CR Surfacing Laboratories
Since 1976, CR Surfacing have been Australia's premium & most innovative prescription lens manufacturer. TG Pell electrical reached out to Fuseco on behalf of CRS to assist with upgrading their PFC capacity to cater for the expansion of the site. After careful analysis, it was decided that a 2nd Sinexcel 100kVAr wall mounted unit was to be added to the first unit which was installed a couple years earlier.
CR Surfacing Laboratories
Since 1976, CR Surfacing have been Australia's premium & most innovative prescription lens manufacturer. TG Pell electrical reached out to Fuseco on behalf of CRS to assist with upgrading their PFC capacity to cater for the expansion of the site. After careful analysis, it was decided that a 2nd Sinexcel 100kVAr wall mounted unit was to be added to the first unit which was installed a couple years earlier.
THE CHALLENGE
The challenge here was that the only available space that could be used for the installation of the second SVG unit was directly under the existing unit. This is not ideal as the air intake of the second unit would be positioned too close to the heated expelled air coming out of the first unit. However some testing revealed that due to the presence of cool clean air in the immediate vicinity, the air temperature of the second unit's intake air was within the tolerances. Before commissioning, we checked the CT`s location and installation. We found 3 CT`s on the supply side of the SVG & another set (3 CT`s) installed next to the circuit breaker of SVG`s. After all checking was completed, the commissioning was carried out. The CT`s location was set to the load side for both SVG`s & the total capacity was set to 300A for both. All other settings remained identical.
THE SOLUTION
The existing Sinexcel 100kVAr wall-mounted SVG that was installed a couple of years ago has been performing very well and the site has benefited from significant power cost reductions. Now that the site was expanding, adding another unit was a simple decision by management. Sinexcel wall mounted units can be parallel connected in a ‘Master / Master’ type arrangement. This ‘plug and play’ system provides the safest continuous operation. If one unit is shut down for whatever reason the remaining modules remain in operation until the alarm is attended to or the situation resolved.
THE OUTCOME
The unit was installed and commissioned in October 2019. Please note from the screenshots of the second SVG unit in operation that each of the SVG units are now dealing with half of the load each. The existing power factor across the three phases was 0.79, 0.81 & 0.77 which has been corrected to 0.98. The load has been completely balanced and reduced.
The installation of the second Sinexcel 100kVAr wall-mounted SVG achieved all of the customer’s objectives and made it possible for the client to achieve further cost savings as their manufacturing plant was expanded. It was also interesting to confirm that the first SVG unit that had been installed two years earlier was running perfectly and had incurred $0 in maintenance costs.
- If your billing has changed to a kVA demand tariff and you have poor power factor, you are definitely paying for electricity that you are not using. In such cases, the SVG will reduce your electricity bills. Typically, most installations achieve savings of 10%-30%.
- No capacitor banks therefore no maintenance costs & performance issues associated with capacitors.
- Excellent power factor correction performance - Can maintain a PF of 0.99 lagging or unity if required.
- Dynamic Step-Less Compensation - Profiles the load and operates with a response speed of <15ms. No possibility of over or under compensation, will only inject the kVAr that is needed in that moment.
- Corrects load imbalance.
- Compensates both inductive and capacitive loads - corrects lagging and leading power factor.
- Can work with & enhance existing capacitor-bank based systems.
- Not affected by resonance.
- Can operate at low voltages.
- Excellent ROI (Return on Investment).
THE SINEXCEL SVG - BENEFITS
Simple PFC solutions incorporate banks of capacitors that work as silent reactive power ‘generators’. These systems were designed many decades ago when electrical environments were a lot simpler than they are today. They are common, very economical and suitable for linear load environments.
However, in today’s modern electrical environments, linear loads are not easy to find. Due to the proliferation of LED/energy efficient lighting, switch-mode power supplies, VSD’s, UPS’s, servers/computers and typical appliances, today’s electrical systems experience complex, dynamic non-linear loads. Loads are being switched so fast that the traditional capacitor bank PFC systems struggle to maintain an effective compensation set-point. Therefore, they are perpetually ‘chasing’ the load, either under or over-compensating but rarely providing effective compensation.
Fuseco offers the latest generation of advanced performance PFC solutions that offer instantaneous, dynamic step-less compensation, ideal for the challenging demands of modern electrical environments. The Sinexcel SVG solutions do not need a capacitor bank and offer many advantages due to their compact & modular configuration (including wall-mount options).
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From the moment the AHF and SVG units were turned on our power factor issues were a thing of the past. At both sites our PF is now 0.99 on all phases all the time, the units react instantaneously to our fluctuating load and power factor and the result has been an excellent return on investment.
Brad Kilner
OPERATIONS MANAGER AT KILNER'S ENGINEERING
The PFC units are now installed and running. They are doing a great job at maintaining a constant PF of 0.99 across all phases. Great product and excellent support from both of you. Very pleased doing business with you. Your help has been much appreciated.
Darren Brownscombe
ENGINEER AT TURBOSMART
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