


VSI AC Drive During a Single-Phase Sag
(Van = 100%, Vbn = 100%, Vcn = 0%)
DC Bus Voltage (in Volts)
DC Bus Voltage
Bridge Rectifier Output
Trip Level
700
600
500
400
300
200
100
0
0
0.005
0.01
0.015
0.02
Time (in Seconds)
57
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Line-Side and Motor-side Contactors
58
© 2015 Electric Power Research Institute, Inc. All rights reserved.
29
EPRI / Penelec PQ/EE Workshop
May 5, 2016
ASD Enable/Run Signal
Drive
Enable/Run
Contact on
120 V AC relay
59
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Embedded Solution
Approaches through
equipment design strategy
(with demos)
Mark Stephens, PE, CEM, CP EnMS
Principal Project Manager, EPRI
© 2015 Electric Power Research Institute, Inc. All rights reserved.
30
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Mitigation Levels
Embedded Solutions
61
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Method 1: Design with DC Power
 One of the best methods of
increasing the tolerance of control
circuits is to use direct current (DC)
instead of alternating current (AC) to
power control circuits, controllers,
input/output devices (I/O), and
sensors.
 DC power supplies have a “built-in”
tolerance to voltage sags due to their
ripple-correction capacitors, whereas
control power transformers (CPTs)
and AC components do not have
inherent energy storage to help them
ride through voltage sags
 Many OEMs are moving in this
direction to harden their equipment
designs
DC Powered Emergency Off Circuit
62
© 2015 Electric Power Research Institute, Inc. All rights reserved.
31
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Demonstration Time – PLC using DC Power Supply
Rather Than CPT
How Much Better is the
DC solution?
– Depth of Sag
– Duration of Sag
What other benefits
does DC have?
What are some design
considerations with DC?
DC Powered PLC Circuit
63
© 2015 Electric Power Research Institute, Inc. All rights reserved.
AC Versus DC Powered PLC Ride-Through Demo
85
SEMI F47
80
Legend
75
70
AC PLC
65
60
DC PLC
55
%Vnom
50
45
40
35
30
25
20
15
10
5
0
0
5
10
15
20
25
30
35
Cycles
40
45
50
55
60
64
© 2015 Electric Power Research Institute, Inc. All rights reserved.
32
EPRI / Penelec PQ/EE Workshop
May 5, 2016
DC Powered PLC System in Weld Shop
100%
Magnitude (Percentage of Pre-Sag Voltage)
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
0
5
10
15
20
25
30
35
40
Duration (cycles)
Min Phase-to-Phase
AB SLC-5/X PLC
65
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Summary of Robust Power Supply Strategies
66
© 2015 Electric Power Research Institute, Inc. All rights reserved.
33
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Summary of Robust Power Supply Strategies:
Relative Power Supply Response at 100% Loading
Ride-Through for
Single-Phase Voltage
Sags
67
© 2015 Electric Power Research Institute, Inc. All rights reserved.
DC Power Supply Buffer Module
 DC Buffer modules are
devices that are installed in
parallel with the output of DC
power supplies to offer
extended voltage sag ride
through protection.
 There are several
manufacturers of DC voltage
buffers
 Most manufacturers assert
that buffers may be used in
parallel to supply more
energy.
 These modules can supply
power up to 15 seconds at full
load current in the event of an
interruption of DC power.
Ref: ABB Buffer module CP-B 24/20.0 data sheet
68
© 2015 Electric Power Research Institute, Inc. All rights reserved.
34
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Method No. 2: Utilize Sag Tolerant
Components
 If AC Relays and Contactors
are used in the machine
design, then utilize compliant
devices.
 Consider response at both 50
and 60 Hz.
 We have certified a many
relays and contactors to
SEMI F47.
69
© 2015 Electric Power Research Institute, Inc. All rights reserved.
New Solution for an Old Problem: “Nice Cube”
Concept
Original “AC Ice Cube”
Drop out ~70% Vnom
Remove “AC Ice Cube” Insert
“Nice Cube” Puck Into Base
Insert “DC Ice Cube”
Drop Out ~ 25-30% Vnom
70
© 2015 Electric Power Research Institute, Inc. All rights reserved.
35
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Nice Cube Relay
71
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Nice Cube Costs
Nice Cube
Model
Number
120Vac
24Vac
Comments
UL and CE
Compliant
UL and CE
Compliant
Price/unit
$85
$85
72
© 2015 Electric Power Research Institute, Inc. All rights reserved.
36
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Nice Cube Demo
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Example Robust Contactor
Telemecanique LC1F150 Coil LX9FF220
Voltage Sag Ride Through Curve
Voltage (% of Nominal)
DUT 60HZ
SEMI F47
DUT 50HZ
100%
80%
60%
40%
20%
0%
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
Duration (in seconds)
74
© 2015 Electric Power Research Institute, Inc. All rights reserved.
37
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Example Voltage Sag Response of Motor Controls
Based on Robustness of Components
75
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Method 3: Apply Custom Programming Techniques –
Delay Filters



Delay filters can be verify the
presence of power and work as
a “de-bounce” mechanism for
when components drop out due
to a voltage sag. The PLC
motor-control circuit shown
demonstrates how this method
can be applied.
The program is designed to
detect whether the auxiliary
contact is open for more than
250 milliseconds.
If the contact is open for more
than that preset time, then the
“Timer On Delay Coil” in Rung 2
will be set and unlatch the
previous rung to remove voltage
from the motor starter.
76
© 2015 Electric Power Research Institute, Inc. All rights reserved.
38
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Method 3: Apply Custom Programming
Techniques –State Machine Programming



State Machine Programming is
based on the idea that
manufacturing processes are
comprised of a number of steps
with the goal of producing and
moving a product.
Therefore, machine-state
programming keeps track of
every sequential process state
and associated variables by
writing variables to non-volatile
memory in the event power is
lost.
When power returns, the
processing step number and
variables can be recalled so that
the machine can continue from
where it stopped.
77
© 2015 Electric Power Research Institute, Inc. All rights reserved.
YMCA BOT Demo
 By writing the process step into non-volatile memory, the YMCA Bot is able to
remember which letter it was doing before it shutdown and pick up afterwards.
78
© 2015 Electric Power Research Institute, Inc. All rights reserved.
39
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Method 3: Apply Custom Programming
Techniques – Programming Using
Phase/Voltage Sensing Relay
 A phase monitor or voltage
sensing relay, used in
conjunction with
programming, can also
protect against the effects of
voltage says.
 The relay contacts can be
used to run a check on the
system, retrieve past
information stored in
memory, or hold control
parameters constant until
the event is over.
Potential Sensing Devices For Voltage Sags
(Left to Right)
Phase Monitoring Relay
PQ Relay
“Original” PQ Relay (AC Ice Cube)
79
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Method 4 – Examine Configuration Settings
 A low-cost or perhaps no-cost
method of increasing the
tolerance of AC and DC motor
drives to voltage sags is through
software configuration settings.
 This method applies to all types
of drives, including, but not
limited to, AC pulse-width
modulation (PWM), directcurrent, AC-pulse, stepper, and
servo drives.
80
© 2015 Electric Power Research Institute, Inc. All rights reserved.
40
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Method 4 – Examine Configuration Settings
Functional Description:
Automatic Reset and Automatic Restart
 In most cases, drive
manufacturers give users
access to basic microprocessor
program parameters so that the
drive can be configured to work
in the user’s particular
application.
 A drive’s programming
parameters associated with
reducing the effect of voltage
sags are seldom describes in
one section of the user manual.
81
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Method 4 – Examine Configuration Settings
Functional Description: Motor Load Control
Motor-load control uses the motor’s inertia or controlled
acceleration/deceleration to ride-through voltage sags.
82
© 2015 Electric Power Research Institute, Inc. All rights reserved.
41
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Method 4 – Examine Configuration Settings
Functional Description: Phase Loss and DC Link Undervoltage
Detecting a loss of phase enables a drive to delay a fault condition
and ride through the loss of phase. The DC link undervoltage trip
point can be adjusted to enable a drive to ride through sags.
