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Member Since 11 Aug 2010
Offline Last Active Aug 12 2010 02:01 PM

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In Topic: Power Factor Controllers

12 August 2010 - 01:24 PM


I agree with your assessment and analysis; thank you for the validation...

Our equipment began development in 2003 with over four years of R&D. This product was only offered to industrial/commercial clients (3-Ph.) in 2008. We now have approximately four hundred successful installations, and continue to improve and refine our productů

We are conducting discussions with BMW where they have been putting oversize sheaves on their air-handlers (AH) in an effort to reduce power consumption. The problem with this method is while it is a cheap solution; it is also a highly inefficient one. When the air-handler (AH) requires extra cooling (Airflow) it is no longer available. Our system will slow down the AH Motor when it is appropriate, but will still be able to run "Full-speed" when required.

A better application was reviewed for Michelin tire; where they have a 125 HP boiler feed water pump that only operates (Feeds the Boiler) 60% of the time. The rest of the time, this pump re-circulates water into a tank in bi-pass mode. This is a 24 hour/365 day application; we have shown a 40% savings in this application.

Our equipment is similar to the latest Ultra-high (23+) SEER HVAC (High Efficiency) equipment currently offered by Mitsubishi and Trane (DDC, with improvements). However, our system is "Stand-alone" equipment and can be installed onto any brand of existing HVAC system and emulate the savings of these new (U/H SEER) systems.

We have recently gathered motor data for a current (Domestic) HVAC Installation by using a Hioki 3169-20 power analyzer/recorder (Certified 4/30/2010). The electrical consumption data comparison is as follows:

Normal HVAC Operation from 12:15 on 5/13 until 9:45 on 5/14; Equaling: 21.5 hours.

Consumption Averages: Current (A): 7.831, Active Power: 5.124 (kW), Reactive Power: 4.288 (kvar), Power Factor: 0.7649, Apparent Power: 6.689 (kVA)

Energy Saving Operation from 12:15 on 5/15 until 9:45 on 5/16; Equaling: 21.5 hours.

Consumption Averages: Amperage: 4.949, Active Power: 2.197 (kW), Reactive Power: 0.153 (kvar), Power Factor: 0.9976, Apparent Power: 2.202 (kVA)

We save similar amounts (30%) of electrical energy on pumps, compressors, fans, chillers, elevators/escalators, etc. Since the electrical consumption of this higher horsepower equipment is greater, the savings and the ROI are also higher.

Our biggest problem is getting clients to believe the methods we are using really do WORK and are not typical "Smoke-and-mirrors" like a lot of the other "Energy Saving Equipment" offered by our competition.

Do you have any ideas on a good method to educate/convey this method/technology/information to prospective clients? No matter how much data, client reports, or "Success Stories" we provide, our U.S. customers are a skeptical bunch (Thanks to the "Junk systems" on the market)...

Have a great day; and Best Regards,


In Topic: Power Factor Controllers

12 August 2010 - 12:17 AM

QUOTE (marke @ Dec 26 2008, 11:58 PM) <{POST_SNAPBACK}>
Hi Mikie

The product being offered by Sienna was the Somar PowerBoss and there are a number of threads about this type of product.

The concept is based on an initial patent by Frank Nola of NASA back in the 1970s where the iron loss in the motor was reduced by reducing the voltage applied to the motor.
The algorithm proposed by Frank Nola was to monitor the power factor of the motor and if the power factor was low, reduce the voltage to maximize the power factor. The effect of this is to minimize the magnetizing current and therefore minimize the iron loss.

On small single phase inefficient motors, this principle works well, but on larger three phase motors, the iron loss is already very small and any reduction is insignificant. Additionally, the principle only really works when the load current is less than or equal to the magnetizing current.

Have a look at the efficiency of modern motors. In many cases there is very little improvement possible.

Have a look at http://www.LMPhotonics.com/energy.htm

Best regards,

Everything old is new again...
We have recently gotten involved with "The Next Generation" of this energy saving equipment and it does not rely on the "Lost Iron" as previously stated. I have not developed or patented the technology and am only trying to offer it to the United States.
Basically, our system uses transducers (Pumps) or thermocouples (HVAC) to determine process load requirements. This data is fed into a "Smart Controller" (Patented algorithm) that interprets the data, and adjusts the motor cycles (VFD, between 30-60 Hz.) to meet the operational needs. The proprietary electronics also adjusts (Conditions/aligns) the electrical signal being supplied to the motor. This equipment has been designed to work with non-VFD type motors and equipment.
I know (From the selections I have read here) that you are not a big proponent of this type of equipment. However, we have collected actual motor data that confirms the energy savings. Additionally, the manufacturer has hundreds of successful installations that have shown a significant reduction of electricity consumed by using this equipment.
If you can discredit this equipment, I welcome this information. I need to know how my potential clients may address and view our claims and operational explanation.
Please bear in mind that I am a Mechanical Engineer and all of my electrical knowledge of this product has been obtained through osmosis...
Thank you for your input and analysis,