0.94 → 0.99
.....
Raised power factor to optimise energy use and cut costs.
82.94 kVAR → 5.50 kVAR
.....
Reduced reactive power to boost system efficiency.
20% THDi → 10% THDi
.....
Minimised harmonic distortion to stabilise PFC performance.
Overview
Middeltuin Farm, an agricultural operation located in a remote area, faced rising energy costs and operational inefficiencies due to poor power quality and harmonic distortion.
The farm's electrical system suffered from high reactive power, which wasted energy and caused the equipment to underperform, increasing maintenance costs. System Integrator (SI), C7 Power Products (C7), stepped in to help.
The solution? A comprehensive Power Factor Correction (PFC) system and harmonic mitigation measures from ElectroMechanica (EM) to improve power quality and efficiency at the farm.
The Challenge
Middeltuin Farm encountered several critical issues with its electrical system, which were not only affecting its productivity but also driving up costs:
Challenge 1
Suboptimal Power Factor:
Middeltuin Farm’s electrical system was experiencing high reactive power levels (82.94 kVAR), which significantly reduced energy efficiency and drove up electricity costs. This inefficiency affected the overall performance and reliability of critical equipment, such as pumps and variable frequency drives (VFDs). Implementing Power Factor Correction (PFC) was essential to optimise power usage, reduce energy waste, and improve the stability of farm operations.
Challenge 2
Significant Harmonic Distortion:
The farm experienced severe harmonic distortion, with Total Harmonic Distortion in Current (THDi) levels exceeding 20% and Total Harmonic Distortion in Voltage (THDu) approaching 9%. This distortion disrupted the smooth operation of electrical equipment and increased the risk of failure, contributing to higher maintenance costs and downtime.
Harmonic distortion, a by-product of electrical loads, often disrupts power factor correction systems by preventing them from achieving optimal efficiency. By reducing harmonics to a manageable level, a PFC system can maximise energy savings, balancing cost with performance.
Challenge 3
Equipment Strain and Maintenance:
The inefficient electrical system placed excessive strain on farm equipment, reducing its lifespan and leading to frequent repairs. The lack of power quality also caused unreliable performance during critical operations like irrigation and water pumping, which is essential for the farm’s productivity.
The Solution
In collaboration with C7, EM provided Middeltuin Farm with a targeted solution to tackle both power inefficiencies and harmonic distortion. The combined expertise of EM and the C7 ensured the seamless implementation and ongoing success of the project.
Power Factor & Harmonic Report: Findings and Conclusions, June 2024
The purpose of the recording is to confirm the PFC and AFP performance.
Finding:
The power factor system installed has maintained a power factor 0.99 with the recorded average kvar of 5.498 compared to an average kvar of 82.94
With regards to harmonics see below the improvement on the harmonics.
L1 - before values, l1' - after values.
| THDI % | THDU % | Current (A) | Harmonic Current (A) | |
|---|---|---|---|---|
| L1 | 21.45 | 9.23 | 606.6 | 129.9 |
| L1' | 9.54 | 5.59 | 511.3 | 129.9 |
| L2 | 21.37 | 9.11 | 601.4 | 128.51 |
| L2' | 11.34 | 5.73 | 484.4 | 54.93 |
| L3 | 22.99 | 9.31 | 575 | 132.19 |
| L3' | 11.89 | 5.72 | 466.2 | 55.43 |
The 200A AFP's in parallel, reduced the harmonic content to nearly under 10% and 6% on both the THDi and THDu respectively. The reason the 200A AFP system could not completely mitigate the average 130A current harmonic was due to a high voltage harmonics which was reduced to under 6%. To completely remove the current harmonics and maintain a voltage harmonics under 3% a 100A AFP will need to be added to the existing 200A system.
"PFC and APF Performance"
| Solution Component | Description | Impact |
|---|---|---|
| Power Factor Correction (PFC) | EM’s PFC system was installed to optimise the farm’s power factor. | Reduced reactive power, optimising energy use and lowering electricity costs. The farm now uses power more effectively, significantly improving efficiency. |
| Active Power Filters (APFs). | 200A APFs were deployed in parallel to mitigate harmonic distortion. | Reduced Total Harmonic Distortion in Current (THDi) and in Voltage (THDu), enhancing equipment reliability. |
| System Integration & Scalability | The modular design of the system allows for future expansions without needing major equipment upgrades. | Middeltuin Farm can easily expand its power system as needed, ensuring long-term sustainability and the ability to handle increasing loads without additional large investments. |
Impact Summary
The PFC system drastically improved the efficiency of the farm’s energy usage by minimising reactive power.
APFs significantly reduced harmonic distortion, ensuring equipment operated smoothly and reliably, with less need for repairs.
The system is future proofed for scalability, allowing the farm to expand operations without costly upgrades.
Results
The implementation of ElectroMechanica’s PFC and harmonic mitigation solutions produced measurable, transformative results at Middeltuin Farm:
Power Factor Improvement: The farm’s power factor was raised from its inefficient levels to an average of 0.99, reducing energy waste and optimising electricity usage.
Harmonic Reduction: The Total Harmonic Distortion in Current (THDi) was reduced from over 20% to under 12%, while the Total Harmonic Distortion in Voltage (THDu) dropped from 9% to under 6%.
Reactive Power Reduction: Reactive power decreased from 82.94 kVAR to just 5.498 kVAR, improving energy efficiency and reducing the farm’s energy costs.
Cost Savings: With improved power quality, the farm has reduced energy consumption, minimised maintenance needs, and lowered operational costs by eliminating downtime and reducing strain on equipment.
Long-Term Sustainability: The farm is now better positioned for future expansion, with the ability to scale its power systems without major upgrades, thanks to the modular design of the PFC and harmonic filters.
Enhanced System Integration: The installation resolved issues with the farm’s computerised systems, including seamless generator transfer and solar integration, ensuring reliable and efficient operation of essential processes.
Improved Equipment Reliability: Excessive heat in the VFD room was eliminated, reducing strain on equipment and enhancing overall system performance.