83
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Method 4 – Examine Configuration Settings
Functional Description: Limits
Rate of acceleration, rate of deceleration, current limit, and
torque limit are parameters that affect the way a drive
attempts to recover after a voltage sag.
84
© 2015 Electric Power Research Institute, Inc. All rights reserved.
42
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Example Settings Rockwell Power Flex 70 & 700
 Conducted SEMI F47
compliance Testing on Power
Flex 70 and 700 Series drives in
EPRI Lab.
 Drives have built in parameters
that can be used to improve
voltage sag performance.
 Drives loaded to 100%
85
© 2015 Electric Power Research Institute, Inc. All rights reserved.
PowerFlex 70 and 700 Ride-Through Parameters
• Two distinct modes of operation, ASD, to help with “Ride-Through”
 “Inertia ride-through” or “Decel” mode
 ASD attempts to maintain the DC bus voltage at certain
level by regenerating power from load
 More output speed droop relative to “Continue Mode”
 For a given sag duration, DC bus voltage will not droop as much as
“Continue” mode
 “Continue Mode”
 For a given sag duration, larger DC bus voltage droop than “Decel” mode
 Less output speed droop relative to “Decel” mode
 Drive is allowed to run at set-speed and load
 Depending on duration of sag and the level of bus voltage droop
• May result “undervoltage” fault
 Increased output current to maintain load
• ASD may trip on “Overload”
86
© 2015 Electric Power Research Institute, Inc. All rights reserved.
43
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Example Response
 Example Worst
Case Speed
Deviation: 12
Cycles, 50% Vab
without Line
Reactor
 Set for P184=
“DECEL” mode
87
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Example Response
 Example Worst
Case Speed
Deviation: 12
Cycles, 50% Vab
without Line
Reactor
 Set for P184=
“Continue”
mode
88
© 2015 Electric Power Research Institute, Inc. All rights reserved.
44
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Video Time:
Visualizing PQ Drive
Parameters for
Improved Voltage Sag
Ride-Through
Video 1: Visualizing PQ Drive Parameters for Improved Voltage Sag Ride-Through
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Method 5 – Select Appropriate Trip Curves for Circuit
Breakers
 Some equipment, especially equipment with AC-to-DC converters,
may respond to a voltage sag by drawing inrush current when the
voltage supply returns to normal.
 During a voltage sag, the AC-to-DC converter capacitors
discharge. At the end of the sag, the sudden presence of a full
voltage causes the discharged capacitors to rapidly recharge.
 The magnitude of this inrush of current depends on the depth and
duration of the voltage sag. The resulting current transient may be
large enough to trip circuit breakers that have a quick response
time.
 Process machines with any type of AC-to-DC converter—such as
DC power supplies, AC or DC variable-speed drives, and servo
drives—can not only cause such transients but may also be
susceptible to breaker trips caused by the transients.
90
© 2015 Electric Power Research Institute, Inc. All rights reserved.
45
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Method 6: Control Power Transformer Tap Adjustments
 If CPT output voltage is not at rated output:
– Adjust CPT taps up (if available on transformer)
 1) Lower Input Tap (i.e. from 460/480 to 440/460)
 2) Raise Output Tap (i.e. from 110/115 to 115/120)
– Lowers susceptibility of control components to voltage sags by
raising the nominal voltage.
– Check against unloaded condition to insure you do not overvoltage
the control power
A
B
91
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Method 7: Coordinate Control Power Transformer Wiring
Adjustments
 Within a process line with multiple control cabinets, the Control Power
Transformers (CPTs) may be derived from various phase-to-phase
combinations and be at various output voltages.
 A voltage sag on most any phase combination will cause the line to trip
somewhere.
A-B
A-B
B-C
A-B
B-C
A-C
B-C
92
© 2015 Electric Power Research Institute, Inc. All rights reserved.
46
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Method 7: Coordinate Control Power Transformer Wiring
Adjustments (2)
 Coordinating which phases the CPT wiring is derived from within a line can
make it less apt to drop out during a sag on a specific phase or phases.
 In this case a phase C, A-C, B-C voltage sag is less likely to cause the line
to drop out.
LINE 1
A-B
A-B
A-B
A-B
A-B
A-B
A-B
93
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Method 7: Coordinate Control Power Transformer Wiring
Adjustments (3)
 Coordinating between
will raise the chances
that some lines may
ride-through an event.
 What lines are likely
to ride-through for:
– A sag on line A-B?
– A sag on line C?
 Probability Game!
94
© 2015 Electric Power Research Institute, Inc. All rights reserved.
47
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Method 8 – Specify a Voltage Sag Recommended
Practice for OEMs!
 A new recommended
practice for voltage sag
immunity was published by
IEEE in the fall of 2014.
 IEEE P1668 is based on
SEMI F47 but includes
requirements for three
phase voltage sags.
 This recommended
practice defines test
requirements and test
criteria.
95
© 2015 Electric Power Research Institute, Inc. All rights reserved.
IEEE P1668 – User Specs Desired Machine Response
 Full (normal) operation – equipment performs as expected or intended and all
of its relevant parameters are within technical specification or within allowed
tolerance limits. Equipment performance should be expressed and measured
against the set of relevant/critical “equipment outputs” (e.g. speed, torque,
voltage level, etc.), which have to be defined as per the process requirements.
 Self-recovery – equipment does not perform intended functions, or its outputs
vary outside the technical specification/limits, but equipment is able to
automatically recover after the end of voltage sag event without any
intervention from the user.
 Assisted-recovery – equipment does not perform intended functions, or its
outputs vary outside the technical specification/limits, and equipment is not able
to automatically recover after the end of voltage sag event. Assisted-recovery
criteria should be applied only when there are dedicated and/or trained
personnel/staff, who either operate the equipment, or are responsible for
supervising the equipment at all times when equipment is in use. If some
external control circuit is applied for automatic restarting of equipment, this
should be treated as a self-recovery criterion.
96
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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EPRI / Penelec PQ/EE Workshop
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IEEE P1668
 Spec. Sheet
format to be used
for Single-phase
equipment
testing
requirements.
97
© 2015 Electric Power Research Institute, Inc. All rights reserved.
IEEE P1668
 Spec. Sheet
format to be used
for 3-phase
equipment
testing
requirements.

98
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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EPRI / Penelec PQ/EE Workshop
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Other Considerations
 Make sure the device rated voltage matches the nominal
voltage. Mismatches can lead to higher voltage sag
sensitivities (for example 208Vac fed to 230Vac rated
component).
 Consider Subsystem performance. Vendor subsystems
must be robust for the entire system to be robust.
Otherwise, power conditioning may be required for the
subsystem.
 Consolidate Control Power Sources. This will make the
implementation of any required power conditioner scheme
much simpler and cost effective.
 Use a targeted voltage conditioning approach as the last
resort. Apply Batteryless power conditioner devices where
possible (next session)
99
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Embedded Solutions
through targeted
power conditioning
with demos
Mark Stephens, PE, CEM, CP EnMS
Principal Project Manager, EPRI
© 2015 Electric Power Research Institute, Inc. All rights reserved.
50
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Example Cost vs. Coverage
101
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Typical PQ Mitigation Devices
Comparison of Power Conditioning Devices
Coverage (Vnom) / Duration
Application
Device
11 
 -- 

33 
3
ProDySC
0% / 2 sec.
30% / 2 sec.
50% / 2 sec.
3
AVC (two rated
models)
45% / 30 sec.
45% / 30 sec.
50% / 30 sec.
25% / 30 sec.
25% / 30 sec.
50% / 30 sec.
1 Contrl Ckt
PowerRide RTD
0% / 2+ sec.
0% A-B, B-C; 7080% C-A / 2+ sec.
70-80% / 2+ sec.
1 Contrl Ckt
MiniDySC
0% / 0.05 sec.
50% / 2 sec.
n/a
n/a
1 Contrl Ckt
CVT
40-50% / 2+ sec.
n/a
n/a
1 Contrl Ckt
VDC (6T Model)
37% / 2+ sec.
n/a
n/a
1 Contrl Ckt
Coil Hold-in (CoilLock
and KnowTrip)
25% / 2+ sec.
n/a
n/a
1-phase
Supercapacitor UPS
Notes
at full load
at full load
3-phase Input, 1-phase Output
for relays, contactors, motor starters
0% /15 sec.
