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Quad Plus

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  1. Power Company Issues & High Voltage Design Chris Tooley President Quad Plus

  2. Power Company Issues & High Voltage Design • Presentation Overview • Introduction • Getting Power Company approval • Power Studies • Shredder Drive options • Static VAR compensator • High voltage design on your site Quad Plus

  3. Power Company Issues - Power Quality • Voltage Fluctuation – Flicker • Motor Startup • Changing Load • Power Factor • Harmonics Quad Plus

  4. U.S. Electric Power Industry Average Retail Price of Electricity by State Quad Plus

  5. Power Company Issues Joseph Crosetto – Recycling Industry Manager Quad Plus

  6. Power Grid Basics Quad Plus

  7. Power Company Issues • Power Company Perspective • Power grid getting stretched thin • Power grid built and changed over many years • Car Shredders are an unusual load • New infrastructure must work now and in the future • New customers pay for line upgrades Quad Plus

  8. Power Company Issues • Strict Standards • IEEE 1453 – Flicker • IEEE 519 – Harmonics • Upside • You can do the same analysis as power company • If you meet standards you probably won’t have problems • Downside • Traditional shredder plant may require dedicated circuit Quad Plus

  9. Power Company Issues • Connecting to the existing distribution lines • Generally less expensive • Dedicated service • Generally more expensive • Cost can kill a shredder project Quad Plus

  10. Power Company Issues • Construction Allowance • Estimated power bill • Primary Metering • Yard owns transformer – lower power bills • Secondary Metering • Power company owns transformer – higher power bills Quad Plus

  11. Power Company Issues • Traditional Shredder Plant • Dedicated Service • Other Shredder Drives • Possible connect to existing distribution lines Quad Plus

  12. Power Company Issues • Picking a Shredder Drive • Research the grid • Understand your options • Buy a shredder drive you know will work Quad Plus

  13. Power Company Issues • Submit request for service to power company • Wait months • Yes/No answer • Use a Power Quality Specialist • Gets info about the power grid • Models various solutions • Give you options which will work • Give you complete analysis • Submit the best option for you that you know will work Quad Plus

  14. Power Company Issues • Power Company Evaluations (sometimes) • Overly Conservative • Less thorough • Make future planning easier • Not have resources / modeling software • Could make mistakes Quad Plus

  15. Power Company Issues • Don’t annoy the Power Company • Don’t make frivolous requests for service • Finalize your equipment before requesting service • Fill out service request form as best as possible • Also supply logical electrical requirements • Have the right person on your end of the line • Offer to do the analysis yourself • Propose a system you know will work Quad Plus

  16. Power Studies - Flicker Quad Plus

  17. Power Studies - Harmonics Quad Plus

  18. Power Studies • Initial calculations • Consultation with the customer • Final report • Power company approval Quad Plus

  19. Shredder Drive Options Joe Kowalkowski Technical Manager for the Recycling Industry Quad Plus

  20. Shredder Drive Options • AC Wound Rotor Motor controlled by Liquid Rheostat • DC Shredder Drives • AC Squirrel Cage Motors • AC Wound Rotor Motor controlled by SPR Drive • Static VAR Compensator Quad Plus

  21. Shredder Drive Options • AC Wound Rotor Motor controlled by Liquid Rheostat • 3000 – 9000 HP – 80”, 98” & 120” mills • Issues with flicker Quad Plus

  22. Shredder Drive Options • AC Wound Rotor Motor controlled by Liquid Rheostat • Issues with flicker Quad Plus

  23. Shredder Drive Options • AC Wound Rotor Motor controlled by Liquid Rheostat • Poor power factor Quad Plus

  24. Shredder Drive Options • AC Wound Rotor Motor controlled by Liquid Rheostat • Wasted energy in the liquid rheostat • High demand charges Quad Plus

  25. Shredder Drive Options • DC Shredder Drive • 1000 – 9000 HP – 60”, 80”, 98” & 120” mills • Better with flicker Quad Plus

  26. Shredder Drive Options • DC Shredder Drive • Better Power Factor • Lower Demand Charges Quad Plus

  27. Shredder Drive Options • DC Shredder Drive • Problem with harmonics Quad Plus

  28. Shredder Drive Options • AC Squirrel Cage Motor • 500 – 1500 HP – 60”, occasionally larger mills • Worst Flicker • High Demand Charges Quad Plus

  29. Shredder Drive Options • AC Wound Rotor Motor Controlled with an SPR Drive • 3000 – 9000 HP – 80”, 98” & 120” mills • New to the recycling industry • Controls Flicker • Better Power Factor Quad Plus

  30. Shredder Drive Options Kurt Schroeder – Medium Voltage Specialist Quad Plus

  31. Shredder Drive Options • Static VAR Compensator • Reduces Flicker • Maintains Voltage • Improves Power Factor • Improves productivity Quad Plus

  32. Static VAR Compensator Quad Plus

  33. Static VAR Compensator Quad Plus

  34. Static VAR Compensator • Boosting Shredder Performance – No SVC Quad Plus

  35. Static VAR Compensator • Boosting Shredder Performance – No SVC Quad Plus

  36. Static VAR Compensator • Boosting Shredder Performance – Compare SVC Quad Plus

  37. Static VAR Compensator • Boosting Shredder Performance • Dramatic gains with SVC Quad Plus

  38. Static VAR Compensator • Boosting Shredder Performance • Dramatic gains with SVC Quad Plus

  39. High Voltage Design Tom Engel – Vice President, Engineering Services Quad Plus

  40. High Voltage Design • High Voltage Design Engineers • Hand Shake with the power company • Design the site medium voltage distribution • Size and specify switch gear • Substation design • Sizing Transformer for auxiliary equipment • Fusing and protection coordination • Equipment spacing and set back • Electric code requirements Quad Plus

  41. Early Considerations in Design • Where is your yard located in the overall power grid? • Is you supply of power from the utility Stiff or Soft? • Will you be required to pay to bring more power to your site? • If so, what voltage will it be supplied at and why? • What other utility requirement do you need to satisfy? • Is your mill drive AC, DC? • What voltage is your drive going to operate at? • Do you want a dedicate source for your drive, or can you share the incoming power? What are the advantages and disadvantages of each? • What is the distribution of loads in your yard • What is the planned timing of your start up? • Do you plan/ want to use existing equipment? Will it even work? What are other considerations? Quad Plus

  42. Electrical Design – One Line Quad Plus

  43. Electrical Design – Plot Considerations Quad Plus

  44. Low Voltage/ Medium Voltage Comparison 1st - 1250HP Motor, 13.2kV Source (Efficiency and Power Factor Estimated at 85%) HP1≔1250 ehp E1≔13200 V Eff≔0.85 PF≔0.85 Quad Plus

  45. Thank You! Questions or Comments? Quad Plus

  46. AC Wound Rotor Motor Curves Quad Plus