Revealing power quality as a process variable - Carotek Process Solutions Summit

The presentation that follows was given during
Carotek’s Fifth Annual Process Solutions Summit in
Charlotte NC September 24 – 25, 2014.
Used with Permission.

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Prolog
Power Quality Pioneering
Brian St. Pierre
Regional Business Development Manager
(517) 294-0087
bstpierre@ra.rockwell.com

Who …………and ………What:
SoftSwitching Technologies / RA
 A technical Innovator in the Power
Quality Field
 Founded in 1995 through University of
Wisconsin
 Manufacturing Facility and offices located
in Middleton, WI
 Acquired by Rockwell Automation on
March 12th, 2012
 Part of the Industrial Components
Business at Rockwell
Power Quality Monitoring
Notification + Reporting
Power Quality Mitigation
Eliminate Downtime
Protect Investment
3
“…the hottest
new
technology
comes from
startup
SoftSwitching
Technologies”

SoftSwitching’s / RA’s Product Line
4
1-50 A
Single Phase
25-200 A
3 Phase
400-2400 A
3 Phase
I-Sense Monitor

Food and Beverage
Aseptic Packaging
Dry Extrusion
Bakeries
Batch Processing
Automotive
Robots
Test
CNC Machining
Positioning Equipment
Semiconductor
Lithography
Process Tools
Facilities
Ovens
Healthcare
Imaging Equipment
Non Invasive
Generator Test Ride Through
Other
Pharmaceutical
Pulp and Paper
Oil and Gas
Plastics
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

Revealing Power Quality as a
“Process Variable”

Power from Two Perspectives —
What is the difference?
 Power/Energy Management:
 Providing solutions that enable a customer to optimize the
consumption of energy in their plant or at a specific process.
 Power Quality Management:
 Providing solutions that eliminate “unscheduled downtime”
caused by both external and internal power quality
events/conditions that can impact the profitability of a plant or a
specific process.
 Both solutions have similar aspects or parts:
 Power Monitoring, Data organization or analysis through a tool or
software, *System optimization
 *Very different remediation solutions (Solving a different problem)
 Today we’ll focus on how Power Quality acts as a Process Variable!
7

The Consumer is Responsible for
Power Quality
 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
8

I-Grid (Monitoring the Power Grid with I-Sense)
 One pin per postal code
 Over 3000 I-Sense monitors active in the USA today

Healthcare’s i-Grid Network
(Today there are approximately 750 active sites)

The Story / “Background Basics”
FrequencyofOccurrence
Typical Incident Cost
$ $$ $$$ $$$$
LowVeryLowMediumHigh
Notching (Constant) Interruption (0.5 cycles – >1 hr)
Swell (0.5 cycles – 60s)
Noise (Constant)
Harmonics (Constant)
Transient (<50 ns – 5 ms)
Unbalance (Fluctuating)
Undervoltage (>1 minute)
Overvoltage (>1 minute)
Sag (0.5 cycles – 60s) EPRI (Electrical Power
Research Institute)
• Monitored 300 sites for 2+ years.
• 1993 study: 92% of all events were
voltage sags under 2 seconds
• 1995 study: 96% of all events were
voltage sags less than 2 seconds
Grid
Related
Facility
Related
11

Measuring Power Quality --
Voltage Sag (Dip) Characterization
 Sag - RMS voltage reduction between 1/2 cycle - 60 sec
 Magnitude and Duration
12
-1
-0.5
0
0.5
1
0 1 2 3 4 5 6 7 8
Duration: 4 Cycles
Magnitude: 60% Remaining

0.0
0.2
0.4
0.6
0.8
1.0
1 10 100 1000
Duration (ms)
Magnitude(perunit)
90%
Tracking Voltage Sag Events
13

Electrical Design Standards used in NA
(Sags Captured at High-Tech Mfg. Sites)
 Very few outages, still
many sags!
 1000 sag events from
15 Semi plants
 Avg. 5.4 events below
CBEMA per year…with
transmission-level
service!
 SEMI F47
source: International SEMATECH & EPRI, 1999

Plant Wall
480V Bus
1
2
3
Machine B
Machine C
PLC
Input
Output
Error Light
Intermittent Failure
Program Loss
Mis-feeds / Jams
Damaged Equipment
Downtime
XfrmrXfrmr
SensorsRelays Counters
Control
Feedback
Analog
Inputs
Digital
Inputs
My Machine or process just
went down but not others,
Why Not?
What broke?
What do I need to do?
Machine A
Typical Dilemma
Typical 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

Or the much more common--Squirrels on Holiday
cause similar problems: Downtime and Damage.