102
© 2015 Electric Power Research Institute, Inc. All rights reserved.
51
EPRI / Penelec PQ/EE Workshop
May 5, 2016
“Selective” Conditioning
The Premise:
All equipment power users are not ultra-sensitive.
The Plan:
To prop up the single-phase “weak links” only.
The Weak Links:
Small, single-phase 100Vac-230Vac, typically power
supplies, sensors and controls.
The Benefit: Lower Cost than Macro Solutions.
103
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Uninterruptible Power Supply (UPS)
For Control Loads
Small 500Va to
3kVA
UPS Systems are
sometimes Used
Battery Based
UPS
Are Often
“Overkill”
“Abandoned in Place” UPS Systems
104
© 2015 Electric Power Research Institute, Inc. All rights reserved.
52
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Industrial UPS Example:
SDU DIN Rail DC UPS Series
















Features
Modular, rugged industrial grade design
Microprocessor based controls
Automatic self-test feature for UPS function
and battery management check
Power module wide operation temperature range (20 to +50°C)
Flexible batteries back-up expansion capabilities
Overload protection in normal and battery modes
User replaceable batteries
Both power and battery modules are UL508 Listed
IP-20 rated input and output screw terminals
No internal fan, no extra cooling required
Sturdy, reliable all metal DIN Rail mounting
connector
LED Status Indicators
Universal Dry Contact Relay terminals provide
remote signaling
Monitoring, diagnostics, and remote turn-on
and shut-off capabilities
Limited two-year warranty
Cost/Unit ~$500 USD
105
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Supercapacitor UPS
 New Product from Marathon
Power
 “Batteryless” UPS
 Supercapacitors store energy
 3kVA, 2100 W
 120V, 208V, 230V models
 Interruption Coverage:
– 15 seconds at full load
– 45 seconds at ½ load
15 to 45 Seconds @
Full Load
106
© 2015 Electric Power Research Institute, Inc. All rights reserved.
53
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Constant Voltage Transformer (CVT)
107
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Output Voltage
 On-line Device. In-Rush Current
of load(s) MUST be considered in
sizing.
 Output of CVT can collapse when
in-rush current gets close too high
( around 4 x rated size).
 Sub-Cycle Response.
 Should be oversized to at least 2
times nominal of load to increase
ride-through.
 Acts as an isolation transformer
and protects against voltage
sags.
Input Voltage
CVT Application & Features
108
© 2015 Electric Power Research Institute, Inc. All rights reserved.
54
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Sample CVT Sizing
Recommendations
Specs
Recommended Max
Nominal Load VA/
Current @ 120Vac
Recommended Max
Inrush Load VA
Current @ 120Vac
Dimensions (inch)
Weight (lbs)
250VA
100 VA / 0.83 A
500VA
200 VA / 1.67 A
1kVA
400 VA / 3.33 A
3kVA
1200 VA / 10 A
500 VA / 4.16A
1000 VA / 8.33A
2000 VA / 16.67 A
6000 VA / 50A
9.88x4.5x7.44
27
12.69x7.78x6.44
37
16.75x7.78x6.44
62
18.69x10.56x9.03
142
MIN SIZE = 2.5 X Nominal VA
or
1/2 Max Inrush VA*
(whichever is larger)
*most critical with contactor loads
109
© 2015 Electric Power Research Institute, Inc. All rights reserved.
CVT Typical Costs ($USD)
110
© 2015 Electric Power Research Institute, Inc. All rights reserved.
55
EPRI / Penelec PQ/EE Workshop
May 5, 2016
CVT Coverage vs. Sample Historical Data
111
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Example CVT Application to Avoid: 500VA control power
transformer and a NEMA type 6 starter
2 X Nominal VA = 2 x 500VA = 1kVA – Would Likely Collapse (Inrush around 4 x CVT Size)
112
1/2 Max Inrush VA = 2kVA to 3kVA ~ $3,000 – Not cost effective!
© 2015 Electric Power Research Institute, Inc. All rights reserved.
56
EPRI / Penelec PQ/EE Workshop
May 5, 2016
The Dip Proofing Inverter
 No batteries; therefore, no replacement
and maintenance costs or hazardous
waste.
 Fast (<700µS) transfer, off-line system
develops little heat & fails to safety.
 Able to withstand high inrush currents;
no need to oversize as with UPS’s &
CVT’s.
 Lightweight, small & easy to retrofit; no
step-up transformers or batteries.
 Accurate application control; adjustable
ride through time & variable transfer
level.
 Primarily designed for inductive and low
power factor loads.
113
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Typical Connections
114
© 2015 Electric Power Research Institute, Inc. All rights reserved.
57
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Sample DPI Specifications
(120V Models)
Specs
Nominal Load
Current
Useable Stored
Energy
Ride-Through
Timer Range
Transfer Level
Range
Dimensions (inch)
Weight (lbs)
250VA
2A
500VA
4A
1kVA
8A
3hkVA
25A
45J
90J
180J
540J
0.01 to 2.56 Seconds
7.68x12.25x6.4
11
50% to 80%
50% to 90% Recommended (Special Order)
11.4x12.25x6.4
15.75x12.25x6.4
21x12.25x6.4
17
22
31
Ride-Through Time = Stored Energy (Watt-Second)/Load (Watts)
Example:
500VA DPI Unit has 90 Joules = 90 Watt-Seconds
Circuit Load = 45 Watts
Ride-Through Time = 90 Watt-Seconds/ 45 Watts = 2 Seconds
115
© 2015 Electric Power Research Institute, Inc. All rights reserved.
DPI Output
Output Voltage
Input Voltage
Square Wave not compatible with some PLC AC Input Cards.
•1-3 second ride-through based on real power required and sizing.
116
© 2015 Electric Power Research Institute, Inc. All rights reserved.
58
EPRI / Penelec PQ/EE Workshop
May 5, 2016
DPI Coverage vs. Sample Historical Data
117
© 2015 Electric Power Research Institute, Inc. All rights reserved.
DPI Typical
Costs
118
© 2015 Electric Power Research Institute, Inc. All rights reserved.
59
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Voltage Dip Compensator (Vdc)







No batteries; no maintenance.
Fast compensation.
Able to withstand high inrush
currents.
Small footprint, easy to retrofit.
Support exceeds SEMI F47
standard requirements.
Handles inductive and low power
factor loads.
120Vac and 208Vac Models
119
© 2015 Electric Power Research Institute, Inc. All rights reserved.
VDC Output
AC Output is a Sine Wave
instead of a Square Wave
Product by Dip Proofing Technologies
www.dipproof.com
www.measurlogic.com
120
© 2015 Electric Power Research Institute, Inc. All rights reserved.
60
EPRI / Penelec PQ/EE Workshop
May 5, 2016
VDC Coverage
4T Model – Down to 50%
121
© 2015 Electric Power Research Institute, Inc. All rights reserved.
VDC Coverage (4T Model) vs. Sample Historical Data
122
© 2015 Electric Power Research Institute, Inc. All rights reserved.
61
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Typical VDC Pricing
123
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Dynamic Sag Corrector
MegaDySC
Three-Phase Protection
 Draws power from remaining
sagged voltage down to 50% of
nominal voltage, and injects a
series voltage to regulate a
sinusoidal output voltage
 Below 50%, draws power from
internal storage capacitors
 Mega and Pro DySC have on
board event logging.
400-3200Amps
ProDySC
Three-Phase Protection
25-200Amps
MiniDySC
Single-Phase Protection
1-50 Amps
124
© 2015 Electric Power Research Institute, Inc. All rights reserved.
62
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Example DySC Output
500
400
300
200
100
0
Input Voltage (Van)
- 100
- 200
- 300
- 400
- 500
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
t ( s)
500
300
Missing Volts
100
- 100
- 300
- 500
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
t ( s)
600
400
DySC Output Voltage
200
0
- 200
- 400
- 600
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
t ( s)
125
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Voltage Sag Correction & Ride-Through Times
 Ride-Through Times: (Based on
100% load, 0.7PF at 60Hz line
frequency)
 Standard Runtime:
2 seconds for sags from 87% to
50% of nominal voltage every 60
seconds
– Up to 5 seconds coverage on
Extended Run-Time Models
 3 cycles for Standard Outage units
from 50%-100% (zero voltage
remaining)
 12 cycles for Extended Outage units
from 50%-100% (zero voltage
remaining)
126
© 2015 Electric Power Research Institute, Inc. All rights reserved.
