Florida Water Reclamation Facility

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HGA HarmonicGuard Active Harmonic Filter

Problem

A Florida Water Reclamation Facility recently had a substantial expansion to accommodate large residential growth in the region, successfully increasing their capacity by 50%. However, a large number of non-linear loads were added throughout the facility throughout different sections of the reclamation process. Harmonic mitigation was needed to address these loads, with a focus on reaching different physical locations economically and effectively.

Solution

After a close evaluation of the harmonic distortion being produced by multiple non-linear loads which were spread over the large facility, our team recommended the installation of multiple HGA Active Harmonic Filters of varying sizes. HGA Active Filters were installed, ranging from one of our small 50A units to as large as the 350A unit. These generator-friendly units were successfully placed around the facility so that the entire operation produced less than 5% overall TDD.

Wisconsin Lift Station

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HGA HarmonicGuard Active Harmonic Filter

Problem

A new lift station was built with two dry well pump chambers with each chamber housing two submersible sewage pumps. Each pump is controlled by a VFD. Both chambers can be run together or individually so that one can be taken off-line for maintenance. The entire load was non-linear and the harmonic mitigation solution had to work with either both chambers in operation or just one.

Solution

A single 100A HGA active harmonic filter was installed in the lift station. The one filter can address the harmonics produced by both chambers running together or immediately adjust to the harmonics produced by only one chamber in operation. And in the event that the lift station needs to switch to its on-site back-up generator, the active filter will continue to operate normally regardless of the power source.

Wisconsin Pump Station

Featured Products

HGA HarmonicGuard Active Harmonic Filter

Problem

A booster station was added to as growing neighborhood in Wisconsin, but space was limited. Multiple Variable Frequency Drives (VFDs) used to run booster pumps required harmonic mitigation. The small layout, which included a generator, called for a solution that was physically small as well.

Solution

The HGA Active Harmonic Filter fit perfectly in the tight space, with a compact enclosure of 26.77 in. X 16.58 in. X 13.74 in. The filter’s 50A rating effectively addressed the harmonics produced by multiple VFDs. The active filter is designed to work well with sensitive generators, allowing the application to run smoothly.

Stadium Upgrades for Reading Phillies

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HGA Active Harmonic Filter

Problem

FirstEnergy Stadium, home of the Reading Fightin Phils, unveiled a new player development facility and community center for the 2024 season. The Fightin Phils new Redner’s Event Center will house the home and away team clubhouses, batting cages, weight rooms, female locker rooms, dining areas and kitchens and training room facilities. It also offers a banquet hall that can serve up to 500 guests.

The size of the facility requires some powerful HVAC equipment, which can cause some major harmonics on the grid. During the planning stages of the project, TCI was contacted to assist in mitigating the harmonics before they became a major problem to surrounding neighbors and the power company.

Solution

Two active filters were ordered and put into place: 100 amp and 50 amp HGAs. As a result to adding the two active filters, the Utility company has approved the harmonic limits output from the facility, their sensitive HVAC equipment will continue to run smoothly, and the facility won’t be putting harmful harmonics back onto the power grid affecting neighborhoods surrounding the stadium.

Protecting ECMs from Harmful Harmonics

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HSE Passive Harmonic Filter

Problem

An HVACR manufacturer reached out to TCI because they needed help mitigating the harmonics caused by their Electrically Commutated Motors (ECMs) on a fan wall. TCI’s application engineers worked to configure different approaches that would successfully remove the harmonics putting the ECM’s at risk.

Our experts gave two solutions – either do a larger filter big enough to mitigate the harmonics, or two smaller filters in tandem. The bigger filter would be the more economical approach but would be more difficult to install and manage electrically and physically than two smaller harmonic filter units.

Solution

The HVACR Manufacturer decided to go with the second option – two smaller units. TCI recommended two 150 HP HSEs with PQconnect for ease of installation and to successfully mitigate the harmonics at a level that no longer posed a risk to the facility by harming expensive equipment and creating downtime. The HSE is part of TCI’s HarmonicShield passive filter line, and is specifically designed to work with any type of EC Motor, and the addition of PQconnect allows for real-time data and monitoring.

