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Messung joins hands with Fuji Electric Consul Neowatt, the No 1 Indian Active Filter company for their solid state Active Harmonic Filters

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Industrial Servo Stabilizers from Messung

Voltage stabilizers are an essential and mandatory part of any office, commercial or industrial use. During the 1990s, manual stabilizers were widely used but today, with the evolution of electronic circuitry, servo stabilizers are used for industrial purpose.

WHAT IS A SERVO STABILIZER?

A servo stabilizer is an integral part of any facility that uses electrical appliances and machinery. But what does a stabilizer do? A servo voltage stabilizer is a servo-controlled stabilization system or device used to provide a constant voltage for equipment. With servo stabilizers in place, expensive machines are protected from any voltage fluctuations. The function of a stabilizer is to maintain optimum and steady voltage supply and also help to save on excess electricity usage.

Servo based voltage stabilizers are used for appliances/ equipment which are very sensitive and need accurate input power supply (±01%) for performing intended functions.

COMPONENTS OF A SERVO STABILIZER

There are seven main stabilizer parts or components:

1. Dimmer (Variable Transformer): The basic purpose of dimmer is to increase or decrease the voltage which is fed to the buck boost transformer. 50% of the output voltage is increased or decreased by dimmer only.

2. Carbon Brush: a moving part fitted in the shaft to make the contact with dimmer. If the input voltage variation is very frequent, the carbon brush will erase early and need to be replaced frequently. Servo stabilizer manufacturers are advised to use best quality carbon brush.

3. Servomotor: the main part of a servo stabilizer. The motor rotates the arm connected on the dimmer in clockwise or anti clockwise direction according to input voltage.

4. Buck Boost Transformer: acts as a connector between the input and output load terminals. It is a transformer that manages the voltage settings that are remained upon voltage increase or decrease by the dimmer.

5. Contactor or Relay: contactor cuts the output voltage of any servo voltage stabilizer if it exceeds or goes higher than the prescribed limit.

6. MCB, MCCB: MCB is used for the protection of short circuit and MCCB is used for overload protection.

7. Electronic Circuit: connects all the components of the servo voltage stabilizer so that the signal passes in the correct way for effective working of the stabilizer.

WORKING OF SERVO VOLTAGE STABILIZER

No doubt you want to know, how does a stabilizer work? When the servo voltage stabilizer receives an input current with fluctuating voltage, the microprocessors in the electronic circuitry triggers the Servo motor driver. This in turn activates the servo motor, which moves across the windings of the auto-transformer. As the servomotor’s shaft is connected to the primary of the Buck Boost transformer, the movement automatically adjusts and increases or reduces the voltage value to the prescribed limit almost instantly. This adjustment of input voltage to the correct output voltage is the aim of the servo motor and the purpose of a servo stabilizer.

This controlled voltage is relayed through the secondary of Buck Boost transformer, and then fed to the appliance or machinery in use.

Circuit Diagram of Servo Based Voltage Stabilizer

Servo voltage stabilizer is the only electric stabilizer that can be used across single-phase and three-phase connections.

TYPES OF SERVO STABILIZERS

There are two types of servo stabilizers in the market: air-cooled and oil-cooled. While both work on the same principle, the oil-cooled stabilizer has a higher sustained overload capacity.

Servo voltage stabilizers can be single-phase or three-phase balanced types or three-phase unbalanced types.

Oil-cooled stabilizers are suitable for engineering & machine tools, CNC machines, elevators, plastic machines. Applications of air-cooled stabilizers include medical equipment, textile machines, telecom & data centres, printing machines, machines with sensitive microprocessors.

BENEFITS OF SERVO STABILIZERS

Electrical equipment like the X-Ray machines, PH-meter, etc. gets affected when there is a high voltage whereas compressors, refrigerators, etc. get damaged due to low voltage. Also, industrial equipment, analytical instruments, simple household electric machines, elevators, etc. get damaged (partially or completely) due to the high or low voltage supply. Electricity boards are also unable to provide clean power as the load is enormous and the number of electrical appliances running is too high.

Servo stabilizers help to control and avoid such problems, and offer several benefits:

·         Regulates voltage levels in various types of equipment

·         Protects equipment, assuring safety to industrial machinery and household appliances

·         Increases the performance and lifespan of the equipment

·         Enables limited usage of power, reducing electricity bills by 10-30%

·         Prevents the risks of power-related accidents during short-circuits or overloads; save life and property

·         Minimum maintenance required

·         Customizable to the current strength and voltage rates easily making it suitable for both industrial and residential uses.

SERVO STABILIZERS FROM MESSUNG

Messung Electrical Engineering Division has partnered with Fuji Electric Consul Neowatt to market and supply Fuji's reputed range of air cooled and oil cooled industrial servo voltage stabilizers for both balanced and unbalanced loads in a range from 3 to 3500 KVA.

As renowned servo stabilizer manufacturers, Fuji offers models for both indoor and outdoor applications and also provides customized products based on application requirements. They also offer a full range of isolation, ultra-isolation and K-rated transformers for various applications in a range from 3 – 1000 KVA.