63
EPRI / Penelec PQ/EE Workshop
May 5, 2016
MiniDySC Coverage vs.Sample Historical Data
127
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Catalog #
2 Amp
1608N‐002A120V2S
1608N‐002A120V2E
http://ab.rockwellautomation.com/Power- 4 Amp
DS10004A120V2SH1000A
Supplies/Voltage-Sag-Protector
DS10004A120V2EH1000A
6 Amp
1608N‐006A120V2S
1608N‐006A120V2E
12 Amp
1608N‐012A120V2S
1608N‐012A208V1S
1608N‐012A220V2S
1608N‐012A230V2S
1608N‐012A240V1S
1608N‐012A240V2S
25 Amp
1680N‐025A120V2S
1680N‐025A120V2E
50 Amp
1680N‐050A120V2S
1680N‐050A120V2E
MiniDySC
Cost www.softswitch.com
Price
1,165.00
1,551.00
1,498.33
1,949.88
2,193.00
2,193.00
2,321.00
3,087.00
3,087.00
3,087.00
3,087.00
3,087.00
2,579.00
3,382.00
4,159.00
6,431.00
128
© 2015 Electric Power Research Institute, Inc. All rights reserved.
64
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Coil Hold-in Devices
• Designed to “Prop Up” individual relays and
contactors. Available at 120, 230 and 480Vac.
• Holds in down to 10 to 20% of %Vnominal.
• Ideal for Motor Control Center Applications.
• Size Based on Voltage and Coil Resistance.
• Cost: less than $130 per unit
CoilLock
Low Voltage
Ride Through
Module
129
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Coil Hold-In Device Ride-Through Curve
SEMI F47
130
© 2015 Electric Power Research Institute, Inc. All rights reserved.
65
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Coil Hold-In Device Costs
Know Trip
DESCRIPTION
PQSI Coil Lock
Model
Number
1000-120V
1001-120V
1002-120V
MODEL 120 8.0 - 35 OHMS
Coil Resistance
Measured with
DC Ohmmeter
801 to 4.5k Ohms
[1]
201 to 800 Ohms
[1]
Comments
UL Compliant File
E255764
UL Compliant File
E255764
UL Compliant File
8 to 200 Ohms [1] E255764
UL & CE Compliant
(50 ma no load, 0.4
1002-120V-CE 8 to 200 Ohms [1] Amp w/8 Ohm Coil)
UL Compliant File
1003-120V
3 to 7.9 Ohms [1] E255764
601 to 17.5k
UL Compliant File
1001-240V
Ohms [2]
E255764
155 to 600 Ohms UL Compliant File
1002-240V
[2]
E255764
20 to 154 Ohms UL Compliant File
1003-240V
[2]
E255764
Price
120
120
120
140
120
140
140
140
MODEL 120-8.5 36 - 200 OHMS
MODEL 120A 201 - 800 OHMS
MODEL 120B 801 OHMS and UP
PART
NUMBER
MODEL
120
MODEL
120-8.5
MODEL
120A
MODEL
120B
MODEL
120HP
MODEL
MODEL 240 151 OHMS and UP
240
MODEL
240A
MODEL 240A 5 - 35 OHMS
MODEL
240B
MODEL 240B 36 - 150 OHMS
MODEL
480
MODEL 480 151 OHMS and UP
MODEL
480 &
MODEL 480 and RC4 40 - 150 OHMS RC4
MODEL 120HP .5 - 7.9 OHMS
LIST
PRICE
$268
$268
$268
$268
$696
$417
$1,006
$1,006
$423
$615
131
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Machine and Panel Level Solutions
Mark Stephens, PE, CEM, CP EnMS
Principal Project Manager, EPRI
© 2015 Electric Power Research Institute, Inc. All rights reserved.
66
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Machine and Panel Level Solutions
133
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Technologies Covered
Pro DySC (larger version of MiniDySC)
Omniverter AVC
Active Power Flywheel
–(a.k.a CAT UPS)
134
© 2015 Electric Power Research Institute, Inc. All rights reserved.
67
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Dynamic Sag Corrector
MegaDySC
Three-Phase Protection
 Draws power from remaining
sagged voltage down to 50% of
nominal voltage, and injects a
series voltage to regulate a
sinusoidal output voltage
 Below 50%, draws power from
internal storage capacitors
 Mega and Pro DySC have on
board event logging.
400-3200Amps
ProDySC
Three-Phase Protection
25-200Amps
MiniDySC
Single-Phase Protection
1-50 Amps
135
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Example DySC Bypass Configuration
136
© 2015 Electric Power Research Institute, Inc. All rights reserved.
68
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Omniverter Active Voltage Conditioner
 Inverter controlled power conditioning
for high power applications
25 kVA to 5 MVA at Low Voltage and
1 MVA to 50 MVA + at Medium Voltage
2-36kV
 The AVC is a 3 phase device and
corrects voltages Line to Line.
 The AVC is a LOAD dedicated device
and as a standard does not provide
correction back to the supply
137
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Single Line Diagram
Active Voltage Conditioner AVC2
Input
Sag/Swell
3ph Utility
Supply
3ph Output
Load
secondary
Distribution
Transformer
primary
Input
Circuit
Breaker
Boost
Transformer
Bypass
Transformer
(Non 400/480V
Supply )
Rectifier and Inverter
Rectifier Fuse
138
© 2015 Electric Power Research Institute, Inc. All rights reserved.
69
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Transmission Sag Correction
V1=82
V2=58
V3=87
Input
V1=97
V2=98
V3=97
Output of AVC
30,000.00
25,000.00
V1 V2 V3
20,000.00
15,000.00
10,000.00
5,000.00
0.00
-5,000.00
-10,000.00
-15,000.00
-20,000.00
-25,000.00
Case Studies
139
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Specifications AVC2
 Load Capacity
200kVA - 6MVA (low voltage)
1MVA- 60MVA (MV to 36kV)
 Response time
– Correction starts in <800 microseconds complete <1/2 cycle
 Efficiency >98% typical 99%
 Correction 40% unit for 30 seconds at Full Load
– 3Ph sag from 60% remaining voltage > 100%
– 3Ph sag from 50% remaining voltage > 90%
– 1Ph sag from 25% remaining voltage > 100%
 Overload capacity from 100%
– Supply 150% for at least 30 second, once per 500s
~$200/kVA for units >1000kVA
Installation not included.
140
© 2015 Electric Power Research Institute, Inc. All rights reserved.
70
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Graphic Display Module
Event Log
Event Summary
141
© 2015 Electric Power Research Institute, Inc. All rights reserved.
2MVA, AVC, Jacksonville, Florida.
2000kVA, 26KV
142
© 2015 Electric Power Research Institute, Inc. All rights reserved.
71
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Example Distribution Panel Recommendations
 Sometimes the most effective
solution is to provide
conditioned power for the entire
IPP Panel. Advantages of this
approach include:
– Simplified Cut Over/Fewer
Touch Points
– Single Power Conditioner for
many loads
– When sized to support kVA
of transformer, this approach
will support future expansion
in panels
143
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Example Measured Loading of IPP Panel
 Panel Lightly Loaded
– Several Spare CB in Panel
– 480Vac CB Rating is 50A
– 480Vac Phase Currents
 Phase A – 4.89A
 Phase B – 4.11A
 Phase C – 1.67A
 Measurements were taken when
line was running.
 It is possible that some loads
could be cycled off.
144
© 2015 Electric Power Research Institute, Inc. All rights reserved.
72
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Example Three Phase Solution – ProDySC
 The Dynamic Sag Corrector
from Softswitching Technologies
 Deep Sag Coverage especially
when lightly Loaded
 Has Capacitors that allow for
some ride-through for
interruptions
145
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Example Three Phase Solution – AVC
Coverage out to
30 Seconds
146
© 2015 Electric Power Research Institute, Inc. All rights reserved.
