IEEE 1584 · Engineering

Harmonic Study & Analysis - Carelabz Hungary

Carelabs delivers harmonic study and analysis for industrial and commercial facilities across Hungary, measuring total harmonic distortion with a harmonics analyser and modelling system impedance versus frequency to identify resonance risk. Where levels exceed the limits set in MSZ EN 50160, we recommend mitigation — harmonic filters, relocated power-factor correction capacitance, or higher-pulse-number rectifiers — and verify compliance with MSZ HD 60364.

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Before the drives arrive on site

A variable speed drive retrofit is usually justified on energy savings. What rarely gets modelled beforehand is what those drives do to the network they are being connected to.

What We Deliver

The planned load modelled first

Proposed drives are added to a model of the existing network and the resulting distortion is calculated before equipment is ordered, which is the only point at which the specification can still change cheaply.

WHY IT MATTERS

The retrofit that created a new problem

Drives are installed, energy consumption falls as promised, and within months capacitors begin failing and breakers trip without explanation. The retrofit is rarely connected to the new faults because nothing obviously links them.

Existing distortion measured before the addition, so the baseline is known and any later change can be attributed rather than argued about.
Planned drives modelled with their actual topology, since six-pulse and active front end designs produce substantially different spectra.
Existing power factor correction assessed for resonance against the new spectrum, not only against the present one.
Transformer thermal position checked, because additional distortion consumes capacity that the retrofit's own load growth may also be claiming.
Mitigation specified with the drives where needed, as fitting it at procurement is far cheaper than retrofitting after commissioning.

DELIVERABLES

What you receive

Issued against MSZ HD 60364 and the applicable distortion limits, with the pre-installation baseline stated.

1Measured baseline distortion before the addition, with the full spectrum
2Predicted distortion after the planned drives are connected
3Resonance assessment for existing power factor correction against the new spectrum
4A mitigation specification that can be issued with the drive procurement
5The calibrated ETAP model, so the next addition is assessed rather than assumed

Reach Out

How the study runs

Measure what exists

Present distortion is recorded across a representative period, establishing the baseline the retrofit will be judged against.

Model the existing network

The network is built in ETAP from verified data, with a frequency scan establishing where resonance currently sits.

Add the planned load

Proposed drives are modelled with their real topology and rating, producing a predicted spectrum rather than a general expectation.

Test the resonance

The frequency scan is repeated with the new load in place, which identifies whether the addition moves resonance onto an order the plant will now produce.

Specify mitigation

Where limits would be exceeded, mitigation is specified at the drive rather than at the busbar wherever that is sufficient, since it is far cheaper.

Issue for procurement

Findings are issued in a form that can accompany the drive specification, so the requirement reaches the supplier rather than the commissioning engineer.

Frequently asked questions

Because drives are non-linear loads and the savings case rarely accounts for what they inject. Modelling beforehand establishes whether distortion will exceed limits and whether existing capacitors will resonate. Both are inexpensive to address at specification and expensive to address after every panel is installed.

Marginally, and far less than the cost of retrofitting mitigation later or replacing failed capacitors. A reactor introduces a small loss while substantially reducing injected harmonic current. Where distortion would otherwise breach limits, that trade is almost always favourable on a whole-installation view.

Considerably. A six-pulse drive produces strong 5th and 7th harmonics, a twelve-pulse arrangement cancels much of those, and an active front end produces very little distortion at higher cost. Where distortion is the binding constraint, topology becomes a specification decision rather than a detail left to the supplier.

Yes, though the options narrow. Measurement establishes the actual spectrum and attribution identifies which drives dominate, after which reactors or chokes can be fitted to the worst contributors rather than all of them. That targeting is what keeps a retrofit affordable.

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