Energy Saving Evaluation - OppFilm TR 2

Evaluation Report | Energy Saving | Oppfilm – TR 2
Oppfilm
TR 2
www.elspec-ltd.com | 4 Hashoham St. Zone 23, Caesarea Industrial Park, 38900, Israel | Tel: +972-4-6272470 | Fax: +972-4-6272465
1. General
1.1. Background
This report and all the materials attached to (Hereinafter "Information") which are
provided in this document are for energy saving assessment only.
Elspec is not committed to the accuracy of the information under any circumstances
and it should be noted that the information can be used for evaluation purposes only
under customer's sole discretion.
Without derogating the above mentioned, the information provided by Elspec shall be
referred to “as is”, and is provided without any warranty, whether express or implied,
as to its accuracy or completeness, operability, use or fitness for any purpose.
Commitment to saving percentage can be discussed and agreed between parties under
agreement.
The following report is based on the measurements and simulation and includes the
following steps:
1.1.1. Simulation
In this step the plant is presented by one line diagram for simulation purpose
where static load is replaced by dynamic (cycle by cycle).
1.1.2. Saving due to Current reduction
In this step, losses saving due to current reduction as a result of reactive
power compensation are calculated by simulation.
1.1.3. Saving due to Harmonic losses
The harmonic losses, including skin effect, hysteresis & negative sequence are
calculated and estimated in two modes of operation:
Without compensation and filtration
With compensation and filtration (EQ1080KVAr, detuned 7%).
 The saving is the difference between the 2 modes.
1.1.4. Saving due to voltage control
The minimum voltage level is determined based on long period of
measurement. The consumption before and after voltage tap down is
calculated by simulation and the saving is the difference.
Total saving is the sum of the losses reduction due to current and
harmonic reduction and the saving which is created due to voltage tap down.
1.2. Report Summary
The following report is derived from the data obtained in measurements carried-out
at Oppfilm plant which is part of the packaging films Industry on Transformer TR 2
during a 2 days period starting on 10/02/2016.
This report present two options for saving can be obtained:
 for Voltage reduction by tapping down the transformer by 2.5% - the TOTAL
SAVING obtained is up to -3.67%
 for Voltage reduction by tapping down the transformer by 5% - the TOTAL
SAVING obtained is up to -8.19%
2. Simulations
2.1. General
FIG1 presents a single line diagram of a plant for simulation purpose only. This
diagram includes TR1 and Line1 parameters. TR1 is the feeding transformer to the
plant and Line1 is the connection between the transformer secondary and the
switchboard. Load in the schematics presents different load in the plant (Load1
through Load-N). These loads will be replaced by dynamic load calculated cycle by
cycle. The schematic also include compensation system.
2.2. Single line diagram for simulation purpose is described in FIG1
FIG1: Single line diagram
3. Simulation setup
This paragraph presents a procedure for simulation setup. Long period measurement of
the total load is taken by the EG4K and presented in FIG2. Simulation is presented in FIG3
and results are described at Table 1.
Note: deviation between measurement and simulation can be reduced to a minimum by
slight adjustment of the transformer and Line1 in the schematics (as a result of small
deviation in the initial values).
FIG2: Long period measurement of the load
FIG3: Measurement (Black) and simulation (Pink)
PARAMETER ERROR
Voltage -0.00%
Current -0.03%
Active Power -0.06%
Reactive Power -0.03%
Table 1: deviation between measurement and simulation
4. Saving due to current reduction

In first step, copper losses are calculated during the measurements period without
EQ1080KVAr. Calculations are carried out by simulation (described in paragraph 2.0). In
the second step EQ1080KVAr is added to the simulation module. FIG4 describes the
simulation results with and without EQ1080KVAr.
Table 1 provides the savings due to current reduction. The savings are the difference
between the copper losses which are measured in step 1 (without EQ1080KVAr) and step
2 (with EQ1080KVAr). The savings presented in table 2 are in two columns, where one
column describes the losses relatively to the actual average consumption in the measured
period, and the second column describes the losses relatively to the apparent power (KVA)
of the feeding transformer.
FIG 4: measurement without compensation (Black) and simulation with EQ1080KVAr (Pink)
LOSSES RELATIVE LOSSES RELATIVE