73
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Active Power/CAT UPS Solution
For continuous power
after 10-15 seconds
Diesel
Genset
CLEANSOURCE
CS 600
On-line
Temperature: OK
Current: OK
Voltage: OK
Battery: OK
UPS
Utility
Power
DC Flywheel
Critical Load
UPS
147
© 2015 Electric Power Research Institute, Inc. All rights reserved.
CAT UPS

250kW/300kVA unit costs in the range of $100k-$140k depending upon accessories
and options. Flywheel speed  8000 RPM. In recent years there has been a number
of installations in US for bridge power application; provides 15 second protection
under rated load condition.
148
© 2015 Electric Power Research Institute, Inc. All rights reserved.
74
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Flywheel During Recharge or Float
DC Buss
IGBT Inverter
Motor,
Generator
To UPS
&
Battery Input
Flywheel
Energy
DC Monitoring
AC Monitoring
IGBT Control
Drive
Bearing
Field
Drive
Sensors
Flywheel
Storage
Flywheel Sensors:
Over speed
Control and System Monitoring
Over voltage
Over temperature
Comm
120 VAC
Vibration
Local EPO
149
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Flywheel During Discharge
DC Buss
IGBT Inverter
Motor,
Generator
To UPS
&
Battery Input
Flywheel
Energy
DC Monitoring
AC Monitoring
IGBT Control
Drive
Bearing
Field
Drive
Sensors
Flywheel
Storage
Flywheel Sensors:
Over speed
Control and System Monitoring
Over voltage
Over temperature
120 VAC
Comm
Vibration
Local EPO
150
© 2015 Electric Power Research Institute, Inc. All rights reserved.
75
EPRI / Penelec PQ/EE Workshop
May 5, 2016
The Cat UPS Family
UPS 300
480Vac, 60Hz
UPS 300E
UPS 600
UPS 900
151
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Continuous Power System
Non-Critical
Auto Transfer
Switch
Load
From
Utility
Cat UPS
Parallel On-Line
Critical
Load
Cat
Gen Set
152
© 2015 Electric Power Research Institute, Inc. All rights reserved.
76
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Dynamic Voltage Regulation
+10%
+2%
Nominal Voltage
RMS Voltage sampled
every 5 cycles
-2%
-10%
153
© 2015 Electric Power Research Institute, Inc. All rights reserved.
CAT UPS Performance from Test in EPRI Lab
154
© 2015 Electric Power Research Institute, Inc. All rights reserved.
77
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Technology Summary
 Active Power /CAT UPS:
 UPS is integrated into package
electronics
 Bearing
 On Board Vacuum Pump Included in
system
 800lb flywheel
 Spins at 8,000 RPM
 150,300,600,900kW for 10+ seconds Multiple sizes
 Flywheel standby power is about 2500W
 Maintenance:
– Air filters as needed
Vac pump oil, six ounces once a year
– Major Maintenance every 3 to 4
years, $6,357 dollars per unit for
bearing change
155
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Relevant Case Studies
Mark Stephens, PE, CEM, CP EnMS
Principal Project Manager, EPRI
© 2015 Electric Power Research Institute, Inc. All rights reserved.
78
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Display Manufacturer
Case Study
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Production Lines
Line A manufactures 19" Displays for monitors with provisions for 21"
Line B manufactures flat panel 19” Displays for monitors with provisions for 17”.
Pegasus Line manufactures 17” Displays for PC monitors.
32” line manufactures TV Displays .
27” Line manufactures TV Displays
20” Line manufactures TV Displays.
158
© 2015 Electric Power Research Institute, Inc. All rights reserved.
79
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Financial Impact of Three Events
Date
Impact
# of
Units
Rejected
(A)
Downtime
in Minutes
# of Units missed
due to downtime
(based on 28
second Mercury
Index time)
(B)
Total #
of
Units
missed
(A) +
(B)
Total
Cost
(based
on $180
per unit)
11/19/98
Power
fluctuation
caused CS light
houses to trip
30
20
43
73
$13,140
11/23/98
Power
Glitch
AG, SCR, PII,
Lost
all
screening
73
48
103
176
$31,680
01/26/99
Power glitch in
screening
process
44
10
22
66
$11,880
147
78
168
315
$56,700
Total
159
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Voltage Sag Characteristics Inside the Plant
Cumulative Histogram for 208V
1994
1995
1996
1997
1998
1999
50
43
45
Number of Events
40
35
29
110 Total Events
30
25
20
15
11
10
1
5
20
1
1
1
65
1 1
60
2
10
5
5
8
4
2
95
100
90
85
80
75
70
55
50
45
40
35
30
25
15
0
RMS Voltage Magnitude (in % of Nominal)
160
© 2015 Electric Power Research Institute, Inc. All rights reserved.
80
EPRI / Penelec PQ/EE Workshop
May 5, 2016
Type of Events
Momentary
3-Phase
2-Phase
1-Phase
Number of Events
20
15
15
12
11
10
10
9
9
8
8
6
5
4
3
3
3
3
2
2
1
0
1
0
0
1994
1995
0
1996
0
1997
1998
0
0
1999
Year
161
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Sensitive Equipment
162
© 2015 Electric Power Research Institute, Inc. All rights reserved.
81
EPRI / Penelec PQ/EE Workshop
May 5, 2016
How Sensitive?
90%
% of Nominal Voltage
80%
70%
60%
50%
40%
30%
20%
10%
AC Contactor
Servo Drive
PLC @120 &
208V
PLC @ 120V
PLC @ 208V
PLC @ 120V
PLC @ 208V
24V DC PS
24V DC PS
24V DC PS
0%
163
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Embedded Solution
Change PLC Input from AC to DC
input.
Use a 3-Phase AC input to 24VDC
output Power supply.
If PLC AC power supply is
integrated to the Module use a
small power conditioning (e.g., Dip
Proofing Inverter or CVT).
164
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AC Versus DC Input for PLCs
165
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How Effective is a 3-Phase AC Input to 24V DC output
Phoenix Contact PS
PLC Power
Supply unit
24V DC
Source
Loading on
24V DC
Source
Voltage Sensitivity Threshold (in %) for 30 Cycle
Ride-Through
Three Phase
Sags
Two-Phase
Sags
Single-Phase
Sag
CV500-PS211
Phoenix
Contact
20%1
0%
0%
0%
CV500-PS211
Phoenix
Contact
35%
45%
0%
0%
CV500-PS211
Phoenix
Contact
60%
50%
0%
0%
166
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How Effective is this Solution?
Impact of Decreasing Voltage Sag Sensitivty of PLC
With No Improvement
Redcuing Sensitivity of PLC to 50% of Nominal
20
18
18
Number of Process Upsets
16
15
14
12
12
10
8
6
6
6
4
3
2
1
1
1
0
0
1994
1995
1996
1997
1998
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Lessons Learned
 In designing new process lines use DC input controllers
wherever possible.
 Use a robust DC source for all your DC inputs (such as, 3Phase AC to 24V DC power supply)
 Know the sag immunity of your DC power supplies in your
plant.
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A “Nice” Power
Quality Solution at a
Plastics Plant
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Monofilament Plastic Extrusion Plant
 Plant has multiple lines with
various vintages of technology
throughout the separate lines:
– Early 1980s through Late 1990s
 Plant was experiencing high
number of voltage sag related
shutdowns due to power quality.
 Utility asked EPRI to come in
and do a PQ Audit to determine
how to make the processes more
robust.
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Site Power Quality Data
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Correlated Voltage Sag Shutdowns per Line
Correlated Vsag Induced Shutdowns
No. Shutdowns
10
9
8
8
7
6
4
4
3
2
0
1
1
7A
3P
3
0
5A
3A
9A
Line
8A
1A
2A
4A
172
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Monofilament Line Control Layout
173
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PQ Events against AC “Ice Cube” Relays
3 Interruptions
Note Shown:
4.74,3840, & 3300
Seconds in duration.
174
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Solution Options
EPRI / Penelec PQ/EE Workshop
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© 2015 Electric Power Research Institute, Inc. All rights reserved.