Fuji’s servo controlled voltage stabilizers are suitable for CNC Machines, CMM, Textile & Spinning mills, Cold Storage units, Food processing equipment, CT Scan, MRI machines, Retail outlets, Restaurants and Office applications.

Based on your application and the type of machinery or electrical equipment involved, Messung can provide the most appropriate and efficient model of

servo controlled stabilizer

for your needs.

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POWER QUALITY ANALYZER FROM MESSUNG

Whether you in a manufacturing facility, data centre, industrial plant, hospital or commercial centre, a power quality analyzer must be at the heart of your energy management system. 

WHAT IS POWER QUALITY?

The term is used to describe electric power that drives an electrical load and the load’s ability to function properly. Without the proper power, an electrical device (or load) may malfunction, fail prematurely or not operate at all.

WHY IS POWER QUALITY IMPORTANT?

Today any interruption of business operations due to poor power quality has a direct impact on the profitability of an enterprise. The increased use of automation and electronic devices and their sensitivity to PQ problems turns the availability of electric power with quality into a crucial factor for competitiveness in every sphere of business activity.

The most critical areas are the continuous process industry and the information technology services. Insufficient power quality can inflict serious losses on business and economy. In the worst-case scenario, it may pose a threat to human life in mission critical applications and highly sensitive environments, such as hospitals.

Power quality monitoring and power quality improvement allows you to optimise and reduce power consumption – saving money on your electricity bill and thereby, your carbon footprint. Direct savings to consumers come from lower energy cost and reactive power tariffs. Indirect savings are gained by avoiding circumstances such as damage and premature aging of equipment, loss of production or loss of data and work.

It also reduces the risk of equipment overheating, malfunctioning or breakdown, and minimises ‘wear and tear’ so your equipment works better and lasts longer.

WHAT IS A POWER QUALITY ANALYZER?

A power quality analyser is equipment used to measure electric power signals to determine the load’s ability to function properly with that electric power. Incorrect power quality can cause the electrical equipment to malfunction or fail prematurely.

Power quality analyzers are used for continuous electrical power quality monitoring, and to capture power quality and energy data so you can identify power quality and energy efficiency issues with ease. Flexible software enables visibility to invaluable insights about the performance of your electrical system.

WHY DO WE NEED A POWER QUALITY ANALYZER (PQA)?

Poor power quality can cause a multitude of problems which can negatively impact efficiency and sustainability of your facility. Some of these issues include:

insulation damage

pulsating torque in rotating machinery

interference with communication. control and signal circuits

reduced efficiencies

malfunction of equipment

increased operating temperature on equipment, cables, switchgears, motors, transformers

reduced equipment life

high maintenance costs

reduced capacitor life/capacitor failures

blown fuses and tripping of switchgear

increased copper losses

PQ monitoring and power quality analysis can help your energy management system tackle these problems. Trust a good PQA to:

Identify source and frequency of events

Establish precise location and timing of events

Assist in preventative and predictive maintenance

Develop maintenance schedules

Monitor and trend conditions

Analyze harmonics, flicker, transients, frequency variation, voltage variations (sag & swell)

Ensure equipment performance

Assess sensitivity of process equipment to disturbances

Evaluate performance against specifications

The PQA generates a final report that provides a complete picture of the electrical system’s correct state of operation. The report is a tool of primary importance for preventive maintenance, in that it lists all the measures to be taken promptly when disturbances are detected, before the negative impact on production and the running of the equipment is felt.

POWER QUALITY ANALYZER FROM MESSUNG

Messung, as authorised distributor for Janitza Electronics GmbH, brings you their fixed Class A power quality analyzer. Just what you need for reliable power quality monitoring & analysis in accordance with current standards,e.g. EN 50160, IEEE519, EN 61000-4-30.

Janitza’s UMG 512 PRO will help your business to fulfil mandatory requirements while you maintain supply stability, ensure power quality, minimise downtime of critical assets, and reduce costs.

Main Features

Class A

Power quality

Residual Current Monitoring (RCM)

Measuring devices homepage

Ethernet-Modbus-Gateway

BACnet

Applications of UMG 512 PRO

Continuous monitoring of the power quality

Harmonics analysis with power quality problems

Checking the internal supply network according to EN 61000-4-7, EN 61000-4-15, IEC 61000-4-30

Fault analysis in case of problems with the energy supply

Documentation of the power quality for customers and regulatory authorities

Ethernet Gateway for subordinate measurement points

Report generator for power quality standards: EN 50160, IEEE 519, EN 61000-2-4, ITIC …

Report generator for energy consumptions

Energy Dashboard

Remote monitoring of critical processes

ABOUT MESSUNG ELECTRICAL ENGINEERING

Messung is committed to serving the Electrical industry with world-class products and solutions that answer today’s critical electrical power distribution & management challenges. Messung has joined hands with Janitza electronics GmbH, to bring to India their advanced system solutions for modern energy data management (e.g. ISO 50001), power quality and residual current monitoring. Power quality analyzers, power quality meters, software and apps – Messung supplies the full range of Janitza solutions.

Messung offers the complete, customised energy management solution to help enterprises optimise power usage, improve power protection and increase productivity by reducing downtime, safety risks and electricity bills.

