ElectroFlow TM

Systems Information
Prepared By

Electenergy Technologies, Inc.

ElectroFlowTM Systems Information

 CONTENTS

Outline Of The ElectroFlowTM Approach….........................................1

ElectroFlowTM Operating Parameters…...............................................4

Designing Of An ElectroFlowTM System.............................................6

Problems And The ElectroFlowTM Solution…....................................8

 OUTLINE OF THE ELECTROFLOWTM APPROACH

Initial Survey
The initial reading tests and measures the electrical load(s) and the distribution(s) in a
facility. From this information, both the impedance or z factor of the system and the X/R ratio are
determined. X being the reactance of the system and R being the resistance of the system. From
that, we are able to point out the areas in your plant where energy is being wasted.

To obtain an accurate report of savings and payback, the following criteria/data are
required:

- Plant operations must be equal to or greater than 70% at the time the measurements
are to be taken otherwise distorted results will be obtained.
- Access to the main distribution(s).
- Copies of the most recent 12-month electric bills. Just the monthly total charge is not
sufficient. The computer analysis we perform incorporates the actual KWH consumed,
the energy charge, KWD, KWD charges, and any discounts.
- Explanations of any unscheduled operating changes for the past year from normal
yearly cycle/operations.
- Details of any future changes to normal plant operations, such as, expansion, product
changes cutbacks, etc.
- List of any known problems suffered in the electrical system, such as,
surges, harmonics, unusual failure or breakdown of equipment or machinery,
etc.
- If Power Factor Correction Capacitors are installed. If they are, we require a list of
where they are installed, the type, and the sizes in KVAR.
- Access to the main transformer is preferred. This is to obtain the size (KVA),
impedance, primary and secondary transformer voltage ratings, delta or wye
configurations, and if it is dry or liquid cooled.
- The estimated percent of DC load related to the normal total load.
- Notification of any variable frequency drives and SCR controls.
- Number of transformers/total transformers on each electric bill.
- If metered on the primary side or the secondary side.
- Site plan of electrical system, if available.
- Hours of Operation. This refers to the adjusted hours of continuous normal operation
of the electrical load reflecting “percent in operation” in hours per week, per each
measurement location.

Proposal
Once the initial survey has been completed, an ElectroFlow TM Systems proposal will be
presented. The proposal contains the following information:

- Executive Summary
- ElectroFlowTM Benefits and Features
- Introduction and Qualification
- Engineering Analysis
- Electric Bill Breakdown

1
 - Electric Bill Analysis
- Existing Power Profile
- ETI Report Information
- Audit Measurements
- Existing Resultants
- Projected Resultants
- Savings Profile and Payback Chart
- Calculation Tables
- Existing and Projected Energy and Savings charts
- Outline of Other Benefits
- Performance Guarantee
- General Terms and Conditions

Note: If there are any drastic changes found after the Link Analysis is performed from the initial
survey, the original price/proposal may be subject to change.

Link Analysis
Upon acceptance of the proposal, a link analysis will be performed. The link analysis is
conducted for the following reasons:

- To check the original measurements and any possible variations thereof.

- To take measurements or to identify a more economical or effective method to
address the problem(s) and savings.
- To determine the location at the site where the ElectroFlow TM System will be
connected.
- To determine breakers/disconnects, cables, and conduit sizes, and what is presently
available at the facility.

The link analysis is a complex computer analysis that identifies the effects of various large
loads switching ON and OFF on various sub mains and the hand shaking effect that occurs between
each of the sub mains or branch circuits.

The following situations are a guide to when and where the link analysis measurements
will be taken:

- Re-measure main distribution(s).

- Distribution panels with one or more motor loads of 50HP or greater.
- Distribution panels 200Amps or greater.
- Distribution panels where welders or significant DC loads are connected.
- Distribution panels or motors which have a specific engineering problem that the
ElectroFlowTM System is targeted to solve.
- The distance of sub main feeds between the main distribution(s) and distribution
panels.

Note: If the period between the original measurements and the link analysis is in excess of three
months, it will be necessary to provide copies of the electric bills for the period from the last
measurement to the time of the link analysis.
Physical Mounting of System Components
- ElectroFlowTM units must be installed within 20 linear feet of the distribution feeder
attachment point.
- Each ElectroFlowTM unit will be installed using good engineering practice and will be
in accordance with applicable national and local codes.
- If an ElectroFlowTM unit is to be mounted near a ceiling, a minimum of 12 inches is
required between the top of the unit and the ceiling.
- If ElectroFlowTM units are to be mounted side by side, a minimum of 1 inch between
enclosures is required.