And rare, but well-meaning Misguided Reindeer

Cuban Tree Frog chasing the “Corona”
21

Downstream of Switch: Outage
Upstream of Switch: Voltage Sag
How the Grid Works
230kV
Transmission
69kV
Transmission
13kV
Distribution
A
B
C
S
S
S
S
S
S
S
S
S
S
S
S
S
S S SS
S S S
S S
S
Up to 200 Miles
The Grid Self Heals within 2 seconds or
Trucks 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

Past Year on Three Separate
Electrical Feeds in Durham NC

19 of 29 (63%) Events fell below the CBEMA curve
CBEMA
Curve

Confirmation and Corroboration

Friday May 31, 2013 Sag to 30%, (~10 Cycles)

Past Year in Lumberton NC

CBEMA
Curve

Past Year in New Bern NC

CBEMA
Curve

Past Year in Chapel Hill NC

Past 3 Months in Greensboro NC

CBEMA
Curve

Monday Feb 3, 2013 Sag to 58%, (~2.5 Cycles)
37

May 2011 to May 2012 in
Burlington NC

CBEMA
Curve

Where are the Applications?
The Plant Floor!
There is More Micro-processing
Power on the Factory Floor Than
in the Average IT Room
Most Factory Automation
is Left Unprotected
And Can Represent as Much as 30%
Of A Plant’s Unplanned Downtime

DEMO
How does this affect your equipment?

EPRI’s IEC Relay Profile
Failure
Zone
EPRI - Electrical Power Research Institute

Variable Speed Drive Profile
Failure
Zone

PLC Profile
Failure
Zone

Industrial PC Profile
Failure
Zone

480V Bus
1
2
3
Machine B
Machine C
PLC
Input
Output
Error Light
Program Loss
Misfeeds / Jams
Damaged Equipment
XfrmrXfrmr
Control
Feedback
Analog
Inputs
Digital
Inputs
Machine A
Power Analysis With I-Sense / I-Grid
Install I-Sense At Spare Breaker
on 480V Bus. Connect to E-Net or
analog Phone Line.
View Data at www.igrid.com

Durham NC Area 2013/14 PQ Report
Protecting a the “Average” PLC and not protecting any relays will still
result in downtime of a typical control system
“Dots” below and to right of curve
represent events that will cause
profiled devices to “trip”
UPS Times Out
(5 Minutes)
Actual Data
Recorded by I-Grid
Monitoring System
Data Taken
From a Monitor
In the Durham NC
Area Over 12 Month
Period During 2012/13
1 Events over 1 second.
Average Relay Tolerance
Average PLC Tolerance
Source: IEEE Std 1346-1998
No Over Voltage Or Surges During 2012/13 at Monitored Sites
The Average Site in Durham
Experienced 17 Voltage Sags Severe
Enough to Impact Production During
2012/13

Burlington NC Area in past (2011 -2012)
Protecting a the “Average” PLC and not protecting any relays will still
result in downtime of a typical control system
“Dots” below and to right of curve
represent events that will cause
profiled devices to “trip”
UPS Times Out
(5 Minutes)
Actual Data
Recorded by I-Grid
Monitoring System
Data Taken
From a Monitor
In the Burlington NC
Area Over 12 Month
Period During 1022/12
No Events over 1 second.
Average Relay Tolerance
Average PLC Tolerance
Source: IEEE Std 1346-1998
No Over Voltage Or Surges During 2013/14 at Monitored Sites
The Average Site in Burtlington
Experienced 17 Voltage Sags Severe
Enough to Impact Production During
the past 6 months of 2011/12

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
5
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
50

480V Bus
1
2
3
Machine B
Machine C
PLC
Input
Output
Error Light
Program Loss
Misfeeds / Jams
Damaged Equipment
XfrmrXfrmr
Control
Feedback
Analog
Inputs
Digital
Inputs
Voltage Sags Cause
Erroneous Data to PLC or
Control System Resulting in
Intermittent System Failures
That are Commonly
Misdiagnosed by Operators
And Maintenance Personnel
Machine A
Root Cause Established
Single Phase Fault
On Grid Causes One
Phase In Plant to Drop
For Several Cycles
Local Voltage Sags
Impact Plant Production 10 – 20 Times Per year
And Are Almost Impossible to Detect Without
An Event Capture Monitoring System

Power DSP – constantly monitors incoming power, system integrity and load
Static Switch – is closed, sending power directly to the load. The switch has an overall
efficiency rating in excess of 99%.
Power Matrix – is idle
Double Conversion Power Core (dCPC) – is idle
Auto 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.
Power
Matrix
Double Conversion
Power Core
Static
Switch
Auto
By-Pass
Utility
Load
DySC
Power DSP
Rectifier Inverter
The Solutions:
UPS, Flywheel or DySC

Sag Correction Solution Envelope
CVT
Protection
On-Line UPS
Protection
Stand-by UPS
ProtectionDySC Protection
53
53

Power DSP – detects the leading edge of a voltage sag, immediately routing power thru the
Power Matrix and dCPC and continuously corrects to insure true sinusoidal output
Static Switch – is open
Power Matrix– pulls power additional from the grid
Double 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
Static
Switch
Auto
By-Pass
Utility
Load
DySC
Power DSP
Inverter
Power
Matrix Rectifier
DySC is “On” in under 2 milliseconds

DEMO
How does this protect your equipment?

One Year of data after installation of the DySC

A 6 channel I-Sense:
The Event and the DySC correction
3 phase Sag to 10% remaining
.860 Seconds long
Corrected by 100 Amp HC DySC
Site located on
the Florida Coast
3 years of flawless
performance

UPS Product Offering
58

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
59

Energy Consumption Comparison
GT DySC; A “GREEN” Solution: >99% efficient
and no Batteries!
92 kVA HC GT DySC
24”D x 41”W x 78”H

www.rockwellautomation.com
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Thank you for your attention. Questions?

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