With their expertise in electrical engineering, and incorporating best-in-class products from Janitza and Fuji Electric Consul Neowatt, Messung enhances productivity and the reliability of your critical electrical assets.

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POWER QUALITY MANAGEMENT

Electrical power is an intrinsic and essential part of modern life. It is generated and delivered across miles to power homes and businesses,operate a wide range of equipment and devices. We take power for granted, rarely bothering to ask “how good is the quality ofthe power I am using?”; “am I using it correctly?”; “is my equipment compatible to function with the power provided?” etc.

Yet power quality can be the key to saving energy bills, improving productivity and the lifespan of your machinery.

Read on to know more about this crucial aspect of electrical power distribution and usage.

WHAT IS POWER QUALITY?

As per Wikipedia’s power quality definition, ‘Electric power quality is the degree to which the voltage, frequency, and waveform of a power supply system conform to established specifications. Good power quality can be defined as a steady supply voltage that stays within the prescribed range, steady a.c. frequency close to the rated value, and smooth voltage curve waveform (resembles a sine wave). In general, it is useful to consider power quality as the compatibility between what comes out of an electric outlet and the load that is plugged into it. The term is used to describe electric power that drives an electrical load and the load’s ability to function properly. Without the proper power, an electrical device (or load) may malfunction, fail prematurely or not operate at all. There are many ways in which electric power can be of poor quality and many more causes of such poor quality power.’

Power quality has a huge impact on the performance and cost of a power system. So it is necessary to make sure that the power coming in is of the right quality and that your machines are set to function properly with the power they are supplied.As modern equipment gets increasingly sensitive to any changes in power quality, and as governments enforce policies regarding power quality, utilities, manufacturers, enterprises and consumers – all have to be aware and concerned about power quality issues.

SYMPTOMS OF POOR POWER QUALITY

It’s time for an in-depth Power Quality Audit if your building or enterprise suffers from any of the following:

·         Short or extensive power interruptions

·         Noisy electrical equipment

·         Voltage sags

·         Voltage surges

·         Harmonic distortion

·         High-speed transients

·         Ground loops

·         Damage from lightening

An audit will identify hidden problems and the resultant actions will, over time, make a significant difference to a company’s energy consumption and energy bills.

Installation of a power quality analyzer will enable power quality monitoring and power quality analysis on a continuous basis. This helps energy experts to pinpoint problem areas and resolve power quality problems so as to make power supply more reliable and energy usage more efficient.

HARMONICS IN POWER QUALITY

There are a number of electrical devices that have nonlinear operating characteristics. These nonlinear devices used in power distribution circuits create nonlinear currents and which subsequently causes voltage distortions. These nonlinear currents and voltages are generally referred to as harmonic currents and voltages.

Harmonic currents and voltages can cause many unfavourable effects on the power system and the connected loads. These include malfunctioning of electronic equipment, capacitor failure, transformer and neutral conductor overheating, excessive heating in rotating machinery, etc.

The proliferation of electronic switching devices in modern equipment has resulted in a significant increase in the amount of harmonic pollution in the electrical distribution systems. Some nonlinear loads include:

·         LED, CFL Lighting

·         Power supply units (computers)

·         Variable speed drives

·         SCR Rectifier UPS

·         Arc furnaces & SCR temperature controllers

·         Battery chargers & Rectifiers

NEED FOR GOOD POWER QUALITY

The increased use of automation and electronic devices; the sensitivity of the vast majority of processes and equipment (industrial, commercial, healthcare, services and even residential) to PQ problems turns the availability of electric power with quality is a crucial factor for competitiveness in every sphere of business activity. Today any interruption of business operations due to poor power quality has a direct impact on the profitability of an enterprise. The most critical areas are the continuous process industry and the information technology services.

Insufficient power quality can inflict serious losses on business and economy. In the worst-case scenario, it may pose a threat to human life in mission critical applications and highly sensitive environments, such as hospitals.

Power quality improvement allows you to optimise and reduce power consumption – saving money on your electricity bill and thereby, your carbon footprint. Direct savings to consumers come from lower energy cost and reactive power tariffs. Indirect savings are gained by avoiding circumstances such as damage and premature aging of equipment, loss of production or loss of data and work.

It also reduces the risk of equipment overheating, malfunctioning or breakdown, and minimises ‘wear and tear’ so your equipment works better and lasts longer.

Messung brings Janitza, the world’s leading energy management technology to India. Janitza offers a comprehensive product range for power quality monitoring, energy management and residual current monitoring – in a single system environment.

Messung, in partnership with Janitza, delivers customised solutions to enable power conservation, optimise power consumption and improve quality of power. By leveraging the power of IoT, we ensure connectivity and real-time data analyses for prompt, informed decision making.

To ensure high-quality power for your business, invest in Janitza’s cutting-edge power quality analyzer, energy measurement devices and GridVis software for effective energy management that will help you optimise energy efficiency, reduce power bills, minimise downtime and enhance productivity of your enterprise.