Ambient Temperatures
High ambient temperatures will reduce the life of the ElectroFlow TM System. Therefore,
the system should be located in an area of unrestricted ventilation and mounted away from hot
objects and surfaces.

Maximum safe ambient temperature is 500C. Should the temperature fall below –400C
before the ElectroFlowTM System is energized, internal damage to the capacitance cells may occur
when the system is turned on. To prevent this, the components should be brought to at least
-120C before being energized. If extremely low temperatures are expected, it is advisable to keep
the capacitors energized in order to maintain their internal temperature above the critical point.
 ELECTROWFLOWTM OPERATING PARAMETERS

An ElectroFlowTM System provides the following standard benefits and features for an
electrical distribution:

1. Improves and levels out the voltage, thereby, increasing equipment efficiency
and longevity.
2. It can balance the three phases, thereby, reducing Kilowatt Demand while
increasing longevity of the system.
3. Filters harmonics, surges and transients, thereby, improving longevity of
equipment and eliminating downtime.
4. Reduces line, eddy current, and hysteresis losses, thereby, reducing the
Kilowatt Demand and Kilowatt Hour consumption.
5. Improves power factor by reducing reactive and apparent power, thereby,
improving system efficiency while eliminating possible related charges. This
is done without any capacitor's deleterious side effects.
6. Frees up wasted KVA capacity of the electrical system, thereby, allowing
additional loads without requiring any transformers or capital expenditure.

An ElectroFlowTM unit comprises of a combination of components which include

inductors, reactors, capacitors, resistors, filters, contactors, breakers, Self Diagnostic Feature(SDF),
and in some cases an ElectroFlowTM Regulator(microprocessors). The unique features of the
ElectroFlowTM System are achieved by the design of the system and its Ladder Logic response.

The sampling rate of an ElectroFlowTM unit is 3840 samples per second all the way up to
15000 samples per second. This sampling rate is handled by utilizing Motorola microprocessors
HC6811 and HC6816. The ElectroFlowTM unit samples voltage, amperage, power factor, and
current threshold. After the samples have been taken, it calls for different stages and different
configurations and different hybrid configurations of the stages to address a particular or multiple
problems that exist. The unit then reads again to see that the steps it took corrected the problem(s).
If the problem(s) were not corrected, it stops and samples again. If the problem is fixed, it
continues to correct the problem(s). In other words, it works with the plant’s electrical load. As
the load changes, the performance of the system changes – it moves with the load. The more
problems there are, the more the system will activate the various stages. The less the load, the less
the system will bring on and off line.

The primary operation of an ElectroFlowTM system is based on tuned tank circuits - LCR
(inductive/reactive, capacitive, resistive). These tuned tank circuits have minimal resistive
components, therefore, they do not waste energy but save energy.

Tank Circuit
L C
C = -900 leading PF
L = +900 lagging PF i = C*(dv/dt)
R = 00 PF=1 V = L*(di/dt)

R
 The principle of the operation is based on Ladder Logic for the activation of the various
circuits. There are 18 circuits per stage in an ElectroFlow TM unit. The system is sized for three
phase systems operating from 208 volts to 345 kilovolts regardless of the line frequency (40Hz to
400Hz). The largest system installed is over seas with a size of 300 Megawatts.

ElectroFlowTM's multistage system is triple protected with each stage independantly

monitored, protected, and activated which means that each stage stands by itself. This is a definite
advantage in case of any failure of any components in a stage, it will isolate itself off line and the
rest of the system will continue to deliver its functions. The system is triple protected and in 98%
of the cases, the system is connected in the distribution in parallel ensuring that it will not disrupt
the plant’s operation.

In most cases, contactors of different ratings are used because 99.9% of the time you do
not need that fast of a response to rectify a problem. We have the technology which we can offer
for a much faster response if it is required. The design is to deliver a more uniform and damped
response because it does not require that immediate response to the load and inrush currents.

The system is equipped with a self diagnostic feature (SDF) which will identify any
component failure in itself on both per phase and per stage basis. The reason this system is
equipped with a SDF is, since the systems are worldwide, it would be too expensive to send
technicians. The in-house electricians will be able to identify the problems of the system in ten to
fifteen minutes.

SUMMARY OF WHAT IS ELECTROFLOWTM?

ElectroFlowTM (dynamic) is an integrated system which is equipped with a microprocessor

based Regulator, which monitors voltage, current, power factor, and current threshold at 3840-
15000 samples per second.

The system consists of multi-stage LCR tank circuits which are activated according to the
preset designed parameters based on the Ladder Logic Principle.