Economic Analysis: Option 1 - Lowest Cost, Lowest
Coverage
 Initial Outlay - ~$2,299
 Installation Cost - ~ $2,000
 Annual Benefit – possibly avoid
up to 3 upsets per year at
$5,000/process upset –
Maintenance Costs
– Payback 4 months
 Investment - $4,299
 Return - $14,000/yr
– Net Present Value $51,599
 5 yr lifetime
– (based on max remaining life on line
drives)
 8% discount rate
176
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Example Nice Cube Solution on Lines
Also Configure Drives for Ride-Through Where Possible
177
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Result Example from Line 1A
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Other Findings – Off-Line UPS not Fast Enough for
Control Applications
 Process Line 2A had a
UPS installed on the
process controls.
 However, testing showed it
would not react fast enough
to keep loads from
dropping.
 Removed UPS after Nice
Cube installation.
179
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Voltage Sag study at a Natural
Gas Separation and Pumping
Station
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Introduction
 Located in a rural area, a natural gas (NG) separation and pumping
station was experiencing voltage sag induced shutdowns causing
critical sections of the process to shut down.
 Working in cooperation, the NG pumping facility and the Utility brought
in EPRI to:
– review the electrical environment
– plant equipment
– offer possible solutions to show what could be done at the plant to
maintain service during normal system conditions, which typically
includes some level of voltage fluctuation.
 This presentation presents a case study of the analysis, findings, and
details the successful outcome of the work at the NG pumping and
separation facility.
181
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NG Pumping and Separation Process
 The Process:
– Fuel is compressed and delivered via pipelines
 Fuel prepared for separation
– Pigs push condensate into slug catchers.
– Stabilizers removes water and hydrocarbons
 Remaining gas is sent to three compressors:
– Demethanizers strip the methane
– Remaining product to depropanizers
 Extract HD5, 97%-98% grade propane to
storage tanks.
 Remaining product to fractionation plant:
– Gas split into mixture of butane and gasoline.
– Debutanizer to separate to iso and normal
butane
– C5+,referred to as natural gasoline, but basically
all octane used to boost gasoline in refining.
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NG Process Sensitive Process Areas
 MV compressors trip
– Compressor trip causes the pressure in the facility to rise.
– Emergency overpressure valve opens resulting in NG
release into the atmosphere.
– Initially thought auto restart of compressors not possible
 Procedure was manual restart
 Hot Oil Process
– If process trips the system has to be purged before the
burners may restart
 UPS in drives area
– Alarm Condition
– powering critical gas chromatographs
183
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Why was this Audit Chosen as a Case Study?
 Sensitive controls were discovered throughout the
facility.
 MV compressors shut down causes pipeline
pressure buildup
– Release gas into the atmosphere
– Creates PR issues for the facility
– Facility blames Utility for compressor shut
down.
 Utility isolates distribution level customer to a
dedicated substation reducing number of events
– Facility has transmission level PQ environment
– Utility can no longer capitalize on the
remaining capacity in the substation
 EPRI engineers contacted the MV compressor
drive manufacture and discovered an automatic
restart option was available for the compressor
adjustable speed drives.
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Power System Overview
 Facility is fed 25kV from Secondary Substation.
 The Utility opened the tie breaker between the Secondary and the Main
Substation.
– Reduce exposure to voltage sags caused by loads and environmental
events downstream of the Main Substation.
– The facility is now the only load fed from the Secondary Substation.
185
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Facility Circuit Exposure
 With Tie Breaker open facility circuit exposure reduced by 4.75 miles or 88%
 Short distance for a 25kV distribution line.
 Main Substation Breaker Closed
– Total exposure:5.38 miles
 Main Substation and Secondary
Substation Tie Breaker Open
– Total exposure: 0.63 miles
 Less exposure = less risk
186
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Utility Recommendations
 Initial action by the Utility was isolate the facility from the
other circuits loads reducing exposure to PQ Events by
opening tie breaker.
 EPRI recommended installing PQ monitors at both
substations:
 Baseline the individual circuit performance
– Main Substation: monitor determines the PQ environment of the
parallel loads formerly part of the facilities power system.
– PQ Data may be used to correlate external events contributing to the
shut downs of the MV compressor drives and hot oil pumps.
– Secondary Substation: monitoring determines the PQ contribution of
the facility to the power system.
187
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Production Areas Evaluated
 List of the process areas viewed
during the site visit
Hot Oil Tanks
 The problematic equipment:
 Hot oil process
 Toshiba T300MVI medium voltage
VFDs
Hot Oil Pumps
Plant DCS and Control Room
Depropanizer #4
Medium Voltage (MV) Compressor
– Feed critical process
compressors.
– Either of the two processes shut
down it effects the whole plant.
Process Building A
Building 1 MCC
Building 3 MCC
Process Building B
Expander Compressor
Refrigerant Compressor
Process Building C
Refrigeration Compressors K-201A
and K-201B
Distribution Panel fed from UPS in
DCS Control Building
188
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Key Finding 1: MV Compressors
 These drives are used to start the
compressors. As soon as the drive is up to
speed the motor is transferred to line power.
– Three compressors
– One compressor always powered by
drive as a trim compressor
– During voltage sags motors that are
across the line did not trip
– Compressor controlled by the drive did
trip.
– Recommendation:
– Drive manufacturer has a firmware
update that requires a minor amount of
hardware.
– Manufacturer is willing to do the upgrade
at no cost to the facility.
189
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Medium Voltage ASD Consideration
 Facility Engineers said that their
medium voltage ASDs were shutting
down due to voltage sags
 Facility Engineers and A&E firm were
told:
– interruption and voltage sag ridethrough of the ASD limited to 5
cycles.
 Through talking with the manufacturer:
– no cost software and minor
hardware update was identified to
increase the ride-through
190
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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How Does the Toshiba Drive Solution Work?
 Use the magnetic hysteresis in the iron core of the rotor
– Generates a small three phase voltage when rotating
– Controls sync the line voltage
– Drive ramps to full speed
– Low fluctuation in motor speed
– Below is an explanation from a document supplied by Toshiba of how the T300MVi
Speed Search, Ride through, and Restart Capability works.
191
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Key Finding #2 Hot Oil Tank
 This area has several similar burner
control sensors and actuators.
 Field Q Valve Actuators
– Could be AC or DC powered.
 Solenoid Valves
– These valves have an AC coil
– Tested at EPRI and found to be very
sensitive to voltage sags.
 Fire Eye Flame Scanners
– Powered 24Vdc
 Recommendation:
– Verify the Field Sensors are powered
by the UPS
– Make sure UPS is not set for Eco
Mode
– If not powered by UPS then apply
MiniDySC to the control power
transformer
192
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Key Finding #3 Faulty UPS
 This Toshiba WP3 UPS was in an alarm state
and the LCD panel is broken.
– 6kVA 240/240
– According to the facility engineer, this UPS
powers field installed gas chromatographs.
– Recommendations:
 Option 1:
– Document the loads that this UPS
feeds
– Find what is causing the UPS to be
in an alarm state
– Repair the UPS
 Option 2:
– If only sag mitigation necessary
replace UPS with a Mini
Dysc1608N-025A240V1E
 Cost: $4498.00
193
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Types of Control Level Solutions Selected
 MiniDySC
– Control Circuit Mitigation
– Static Series Compensator
with Capacitor Storage
– 50ms of voltage interruption
(more time at reduced load)
– 5 seconds of voltage sag
protection to 50% nominal.
MiniDySC
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Recap of Problem Areas
 Customer’s process was shutting down due to
voltage sags
 The following are the critical findings:
 Medium voltage compressors trip offline
– Pressure buildup in lines cause the pressure
relief valve to open.
– Facility Engineers were told by A&E firm
nothing can be done to harden the drive to
voltage sags.
 Faulty UPS
– Found behind VFD cabinets
– Faulted and alarming
 In a noisy area and unchecked.
– May power critical gas monitoring systems
 Oil Heater Trip off Line
– When system trips it must purge before
restrike
– Oil heating and pumping process shuts down
before burners can restrike.
195
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Recap Facility Recommendations
 Medium voltage compressors
– Collaboration with MV drive manufacturer resulted
in the knowledge of an existing solution.
– Drive manufacturer installed ridethrough feature at
no charge to customer.