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Power quality analyzer with multi colour display; Jasic PLC programming. Use in test fields & for remote monitoring in commercial premises

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MESSUNG: ENABLING INDIAN INDUSTRY TO ACHIEVE HARMONIC STANDARD IEEE 519-2014

The main power quality issues that result in problems are frequency distortion, voltage variation and harmonics. Overloading in the distribution network causes voltage variations resulting in increased faults and losses in the network. At the consumer end, increasing use of semiconductor-based electronic equipment, non-linear loads and rapid integration of non-conventional energy sources into the grid throws up new challenges for the power quality environment.

WHY IS POWER QUALITY IMPORTANT?

An earlier study carried out by APQI shows that the direct costs of downtime in India are in the tune of Rs. 20,000 crore per annum. About 57% of these financial losses are due to voltage sags and short interruptions, while about 35% of the losses are due to transients and surges. However, the cost of prevention for these may be less than 10% of the cost of problems. (http://www.forumofregulators.gov.in/data/achievements/apqi.pdf)

Nowadays, since the current waveform deviates from the ideal sinusoidal wave, voltage waveform distortions are created. Voltage interruptions, transients, harmonics, flickers or start-up currents change the sinusoidal character of the current and thus also the power quality.

Impermissible electrical loading and increased thermal losses are daily occurrences. Both the consumer and the distribution utilities suffer from equipment /process failure and high cost of operation and maintenance due to compromised equipment quality and poor monitoring of consumer establishments. This can result in the equipment operating in a restricted manner or failing completely which may cause production failure.

So, it is a great advantage to identify grid feedback effects early and to implement counter measures.

ABOUT POWER QUALITY IN INDIA

In India, there are various regulations for quality of electricity supply which apply to generation, transmission and distribution companies. State Regulatory Commissions have specified various regulations in their respective states. These regulations, when dealing with the aspect of power quality, vary in approach and applicability. Therefore, there is a lack of consistency in the way different states deal with power quality, and it is evident that the implementation of power quality of electricity distribution, supply and utilisation / consumption are not very structured, nor are they strictly enforced by the Regulators. This has inevitably fostered ambiguity, and limited awareness of the economic importance of power quality in the entire eco system of electricity distribution-supply-utilisation.

IEEE 519 IN INDIA

In India, it is becoming mandatory for industries to ensure harmonic control in electrical power systems as per IEEE 519-2014 standards. In India, Tamil Nadu has already made IEEE 519-2014 compliance mandatory; Maharashtra will enforce it by 2023. No doubt other states will also follow suit.

Industry realises that PQ and reliability are critical for the successful delivery of a product and uninterrupted operation of an industry. It is even more critical for industry to pursue Energy Efficiency (EE) because of the increasing application of electronic loads and digital controllers which are sensitive to the quality of power supplied.

Hence, IEEE 519-2014 compliance will slowly but surely become the norm for industries.

WHAT IS THE IEEE 519-2014 STANDARD?

The IEEE-519-2014 is a system guideline for setting limits on voltage and current distortion, which is being followed by industries around the world.

The IEEE 519-2014 standard defines the voltage and current harmonics distortion criteria for the design of electrical systems. Goals for designing electrical systems that contain both linear and non-linear loads are established in this standard.

It details the recommended practices and requirements regarding harmonic control in electrical power systems. It defines the specific and separate responsibilities for each participant – utilities and users – to maintain the voltage THD within acceptable limits at the Point of Common Coupling (PCC) between the utility and the user, and protect the user and utility equipment from the negative impact of harmonics.

IEEE 519-2014 introduces measurement methods and statistical evaluation techniques to determine compliance with the recommended limits. All measurement methods are referenced to IEC (European) standards:

·         IEC 61000-4-7 for harmonics and inter-harmonics measurements

·         IEC 61000-4-30 for power quality measurement methods

·         IEC 61000-4-15 for Flickering measurement methods

HOW MESSUNG ELECTRICAL ENGINEERING CAN HELP

Messung Systems (Electrical Engineering div.) is recognised as the System Integrator for Janitza electronics GmbH, in India. Janitza provides the best solution for both preventive and corrective action for power quality, residual current monitoring and modern energy management (e.g. ISO 50001).

Janitza offers the complete system solution under one roof – from current transformers through measurement devices, from communication devices through the IT environment, databases and analysis.

A world leader in development and manufacture of energy management solutions, Janitza's energy measurement technology, class A power quality monitoring devices, GridVis® system software, energy data management systems, digital integrated measurement equipment, power factor controllers, harmonics filters and correction systems are setting the standard throughout the world.

Messung supplies Janitza's Energy measurement technology, Class A power quality analysers, energy measurement devices, GridVis® system software, and energy data storage & management systems, for industry across India.

Some Highlights of Janitza Products

1.       Industry 4.0 (Linking of Production and Communication) – Power Grid monitoring software, the energy portal and the Janitza Apps are tightly meshed with measurement devices

2.       3 in 1 Solution – The UMG measurement devices combine three solutions in single product: Energy Management, Power Quality Monitoring and Residual Current Monitoring

3.       Open Communication Architecture – Janitza products easily communicate with numerous protocols (Modbus, Binfile, OPC, Profibus, Profinet, BACnet)

4.       Certifications – Janitza fulfils the ISO 50001 standard as well as requirements for a quality management system as per DIN EN ISO 9001. All measurement devices are tested and certified by Independent Institutes

5.       Measured Data Memory – For select products, measured data memory up to 256 MB.

Janitza Software Features

GridVis® Software - Three applications (EMS, PQ & RCM); One Software

1.       Energy Management certified according to ISO 50001

2.       Networking analysis & evaluation

3.       Security and alarm management

4.       Multilingual and scalable software solution

5.       Reports can be automatically generated and dispatched

 CONCLUSION

As the authorised distributor and system integrator for Janitza electronics GmbH in India, call Messung to solve your energy management challenges, and access Janitza’s globally acclaimed 3-in-1 technology for energy management, power quality and RCM.