ElectroFlowTM can be designed for applications at low, medium, and high voltages as well
as various international line frequencies.

The system is equipped with a unique Self Diagnostic Feature (SDF) which identifies the
status/failure of components on a per phase and per stage basis.

ELECTROFLOWTM IS VIRTUALLY MAINTENANCE FREE!

 DESIGNING OF AN ELECTROFLOWTM SYSTEM

The actual designing of an ElectroFlowTM unit can only begin after a link analysis has been
performed. This is similar to a load flow. Measurements are taken on the secondary load side of
the main transformer on the common buss as well as each subsequent feeder downstream of the
main distribution. The common buss reading identifies the overall picture and the behaviour of the
load profile on the whole for the facility. The measurements downstream help to identify any
specific problems at any one of the downstream feeders.

If the load profile of the

distribution fall within the certain Transformer
criteria/parameters of the problems being
addressed, only one ElectroFlowTM unit
would be installed on the common buss
of the main distribution. The reason the
unit is installed on the main common
buss is to protect the facility from any Load 1 Load 2 Load 3 Load 4
negative effects from the high voltage
side as well as any problems caused by
Link Analysis Measurement
the facility’s operation. In effect, this
protects the facility from the outside and
inside.

Any variations of the facility’s load, such as, inrush currents, short-circuits, will be
protected as well as from any deleterious effects from the high voltage side. This can only be
accomplished by having multiple impedances in the electrical system. There are three levels of
impedance which are designed to address the problems of the facility – lower, equal to load, and
higher impedances. A lower impedance introduces a path of least resistance to filter harmonics,
surges, transients, spikes, and other variances which may “hit” the facility. If the impedance is
lower, according to Kirchoff’s Law, all the problems will “hit” the ElectroFlow TM unit first and not
the facility’s loads. A load/equal impedance to the facility’s electrical system is able to correct
imbalanced conditions based on X/R ratio and z factor. A higher impedance than the facility’s
electrical system impedance allows the stabilization of the voltage.

Load

1
2
3
} ZLow (Surges & Harmonics)

4
5 } ZLoad (Load Balancing)

} ZHigh (Voltage)

This design set up of the ElectroFlowTM system allows the correction of multiple problems
at once, which results in energy savings and power quality. If there are specific problems
downstream at a sub-feeder, for more effectiveness and economic reasons, a unit will be installed
onto that particular feeder. Again, this will only be done if the load profile of the facility’s load
exceeds the standard design criteria and the set level ETI has set for the industry. This will isolate
the specific problem(s) at the specific load feeder and filter them out so the common buss will not
see these problems and as a result, the losses associated between the feeder and the main
distribution will be eliminated.

Transformer

EF
EF

Load 1 Load 2 Load 3 Load 4

EF ElectroFlowTM Unit

ElectroFlowTM Standard Model Specifications

ElectroFlowTM Model

K1 K2 K3
Voltage (Volts) 208-600 208-600 208-600
Frequency (HZ) 40-400 40-400 40-400
Phases 3 3 3
Circuit Control Regulator 1333 CAPTEL 618 CAPTEL 618
Stages 1-6 1-2 1
KVAR 50/Stage 50/Stage 50
Safe Ambient Temperature (0C) -10 – 50 -10 – 50 -10 – 50
Approved Rating CSA,UL CSA,UL CSA,UL
Dimensions (Inches) 302554 20822 8822
Mounting Floor Wall Wall
Design Life (Years) 20 20 20
 PROBLEMS AND THE ELECTROFLOWTM SOLUTION

Voltage
95% of problems faced in industry and commerce relates to voltage. For a low voltage
condition (under rated voltage), you can expect higher current and more losses, etc. For a high
voltage condition, you can expect breakdown of equipment/machinery and insulation.

MO TO R O VERH EATING
In line with the above two conditions, if we
200 have imbalanced voltages between the phases
(single phase loads are most of the problem), you
Temperature Rise (%)

150 can expect, depending on the stability of the supply

100
5 % NEMA Limit voltage from the utility company and plant
Insulation Breakdown Zone conditions, voltage imbalance. If we have a 5%
50
imbalance in the voltage, according to NEMA, this
0 can cause a 50% increase in motor temperatures (2
12345678910 * OV2). This causes heat dissipation which
Voltage Im balance (%)
increases KWD and over time KWH.

