What is Power Quality Monitoring & Analysis, and why is this required? #Industry4.0

Let us understand more about electric power and the power factor (PF) to answer this question. 

Real Power, Reactive Power, & Apparent Power

Electricity supplied to your factory or building comprises power measured in amps and voltage. This alternating current (AC) travels in waves; when the voltage and current waves are out of sync, power distortion takes place. The displacement between current and amps creates inefficiencies, separating power into real and reactive power.

• Real power is the power consumed to run the machines, motors, pump, lighting, and measured in KiloWatts (kW).
• Reactive power is the byproduct alternating current system, measured in Kilo Volt-Amperes Reactive (kvar). 
• Apparent power is the sum of real and reactive power and is measured as kilovolt-amperes (kVA)

A prevalent way to illustrate the difference between these types of power is to compare them to a glass of beer. 

• The actual beer is real power, used by machinery and equipment to do practical work.
• The foam represents reactive power, which doesn't perform any useful work.
• The entire glass—the beer and foam together—is the apparent power.

The Power Factor - Buildings & Factories

The power factor measures the efficiency of a factory or building's electric system, and it is the ratio of real power to apparent power. 

Let us consider, your factory runs at 120kW (useful, working power), and the total apparent power is 150 kVA; you get 0.8, which is only 80% of incoming power that does useful work.

The most efficient is power factories are closest to 1.0, so the higher the power factor, the more efficiently the system operates. Going back to the beer analogy means you want to minimize the foam and maximize the beer.

Power factor is one crucial element contributing to power quality, an overarching term that refers to the power supply characteristics that enable electrical equipment to work correctly. 

Other contributors to power quality are voltage sags and swells, harmonic currents, and more, but improving the power factor will positively impact overall power quality.

Case Study Overview:

In one of the leading automobile industries where with the help of Enture Platform, it is established that with flexible software platform any sophisticated applications as per the customized requirement of the end-user is the only eventuality.

Problem: Highly fluctuating loads, reactive power compensation with cost-effective stepless compensation.

Solution provided: Virtual APFC controller for their Stepless compensation of various ratings about 1000kvar). For further details on the case studies please write to us!

So why do you need power quality monitoring?

A low power factor(PF) is not desirable, and it means your building is using electrical power inefficiently. A low power factor also negatively impacts electricity bills because of penalties, especially for industrial customers.

• Due to low PF, your electrical system has a lower distribution capacity than it should, producing excessively high current flows and can cause excessive voltage drops and poor voltage regulation, leading to overheating and premature equipment failure.
• Most utility providers impose an additional fee or penalty on facilities that fail to meet a particular power factor. Large load centers with poor power factor draw more current from the source, requiring the utility provider to increase its generation and transmission capacity to handle the load. 
• This PF "penalty" is standard among most utility providers. Power factor readings above 0.95 are generally designated as efficient, while power factor levels below 0.85 are considered inefficient.

Green Company Organizations

Organizations that implement a power quality monitoring system are part of a broad objective to reduce operating costs and sustainability. With continuous monitoring and analytics, a facility manager is equipped with data and trends to identify a problem with low power quality and take corrective action, thus reducing or eliminating the punitive penalty applied by the utility.

Facility managers often use capacitor banks to improve power factor efficiency. Both capacitors and batteries can effectively neutralize undesirable electrical characteristics such as power factor lag, relieving utilities from generating additional power. 

Batteries can also be used as a demand response program system, charging them at intervals and using them during the peak to regulate current and power usage and better manage the current going into the building.

Indian Subcontinent with Power Factor

For example, if you can increase your facility's power factor from 0.70 to 0.85, that translates to a 10-15% decrease in your electricity bill with respect to kVAh Billing. For large facilities billed at over $1 million per year for electricity, savings of 7 to 10% represents a substantial sum—and a boon to your bottom line

Please download the excel sheet for state-wise references in India. Please be informed that the data provided are to be substantiated with your current electrical Engineer and proceed accordingly with the latest updates from your respective DisComs.

Conclusion:

Continuous Power Quality Monitoring and Control is the way forward for better power quality and lesser pollution in the Grid.

Nebeskie Labs helps (BEE/Authority Certified) energy consultants and facility managers to monitor the power quality parameters through existing and new OEM smart meters continuously. Addvanced control system and analytics help you to maintain the desired power quality, avoid any penalties, and improve the #energyefficiency of your facility

*Any / some / all of the data provided in this are educational and knowledge sharing only. The reader is recommended to take the advice of the respective authorities and nodal offices as necessary in any subject matter that would arise