Money and Time Saved for Bakken Field Operator

Featured Products

HGA Active Harmonic Filter

Problem

Oil field economics are changing rapidly. As a way to save money and reduce environmental impacts, many oil producers are using multi-well pad drilling as an alternative to single well sites. Over the life of a well, different types of artificial lift equipment may be employed to maximize production. Unfortunately, with more wells there is an increase in harmonics, and also in voltage distortion. This is presenting a problem for many multi-well pad drilling sites.

A field operator in the Bakken region called upon TCI to find the best solution for reducing the costs of mitigating harmonic issues over the lifetime of their site. The customer’s site was a multi-well pad with 18 wells that could transition through various artificial lift technologies over their lifecycle. If single well solutions are3 used, each time that a pump change was made to the site, new harmonic filters were required. This field operator was looking for a single solution that could handle all of their harmonic needs throughout the lifecycle of the site. The operator contacted TCI for assistance in solving their significant harmonic current and high background voltage distortion problems.

Solution

TCI engineers found that the best solution to the harmonic current and voltage distortion problems was to install one HarmonicGuard Active Filter (HGA) at the PCC. Over the lifetime of multi-well pads, a single HGA can replace multiple passive harmonic filters, multi-pulse drives, or active front end drives. Throughout the pads lifecycle, the HGA will enable the use of simple, quick ship, six-pulse VFDs. The HGA is a one-time installation with one disconnect per site. The HGA is IEEE-519 compliant at the point of common coupling. It is a shunt device, which means that a fault in the filter will not halt the VFD operation and oil production.

Harmonics Become Issue for Potato Grower

Featured Products

HGA Active Harmonic Filter

Problem

With limited harvesting time and a long term storage process, potato growers face a variety of electrical demands. The month of October is the height of activity at the potato plant. This is both harvest and preparation time for the potatoes to be shipped or stored for the remainder of the year.

With the increase in activity at the facility, the necessity for maximum power is essential. More than ever, the plant needs to run their HVAC coolers to keep the potatoes at a constant temperature during storage.

The location of the plant and facilities lies on the outer edge of the power grid. With multiple businesses running off the same grid line, the voltage distortion had been driven up and was causing the other businesses issues with their electrical power.

Solution

Two large active filters were ordered and put into place: 300 HP and 500 HP. During off seasons, the larger active filter can be shut down when the equipment is sitting idle. But during the busy peak season, the filter can be running to accommodate the increase in power usage.

As a result to adding the two active filters, the Utility company has approved the harmonic limits output from the facility, the potato farm has avoided penalties from the Utility company, and neighboring businesses are not impacted by harmonics caused by the potato plant.

Indiana Wastewater Treatment Plant

Featured Products

HGP HarmonicGuard Passive Harmonic Filter with PQconnect

Problem

Wastewater treatment plant retrofit project needed additional harmonic mitigation in the form of passive harmonic filters. The plant operator required contactor control and feedback that the harmonic filters were in operation. A combination of 16 different non-linear loads ranging from 10 to 40 HP required harmonic mitigation.

Solution

HGP passive harmonic filters with PQconnect technology were applied to this wastewater treatment plant. This solution enabled the operator to control the filters remotely, and adjust the contactor drop out and pick up as needed. The operator knew that the filters were in continuous operation remotely.

Virginia Pump Stations

Featured Products

HGP HarmonicGuard Passive Harmonic Filter with PQconnect

Problem

Renovation of two pump stations in Virginia that required harmonic mitigation to meet IEEE-519 requirements. One pump station had four 125 HP variable frequency drives and pumps, and a second pump station had four 350 HP drives and pumps. Both pump stations easily exceeded IEEE requirements for allowable harmonic distortion.

Solution

The owner preferred a drive-applied harmonic solution for each station. TCI HGP passive harmonic filters were applied to each drive, reducing total harmonic distortion to less than 5% TDD. The HGP can maintain 5% all the way down to 50% load, if necessary.