HORSEPOWER DERATING
IMBALANCED PHASE VOLTAGES
120
Derating Factor (%)

If we assume the same 5% imbalanced 100 DANGER ZONE

voltage condition and a motor with a horsepower 80
rating of 10, the de-rated real/effective horsepower 60 OBTAINABLE HORSEPOWER
would be 7.0-7.5 HP. 40
20
0 024681 0
Voltage Imbalance (%)

If we have under voltage, over voltage, and/or imbalanced voltage conditions, we can
expect the following problems:

 Overheating of motors lead to insulation breakdown.

 Imbalanced currents.
 Negative voltage sequence.
 Motor bearings failure.
 Speed variation in motors.
 Reduced production quality.
 Reduced motor efficiency.
 In line with the above problems, we can expect energy wasted and reduced power quality
through:
 Increased maintenance of equipment and machinery.
 Wasted energy which leads to higher electric bill – KWD, KWH.
 Wasted investment and operational capital.
 Use of oversized machinery.
 More difficult to provide adequate overload protection.
 Increased noise and vibration.

Voltage Improvement and Stability

ElectroFlowTM Feature #1 - Standard

Unlike UPS, SPS, and Voltage Stabilizers that:

 Waste energy.
 Connect in series.
 Generate harmonics.
 Have limited fixed sizes and are not expandable.
 Are bulky and expensive.

The Solution - ElectroFlowTM

If we have the above conditions in a facility,

ElectroFlowTM offers two solutions – Voltage
Improvement and Voltage Stability. It stabilizes the
three phases from the effects from the supply side and
effects from the facility (minimizes), at the same time,
improves the magnitude of the voltage as a result of
reactive power and resistive power in imbalanced
conditions. The end result is a steady state voltage and
the rating of the voltage would be based on the
secondary transformer voltage rating. This results in
improved system efficiency and savings of energy.
ElectroFlowTM offers real time voltage improvement and
stability, saves energy (KW, KVA, KWH), connects in parallel,
is fail-safe, and it is modular and expandable.
 Current

Imbalanced currents have the following adverse effects:

 Negative voltage sequence. Phase A Phase B Phase C

AC Current (Amps)
 Circulating currents. 1450
IMBALANCED LOAD
1500 1200
 Increased current in neutral conductor 1500
1300 1400 1250
(causes-imbalanced currents and 1350 1450 1200
1300
harmonics). 1300 1350 1200
 Increased neutral to ground voltage (stray voltage 1350
1100
1400 1300 Phase A
or tigal voltage - reduced power quality and 1300 1350 1250 Phase B Phase C
wasted energy). 1400
900 1400 1200
 Overheating of motors which leads to insulation 1350 1400 1250
500
1300 1450 1250
breakdown. 700
 Reduced motor efficiency. 1400 1400 Time 1200
 Motor bearings failure.

In line with the above problems, we can expect energy wasted and reduced power quality
through:
 Increased maintenance of equipment and machinery.
 Wasted energy/higher electric bills – KWD and KWH.
 Wasted investment and operation capital.

Three-Phase Balancing
ElectroFlowTM Feature #2 - Standard

Unlike no other device in existance!

The Solution - ElectroFlowTM

Again, we are addressing energy savings

and power quality. ElectroFlowTM offers three-
phase balancing (the only product we are aware of
that does this) based on X/R ratio and Z factor.
This accomplishes two things: 1) reduces overall
current, both components of current are reduced –
resistive power and reactive power. As well as,
2) balances the
three phases, thus eliminating the problems of
imbalanced currents.

ElectroFlowTM offers real time phase balancing based on X/R

and saves energy (KW, KVA, KWH).
 An example of how ElectroFlowTM balances the three phases:

Assume:
Phase A = 800 Amps, Phase B = 1100 Amps, Phase C = 800 Amps

A
L

Based on X/R ratio and Z (impedance), ElectroFlowTM’s LCR circuits would be configured inRthe following sequence toR balance the three ph

C B

C
L
R

Tconstant = RC

Surges and Transients

Voltage surge, transient or swell – voltage is higher than the rating of the voltage and the duration
is less than or equal to half a cycle.

Voltage sag – is the reduction of the magnitude of the voltage from the nominal rated value that is
assigned for a duration of less than or equal to half a cycle.

Surges and transients have the following adverse effects:

 Increased maintenance and down time.

 Decrease lifetime of equipment. SURGES & TRANSIENTS

 Cause computers to stop execution of Surge

programs.

Amplitude

Create false data in computers.

 Erase data in computer memory.
 Result in hardware damage.
 Cause damage in wire/cable insulation in
transformers and motors.
Transient
 Cause nuisance tripping of adjustable- Time
speed drives.
 In line with the above problems, we can expect energy wasted and reduced power quality
through:
 Increased investment in plant and equipment.
 Wasted energy – KW, KVA, KWH.