Messung has the expertise to customise IEEE 519-compliant energy management solutions that ensure energy efficiency, supply stability, cost savings and maximum uptime. Messung will support you from the development of the conceptual solution till commissioning. They will also help you with the maintenance and support and training your personnel for the secure operation of the energy systems.

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Continuous Power Quality Monitoring Using Janitza

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Welcome to Messung’s innovative Electrical Engineering solutions for safe, efficient and sustainable power distribution control and smart energy management systems.

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Messung offers the complete, customised energy management techniques & solution to help enterprises optimise power usage, improve power protection and increase productivity by reducing downtime, safety risks and electricity bills.

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JANITZA POWER QUALITY ANALYSERFOR THE AUTOMOTIVEINDUSTRY

energy management solution The demand for vehicles is booming worldwide - and so is the demand for automotive companies and ancillaries to reduce energy consumption, cut carbon emissions and increase sustainability.Given that the automotive industry is the most highly automated manufacturing industry, its energy management requirements are also crucial.

Indeed, the quality of electrical power is a business-critical concern. As technology advances, electrical tools and electronic machinery are becoming more sensitive to network disturbances that lead to expensive downtime and production losses.

Harmonics distortions, voltage variations, poor power factor and load unbalance are among the key elements that not only test the reliability of modern electrical systems but also induce overall system losses.

Power supplies affected by harmonics, unbalance and low power factor lead to higher electricity bills, overloading and rapid aging of the electrical infrastructure, resulting in more equipment maintenance and overall expenses.

In the future, power quality is expected to be significantly affected by theon-going shift towards carbon-free power generation. Power quality is further threatened due to the following trends: the integration of many power electronics devices, the use of power cables at all levels of voltage, the increasing amount of fluctuating energy production and, finally, a reduced overall electrical systems stability.

POWER QUALITY IN THE AUTOMOTIVE & AUTO ANCILLARY SECTOR

With a myriad of robotics, programmable controllers and drive systems working in a real-time process environment, automotive manufacturing systems can be vulnerable to power quality issues.

In addition, the use of welding robots and variable-speed drives produces harmonics and a poor power factor, which, in turn, need corrections to avoid penalties from the utility and achieve a more efficient use of energy.

In Auto & Auto Ancillary there are various critical applications which depend on pure power: machining, welding, metal cutting, metal forming, etc.Due to impure power, the most common and regular problems are IGBT card burn out, and main switch MCB burn out. Other voltage issues are welding error, cable burning, heating. Such problems force the company to frequently shut off the power source for 2-3 minutes.

Unscheduled downtime at the main assembly plant or at the outsourced supplier's facility can lead to lower productivity and lost profits.

COMPLETE CONTROL OF POWER QUALITY AND POWER CONSUMPTION

Messung, as authorised distributor for Janitza Electronics GmbH, brings their UMG 512-PRO fixed Class A power quality analyser for reliable power quality monitoring & analysis in accordance with current standards,e.g. EN 50160, IEEE519-2014, EN 61000-4-30.

Using Janitza PQA UMG 512-PRO, enterprises can identify voltage and other Power Quality issues such as Harmonics, Transients, Flicker, etc. at the main incomer, so as to address problems in real time.

Janitza's UMG 512-PRO helps businesses to fulfil mandatory requirements while they maintain supply stability, ensure power quality, minimise downtime of critical assets, and reduce costs.

MAIN FEATURES OF UMG 512-PRO

·         Class A

·         Power quality

·         Residual Current Monitoring (RCM)

·         Measuring devices homepage

·         Ethernet-Modbus-Gateway

·         BACnet

APPLICATIONS OF UMG 512-PRO

·         Continuous monitoring of the power quality

·         Harmonics analysis with power quality problems

·         Checking the internal supply network according to EN 61000-4-7, EN 61000-4-15, IEC 61000-4-30

·         Fault analysis in case of problems with the energy supply

·         Documentation of the power quality for customers and regulatory authorities

·         Ethernet Gateway for subordinate measurement points

·         Report generator for power quality standards: EN 50160, IEEE 519, EN 61000-2-4, ITIC …

·         Report generator for energy consumptions

·         Energy Dashboard

·         Remote monitoring of critical processes

CUSTOMER BENEFITS WITH UMG 512-PRO

·         Energy savings

·         Higher productivity

·         Reliable plant operation at reduced maintenance costs

·         Longer lifetime of electrical and process equipment

·         Additional capacity in existing electrical network

·         Compliance with IEEE 519-2014,IEC 61000-4-30or any other power quality standards and recommendations

·         Quick return on investment

ABOUT MESSUNG ELECTRICAL ENGINEERING

Messung offers the complete, customised energy management solution to help enterprises optimise power usage, improve power protection and increase productivity by reducing downtime, safety risks and electricity bills.

