Post on 26-Mar-2020
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Brian St. PierreRegional Business Development ManagerPower Quality & Energy Management
Why Power Quality MattersWhat is our experience?What are PQ problems actually costing our customers?How can you prove it? What can you do about it?
Industry Success Stories are Available on Noggin
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Dynamic Sag Corrector (DySC)
Dynamic Sag Corrector, DySC Pronounced “Disk” Provides voltage correction during a sag event Uses a series connected design to add the missing voltage to the source voltage Does NOT contain batteries Sag protection up to 50% remaining voltage for 5 seconds (single phase version) Provides Zero Volt Remaining protection (50ms SR, 200ms ER, 1s+ UR)
Many alternatives only provide shallow sag protection
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MiniDySC® (single-phase; 2-50 Amp) ProDySC® (3-phase; 25-200A) MegaDySC® (3-phase; 400-2400 Amp)
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Up to 70% of your Unscheduled Downtime is due to Power Quality Problems!
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When plant is at capacity, the cost of downtime is the Lost Sales or Revenue!
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The ROI can be significant when eliminating Unscheduled Downtime !
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Plant Wall
480V Bus1
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Machine B
Machine C
PLC
Input
Output
Error LightIntermittent Failure
Program LossMis-feeds / Jams
Damaged EquipmentDowntime
XfrmrXfrmr
SensorsRelays Counters
ControlFeedback
AnalogInputs
DigitalInputs
My Machine or process just went down but not others,
Why Not? What broke?
What do I need to do?
Machine A
Typical Dilemma
How can we Prove downtime is caused by Power Problems?
Manufacturing Plant Electrical and Controls Environment
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The correlation between unscheduled downtime and extreme weather is clear
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Others like Drunk’n Utility Poles and wayward Construction Cranes may not be visible on the way to work
Roughly ~60% of Power Quality Problems are caused by Weather…
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Equipment Failures
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The no.1 PQ instigator in Lakeland FL…Cuban Tree Frog chasing the “Corona”
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Downstream of Switch: Outage
Upstream of Switch: Voltage Sag
How the Grid Works
230kVTransmission
69kVTransmission
13kVDistribution
A
B
C
S
S
S
S
S
S
S
S S
S
S
S
S
S S SS S S SS S
S
Up to 200 Miles
The Grid Self Heals within 2 seconds orTrucks have to be sent out
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-35%
-70%-25%
The depth of your Sag depends on the distance you
are from the event
When Lightning Strikes, Squirrels Fry, or the grid Shorts: You feel it
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Voltage Sags Damage Equipment
When voltage returns, high current inrush can occur because the Soft-charge ckt. is bypassed
RF Amplifiers; Gradient Amplifiers; Low Voltage Power Supplies and Variable Frequency Drives, subjected to repeated hits—Over Time Causes Failure.
Typical Rectifier Circuit diagram:
fuse
Line impedance
Soft-charge ckt. DC Loads
Big cap. filter
Diode Rectifier
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How Voltage Sags Damage Equipment
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Example: Inrush current measured for 1kVA electronic load
Note the scale change necessary to get the sagged results on the same page!
Normal inrush Inrush after Sag
• Peak inrush 50A• Soft-charge
circuit bypassed
• Peak inrush 10A• Soft-charge
circuit is active
Volts
Amps
10
0
20
Volts
Amps
40
0
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Power Quality Problems…
All have physical causes
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480V Bus12
3
Machine B
Machine C
PLC
Input
Output
Error LightIntermittent Failure
Program LossMisfeeds / Jams
Damaged Equipment
XfrmrXfrmr
SensorsRelays Counters
ControlFeedback
AnalogInputs
DigitalInputs
Machine A
Step 1. Install I-Sense or PM 5000Capture PQ Events and Related Downtime
Install I-Sense At Spare Breakeron 480V Bus. Connect to E-Net or analog Phone Line. View Data at www.igrid.com
Install PM 5000 on your Factory Talk network and program it for PQ event and wave capture
or
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I-Sense and I-Grid (the key to knowing the Local Power Quality)
I-GridServers
&Database
WebInternet
I-Sense monitors record & report PQ event data via the Internet
•Real-time notifications•Report delivery
I-Sense Owners
Facility Engineer
Utility Engineer
Other users
Use Web browser to:•View event details•Manage accounts and monitors•Generate reports and export data
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I-Grid “Cloud”(Monitoring the Power Grid with I-Sense)
One pin per postal code Over 3000 I-Sense monitors active in the USA today
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Power Quality Problems Travel the Grid
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Distribution Site ~8 mi away Sub Distribution ~11 mi away
6-29-14 61% remaining 6-29-14 71% remaining
I-Sense Provides Automatic Corroboration Reporting “Confirms Grid Events”
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Past year in Watson LA4 of 24 (17%) below CBEMA Curve
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Confirmation and Corroboration
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Sunday May 8, 2016; 67%, (80ms; 4.8 Cycles)
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Past 2 years in Lake Charles LA56 of 152 (37%) below CBEMA Curve
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Confirmation and Corroboration
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Friday May 26, 2015; 41%, (56ms; 3.38 Cycles)
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Past year in Clearwater FL zip 3376042 of 86 (49%) below CBEMA Curve
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Power Quality…What to do about it?