For surges and transients, industry can provide a lot of different products to address these
problems. But, all surge suppressors have two major functions:

1) whether it is a MOV, Zener diode, silicone avalanche diode, they have one thing
in common, the higher the voltage goes over the threshold rating of the device, the lower the
resistance becomes and the closer it gets to zero. The ideal working condition of these devices is to
channel the magnitude of that phase to ground. The idea is to clip the excess, this does protect the
equipment but, if the magnitude of the spike exceeds its designed joules/second, its tanks will
rupture and you take it for granted that it is protecting the equipment (but it is not).

2) when it takes a spike from one phase and channels it to ground (protecting the
equipment), it is wasting the true RMS value(voltage) that otherwise could be collected. If we
could protect the equipment and not waste energy, this would be ideal.

Surge and Transient Filtering

ElectroFlowTM Feature #3 – Standard

Unlike MOV’s, Zener’s, and other Surge Suppressers that:

 Have limited joules/second.

 Re-channel the energy to ground/neutral.
 No status indicators.

The Solution - ElectroFlowTM

ElectroFlowTM offers to clip the surge or

transient, protecting the equipment and it also
absorbs the magnitude of the surge or transient
(true RMS value) an infinite number of times and
channels it inside the tank circuits of each delta
configuration and releases it 1200 out of phase.
Thereby, accomplishing the two criteria, saving the
energy (although minute) but still the savings are
there and power quality.

ElectroFlowTM offers an infinite response to surges and

transients, saves energy, and provides status indication using
SDF (Self Diagnostic Feature).
 An example of how ElectroFlowTM filters surges and transients:

A B C

A
C
L
R

Tank Circuits
B
Tank Circuits

Load

ElectroFlowTM clips surges or transients and releases it 1200 out of phase.

Harmonics

Harmonics by definition is
multiple images of line frequencies. In HARMONICS
North America, the line frequency is
60Hz, therefore, H3 = 180Hz, H5 =
300Hz, etc. Major causes of harmonics
Fundamental h3
are non-linear loads, such as, computers,
Amplitude

h5 h7
electronic equipment, robotics, SUM
electronic lighting ballasts, variable-
speed drives, frequency inverters, UPS
systems, DC drives, battery chargers, Time
etc. These devices are becoming more
and more common in industry. As a
result, the more total harmonic
distortion, the more the distortion of
waveforms, whether voltage or current.
Harmonics cause the following adverse side-effects:

 Overheated transformers (K factor) and rotating equipment. Electrical fires in

industry are generally caused by overheated transformers. The more electronic
equipment and non-linear loads in the electrical distribution, the less the
efficiency of the transformer and the more we have to compensate for the de-
rating of that transformer. For example, if we have a transformer rated as
1000KVA, 480V, 1200A, and non-linear loads of 50% (not uncommon in
today’s industry), we have to de-rate the transformer by 50%. Therefore, the
transformer sizing becomes 500KVA. This has to be done because, based on
all meters in the industry (meters on distribution panels), they measure average
RMS value and they monitor the fundamental waveform. If there are
harmonics present in the system, if you super impose the harmonics curves
onto the fundamental, this is what the meters register because the value of that
is true RMS value.

If you took a true RMS meter and took a measurement on voltage and current,
for example, take the true RMS value based on FFT (that is what the
transformer registers), and compare it to average RMS value, the value of true
RMS is much higher than the average RMS values. The difference between
the two magnitudes, chances are, is caused by harmonics. This may be taken
for granted. Example – look at the panel meter, it reads 800Amps for a
1000KVA transformer, it appears like there is no problem, but, if you take a
true RMS measurement, chances are the draw is much more than 800Amps.
This could lead to overheating/loading of cables, transformers, protective
equipment, buss bars, etc., causing problems without even knowing it.

 Neutral overloading (due to imbalanced conditions and/or harmonics present

which leads to) /unacceptable neutral-to-ground voltages – which means –
current form of the neutral, based on the impedance, can expect a stray voltage
which is undesirable and needs to be filtered out.

 Distorted voltage and waveforms – represents a typical distortion. There are

standards in industry on this. Example – IEC 555 and IEC 1000.

 Failed capacitor banks – capacitors/reactors ( X c = 1/(2fC) ). The higher the

frequency, the lower Xc becomes. The lower Xc becomes, the closer Xc
reaches zero which is a short circuit and the capacitor will rupture. To our
knowledge, if we are dealing with multiple cell configurations of capacitors,
there is not a single capacitor manufacturer in the world that is monitoring
these individual cell failures or the values of the failures. If this happens,
inadvertently, the system is thrown off balance because the supply voltage
across the terminals of the capacitors changes/are different.