Messung has joined hands with Janitza electronics GmbH, to bring to India their advanced system solutions for modern energy data management (e.g. ISO 50001), power quality and residual current monitoring. Power quality analysers, power quality meters, digital energy meters, software and apps - Messung supplies the full range of Janitza solutions.

With their expertise in electrical engineering, and incorporating best-in-class products from Janitza, Messung enhances productivity and the reliability of your critical electrical assets.

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TACKLING POWER QUALITY PROBLEMS IN PLASTICS PROCESSING

Imagine this scenario: Operations at a plastics processing plant are on in full swing. Suddenly, there is a power or motor failure during the plastic formulation process. The plastic, in a molten state, quits flowing and instantly solidifies in the pipes. A large amount of costly material is lost, not to mention the manpower needed to disassemble and clear the pipes of the hardened plastic. Let’s not forget the time lost from production while the plant shuts down for cleaning.

The plastics processing industry utilises varied machines and processes for transforming plastic granulates, powders and liquids into a wide range of diverse products. The primary processing methods include injection moulding, blow moulding, extrusion as well as compression and injection moulding. Other processes are rotational moulding, thermoforming, calendaring, coating, casting, cutting, welding, etc.

Undetected and un-solved power quality problems cost the plastic processing industry thousands of rupees each year in preventable equipment failure, unplanned downtime and prohibitive energy costs.

Let’s understand power quality a little better.

What is good power quality?

Good power quality would be one that's always available, always within voltage and frequency tolerances, and has a puresinusoidal wave shape.

Voltage disturbances occur frequently in the grid, as well as on-site. As on-site machinery becomes more sophisticated thanks to the widespread use of microprocessors, the ramifications of poor power quality have grown substantially. For some devices, even a momentary disturbance can cause scrambled data, interrupted communications, system crashes and equipment failure.

Harmonics too are becoming omnipresent, due to the prevalence of power electronics in computer power supplies, energy saving lamps and motor driven systems with variable speed control.

Poor power quality can dramatically increase the cost of doing business, either through investing in solutions for mitigation, or through adaptation to poor power quality.

Such problems in power quality result in

- premature equipment failure

- transformer failure

- additional heat losses in transformers, cables, motors

- derating of equipment, resulting in need for frequent replacement of equipment

What are the symptoms of poor power quality?

Motor burnout and downtime: The windings inside an inductive motor degrade over time, caused by poor power quality. The winding insulation burns off and eventually causes shorts, reducing motor output and increasing internal heat until it fails.

Controls/Displays, memory loss and downtime: PLCs and microprocessors control mostly used in plastics production equipment, and are extremely sensitive to power fluctuations. Power variations lead to excessive current and heat, or program loss.

Power factor problems and high penalties: VFDs may lower power consumption but they often result in poor power utilisation which attracts penalties on your utility bill.

Transformer failure and downtime: Transformer internals decay over time and fail due to power fluctuations.

 MONITOR, ANALYSE & CONTROL POWER QUALITY WITH UMG 512-PRO

Trust Janitza’s UMG 512-PRO fixed Class A power quality analyser for reliable power quality monitoring & analysis in accordance with current standards, e.g. EN 50160, IEEE 519-2014, EN 61000-4-30.

Using Janitza PQA UMG 512-PRO, enterprises in the plastics processing industry can identify voltage and other Power Quality issues such as Harmonics, Transients, Flicker, etc. at the main incomer, so as to address problems in real time.

Janitza's UMG 512-PRO helps businesses to fulfil mandatory requirements while they maintain supply stability, ensure power quality, minimise downtime of critical assets, and reduce costs.

Main Features of UMG 512-PRO

·         Class A

·         Power quality

·         Residual Current Monitoring (RCM)

·         Measuring devices homepage

·         Ethernet-Modbus-Gateway

·         BACnet

Applications of UMG 512-PRO

·         Continuous monitoring of the power quality

·         Harmonics analysis with power quality problems

·         Checking the internal supply network according to EN 61000-4-7, EN 61000-4-15, IEC 61000-4-30

·         Fault analysis in case of problems with the energy supply

·         Documentation of the power quality for customers and regulatory authorities

·         Ethernet Gateway for subordinate measurement points

·         Report generator for power quality standards: EN 50160, IEEE 519, EN 61000-2-4

·         Report generator for energy consumptions

·         Energy Dashboard

·         Remote monitoring of critical processes

 CONCLUSION

In a plastics processing facility, poor power quality can cause transformers to fail, motors to burn out, controls to suffer memory loss. Due to impure power, the most common and regular problems are IGBT card burn out, and main switch MCB burn out, besides welding errors, cable burning, heating.

Janitza’sUMG 512-PRO can enable reliable plant operation, reduced maintenance costs, longer life of electrical/electronic equipment, energy savings and higher productivity. It also helps your facility achieve compliance with IEEE 519- 2014, IEC 61000-4-30 or any other power quality standards and recommendations.

