Power: The Basics Of Troubleshooting

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PowerThe Basics Of Troubleshooting

• Track 5 Session 5

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• Kent Brown
• Sola/Hevi-Duty
• Dave Trungale
• SoftSwitching Technologies

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Agenda

• Power Quality Basics
• Power Monitoring - New Technologies For Low Cost
  Monitoring
• Solutions

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Integrated Power Quality
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Power Disturbances Present
164 Transients
90 Undervoltages
19 Overvoltages
16 Outages
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The World of Power Quality

• Regulation/Outages
• Isolation/Noise
• Harmanico Filtration
• Transient Voltages
• Power Conversion AC-DC

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Power Conditioning

• Provide a constant sinusoidal output voltage
• Free from all power disturbances including
  harmonics

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How do they work? Simple!
1) A large change in input Voltage
Densidad de Flujo
2) Results in a small change in output voltage
Output Voltage
Input Voltage
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Power Conditioners Applications

• Industrial Automation PLCs
• Machine Tools
• Laboratory Equipment
• Robotics
• Photographic Equipment
• Equipment controlled by microprocessors

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What is a Surge Suppressor?

• A device that reduces random or transient high
  voltage usually of a short duration, to more
  acceptable or less damaging energy
• TVSS Transient Voltage Surge Suppression
• Sometimes referred to as SPD Surge Protective
  Devices

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IMPULS (Transient Spike)

• Definition
• Narrow, high voltage impulse superimposed on the
  AC waveform(

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Where does a transient come from?
35 Exterior
65 Interior
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Uninterruptible Power Supplies (UPS)
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Power Quality
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Power Quality

• David Trungale

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Important Questions Issues in Power Quality

• Power quality is a financial problem not a
  technical problem! Further, cost is all borne by
  the end user.
• For the past 100 years, the utilitys job has
  been to keep the lights on. For todays
  high-tech factories and processes, that is no
  longer sufficient.
• As the reliability of utility service is
  increased, the number of PQ events may actually
  increase!
• If a ¼ second voltage sag takes down a customers
  process for 1 hour, did the customer experience a
  ¼ second or 1 hour power event?
• Without adequate data, the PQ market is based on
  fear!
• First step is knowledge of the problem, then
  comes the solution!

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Power Quality Simplified
1. Fault Occurs.
2. Entire Grid Feeds Fault.
3. Voltage Sag to Grid.
4. Breaker Opens at L1. Power Loss
Downstream of L1.
5. Fault Clears Breaker Reclosure at L1.
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EPRI Distribution Power Quality Study

• Voltage sags are by far the most common power
  quality problem
• Traditional solutions focus on interruptions or
  transient voltage suppression, these does not
  address voltage sag problem

Power quality and reliability problems cost the
U.S. economy approximately 120 to 190 billion
annually (EPRI DOE)
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Availability vs. Process Uptime

• Significant disconnect between utility and
  customer perspective on power quality events and
  their impact
• Utilitys focus is reliability keeping the
  lights on
• Customers focus is to minimize cost of downtime

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Impact of Voltage Sags on Equipment

• Voltage sags and momentary interruptions cause
  equipment to drop off, process downtime can occur
• When voltage returns, high current inrush can
  occur. Unplanned operation of safety devices
  and/or equipment damage can occur.
• Typical Load Single Line Diagram

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Power Monitoring
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Power Quality Reliability (PQR) Monitor

• Customer Needs
• Minimize power-related downtime.
• Obtain good utility support when power issues
  occur.
• Understand the impact of PQR events on
  processes.
• Identify optimum PQR solutions required, if any.
• Existing PQ monitoring solutions are limited in
  performance and/or are very expensive to install
  and operate.
• The cost of monitoring often exceeds cost of the
  solution, and often the cost of the problem!!
• A new paradigm is needed in power monitoring,
  that is low cost, simple to use, requires no
  infrastructure, provides information to user to
  identify and solve PQ problems, if any.
• Solutions are available from SoftSwitching and
  others.

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PQ PR Monitoring Existing Solutions

• Typically provide multi-function monitoring
• Voltage, current, power, VAR, energy, harmonics

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I-Sense monitors record report PQ event data
to the I-Grid server using an internal modem via
the Internet

• Use a web browser to- View PQ event data,
  current historical
• Manage your account I-Sense monitor/s
• Generate reports

I-Grid server archives event data in a
relational database, provides aggregation
reporting capabilities
End Customer
I-Grid Server / Database / Aggregation
Engine (AE)
Internet
Internet
Utility CI Customers
Facilities Mgr
Utility Acct Rep
Email
I-Grid server provides real-time
email/pagernotification to customersand to
utility
Utility Call Ctrs
195 1 Phase 295 3 Phase
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Typical Events at Industrial Plant - Michigan

• With monitoring in place, one can start thinking
  of solutions
• Representative waveforms actually captured by
  I-Grid

Large Industrial Plant, MI 7/28/02
32702 pm
7/28/02 32803 pm
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Power Quality Solutions
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Key Decision Point-of-Pain vs. Facility Wide
Protection
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Dynamic Sag Corrector (DySC)

• Applications
• Premium Grid
• Semiconductor Mfg
• Automotive Mfg
• Fiber Optic Cable Mfg
• Normal Grid
• Plastics
• Steel
• Food Processing
• Paper
• Glass
• All Continuous Processes

DySC Product Family 0.25 kW to 3000 kW

• Effective protection against short duration power
  disturbances
• Meets or exceeds SEMI F47
• Cost effective solution
• Pays for itself with first event in high-impact
  applications
• Proven product
• Over 500 units installed in critical
  manufacturing applications (20,000 kVA installed
  base)
• No batteries, no flywheels, low maintenance,
  long-life, high efficiency, compact size, silicon
  intensive
• Wide power range gives application flexibility
• Provides 100 protection for premium grid
  customers

250 VA MINIDySC
21 kVA PRODySC
50A PRODySC
1000 kVA PRODySC
1 MVA PRODySC
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Results

• Semiconductor Manufacturing Plant
• Automotive Manufacturing Plant

INPUT 3/04/02 12471519
OUTPUT 3/04/02 12471526
INPUT 10/13/2002 081930.490
OUTPUT 10/13/2002 081930.504
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Automotive Application

• Application Body Shop robot welding systems,
  PLC controls, material handling
• Events 8 to 12 major events per year
• Losses 11,000/min 2-4 hrs production loss
• Collaboration Major East Coast Utility
  collaborated with the customer to evaluate
  (test) different solutions recommended
• Solution 1 MW DySC for Body Shop
  power distribution panel, expandable to 1.3
  MW. Capability to add capacitive energy
  storage for additional ride- through. Installed
  I-SenseTM Power Monitors at input output
• Results
• Several saves recorded where body shop kept
  running when other parts of plant shut down.
  I-Sense e-mail reports verified protection by the
  PRODySC.
• Customer preparing to install a larger unit for
  plant expansion.

C A S E S T U D Y
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Conclusions

• Power Quality is a dominant cause of unscheduled
  downtime in critical high-tech manufacturing
  applications
• Voltage sags are by far the most common Power
  Quality disturbance
• Voltage sags cause both downtime AND equipment
  damage
• Monitoring is essential to understand a plants PQ
• Monitoring can be low cost and easy to install
• Variety of solutions are available
• Point-of-use solutions within customer facility
  provide targeted cost-effective PQ solutions
• Available solutions for voltage sags
• DySC, CVT, UPS, Flywheel

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Questions?