 Breakers and fuses tripping – all breakers and fuses are designed,
manufactured, and tested based on the true RMS value and the heat content of
the amperage draw. From time to time, a breaker trips, the technician goes and
takes a measurement expecting to find a short circuit but there is no short
circuit. He turns the breaker on and it works. Quite often harmonics under a
resonance condition, in particular, are the cause of this type of problem.
  Unreliable operation of electronic equipment and generators. As we know, t =
1/f. The higher the frequency, the lower the t (period), the faster the firing
order of the SCRs, and the more breakdowns we can expect in our more
sensitive equipment and the faster responsive equipment purchased for
production.

 Erroneous register of electric meters. A number of studies and papers have

been released on this topic. That is, our electric meters are calibrated for
60Hz. If we have a higher frequency due to harmonics in the system, the
higher the frequency, the higher the percentage error in the register.

 Wasted energy – Inefficient distribution of power. All the energy that is

presently being wasted in/distributed in the distribution, cables, switchgears,
bussbars, transformers (all these true RMS values), if we can filter them out
and ideally re-use it (if possible), will free KVA capacity in the distribution,
cables, switchgears, bussbars, transformers. This would result in two major
benefits: 1) energy savings and, 2) power quality.

In line with the above problems, we can expect energy wasted and reduced power quality
through:
 Increased maintenance of equipment and machinery.
 Wasted energy/higher electric bills – KWD and KWH.

Broadband Harmonics Filtering

ElectroFlowTM Feature #4 – Standard

Unlike active filters that:

 Waste energy.
 Connect in series.
 Generate harmonics (through injection).
 Have limited fixed sizes and are not expandable.
 Are bulky and expensive.

The Solution - ElectroFlowTM

ElectroFlowTM offers broadband harmonics

filtering and the elimination of associated wasted
energy. The filtering of harmonics is handled
through the LCR circuits with the key component
being the inductor/reactor. The filtering
characteristics of the circuits consist of Low Pass –
Untuned, High Pass – Untuned, and Tuned.

ElectroFlowTM offers broadband harmonics filtering, elimination

of associated wasted energy, and modular and expandable system
for additional load.
 Power Factor

PF = cos  = (Real Power(KW)) / (Apparent Power(KVA))

LAGGING PHASE ANGLE

Power factor is the phase
shift between voltage and current.

Amplitude
A lagging power factor is generally
caused as a result of inductive loads
and particularly motors not being
fully loaded.

Voltage
Current
Time

Low power factor causes the following adverse side effects:

 Increased line losses – I2R

 Wasted generation capacity (KVA).
 Wasted distribution/transformer capacity (KVA).
 Wasted system capacity (KVA).
 Reduced system efficiency (KW).
 Increased maximum demand(KVA) and related charges.
 Possible power factor charges.

In line with the above problems, we can expect energy wasted and reduced power quality
through:

 Increased maintenance of equipment and machinery.

 Wasted energy / higher electric bills – KWD and KWH.
 Wasted investment and operation capital.

The oldest solution for a low power factor in

industry, in terms of counter balancing the lagging
power factor, are capacitors. But, there are problems
associated with capacitors which industry is staying
away from because of the potential side-effects to
Without PFCC today’s sensitive equipment (ex. electronics,
computers, etc.).
With PFCC
Characteristics of Power Factor Correction Capacitors (PFCC’s):

 Over-voltage, unregulated supply. Across the terminals of the capacitors, voltage

supplied by the capacitors is higher than the supply/system voltage. This increases the
magnitude of the voltage and as a result with the impedance being lower, this increases
the susceptibility for surges and transients. Low impedance (is the path of least
resistance), and higher voltage, resulting in a spike over riding on the peak of the sine
wave or anywhere along the wave. This would increase the overall magnitude and the
impact of the surge, transient, or spike and therefore, increasing the damaging effects.
All this could be happening and you would not even know it.

 Harmonics magnification – discussed above.

 Resonance and overheating (Xc = Xl). Regardless of which capacitors are used,
automatic, static-dynamic, or aerostatic, the Xc is constant, but Xl (inductive/reactive),
is the load which is constantly changing, as it changes through the course of operation.
If Xc = Xl, a resonance condition occurs. This results in overvoltage conditions,
overheating, and the damaging effects of these conditions.

 Capacitor cell failure (Xc = 1/(2fC)). Ideally, we want f = 60Hz, but, if harmonics are
present, it is not possible (higher number). The higher the value, the lower X c becomes
and approaches zero, resulting in capacitor breakdown, etc.