 Faulty UPS sourcing gas chromatographs
– Repaired faulty UPS and put back in service or
remove UPS and install a battery less voltage sag
solution.
 Oil Heater
– Customer to verify the sensitive gas solenoids are
powered through existing UPS
 Make sure UPS not set for Ecomode.
– Gas valves are very sensitive to voltage sags.
EcoMode may not be able to switch from static
bypass to protection mode fast enough to protect
the load.
196
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Utility and Facility Recommendations
 Utility:
– Monitor both power feeds
– Determine PQ environment of both circuits
 Facility and Utility:
– Apply PQ performance enhancements to facility
equipment
– Verify the PQ data of monitored circuit
– If the PQ events of the total circuit environment
reside above the voltage sag tolerance curve of
the newly protected equipment
 Close tie breaker so utility may capitalize
on the substation capacity.
197
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Economics of Downtime
- Cost/Payback of
Implementing Low Cost
Solutions
Mark Stephens, PE, CEM, CP EnMS
Principal Project Manager, EPRI
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Payback Considerations
 Customers respond more positively to
business cases based entirely on
solving known business or
manufacturing problems
 Decision makers aren’t interested in the
technical details, but rather in the
business effect of the interruptions
caused by the PQ event and how the
proposed solution will improve bottom
line profitability
 Acceptable payback requirements vary.
Typical ranges are from 12 months to
36 months with anything over 18
months being increasingly harder to
cost justify
199
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Calculating Payback
 To Calculate Payback you need
to know
– One Time Capital Outlay
– Cost of installation
– Annual Benefit
– Ongoing Annual Expense
200
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Payback Analysis
Compatibility Financial Analysis from IEEE 1346
Examples
Investment
One-time
outlay
capital Enhanced equip,
Custom Power
+
Installation
Net Investment
Installation cost
Return
Examples
Annual benefit
Cost of reduced
downtime
-
annual UPS
maintenance,
Premium utility
service
Net annual return
Ongoing
expense
Pay back (months) = (net investment/net annual return) * 12
201
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Cost of Solution Varies Based on Knowledge of
Problem
Embedded
Solutions
can be very cost
effective
202
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Example Embedded Solution Costs
 Costs shown for four different plants based
on separate power quality audits where
embedded approaches are recommended
 Price based on fixing most critical
equipment issues in each plant
 For Semiconductor:
– Many Production Tools and Support
Equipment
 For Food Processing:
– Boiler, Labeling, Cooking
 For Automotive:
– Paint Shop and Body Shop Controls
 For Fiber Cable:
– Multiple Lines
(most expensive losses are from
cable jacketing section)
One Time
Capital Outlay
120,000
100,000
80,000
Solution
60,000
Cost
Semiconductor
Food Processing
Automotive Assembly
Fiber Cable Mfr
40,000
20,000
0
203
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Cost of Installation
 For an embedded solution
implementation, the cost of
installing each device must be
considered
 Items to consider:
– Engineering Labor
– Procurement Labor
– Electrician Labor
– Line Downtime Costs to
install solution
– Installation Fixtures
 For some low cost embedded
solutions, the cost of installation
is as much as the cost of the
hardware!
204
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Calculating the Cost of A Power Quality Disturbance
 IEEE 1346 provides a good
resource for calculating the cost
of power quality events.
 In some industries the actual
cost for each event can be
difficult to measure
 In other industries the cost can
be more directly calculated
205
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Annual Benefit
 The annual benefit is best calculated based on a
yearly average of past PQ related losses.
 Can also be projected based on PQ data (number
of events, magnitude and duration), known
susceptibility of equipment and an estimated cost
per event
 May also include production line utilization rate in
calculation.
206
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Ongoing Annual Expense
 For small Embedded Solution
Power Conditioners, the cost of
this is minimal since there are
no batteries to maintain
 An occasional checkup of power
conditioner output, status
indicators, and dust
accumulation is all that is
required
207
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Cable Manufacturer
Payback Example
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Example Cable Manufacturer Payback Estimation
 Assume fiber optic cable manufacturer looses $30,000
per each event when a cable jacketing line is running
and is shutdown due to PQ.
 Seven (7) events below threshold for line equipment to
shutdown last year (based on PQ Data)
 Utilization rate of line is 40%
 Embedded Solution hardware costs is $3,997
 Installation Costs are estimated at $3,000
 Ongoing Annual Expense is estimated at $1,000
209
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Example Payback Time Calculation
 The estimated payback time for implementing a power quality solution is calculated by:
Pay back (months) = (net investment/net annual return) * 12
Net Investment = Power Conditioner costs + Installation Costs
Power Conditioner Costs (including payoff) = $3,997
Installation Costs = $3,000
Net Annual Return = Annual Benefit – Ongoing Expenses
Annual Benefit = (number of events expected below voltage sag threshold next year
multiplied by the utilization rate of the line multiplied by cost of each shutdown) = 7 x
0.4 x $30,000 = $84,000
Ongoing Expenses = $1,000
Payback Period = [($3997+$3000)/(($84,000-1000)]x 12=($6997/$83,000) x 12
Payback Period = 1.0 Month !
210
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Electrification
Technologies
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Case for Electric Technologies
 Economic benefits - save money
over the life
 Noise reduction - productivity and
safety
 Emission reduction - healthier
workplace and region
 Maintenance reduction - save
money over the life of the vehicle
(90% fewer moving parts with no
engine fluids or hoses)
212
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Drivers for Electrification
 Businesses are facing intense economic pressures to
improve productivity, enhance quality, and lower costs to
remain competitive
 Utilities are seeking to serve their customers, manage load
and promote local economic development
 Society seeks to curb emissions to improve quality of life
while growing jobs and stimulating the local economy
 Electrification through application of novel, efficient electric
technologies can address all of these needs
Electrification can be a win-win-win for businesses, utilities, and
society
213
© 2015 Electric Power Research Institute, Inc. All rights reserved.
“Drivers” for Electrification: Case study in CA
Chart Data: TIAX estimates these achievable reductions in greenhouse gas and criteria emissions from electric drive
214transportation
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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EPRI Non-road Electric Transportation Program
 Program at EPRI began in 1994
 Goal: Market enhancement and
expansion
– R&D/technology development
– Technology demos
– Case studies, information tools and
technology transfer
– Standards development through the IWC
 Take action now: Market ready
technologies
215
© 2015 Electric Power Research Institute, Inc. All rights reserved.
EPRI Non-road Electric Transportation Program
Airports
– Ground support
equipment
– Ground power
Mining
– EV’s and Conveyers
Rail
– Locomotives, cranes
Agriculture
– All terrain vehicles
– Tractors
Warehouses
– Forklifts
– Truck
refrigeration units
Truck Stops
– Shore Power
– On-board power
Seaports
– Cranes
– Cargo handling
– Ships/Dredges
Construction
216
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Technology Description and Options
CLASS 1, 2, 3
Designed for Indoor Applications
3 or 4-Wheel
Electric
Sit Down/Stand
up Riders
Narrow Aisle
Walkie/
Reach Truck/ Walkie End
Order Pickers Rider/ Stacker
217
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Technology Description and Options
CLASS 4, 5
Designed for Outdoor Applications
IC Cushion
IC Pneumatic
(3,000 – 15,500 lbs)
(3,000 – 51,000 lbs)
218
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Example of a customer using EPRI forklift tool
Metal Processing Company, CA
Business Driver: Economic
Benefits
 Replaced eight 6,000 and two
10,000 LPG forklifts
 Forklifts are utilized in
manufacturing and distributing on
finished metal products used in
the commercial construction
industry
 Company expects:
– $435,344 in savings over 5 years
(includes the purchase price, net
fuel and maintenance)
2 shift operation, 5 days a week
Units are used 60% outside in all weather conditions and 40% inside the manufacturing plant
219
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Top 20 Forklift manufactures by sales, 2009
220
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Resources
 Web http://et.epri.com/
– Forklift research and life
cycle cost calculator
– Demonstrations
– Case studies and public
reports
– Online training
 Video YouTube
 Local dealer
representatives
 Utility representatives
221
© 2015 Electric Power Research Institute, Inc. All rights reserved.
What is Process Heating?
