EM Energy Solution with great Success in South Korea
20 Feb, 2020
Recently we
had several installations of our units at different locations in South Korea.
The results and feedback have been amazing. We have proven our units unique capabilities in terms of energy reduction, improved equipment performance and a much more reliable electrical system.
Depending
on type of system, equipment connected and incoming power quality we documented
energy savings between 5-17% !!
On one of
the locations we installed our units this savings corresponded over 20 000
USD yearly.
We used an oscilloscope to document the ability of our unit to mitigate voltage spikes and transients. At several of the locations, vast amounts of noise in terms of fast switching transients up 300 – 500 volts peak were present. After installation of our units, not a single spike was detected.This improvement will have a significant impact on the electrical equipment’s lifetime, especially regarding electronics and control systems.
The harmonic distortion was reduced well below the industry standards (EN 50160) at all locations. On one occasion, our unit was installed on a transformer system containing a high-frequency arc-furnace used for casting metal. The total harmonic distortion (THD) was peaking at 23% without the AVE installed. The AVE reduced the harmonics down to an acceptable level of 6-7 %.
One of the best aspects of our success in Korea was to see the tremendous effect that improved power quality has on equipment and machine performance. At Samsung Heavy Industries, the bad power quality resulted in a poor weld quality, which caused substantial extra work and additional man-hours. With these results, we have proven that by installing our units, customers can save significant amounts of energy and costs, which will help them to achieve a reduced carbon footprint and give them a leading-edge.
The Waveform log above is captured by EMES PQA during welding machine operation at Samsung Heavy Industries and shows the exact moment when AVE is activated. The Waveform before the AVE activation is distorted with a high voltage unbalance (8-9%). After AVE activation, we see a short transitional period of 30-40ms where the unit stabilizes the system, removes harmonic distortion, eliminates transients, and reduces voltage unbalance (0.5%). After the AVE is activated, we can see a perfect sinus waveform and a 100% balanced system.The screenshot above shows real-time information from the unit’s power quality analyzer. The screenshot is taken during welding machine operation with the AVE deactivated. In comparison, the screenshot below were the AVE is activated, information from the PQA indicates several power quality problems such as a high voltage unbalance (8,04%)The screenshot above shows real-time information from the unit’s power quality analyzer. The screenshot is taken during welding machine operation with the AVE activated. In comparison to picture above (figure 6) were the unit is deactivated, voltage unbalance went from 8.04% to 0.59 % after AVE activation. The power factor increased from 0.927 to 0.964 and a significant drop in energy consumption was seen after AVE activation. Active power consumption went from 384,586 kW to 340,960 kW, a reduction of 43.626 kW (11.32 %). Reactive energy consumption went from 97.4402 kVAr to 47.0076 kVAr a reduction of 50 %. Apparent power went from 415.086 kVA to 353.817 kVA, a reduction of 14.76 %. The Waveform log above is from Neonent car parts factory in South Korea. The high amount of harmonics and transients are caused by an high frequency arc furnace (heating coil) which is used for metal casting. The waveform shows the exact moment when AVE is activated and the huge difference the AVE has to the power quality. After AVE activation, we see a short transitional period of 30-40ms where the unit stabilizes the system, removes harmonic distortion, eliminates transients, and reduces voltage unbalance . After the AVE is activated, we can see the harmonics (THD) are reduced from 16 % to 5 % ensuring a reliable operation and increased equipment lifespan.Picture shows how fast the AVE reacts to a voltage imbalance and stabilizes the system. The reaction time is less than 0.9ms.Total harmonic distortion (THD) without AVE active.Total harmonic distortion (THD) with AVE active. Well within the industry standard (EN50160)Figure above shows the difference between existing surge protection technology and AVE based on electromagnetism. Existing semiconductor-based surge protection devices are too slow and often allow as much as five times nominal voltage into the system. These transients will drastically shorten the lifetime of any electronics or semiconductor-based equipment. The AVE react with the speed of the current and does not allow any significant increase in the voltage. During laboratory testing the AVE mitigated a charge of 10 000 Volts to a spike of 28 Volt!