 Susceptibility to surges and transients, reduced Z(impedance). Discussed earlier.

 “Ringing” effect during capacitor charging, oscillation.

 No cell failure protection/monitoring. If you have a cell failure, inadvertently the

supply voltage to the load is thrown off balance. Comparatively speaking, in a three
phase system, one phase is drawing more than the other phases or one phase is drawing
less than the other phases. In either condition, a negative voltage sequence and
circulating currents occur and the losses associated with these conditions. If a cell is
lost, dropping the voltage of that phase, an unbalanced supply voltage to the loads
results.

 Leading power factor in low-load or no-load conditions.

 Release KVA capacity. Reduced inductive reactive current/power.

 Increase power factor.

 Increased torque and KW, based on percent loading.

Power Factor Improvement

ElectroFlowTM Feature #5 - Standard

Unlike PFCC's / capacitor bank's adverse side-effects (mentioned above):

 The Solution - ElectroFlowTM

Improving power factor is a great idea

because it increases the efficiency of the
distribution, reduces losses, and power factor
charges are eliminated (if charged). ElectroFlow TM
is able to reduce/eliminate this phase shift and
deliver a steady state power factor between 95%-
100% regardless of the plant’s load conditions
without any side effects.

ElectroFlowTM offers power factor of 95% - 100% with no

capacitor side-effects and the Self Diagnostic Feature (SDF).

KVA Capacity

Wasted KVA has the following adverse effects:

 Additional load requires an increase

in supply size.
 Additional load requires larger
disconnecting means.
 Additional load requires higher rated
protecting devices.
 Cable/bus ampacity must be rated
higher than necessary.

In line with the above conditions, the results are:

 Unnecessary capital expenditure for such wasted KVA capacity.

 More space required for additional equipment.

KVA Capacity Improvement

ElectroFlowTM Feature #6 - Standard

Unlike PFCC's / capacitor bank's adverse side effects…

 The Solution - ElectroFlowTM

Since ElectroFlowTM reduces/eliminates

power factor losses, eliminates harmonic losses,
and other losses (negative voltage sequence,
circulating currents, hysteresis, etc.), this translates
into released KVA (useful power instead of wasted
power). It will release KVA in the distribution
system, whether it is needed or not, it is available.
If you need the increased KVA for expansion, you
have it. If you do not need this extra capacity, your
equipment will run cooler and more efficiently. As
a result, resistive power and reactive power will
both be reduced.
ElectroFlowTM offers balanced-capacity released in KVA, no
adverse side effects, and is more cost effective than any devices
in the market.

Brownouts
155 -0.444
BROWNOUT
156 -0.50325
Amplitude

157 -0.54594
Brownout by definition is low voltage for 158 -0.57008
an extended period of time (greater than half a 159 -0.57431
cycle) in which the magnitude of the voltage is 160 -0.55793
reduced. 161 -0.52098
162 -0.46424
Time
163 -0.3892

Brownouts cause the following adverse effects:

 Temporary low line voltage.

 Shutdowns.
 Loss of microprocessor memory.
 Loss of control.
 Reduced motor torque, which can lead to stalling.
 Overheating of motors – insulation breakdown.
 Protective device tripping.
 Speed variation.

In line with the above conditions, the results would be:

 Increased maintenance and downtime.

 Increased operating expenses.
 Brownout Protection
ElectroFlowTM Feature #7 - Optional

Unlike UPS, SPS, and Voltage Stabilizers that:

 Waste energy.
 Connect in series.
 Generate harmonics.
 Have limited fixed sizes and are not expandable.
 Are bulky and expensive.

The Solution - ElectroFlowTM

ElectroFlowTM offers to improve the voltage

to the secondary nameplate of the transformer thereby
delivering steady state voltage to the equipment and
machinery.

ElectroFlowTM offers real time voltage improvement and

stability, saves energy (KW, KVA, KWH), connects in
parallel, it is fail-safe, and it is modular and expandable.

Intermittent Supply Failure

INTERMITTENT SUPPLY FAILURE

Generally, intermittent supply failures
are caused by the utility company switching
loads, lines, and source supplies. The fastest
this switching can occur is three to five cycles.
Amplitude

During this period, there is a complete drop-

out. This may or may not be a concern for all
industries but intermittent supply failure takes
its toll on the operation and efficiency of
equipment and machinery.

Time

Supply failure causes the following adverse effects:

 Voltage control relay tripping.

