Looking for recommendations on power factor correction equipment for a manufacturing client here in Memphis. MLGW Schedule GSA rate has brutal penalties below 0.90 - we're talking $3,200/month in penalties for a facility pulling 850 kW. The plant runs mostly induction motors and fluorescent lighting, so lots of reactive load. Been quoted on ABB, Eaton, and Schneider Electric systems ranging from $45K to $78K. Anyone have experience with these manufacturers or other suggestions? Need something that can handle the variable load swings.
MLGW Power Factor Correction Equipment Recommendations
Sandra, we installed an ABB PQF system for a client in Raleigh last year - Duke Energy Schedule LGS. Similar situation with motor loads and penalties. The ABB unit has been rock solid and brought their PF from 0.78 to 0.96 consistently. Cost was $52K installed but payback was under 18 months with the penalty savings. The automatic switching is fast enough to handle their variable loads without overcorrection. Make sure whatever you choose has harmonic filtering capability - that's becoming critical with modern electronic loads.
Also here in Memphis and familiar with MLGW's Schedule GSA penalties. Had good luck with Eaton's PowerVar systems for smaller installations. The modular design lets you start with basic correction and add harmonic filtering later if needed. For 850 kW load, you'd probably want their PFC-5000 series. Cost runs about $58K but includes the control system and monitoring software. MLGW actually has rebates for power factor correction equipment - up to $15 per kVAR installed.
Sandra, skip the old-school capacitor banks and go straight to active power factor correction. PNM here in Albuquerque has started penalizing harmonic distortion along with poor power factor - Schedule 21 customers are getting double-whammied. The newer active systems handle both issues simultaneously. Schneider's VarPlus series is excellent but pricey. For your load profile, budget $60-70K for a proper solution with monitoring and automatic control.
Thanks everyone. Chris, I wasn't aware of the MLGW rebate program - that changes the economics significantly. $15/kVAR could mean $7-10K back depending on the system size. Mark, the ABB system sounds promising. How's the maintenance been? These manufacturing environments can be pretty harsh with dust and temperature swings. Also wondering about response time - some of the motor loads cycle on and off pretty frequently.
Sandra, maintenance has been minimal on the ABB unit. Quarterly inspection and annual calibration is all we've needed. The enclosure is NEMA 3R rated so handles industrial environments well. Response time is under 30 seconds for switching steps, which works fine for typical motor starting. The control system logs everything so you can track performance and prove the correction to MLGW if needed. We actually use the data for energy management beyond just power factor correction.
Sandra, if you're looking at that price range, also consider the GE Capacitor Control system. We installed one for an Entergy Arkansas customer in Little Rock - Schedule LGS similar penalties to MLGW. The GE system was $49K installed and has exceeded performance expectations. Power factor went from 0.73 to 0.94 average. The integrated monitoring caught a failing motor before it caused bigger problems. ROI was 14 months with penalty elimination plus maintenance savings.
Helen makes a great point about the integrated monitoring. NES here in Nashville has started requiring power quality data for large customers - Schedule MSD. The monitoring capabilities in modern PFC systems can help with compliance and troubleshooting. Sandra, make sure whatever system you choose can export data in standard formats. The utility relationships are getting more collaborative when you can provide good power quality documentation.
This is exactly the kind of detailed feedback I needed. Sounds like active correction with monitoring is the way to go despite the higher upfront cost. Paula's point about utility relationships is spot-on - MLGW has been pushing power quality initiatives lately. I'm leaning toward the ABB system based on Mark's experience. Will get formal quotes from all three manufacturers and factor in the MLGW rebate. Thanks everyone!
Sandra, one more consideration - make sure the installer is certified by the equipment manufacturer. I've seen too many good systems underperform because of poor installation or commissioning. The manufacturer certification usually includes proper startup procedures and warranty coverage. Also verify the installer understands MLGW's interconnection requirements - they can be picky about power factor correction equipment connections.
Update from Sandra: Got the ABB system installed last month. First bill showed power factor improvement from 0.78 to 0.95. Penalty elimination saved $3,100 the first month. System is performing exactly as promised. Thanks again for all the guidance!