Source: U. S. Department of Energy -Energy Savings Assessment (ESA) Process Heating Assessment and Survey Tool (PHAST) Introduction, Arvind
Thekdi, 2007
222
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Process Heating System Components
Heating devices: generate and supply heat
Heat transfer devices: move heat from source to
product
Heat containment devices: e.g. furnaces,
heaters, ovens
Heat recovery devices
Support Systems: e.g. sensors and controls,
materials handling, emission control, safety, other
auxiliary systems
223
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Categories of Process Heating
 Combustion-based
Boilers and steam generators
Muffle furnaces
Atmosphere generators
Ovens
Blast furnaces
Radiant tube heat treat furnaces
Crucible furnaces
Reverberatory furnaces
Dryers
Salt bath furnaces
Indirect process heaters
Solid waste incineration
Kilns
Thermal oxidizers
 Heat recovery and heat exchange
 Electric Processes (Topic of discussion of this webcast)
Resistance
Electromagnetic Waves
Induction
- Infrared (IR)
- Radio Frequency (RF)
Plasma Arc
- Microwave (MW)
- Ultraviolet (UV)
224
© 2015 Electric Power Research Institute, Inc. All rights reserved.
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Four Major Technologies
Induction Heating
Infrared Heating
Microwave Heating
Radio Frequency Heating
225
© 2015 Electric Power Research Institute, Inc. All rights reserved.
Lunch
© 2015 Electric Power Research Institute, Inc. All rights reserved.
113
FirstEnergy Energy Efficiency 2016
Penelec/EPRI Workshop
The Tom Ridge Environmental Center,
May 5, 2016
Disclaimer
The information contained in this presentation material is intended to
provide generally descriptive or summary information and is subject
to verification. The Companies’ actual Energy Efficiency results will
be included as part of the Program Portfolio Reports filed with the PA
PUC.
2
FirstEnergy‘s Pennsylvania Utilities
3
PA Act 129 : How it works ?
PA Public Utility Commission (PA PUC) sets
energy efficiency goals, rules & penalties for
non‐‐compliance
Spending Cap Set
Utilities Develop and Submit Plans to PUC
PUC Reviews and Approves Plans
www.energysavePA-business.com
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4
4
PA Act 129 : How is this funded ?
Funded by Surcharges on Electricity Bill
Surcharges are set by Rate Class
Program Budgets are Finite
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5
PA Act 129 : Timeline
PA Act 129: Timeline
Phase II : Ends May 31, 2016
Phase III:
5-Yr Plan
Starts June 1, 2016
Ends May 31, 2021
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6
PA Act 129 Phase II – Ending Soon !
IMPORTANT DATES
May 31, 2016: PA Act 129 Phase II Ends
A.
FirstEnergy’s Pennsylvania utilities will accept Phase II
applications until June 30, 2016, for qualifying projects that
have been completed and made operational no later than May 31, 2016
B. Applications for projects completed after May 31, 2016, will be
evaluated as Phase III applications and subject to Phase III program
guidelines and requirements
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PA Act 129 Phase II – Ending Soon !
IMPORTANT DATES
June 30, 2016: Deadline for Phase II Applications and
Documentation
A.
All supporting documentation for Phase II projects, including
invoices, specification sheets, W-9s, letters of attestation (LOA),
and all other supplementary information must be submitted via
the online portal no later than June 30, 2016, to be eligible to
receive Phase II incentives.
B. Phase II applications that are missing required documentation after
June 30, 2016, will be retired and will be ineligible to receive
Phase II incentives.
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© Copyright 2014 CLEAResult. All rights reserved.
Phase III Update
9
PA Act 129 Phase III – What to Expect?
For Phase III, Companies filed a full suite of
Residential, Low-Income, Commercial and Industrial
Programs
In March 2016, PA Commission issued the Order
regarding the Companies’ Phase III EE&C Plans
Accepted the terms of the settlement with parties in the
proceeding
Accepted the majority of the Companies’ Plans
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Phase III Plan Overview
5-Year Timeline: June 1, 2016 – May 31, 2021
Budget: 2% of 2006 revenue, each year, same as Phase I & Phase II
Low Income target: 5.5% of energy savings targets
Government/Non-profit/Institution target: 3.5% of energy savings targets
EEC/DR Targets:
EDC
Met-Ed
Penelec
Penn Power
WPP
TOTAL
2016-2021
Savings
(MWh)
2017-2021 Demand
Reductions (MW)
2016-2021
Portfolio
Budget
($Millions)
599,352
566,168
49
N/A
$124.3
$114.9
157,371
540,986
1,863,877
17
64
130
$33.3
$117.8
$390.3
11
Phase III Plan Overview (cont’d)
Key Plan Design Takeaways
DR programs include large C/I interruptible programs and
small Residential Behavioral DR program tied to Smart Meter
deployment
Continued use of incentive ranges to allow for implementation
flexibility
Significant expansion of Low-Income Programs to meet Phase
III requirement with dedicated programs
12
PA Act 129 Phase III Incentives
Variable Rebates
Rebates ¢ per kWh saved
Prescriptive Rebates
HVAC / Specialty Equipment / LED Exit Signs
LED Traffic Signals / Lighting Controls
Incentive caps:
Lighting: Projects Capped at cost of materials
Custom Projects: Capped at 50% of total project cost
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PA Act 129 Phase III
Eligible Projects
Interior Lighting Equipment & Controls
Exterior Lighting Equipment & Controls
Lighting Updates:
T12 – Phased out effective June 1st, 2016
LED Lighting – PA State Requirement (Energy Star or Design Lights Consortium)
HVAC Systems & Controls
(i.e. heat pumps, PTAC unit, hotel room HVAC controls, dual enthalpy economizers,
building automation systems, etc.)
Kitchen Equipment
(i.e. convention ovens, pre-rinse sprayers, ENERGY STAR® steam cookers, fryers,
etc.)
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© Copyright 2014 CLEAResult. All rights reserved.
PA Act 129 Phase III
Eligible Projects
Refrigeration
(i.e. ECM motors, ENERGY STAR® doors, refrigerators, freezers & anti-sweat
controls)
Buildings Program
Renovations
New Construction
Buildings Automation & Controls
Custom Program
Industrial Process
Chiller Replacement
Variable Frequency Drives ( non HVAC Applications )
Compressed Air Systems
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© Copyright 2014 CLEAResult. All rights reserved.
PA Act 129 Phase III
Application Requirements
Apply online
via FirstEnergy Online Portal
Pre-approval (highly recommended)
Submit within 180-days of
Installation & Operability
Signed letter of attestation
Documentation
• Measure & verification
Post-Installation Data Monitoring for:
Lighting Projects greater than 500 MWh
All other projects greater than 250 MWh
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© Copyright 2014 CLEAResult. All rights reserved.
Program Resources
Website = www.energysavepa-business.com
Calculators and link to Application Portal
Solutions by Facility Type
Program Ally Resources
Eligibility and
Documentation
Requirements
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© Copyright 2014 CLEAResult. All rights reserved.
17
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7
Small Commercial Existing & New Programs
18
Large C/I Existing & New Programs
19
Government Existing & New Programs
20
Recent & Upcoming Activities
The Companies are pursuing implementation of the Phase III programs to
begin June 1, 2016
RFPs have been issued to potential Conservation Service Providers (CSPs)
for the following Phase III programs/services:
– Residential Programs: EE Equipment, Appliance Turn-In, School Education, Audits, EE
Kits, New Construction and Behavioral, Low Income WARM Plus/Multi-Family
– Commercial/Industrial Programs: C&I Energy Solutions for Business Programs, Small &
Large
– Demand Response Programs
– Other: EMV Consultant, Tracking & Reporting System
Contracts have been awarded to CSPs for the EMV Consultant and Tracking
& Reporting System (both CSPs approved by Commission)
CSP selection and proposed CSP contract development are in process for
the balance of the RFPs that have been issued
– Proposed CSP contracts require Commission approval
Additional RFPs are planned to be issued for the Behavioral component of
the C&I Energy Solutions
for
Business
Program
– Small
Act 129
Energy
Efficiency and Conservation
Plan Stakeholder
Meeting
21
Questions & Answers
Closing Remarks
22