 Phase imbalance relay tripping.
  Plant and equipment shutdown – downtime.
 Loss of critical microprocessor memory.
 Possible jogging, pinching, and stalling of motors.
 Loss of control and resetting of equipment.
 Loss of production.

Intermittent Supply Failure Protection

ElectroFlowTM Feature #8 - Optional

The Solution - ElectroFlowTM

ElectroFlowTM is able to supply a steady state

(as a drop-out occurs) sine wave to the distribution for
up to 1 second.

ElectroFlowTM supplies continuous voltage during short

duration (up to 1 second) intermittent supply failure and
H.V. line switching.

Specific Harmonics

Harmonics cause the following adverse effects:

 Overheating of transformers (K-

Factor), and rotating equipment.
% Magnitude


100
Increased hysteresis losses. 90
80

 Distorted voltage and current 70

60

waveforms. 50
40


30
Failed capacitor banks. 20
10

 Breakers and fuses tripping. 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20


Harmonic
Erroneous register of electric meters.
 Neutral overloading / unacceptable
neutral-to-ground voltages.
 Unreliable operation of electronic
equipment and generators.
 In line with the above problems, we can expect energy wasted and reduced power quality
through:
 Wasted capacity – Inefficient distribution of power.
 Increased maintenance of equipment and machinery.
 Wasted energy / higher electric bills (KW,KWH).

Specific Harmonics Filtering

ElectroFlowTM Feature #9 - Optional

Unlike active filters that:

 Waste energy.
 Connect in series.
 Generate harmonics (through injection).
 Have limited fixed sizes and are not expandable.
 Are bulky and expensive.

The Solution - ElectroFlowTM

ElectroFlowTM filters specific and multiple

harmonics to a non-destructive level resulting in
energy savings, improved production, and increased
equipment efficiency and longevity.

ElectroFlowTM offers specific harmonic filtering of any

magnitude, enhanced power quality, elimination of associated
wasted energy, and modular and expandable circuitry.

Phase Loss

Phase loss causes the following adverse effects:

PHASE LOSS
 Imbalanced operation of three phase
Amplitude

motors, resulting in insulation

breakdown and destruction.
 Increased downtime.
 Loss of production.
 Major maintenance and
replacement capital requirement. Time

Phase Synthesis Unlike no other device in existance. The

TM
ElectroFlow Feature #10 - Optional
 Solution - ElectroFlowTM

In case of a phase loss, ElectroFlowTM can

quickly detect and manufacture the lost phase from the
ElectroFlowTM offers phase-loss detection and synthesis remaining two phases, ensuring a continuous supply
system, makes the lost phase from the other two phases, of power to the plant and eliminating loss of valuable
sustains voltage supply to the load continuously with
virtually no downtime.
production time.

3) This leaves 600 to be compensated for to finish establishing the A phase. The compensations which have been made thus far
 Implementation of ElectroFlowTM's phase synthesis unit:

The installation of the ElectroFlowTM phase synthesis unit would be between the main transformer
and the plant’s main distribution panel. The operating time of the phase synthesis unit is
continuous/indefinite(until the lost phase is restored).

If the utility company losses a phase, the protection devices(short-circuit relays, fault currents,
etc.) of the plant have to be bypassed. If this is not done, every time the ElectroFlowTM phase synthesis unit
comes on, it will trip these protection devices. A bypass is used from the secondary transformer and the
plant’s load so there will be no feedback from the lost phase. In other words, if A phase is lost, interlocks
will open and close to make this phase in series through the phase synthesis unit.

Certain criteria have to be taken into account to see if a phase synthesis unit can be installed in a
plant. Some of these criteria are:

1) make sure the ampacity is there for the conductors to carry the load of the other
two phases.
2) the sizing/rating of the short-circuit relays on the primary side so they do not trip.
3) is the transformer capable of sustaining this type of operation.
4) the full load of the main transformer has to be less than 67% at the time the phase
synthesis unit comes on. If the full load of the transformer is greater than 67%, the
phase synthesis unit will not engage. Etc.

The ElectroFlowTM phase synthesis unit is not really intended for North America because phase loss
situations are rare but will be installed if a customer requires it.

Summary: ElectroFlowTM Benefits

Savings

1 – Reduces KW Demand
2 – Reduces KWH Consumption
3 – Eliminates Power Factor
Penalty 4 – Reduces Monthly
Electric Bill
5 – Reduces Maintenance & Downtime

Power Quality

1 – Improves Voltage
2 – Balances Three Phases
3 – Filters Surges, Transients
4 – Filters Harmonics
5 – Improves Power Factor

Customer Satisfaction Is Our Ultimate Goal!