COPPER
COMPONENT TO THE LOAD TO THE
LOSSES [W]
CONSUMPTION TRANSFORMER
Transformer w/o EQ 4147 0.56% 0.28%
Line N.A
Total w/o EQ1080KVAr 4147 0.56% 0.28%
Transformer with EQ 4037 0.54% 0.27%
Line N.A
Total with EQ1080KVAr 4037 0.54% 0.27%
Saving (difference
110 0.02% 0.01%
between with and w/o)
Table 2: Savings results due to current reduction
5. Saving due to harmonic reduction

5.1. Harmonic status
Harmonics losses can be reduced substantially by filtration using EQ tuned to the 5th
harmonic. In this paragraph losses savings in the following components are evaluated:
 Skin effect – Are added to the copper losses by calculation of this component
using the current harmonics components.
 Hysteresis losses – Are calculated and added to the transformer losses, using the
current harmonics components.
 Negative sequence – the effect of the negative sequence field on asynchronous
motors, which are direct connected to the mains (not controlled, such as in variable
speed) can be estimated using the current harmonics components.
Harmonics level in voltage & current is described in FIG5.
FIG5: Typical value for voltage & current harmonics level
Saving due to harmonic reduction is N/A, since a detuned system is used.

5.2. Selection of filter type:
 The network is balance and 7% (detuned type) inductors are chosen in order to avoid
resonance due to the 5th harmonic and above.
6. Saving due to voltage control

Voltage supply to load in a plant is changed due to utility supply and load variation.
The power consumption is depending on the voltage (in linear load it is depended on the
second power of the voltage - V²).
In most cases production rate is not affected by voltage variation around nominal values.
However, a minimum voltage level is required for functional operation and this level
should be agreed and determined.
An Equalizer system can compensate cycle by cycle any demand of reactive energy. As a
result, the voltage is increased and much more stable (the difference between the
maximum and the minimum values of the voltage is minimized).
Based on the Equalizer operation voltage supply level to a plant can be reduced by tapping
down of the transformer input voltage to a lower value, complying with a minimum level
which is required for functional operation with no interruption to production.
Long period measurements before tapping down is presented in FIG6, where maximum,
average and minimum values are marked. The minimum values are related to normal
operation, excluding abnormal effect coming from utility supply (sags).
Zoom in on a short period where the voltage reach the minimum level is presented in
FIG7. The effect of connection of EQ1080KVAr system on the network is carried out by
simulation. The comparison between the measured values without EQ1080KVAr and the
simulation with EQ1080KVAr is presented in FIG8.
The average value of the voltage with the EQ1080KVAr is higher from the measured value
without EQ1080KVAr by 0.45%. The difference between the maximum and the minimum
level with EQ1080KVAr is 21V, while the difference between the maximum and minimum
level without EQ1080KVAr is 27V.
Measurements with EQ1080KVAr after tapping down of -2.5% are presented in FIG9
where the average levels are marked. The effect of connection of EQ1080KVAr system on
the network is carried out by simulation. The comparison between the measured values
without EQ1080KVAr and the simulation with EQ1080KVAr and -2.5% voltage reductions is
presented in the same figure.
Zoom in of EQ1080KVAr and -2.5% voltage reduction on a short period where the voltage
drops because the load is presented in FIG 10 shows that the voltage drop with
EQ1080KVAr is smaller.
FIG6: Measured Data load
FIG7: Measured Data load - Zoom In
10
FIG8: Measurement & Simulation with EQ1080KVAr compensation
FIG9: Measurement & Simulation with 2.5% voltage tap-down with EQ1080KVAr
11
FIG10: Measurement & Simulation with 2.5% voltage tap-down with EQ1080KVAr – zoom in
Measurements with EQ1080KVAr after tapping down of -5% are presented in FIG11 and zoom
in is described in FIG12, where the average levels are marked. The effect of connection of
EQ1080KVAr system on the network is carried out by simulation. The comparison between the
measured values without EQ1080KVAr and the simulation with EQ1080KVAr and -5% voltage
reductions is presented in the same figure.
FIG11: Measurement & Simulation with 5% voltage tap-down with EQ1080KVAr

