Power quality management in industry

PQM Industry

Project description industry

The problem

Transparency regarding energy costs and power quality is continuously becoming more and more important in industrial companies. Energy consumption levels must be allocated to the production stages and the final products in order to simplify pricing policies.

Due to the use of non linear consumers such as frequency converters, problems often arise with electronic equipment and controls. Reactive power compensation systems are usually subject to particularly high loads and, therefore, require skilled engineering. Expensive peak loads can be avoided with intelligent peak demand management.

The task

A supplier to the automobile industry decided to relocate its complete production facilities and construct the buildings in a “green belt” area. The company wanted to collect consumption data for all welding robots together with compressed air consumption and heating supplies and provide the data to the controlling department.

The power quality from the four main feeds needed to be monitored and the four respective PFC systems needed to be integrated in the energy management system. Peak demand management had to be anticipated in order to reduce high electricity costs due to high loadpeeks, shutdowns of compressors and air conditioning units etc. for a short period will be the solution. Intranet was available as a communication medium.

The solution

The UMG 96 of Janitza electronics®, which passes on the effective pulses to the ProData® data logger, was used as a meter for electrical energy. Other pulse meters for compressed air and heating were also connected to the ProData® using the pulse outputs.

Four UMG 503V´s were deployed in the four main feeders in order to determine the power quality. Four Prophi® 12TS reactive power controllers were also visualised using the RS485 in PSW professional software.

Distinctive feature:
The four PFC systems work as a so-called mixed operation, which means that the base load is compensated using the conventional contactors. The rapidly changing load proportions, as caused by welding systems, are switched using thyristor modules.

This means that dynamic PFC can be created for almost the same price as the conventional compensation system. A globally unique feature of the Prophi® controller. The UMG 507E works as peak demand management and as a master for downstream WAGO modules as well as a gateway for the RS485 bus cable to Ethernet/TCP/IP.

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