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VSD Power Factor

05/24/2017 2:36 AM

Morning Folks, We currently trying to reduce energy consumption and improve efficiency to offset rising Electricity costs (50% increment) in a plastics factory environment.

A Salesman for a popular brand of VSD's and Soft-Starters, assured/insisted that his

"Variable Speed Drive and Soft Starter range will not only improve motor power factor but reduce Harmonics."

Not being as up to date with new developments as one would like, I have to ask, can this be true with new technology? The Gentleman assured me that his "VSD's do have capacitors inside" albeit the unit is barely the size of a shoebox.

I understood that VSD's typically use only part of the sine wave thus causing further Harmonic distortion.

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#1

Re: VSD Power Factor

05/24/2017 9:44 AM

What is the product's make & model? Someone here may have actual experience with it and could tell you whether the salesman's claims are legit (or the degree to which they're not, which is more generally the case).

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#2

Re: VSD Power Factor

05/24/2017 11:46 AM

The realistic key to look at is if you do improve your system's power factor what is the real life cost savings you will see from it in energy savings and how do they compare to what the cost of the improvements will be.

If the improvements cost a lot but the real life savings are little the ROI (Return On Investment) is not worth it.

That and most sales people will lie there ass off to get you to buy their products then ignore you when you go to complain about what they sold you not living up to the promises they made.

Some years ago a local university spent a fortune on updating all of its lighting systems because some sales person sold them on the idea that the ballasts and lights they were selling were 50% more efficient than the one they had. Well technically there were 50% more efficient in the sense that 98% efficient Vs 96% efficient is a 50% reduction in losses.

However in reality the 2% gain is so small its energy cost savings will never pay for the new gear plus the crazy labor bill they got hit for for the replacement work.

Rather like their multi tens of millions of dollar geothermal system that was supposed to supply 100% of the campus year round heating yet now they still run off their near 100 year old coal and NG fired boiler systems for much of the winter because the geothermal system falls flat on its face about halfway through the winter in our climate.

Guess they tried to power the geothermal systems heat pumps with all the energy that 50% reduction in lighting power usage freed up for them.

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#3
In reply to #2

Re: VSD Power Factor

05/24/2017 3:16 PM

Ah, yes. The devil's in the details and knowing WHAT questions to ask. I must agree that I too hold a very dim view of sales people in general. While some will flat out lie, others will state things they hope are true without even knowing either way. I'm wracking my brain trying to think of one case where I had dealings with a sales person or real estate agent where they actually had my concerns or welfare in mind. Stumped . . . . maybe it's because I only remember the slimy ones . . . I would like to think there are decent ones out there . . . . somewhere.

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#6
In reply to #3

Re: VSD Power Factor

05/25/2017 3:18 AM

There are good salespeople, and it is a shame that we use the same word for the sleaze bags and con artists. You may not remember the good salespeople as 'salespeople' but rather as professionals in their respective field.

Sales isn't about making the most off a customer when they visit. It is about developing long term relationship beneficial to all parties involved. It isn't as common as the loud push-pus-push or slimy hey-ya-pal overly friendly fiends trying to separate you from your money, but it isn't really that uncommon either.

A good sales experience certainly isn't as memorable as a bad one. Less hightened emotions, less pressure induced stress, no tactical delays/waiting, rarely any arguing, and typically very little if any buyers remorse. Things may go so smoothly that it doesn't compete well with other memories.

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#9
In reply to #6

Re: VSD Power Factor

05/25/2017 1:04 PM

I have had pleasant experiences with sales people when I've been spending the company's money, so yes, that is true. Those were professionals. However, I still can't think of a personal expenditure in which I wasn't screwed over or attempted to be screwed when I've purchased real estate, new cars, appliances or any other purchase that involved a human with a financial stake in the middle of the transaction. There was one exception but we had to go to great lengths find someone with scruples. I listed that below.

As I became older and more wiser to the ways, I was able to defend myself better against these people, including the walk. I've definitely improved my skills at identifying and calling out the B.S. and telling the sales person that if they don't stop it, I'm walking.

Back in 2002 when we were in the market for a travel trailer (RV), we were going to need to order the model we wanted because no one stocked this particular model. At the Chesaco RV dealer in Joppa, Maryland, we told the sales woman what we wanted to order and which options. She proceeded to tell us that they would order this model with the standard options they put in it and then we could add in any additional ones on top of that. Needless to say, their standard options were a bunch of high-margin foo-foo stuff we didn't need or want. We walked.

We hit all the Maryland RV dealers and always felt like we were going to get screwed.

We eventually found a nice mom-and-pop RV dealer called Radabaugh's Camping Trailers in Marysville, Pennsylvania who was happy to order exactly what we wanted, no more, no less and gave us a nice discount off the retail price, and we ordered that day. No haggling, no angst. But why did we have to search high and low to finally find someone who wasn't out to screw us?

When we purchased our Jayco Seneca in 2013 from Albany RV in Albany, NY because they had one on their lot, we were dealing with someone I'll call "Ted the Liar". We eventually got a price we were willing to pay, but that guy lied through his teeth or just made stuff up instead of saying he didn't know the answer and would get back to us. We should have walked, but my wife really wanted that RV. Too long to go into all the particulars. I'd never go back to that place.