In India, Janitza's advanced energy management products and solutions are brought to you by Messung. For modern energy data management (e.g. ISO 50001), power quality and residual current monitoring; for power quality analyzers, power quality meters, digital energy meters, software and apps – contact Messung.

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Messung offers a range of innovative components for panel mounting and Electrical busbar Systems from Wohner GmbH, the globally renowned partner for energy distribution and control technology.

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Messung Electrical Engineering is the official distributor & Supplier of the Wohner Electrical Busbar system and Electrical Power Distribution system in India.

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MESSUNG’S POWER DISTRIBUTION SYSTEM BASED ON IEC 61439 STANDARD

IEC 61439 is the latest standard for low-voltage switchgear and controlgear assemblies. It was launched in 2009 and replaced the earlier IEC 60439, following years of work by an international project group following dissatisfaction with the IEC 60439 series.

The IEC 60439 standards were ambiguous about how to assess compliance of partially type tested assemblies. As a result, manufacturers and testing bodies often treated partially type-tested assemblies differently.

IEC 61439 was drafted with a purpose to harmonise and define all general requirements for low-voltage electrical assemblies, and succeeded in bringing considerable clarityin technical interpretation.

ABOUT SWITCHGEAR AND CONTROLGEAR

For switchgear definition, we can refer to Wikipedia where it states that "In an electric power system, switchgear is composed of electrical disconnect switches, fuses or circuit breakers used to control, protect and isolate electrical equipment. Switchgear is used both to de-energize equipment to allow work to be done and to clear faults downstream. This type of equipment is directly linked to the reliability of the electricity supply."

Electrical control gear definition is one or more devices, possibly integrated in a light source, intended to prepare the mains electricity supply for the electric format requiredby one or more specific light sources within boundary conditions set by electric safety and electromagnetic compatibility. It may include transforming the supply and starting voltage, limiting operational and preheating current, preventing cold starting, correcting the power factor and/or reducing radio interference.

Switchgear and control gear as defined by IEC 60947 for electronics applications encompass all electrical components and devices that are used to activate, deactivate, and protect electrical consumers and include switches, contactors, residual current devices, and motor protection switches.

WHAT IS IEC 61439?

IEC 61439 is the international standard for all low-voltage switchgear and control gear assemblies. It describes the design verification for control gear assemblies and the responsibilities of the manufacturer and panel maker.

The IEC 61439 standard applies to enclosuresfor which the rated voltage is under 1000 V AC(at frequencies not exceeding 1000 Hz) or 1500 V DC.The standard seeks to correct the lack of clarity in three significant ways:

·         Clearly defining the respective roles and responsibilities of original manufacturer, assembly manufacturer and specifier.

·         Replacing the concepts of TTA and PTTA with verified assembly.

·         Clarifying and reinforcing tests and their requirements.

In order to conform to the standard, type tests have been replaced by a design verification which can be carried out by the three following equivalent and alternative methods:

·         Testing

·         Calculation/measurement

·         Design rules

IEC 61439-1defines the general rules for low voltage switchgear assemblies. It gives the definitions and indicates the conditions of use, construction requirements, technical characteristics and verification requirements.

IEC 61439-2 is a product standard which defines the specific requirements (assembly rules).

The new IEC 61439 series of standards thus defines the construction of low voltage switchgear assemblies and their inspection more precisely, specifying there sponsibilities of those involved and differentiating between the role of the original manufacturer and that of the assembly manufacturer (panel builder). 

PARTS OF IEC 61439

The standard mentions many parts but each part cannot be used individually:

ROLES DEFINED BY IEC 61439

The new IEC 61439-1 clearly identifies the various parties involved in specifying and manufacturing equipment and assemblies, along with their responsibilities, as follows:

The Specifier identifies the needs and constraints for design, installation, operation and upgrading of the complete system. This party also checks that requirements have been fully integrated by the assembly manufacturer. The specifier could be the end-user or a design office.

The original manufacturer carries out the original design and associated verification of an assembly system. This party is responsible for the design verifications listed by IEC 61439-2, which governs switchgear and controlgear, including many electrical tests.

The assembly manufacturer (or “panel builder”) is responsible for the completed assembly. This party is responsible for “routine verifications” if the assembly is produced according to the original manufacturer’s requirements. However, any deviation from original manufacturer instructions will force a new, full design verification process. 

MESSUNG’S ELECTRICAL DISTRIBUTION SOLUTIONS

Messung designs and manufactures smart electrical panel as per IEC 61439 Standards, customised for diverse applications. It connects various power sources to a single point, with PLC controls for switching the source – and provides unmatched safety for electric power distribution.

Messung’s SPDS (Smart Power Distribution Solution) for villas, bungalows & farmhouses can also serve applications like Hospitals, Hotels & Commercial Complexes.

For more on Messung’s expertise in Electrical Engineering, visit www.messungelectricalengineering.com

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Messung Is The Official Distributor and Supplier For Wohner Electrical Busbar System.

UNDERSTANDING THE ELECTRICAL BUSBAR

'Busbar' is the tried and tested technology that has transformed the world of electric power distribution. The electrical busbar is proven to make complex power distribution easier, safer and more flexible.

