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From Milliwatts to Megawatts: Measuring Power with LabVIEW
NI Week 2014
Mounzer Saleh, Senior AE
National Instruments
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What do we think of when we
think of measuring power?
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Two Measurements Needed for Power
Voltage
IVP *
Current
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Power Quality Demo
The power strip represents a small grid.
The Grid
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NI PQA Demo CompactRIO Components
cRIO-9068
(Dual-Core ARM 667 MHz,
Xilinx 7 Series FPGA)
NI 9227
5 ARMS
NI 9225
300 VRMS
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High-Voltage Analog Input C Series Modules NI 9242 & 9244, 3-Ch, 50 kS/s, 250 Vrms L-N or 400 Vrms L-N
• Both Modules • 3 AI Ch + 1 Neutral Ch
• 50 kS/s
• 12 AWG
• Delta or WYE 3-phase measurements
• NI 9242 • 250 Vrms L-N, 400 Vrms L-L CAT III
• Ideal for standard output level PTs
• NI 9244 • 400 Vrms L-N, 800 Vrms L-L CAT III
• Ideal for industrial level machine monitoring up to the standard 690 Vrms L-L
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Current Shunt Input Module NI 9238, 4-Ch, 50 kS/s, ± 0.5 V
• Synchronize with NI 9225,
NI 9242 and NI 9244 for
power measurements
• Measure external current
shunts and transducers
• ± 30V overvoltage
protection
• 250 Vrms CAT II Ch-Ch
isolation
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Voltage Measurement
NI 9225 “Grid”
White wire
Black wire
Connection made using spliced power cord
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Current Measurement
NI 9227*
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Transformers & Transducers
Current or
Voltage
• Output voltage or current
• DC or high frequency
• Split or solid core
• Mount or handheld
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Current Measurement
NI 9238
Exposed wires
Black wire passes
thru CT
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LabVIEW Electrical Power Suite 2014
New Features
• Measurement of variable frequency
networks [Full] • Ramp up/down tests for generators/motors
• Aircraft frequencies (400Hz, variable)
• Similar to benchtop PQA functionality
• New example programs • SAR modules (like the NI 9215, NI 9222/23)
• New HV Module Example Programs (NI
9242/44)
• Compliance to the latest PMU standard
(M&P class support) [Pro]
Search for “Electrical Power Suite” at ni.com
Demo
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Turbine Generators
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Power Transmission
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Types of Electrical Loads
Resistive Inductive Capacitive
In Phase Lagging Phase Leading Phase
Demo
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Interruption Swell Sag
Voltage Level (% of nominal)
10%<sag<90%*
Duration
Instantaneous 0.5-30 Cycles
Momentary 30 Cycles – 3
seconds
Temporary 3 seconds – 1
minute
Voltage Level (% of nominal)
110%<swell<180%*
Duration
Instantaneous 0.5-30 Cycles
Momentary 30 Cycles – 3
seconds
Temporary 3 seconds – 1
minute
Voltage Level (% of nominal)
Interruption<10%
Duration
Momentary 30 Cycles – 3
seconds
Temporary 3 seconds – 1
minute
*Levels differ based on duration. Data pulled from IEEE 1159:1995 See standard for full data.
Power Quality Events
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Power Quality Events
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Problems Caused by Poor Power
• Computer Equipment • Lock-ups
• Lost data
• Damage to media storage (disk drives)
• Damage to power supplies
• Occupant comfort and productivity • Flicker (can trigger migraines)
• Lost productivity due to system reboots or outages
• Direct Monetary Loss • Fines from utility company for low power factor
• Process manufacturing losses • Power issues can lead to wasted material and time (scrap and
rework/restart) o Most common in silicon and bio/pharmaceutical industries
• Premature Machine Failure • Insulation breakdown
• Inefficient operation (excess heat, less usable work)
Photo by Florian Hirzinger
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Application for Power Measurement
Utility Distribution
White Goods Testing
Machine Health
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Instrumentation Considerations Synchronization
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Instrumentation Considerations Resolution
Time (ms) 100 200 150 50 0
0
1.25
5.00
2.50
3.75
6.25
7.50
8.75
10.00
Amplitude
(Volts)
16-Bit versus 3-Bit Resolution
(5 Hz Sine Wave)
16-bit
3-bit
000
001
010
011
100
101
110
111
| | | | |
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Calculations are Based on Waveform Data
Features
• Voltage, Current, Power
• Instantaneous
• RMS
• Peak-Peak
• Crest Factor
• Fundamental Frequency
• Power Factor
• Power (reactive, apparent,
real)
Events
• Sag
• Swell
• Interruption
• Flicker
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RMS (Root Mean Square)
AC Equivalent of DC
3 Common Ways to
Calculate
• True RMS
• Peak
• Average
Equation (True)
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Measuring Waveform Data
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Calculations are Based on Waveform Data
Features
• Voltage, Current, Power
• Instantaneous
• RMS
• Peak-Peak
• Crest Factor
• Fundamental Frequency
• Power Factor
• Power (reactive, apparent,
real)
Events
• Sag
• Swell
• Interruption
• Flicker
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Types of Electrical Loads
Resistive Inductive Capacitive
In Phase Lagging Phase Leading Phase
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The Power Triangle Mathematical Analogy
()
Real Power (Watts) = V * I cos ()
Reactive Power (VAR)
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The Power Triangle Mechanical Analogy
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Power Factor = Real Power
Apparent Power
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Power Factor Correction
Circuit Connection
Contactors “Relays”
Bank of Capacitors
Demo
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Case Study: Nucor Steel Corporation
• One of the largest steel producers in the US, and the largest recycler
• Implemented grid power monitoring
• Acted on grid power information
• Saved money and pollution
Monetary fines can be significant.
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Nucor Power Monitoring Station
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Example Power Monitoring Solutions from Elcom
All PQA are compliant wit IEC 61000-4-30 class A
ENA440
ENA460
ENA450
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Power Monitoring Software from Elcom
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Build Your Own and Power it with LabVIEW Demo
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• Power
• RMS current trending
• Power factor
• Load
• Voltage/Current unbalance
• Mechanical
• Bearing vibrations
• Shaft alignment
• Shaft speed
• Thermal
• Temperature
Machine Health
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Floor Demo’s
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• Power
• Energy efficiency
• Power factor
• Load
• Mechanical
• Sound
• Vibration
• Motor speeds
• Flow rate
• Thermal
White Goods Testing
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Power Quality Monitoring
• Electrical
Power
Suite
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Benefits of Power Measurement with LabVIEW
Feature Benefit
Select only the analysis required Easier user interface, less extraneous
information
Custom analysis Ideal for research or installations with
unique power features
Access to raw data Capture and store full waveform data
for post processing with almost any
SW package
Fully programmable Automated reporting and web hosting
to suit specific requirements
Open communication Integrate with existing systems
Expandable I/O Add more voltage/current lines, OR
mix with measurements such as temp,
pressure, vibration etc.
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Thanks for Attending!
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