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#10
In reply to #9

Re: VSD Power Factor

05/25/2017 2:37 PM

The reason you had to look so long for a decent honest sales professional is that lying cheating underhanded sliminess is accepted by far too many who either don't see what's happening, or are willing to tolerate it because they want that one, or get exhausted by the techniques to intended to wear the customer out....and just want it to end.

Walk out. On every major purchase, shop several sellers and walk out of every one at least once, just to watch their reaction. If more than one acceptable example exists, call or fax in your order into the manager letting them know there are time constraints and that they are in a condition/accessories adjusted bidding war with other sellers. Disqualify those who try to skirt the rules or otherwise behave dishonestly (be sure to inform each disqulified seller of the specifics of the dishonesty that took them out of the competition and the person making the misrepresentation and request to be notified or remedial action taken)Make your purchase accordingly.

Encourage others to do the same. Weed out the lying extra weight.

W

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#4

Re: VSD Power Factor

05/24/2017 4:49 PM

99.99999% of LOW VOLTAGE (690V and under) VFDs have capacitors inside. There is only one product from one company that does not and it is a highly expensive very specialized product that would not be used on the type of application where you just want to save energy.

VFDs, BECAUSE they have capacitors inside, will indeed improve the PF as seen by your source to .95, as long as you are only interested in DISPLACEMENT power factor, not distortion power factor. Distortion power factor is a product of the harmonics that VFDs create, but depending on the sophistication of the utility metering system, may not be seen by their VAR meters, so would be irrelevant. Power factor improvment however is NOT the same as "energy savings". It might, at best, result in a lower energy TARRIF rate by avoiding penalties, but that is dependent upon what those penalties are (if any) and how they are assessed.

Soft starters do NOTHING toward improving power factor OR saving energy, unless, in some RARE cases, you can use them without a bypass contactor and employ what's called a Nola Energy Saver Circuit. That circuit reduces a SMALL FRACTION of the losses inherent in an UNLOADED induction motor, and that concept is often seriously over sold by unscrupulous salesmen who know that most users will not understand the complex nature of how it functions and why it MIGHT save energy (it rarely does). Most of the time though, you cannot use a soft starter in an industrial environment without having a sealed dust / moisture tight enclosure, which means using what's called a Bypass Contactor to avoid it cooking itself. So if you use a Bypass Contactor, even that tiny possibility of reduction in motor losses is not possible.

Bottom line, your "salesman" has demonstrated only two things: 1) He has no clue what he is talking about, and 2) he will not let that get in the way of taking your money, so he will go ahead and lie about it to get you to buy something anyway.

Run the other way, FAST.

The ONLY way you can save energy using VFDs is if you have ALL of the following conditions:

  1. You have machines that are centrifugal (also known as "quadratic" ) in nature, meaning centrifugal pumps or centrifugal fans. NOTHING ELSE will qualify for saving you energy.
  2. Those centrifugal loads have some existing means of FLOW CONTROL, so like a throttling valve on a pump or vane controls on a fan.
  3. The flow VARIES from time to time, meaning you need full flow some of the time, but not all of the time, so you are using that throttling control to make that happen. In other words if you do have throttling control, but it runs at the same flow rate ALL the time, a VFD is not the right way to save energy on that.
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#5

Re: VSD Power Factor

05/25/2017 2:18 AM
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#7

Re: VSD Power Factor

05/25/2017 3:28 AM

<...trying to reduce energy consumption and improve efficiency to offset rising Electricity costs...>

There are more economic ways to do this, and they are incremental:

  • Elimination of generation of off-spec product and waste materials
  • Nagging people to turn stuff off once they have finished with things
  • Draught excluders on doors
  • Door closing devices
  • Enhanced thermal insulation on building walls and under their roofs
  • Time-switches on equipment rather than leave it on all the time
  • Thermostats on heat-emitting equipment
  • Occupancy detectors on room lighting
  • High-efficiency replacement light emitters such as compact fluorescent and LED-based devices
  • Etc., etc.

After all the above has been carried out should further improvements be considered.

  • Only if the facility's power consumption has a power-factor-based tariff, then look at power factor correction equipment.
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#8

Re: VSD Power Factor

05/25/2017 8:23 AM

Harmonic Distortion is most common in cheap power supplies that only conduct when topping off the capacitor that stores the captured energy. Since most electronic equipment operates on DC, it must be converted from AC. That storage capacitor retains the supply of energy that is needed by the DC load. As that energy is consumed, the voltage drops. Only when the AC peak is higher than the stored voltage will it conduct. This creates gulps of current during the brief peak which is when the harmonic energy is created. It is as if your tire suddenly changed into a stick of lumber while speeding down the road. Not very smooth!

A VSD changes the AC to DC and then re-creates the AC needed by the motor. The newer VSD's do have a more sophisticated power changer so if you are replacing an old one then it might be an improvement. But the power company won't care very much about that. Harmonic energy is usually converted to heat by the large power transformers that change high voltage to useable voltage. Harmonics can bounce around within your facility or a neighboring facility if connected to the same transformer. That can cause other problems if it becomes significant.

Soft Starters may reduce the peak current required to accelerate a motor, but you never escape physics. It is always going to take more energy to accelerate than it is to maintain a given velocity. You really must know the fine details to keep from being taken advantaged of by fast talking salesmen.

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