why power quality mattersdynamic sag corrector, dysc pronounced “disk” provides voltage...

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

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

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)

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 5

Up to 70% of your Unscheduled Downtime is due to Power Quality Problems!


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

23

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


The correlation between unscheduled downtime and extreme weather is clear


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…


Equipment Failures


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


-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


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


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


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

Email

Use Web browser to:•View event details•Manage accounts and monitors•Generate reports and export data

http://www.eyewire.com/cgi-bin/WebObjects/View.woa/wa/viewProduct?product=53611




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


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”


Past year in Watson LA4 of 24 (17%) below CBEMA Curve


Confirmation and Corroboration


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


Confirmation and Corroboration


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


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


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


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


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


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


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


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?

why power quality mattersdynamic sag corrector, dysc pronounced “disk” provides voltage...

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