12
FIG12: Measurement & Simulation with 5% voltage tap-down with EQ1080KVAr – zoom in
Average Minimum Change on

Description
voltage voltage minimum
Actual voltage levels 397.6V 381V

Tapping down by 2.5% the
389.7V 380V -0.26%
transformer with EQ
Tapping down by 5% the
380.5V 370V -2.89%
transformer with EQ
Table 3: Average and minimum voltage values 1
1
It should be noted that by tapping down 5%, the minimum voltage decreases in comparison with the original
minimum voltage level. This situation should be considered carefully before tapping down of this level.
13
7. Power saving results

Power saving results is calculated by a simulation.
The difference between power consumption without EQ1080KVAr and before voltage
reduction to with EQ1080KVAr and after voltage reduction (-2.5%) and (-5%) is shown in
Table 4.
Description Power
Difference
Consumption
Power consumption without
EQ1080KVAr and before voltage 734.2KW
reduction
Power consumption with EQ1080KVAr
743.0KW +1.20%
and before voltage reduction
With EQ1080KVAr and after voltage
707.4KW -3.65%
reduction (-2.5%)
With EQ1080KVAr and after voltage
674.2KW -8.17%
reduction (-5%)
Table 4: Saving results due to voltage reduction
14
8. Total evaluation of potential savings

The saving due to current and harmonic reduction and lower power consumption due to
voltage reduction by 2.5% are described in Table 5, by 5% are described in Table 6.
Parameter Improvement Saving %
Current reduction (refer to section No. 4) -0.02%
Harmonic reduction - estimation (refer to

N.A
section No. 5)
Voltage control (refer to section No. 6) -3.65%
TOTAL SAVINGS -3.67%
Table 5: Total saving by tapping down the transformer by 2.5% - summary
Parameter Improvement Saving %
Current reduction (refer to section No. 4) -0.02%
Harmonic reduction - estimation (refer to

N.A
section No. 4)
Voltage control (refer to section No. 5) -8.17%
TOTAL SAVINGS -8.19%
Table 6: Total saving by tapping down the transformer by 5% - summary
15

Energy Saving Evaluation - OppFilm TR 2

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Energy Saving Evaluation - OppFilm TR 2

Încărcat de

Drepturi de autor:

Formate disponibile

Evaluation Report | Energy Saving | Oppfilm – TR 2

1.2. Report Summary

This report present two options for saving can be obtained:

2.2. Single line diagram for simulation purpose is described in FIG1

FIG1: Single line diagram

FIG2: Long period measurement of the load

FIG3: Measurement (Black) and simulation (Pink)

Table 1: deviation between measurement and simulation

4. Saving due to current reduction

LOSSES RELATIVE LOSSES RELATIVE

Table 2: Savings results due to current reduction

5. Saving due to harmonic reduction

FIG5: Typical value for voltage & current harmonics level

Saving due to harmonic reduction is N/A, since a detuned system is used.

6. Saving due to voltage control

FIG6: Measured Data load

FIG7: Measured Data load - Zoom In

FIG8: Measurement & Simulation with EQ1080KVAr compensation

FIG11: Measurement & Simulation with 5% voltage tap-down with EQ1080KVAr

Average Minimum Change on

Actual voltage levels 397.6V 381V

7. Power saving results

8. Total evaluation of potential savings

Parameter Improvement Saving %

Current reduction (refer to section No. 4) -0.02%

Harmonic reduction - estimation (refer to

Voltage control (refer to section No. 6) -3.65%

TOTAL SAVINGS -3.67%

Table 5: Total saving by tapping down the transformer by 2.5% - summary

Parameter Improvement Saving %

Current reduction (refer to section No. 4) -0.02%

Harmonic reduction - estimation (refer to

Voltage control (refer to section No. 5) -8.17%

TOTAL SAVINGS -8.19%

Table 6: Total saving by tapping down the transformer by 5% - summary

S-ar putea să vă placă și