When Two Transformer Incomers Have Different Power Quality Problems.
A cement manufacturing plant was experiencing low power factor and harmonic distortion at two transformer incomers.
At first, the requirement seemed straightforward: improve the plant's electrical performance.
But there was an important question to answer first:
Were both transformers actually facing the same problem?
Clariant Power set out to find that out.
It Started With the Measurements
Clariant Power conducted a detailed Power Quality Analysis using a Fluke Power Quality Analyzer at both transformer incomers.
The study measured key electrical parameters including power factor, current, VTHD and ATDD.
The results showed that the two incomers had noticeably different conditions.
Transformer 1
At Transformer 1, the power factor was 0.85, with ATDD at 7.2%.
Transformer 2
At Transformer 2, the power factor was lower at 0.77, while ATDD reached 35.3%.
That difference was important.
It meant that simply applying the same corrective configuration to both transformers would not address the actual requirement.
The Measurements Shaped the Engineering
Based on the conditions identified during the analysis, Clariant Power configured the solution for each transformer.
Transformer 1
The RTPFC panel was configured to address the power-factor requirement identified at the incomer.
Transformer 2
Here, the significantly higher harmonic distortion called for additional harmonic mitigation alongside power-factor correction.
The solution was therefore not based on a standard configuration.
It was based on what the measurements showed.
Then We Measured Again
After implementation, the electrical parameters were measured again to verify the improvement.
Results
| Parameter | Transformer 1 | Transformer 2 |
|---|---|---|
| Power Factor | 0.85 → 0.99 | 0.77 → 0.99 |
| Current | 1432 A → 1221 A | 1034 A → 800 A |
| VTHD | 2.5% → 1.9% | 5.4% → 4.2% |
| ATDD | 7.2% → 5.9% | 35.3% → 7.4% |
The most significant improvement was seen at Transformer 2.
Its power factor improved from 0.77 to 0.99, while current harmonic distortion reduced from 35.3% to 7.4%.
Across both transformer incomers, the case study reports that voltage and current harmonic distortion were brought within IEEE-519 limits after implementation.
One Plant. Two Conditions. One Measurement Led Approach.
This project shows why power-quality correction cannot always be approached with a one size fits all configuration.
The two transformer incomers were part of the same plant, but their electrical conditions were different.
Clariant Power's approach was simple:
- Measure the condition.
- Understand the requirement.
- Engineer the solution.
- Measure the result.
Project Snapshot
Industry
Cement Manufacturing
Application
Transformer Incomers
Solution
RTPFC + Active Harmonic Filter
Power Factor
Up to 0.99
ATDD at Transformer 2
35.3% → 7.4%
Facing a similar power quality requirement?
Talk to Clariant Power's engineering team.
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