Today, electrical busbar systems are the backbone of most power applications. Let's find out more about busbar technology.

 WHAT IS A BUSBAR?

As per Wikipedia, busbar means a metallic strip or bar, typically housed inside switchgear, panel boards, and busway enclosures for local high current power distribution.

Electrical busbar has also been defined as a type of electrical junction in which incoming and outgoing electrical current meet. It is available in different shapes but the rectangular busbar is the most commonly used one. Busbars can be fully enclosed or with a continuous access open channel.

Also known as busbar trunking system, the busbar system both grounds and conducts electricity with greater ease and flexibility than other forms of distribution. The material generally used for busbar is copper, however brass or aluminum are also used.

Copper busbar is usually chosen for its resilience to higher temperatures which provides extra security during short circuits. The metal copper also offers higher performance inclamped joints, high recovery value, lower coefficient of linear expansion and durability.

The copper busbar current carrying capacity is 1.2 times its product of width and the thickness. Which means, take a copper bus bar of 100 mm width and 10 mm thickness, the area of the copper bus bar is 10 * 100 sq.mm. The total current carrying capacity of the busbar is 1.2 * area => 1000 sq.mm* 1.2 =1200 Amps. 

TYPES OF BUSBARS

Based on their construction, busbars are categorised as follows:

Single busbar system

This is a simple arrangement with only one busbar along with the switch. All the substation equipment like the transformer, generator, the feeder is connected to this bus bar. Advantages of the single busbar system include:

-          low initial cost

-          less maintenance

-          simple operation

Double busbar system

In these busbar panels, low voltage and high voltage busbars are duplicated - either section can be used as desired. The arrangement requires two circuit breakers,and a coupling switch that helps transfer operation from one busbar to the other.

This type of system provides maximum reliability in supply. Maintenance or faults do not disturb the continuity as the load is simply transferred from one bus to the other.

Due to its high cost, double busbar system is rarely the preferred busbar in substation. 

Ring busbar system

In this type of busbar, the end of the busbar is connected back to the starting point of the bus to form a ring. This arrangement provides two parallel pathsfor the circuit,hence a fault or failure of one path will not interrupting power supply completely. Maintenance of the circuit breakers is possible without interruption of service.

APPLICATIONS OF BUSBARS

When space is limited or alternative electrical distribution is involved, busbar application is recommended as they offer a suitable solution for many industries and applications.

3-phase busbar panels are found in environments that require three-phase power distribution systems, such as:

·         Factories

·         Data centres

·         Retail facilities

·         Laboratories

·         Hospitals

·         Universities

Busbar systems are also widely used in

·         Telephone exchange systems

·         Cellular communication systems

·         Base stations

·         Large network equipment

·         Power generation

·         Power switch

and also in:

-          Switching cabinets

·         Transformers and charging stations

·         Power link for generators, and many more.

 ADVANTAGES OF BUSBAR SYSTEMS

Busbars are crucial in electrical distribution systems and offer several benefits:

 BUSBAR VS CABLE

Today, more and more people are opting for busbar technology. The superiority of busbar vs cable is clear to see. Besides improved, more reliable electricity distribution performance, here are some of the top reasons why busbars are the preferred choice.

Compact design Busbars uses less space than cable systems. Unsightly tangles of cables are avoided. What's more, the compactness of the busbar enclosure means the tightly compressed conductors inside are reliably isolated.

Better resistance Short circuit testing has shown that busbars have better resistance than cables. A thin flat tire helps in optimal distribution of density of current, and reduces resistance. Voltage loss is much lower.

Flexibility Busbar, being a modular design, is able to fit into any structure. They can be easily relocated, re-installed and modified to fit, without any capital expenditure and only minimal interruption of service. The possibility of moving, reconfiguring and expanding cable systems can be disruptive and expensive.

Lower lifetime cost Easy installation, faster assembly time and lower material costs make busbars more competitive than cable systems. C zmsdistribute power more economically and are practically maintenance free. They cannot be damaged by rodents and offer better weather-resistance - so their lifetime cost is much lower than cables.

Faster and safer installation Busbar systems are pre-designed to fit the installation space, and can be installed quickly and easily, resulting in lower material and on-site costs. Less manpower is needed; no special tools are required; installers can install up to 10 mtrs of busbar at a time.

Future proof Being a flexible system, busbars can be easily adapted for upgrades and changes in the future. Busbars allow customers peace of mind, and confidence that their power distribution system will safely and efficiently provide power for years. 

CONCLUSION

Messung Electrical Engineering is the authorised distributor for the world’s leading busbar company, Wöhner GmbH, Germany.

With more than 100 registered patents, Wöhner has been shaping the future of energy distribution and control technology. Wöhner serves customers in over 80 countries through an extensive network of 11 subsidiaries and representatives across the world.

Messung brings Wöhner's electro-technical safety systems, panel mounting and busbar assembly for discerning customers in India. Using Wöhner's busbar power distribution products, Messung develops the total low voltage power distribution control system. Messung's Industry 4.0 compatible, Cloud-based solutions provide 'anytime, anywhere' supervisory and control features for every application - be it a water treatment plant or machine tool.

To know more about Messung’ sbusbar panels or busbar price, contact Messung today.