Industry: Distribution Centre/Logistics
Location: Canada
Timeline: 2023-2024
Background
One of Canada’s largest logistics companies encountered operational stoppages due to power quality issues at one of its main distribution centres. They sought a solution to eliminate these recurring problems and troublesome interruptions. Comsys Partner, ADM Engineering, conducted power quality studies and provided an analysis report identifying the root cause problem, along with a recommendation for the best and most cost-effective solution to end these costly stoppages.
Challenge
The challenge facing ADM was to diagnose the cause of generator instability during emergencies and propose a reliable solution. Through multiple audits aimed at understanding loads and their designs, as well as on-site measurements and subsequent data analysis by ADM and Comsys, the root cause was pinpointed. The culprit was identified as severely leading power factor and high harmonic levels stemming from the plant's nonlinear loads across all switchboards. These power quality issues posed a threat to generator integrity and system stability, primarily due to the presence of 6-pulse VFDs equipped with special capacitive input filters to reduce THDI to 40% levels. Based on these findings, ADM recommended the implementation of Active Dynamic Filters (ADF), Comsys’s patented active harmonic filter technology, as the most viable solution to the site's persistent problems. In the interim, operators opted to deploy load banks as temporary corrective measures until ADM could manufacture and implement the solution.
Solution
ADM engineered and assembled two custom Active Dynamic Filters (ADF P300 series) consisting of an 880A and a 770A ADF, utilizing advanced PPM300 modules.
Result
The ADF solution has been operating successfully since January 2024, eliminating harmonics as well as providing near unity lagging power factor. Cost savings alone have are estimated to be around $20,000 per month by eliminating harmonics and correcting the power factor. Increased uptime and productivity provide even more value.
Key Results:
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Plant operational stoppages significantly reduced, enhancing operational reliability
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Reduced temperature of transformers and generators
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Significant decrease in losses resulting in energy savings and avoidance of PF penalties
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Achieved a fixed lagging power factor of 0.99 under all load and supply conditions
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Reduced voltage variations to nominal values
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Reduced current and voltage harmonics
Loads conntected to utility (Generators off)
Loads conntected to Generators (Utility disconnected)
We've received excellent feedback from the customer, and we're delighted to have resolved their issues, taking a significant step towards a more sustainable future. We're incredibly excited to continue leveraging our engineering expertise to enhance power quality across North America.