Iowa Wastewater Treatment Plant

Featured Products

HGA HarmonicGuard Active Harmonic Filter

KDR Line Reactors

Problem

The electrical engineering firm was in the process of renovating a WWTP in Iowa which required several small to medium horsepower VFDs. They wanted a design that met IEEE-519 and was simple for their customer. With VFDs on several pieces of OEM equipment, from small pumps to larger aeration systems with blowers, it was going to be difficult to specify larger, more complicated, and expensive 18 pulse or active front end VFDs that were uniform on all of the different pieces of equipment. OEM suppliers often do not offer the option of specifying the type or brand of VFD that comes with their equipment.

Solution

Adding just one TCI HGA active harmonic filter, with a few inexpensive line reactors placed at certain loads, gave the plant a single, cost-effective harmonic solution that worked effectively with the variety of OEM equipment. The active filter was placed at the service entrance, filtering the entire plant, and resulting in a large cost and space saving package. The active filter was also sized for power factor correction due to local utility demands. While operating in “dual mode,” the filter lowered harmonics down to 5% ITHD and kept power factor at a .95 lagging.

Illinois Wastewater Treatment Plant Renovation

Featured Products

HGP HarmonicGuard Passive Harmonic Filter with PQconnect

Problem

New state requirements for phosphorus removal meant that the wastewater treatment facility in St. Charles, Illinois had to be upgraded to accommodate the change. This meant that the facility needed to convert to a three-stage A2O system, with aerobic, anoxic, and anaerobic zones for biological phosphorus removal. They needed to add a new internal recycle pump station, a primary sludge fermenter, and replace sludge and biogas storage tanks. In the process, they rehabilitated the digesters and biogas system as well. Some of the changes required adding non-linear load variable frequency drives which added harmonics to the system.

Solution

The addition of HGP Passive Harmonic Filters on non-linear VFD loads will reduce harmonic distortion to less than 5%. Renovations like this typically include additional stages of pumping that require VFDs, and thus additional harmonics for the entire plant. Applying passive filters to the new VFDs is an easy and inexpensive way to get the facility back to a low level of harmonic content, which is ideal for the equipment in the entire plant. The article in Treatment Plant Operator magazine, Upgrading to a Bio-P Process Required Open Communication and a Proactive, Patient Approach at Wastewater Facility, by Jim Force, describes in detail how the wastewater facility had to be upgraded, and is the source of the information and picture for this case study.

Alabama Reverse Osmosis Stations

Featured Products

HGA HarmonicGuard Active Harmonic Filter

Problem

The renovation of two reverse osmosis stations at a wastewater treatment plant in Alabama required harmonic mitigation. Each station’s total non-linear load, and resulting harmonic distortion, required 670 corrective amps. Without a solution the distortion would potentially cause the equipment to go off-line due to nuisance tripping. The owner considered the addition of multiple 300 amp active filters in parallel, equating to three units per station. Due to space and cost constraints, the customer struggles with this solution.

Solution

TCI offers the largest single-unit amp rated active filters in the market, an ideal solution for this application. The owner installed one 700 amp TCI active harmonic filter per station. The benefits included significant cost savings over alternative solutions and the smaller footprint allowed the installation to proceed without other costly modifications. The stations now meet the IEEE-519 requirements eliminating the nuisance tripping caused by harmonics.

Southeastern Aquarium

Featured Products

HGA HarmonicGuard Active Harmonic Filter

Problem

The pumping requirement was immense at one of the largest aquariums in the world, in the southeastern region of the United States. The large number of pumps and horsepower required to move so much water resulted in enough VFD load to require significant harmonic mitigation. An initial set of active harmonic filters from another manufacturer was installed for the application. Immediately there were problems between the active filters and the VFDs. The drives were tripping due to an inrush of current from the active filters coming online. The pumps were not able to move water with the drives offline due to the harmonic filters.

Solution

The facility was retrofitted with TCI HGA active harmonic filters. The HGA is designed with a pre-charge circuit that allows for the filter to slowly come online, which allows the VFDs to operate continuously. The pre-charge circuit enables the harmonic filters to softly engage with the system. The operation is not affected by any inrush surges from the HGA active filters but receives the benefit of the harmonic mitigation.