Over sizing generators is guzzling energy (higher fuel), money (higher cost) and larger space (high footprint). By applying Harmonic Filter, that depending upon load types, say metal, rolling mills, or much easier loads like buildings, textile plants etc., one can load the Generator and Engine by nearly to 100% of its capacity sustainably. In the past few decades, we have done over several hundreds, if not thousands, of jobs applying Harmonic Filter with generators, both LT (415/ 433/ 440V) and HT (11kv), and across all industry segments.
In a major Induction Furnace load running with 11kv generator, I have seen the reverse phenomenon, that restricts the generator capacity to almost half of its rated power. The generator terminal voltage INCREASE (instead of decreasing) with Load and at about 50% power it trips the generator on over-voltage, also engine rpm drops with load.
When it comes to Size reduction of generators, along with the Harmonics, Reactive Power Control for highly fluctuating loads and Unbalance compensation can be equally or even have more applications in the industry.
Recently we have come across a Rolling Mill where they are taking Power from a local supplier using small scale Power Generation of about 25MW. The load requirement of this specific rolling mill was about 8MW. However, whenever the load comes into picture, the Generator itself is tripping due to over load. Thanks to our solutions based on IGBT based system for Reactive Power along with PF and Negative Sequence, now they are able to run the system clearly. The fast and reliable response of any IGBT based system slices off the overshoot in the reactive power before even the generator realizes it. Beautiful to watch the Analog Ampere meters set in the Active Compensators going crazy up and down.
In simple terms, I wanted to add Reactive power & unbalance too.