Utility cannot provide perfect power quality and are not required to. (e.g., Wisconsin PSC 113.0703) Customers having equipment or operations that are sensitive to such voltage
fluctuations … may find it necessary to install, at their own expense, power conditioning equipment or other modifications …
Job is to “Keep the lights on.”
Goals of Utility Deliver maximum energy through the existing infrastructure Maintain +/-10% (on average) voltage at service entrance Minimize outages longer than 2-5 minutes 60.00 Hz, when averaged over 24 hours Keep large industrial customers satisfied Minimize large customers disrupting neighbors’ power quality
The utility is responsible for reliability, not quality of power….the customer isresponsible for protecting their sensitive equipment at their own expense
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Is the Power Company Doing Their Job? (Check for Regulation and Imbalance)
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Step 2: Analyze the Data from Monitoring and the Manufacturing Processes
Analyze
Warning signsEquipment alarmsControl system faultsElectrical component failures
Electrical power symptomsSags/SwellsIntermittent phase lossTransientsVoltage stabilityPower factor variabilityElectrical noiseHarmonics
Downtime Events Control Panel drop outs Compressor drops Pumps drop off line IT Switches drop out
Burner and Oven Controls drop out
Boiler / Refrigeration Controls go off-line
3 phase (480V and lower) Control failure
Complex Positioning Equipment miss-alignment
Aseptic Packaging Processes goes down
Robots need re-homing Pre-mature VFD failure CNC tool breakage Semi Conductor Tools stop
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Power DSP – constantly monitors incoming power, system integrity and loadStatic Switch – is closed, sending power directly to the load. The switch has an overallefficiency rating in excess of 99%.Power Matrix – is idleDouble Conversion Power Core (dCPC) – is idleAuto By-Pass – is idle
Normal Operation - The DySC monitors PQ continuously, while the power electronics are in standby 99.999% of the time; making the DySC the most energy efficient PQ device on the market.
PowerMatrix
Double Conversion
Power Core
StaticSwitch
AutoBy-PassUtility
Load
DySCPower DSP
Rectifier Inverter
The Solutions: UPS, Flywheel or DySC
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Power DSP – detects the leading edge of a voltage sag, immediately routing power thru thePower Matrix and dCPC and continuously corrects to insure true sinusoidal outputStatic Switch – is openPower Matrix– pulls power additional from the gridDouble Conversion Power Core (dCPC) – rectifies and inverts to recreate a true sinusoidal Output (tSR)Auto By-Pass – is idle
Voltage Sag - Most medical facilities experience 20 - 30 deep voltage sags each year; lasting typically less than a 1/2 second. Given the short duration of the actual voltage sag means the DySC power electronics run less than 30 seconds per year. The DySC is an extremely reliable machine.
Double Conversion
Power Core
StaticSwitch
AutoBy-PassUtility
Load
DySCPower DSP
InverterPowerMatrix Rectifier
DySC is “On” in under 2 milliseconds
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A 6 channel I-Sense: The Event and the DySC correction
3 phase Sag to 10% remaining.860 Seconds longCorrected by 100 Amp HC DySC
Site located on the Florida Coast8 years of flawless performance
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DySC Demo Video available!
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DySC® (Dynamic Sag Corrector)
DySC® (pronounced “Disk”) is an adaptive power supply that optimizes the remaining power during a sag by using patented inverter technology to compensate for the sag thereby maintaining an uninterrupted flow of optimal power to the load thus maximizing uptime, minimizing inventory loss and reducing maintenance costs
MiniDySC® (single-phase; 0.25-12 kVA) ProDySC® (3-phase; 9-167 kVA) MegaDySC® (3-phase; 263-2000 kVA)
Up to 5 seconds of ride through
U.S. and International voltages available
Scalable solution
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Application Comparison for a 1200 Amp 480V loaded circuit (must oversize the UPS)
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Uses $450,000 less in electricity, in just 5 years than a comparable UPS
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Next Steps
Discuss, Identify and Prioritize, the most costly or painful manufacturing processes that go down in your plant.
Use 1-line diagrams or survey the site for breaker sizes and floor space (wherever the processes are powered from).
Correlate unscheduled downtime at your sites with data from our local I-Sense monitors or other monitors from your site If no data is available, immediately install an I-Sense
Measure the running loads of each (priority) process you would like to protect.
Build your ROI for mitigating PQ events with manufacturing history and data38
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Food and BeverageAseptic PackagingDry ExtrusionBakeriesBatch Processing
AutomotiveRobotsTestCNC MachiningPositioning Equipment
SemiconductorLithographyProcess ToolsFacilitiesOvens
HealthcareImaging EquipmentNon InvasiveGenerator Test Ride Through
OtherPharmaceuticalPulp and PaperOil and GasPlastics
Rule #1: All Factories Experience Voltage Sags
Rule #2: The DySC Will Make - Any Component- Any Machine- Any Process- Any Plant
On Average Break 10-14 Fewer Times Per Year
Key Applications and Industries
Thank you for your attention. Questions?