Learn how you can easily and cost consciously diagnose your power quality problems.
What is Power Quality?
Power quality is an electrical grid's ability to supply a clean and stable power supply. A perfect power supply is always available, is noise-free, and is always within voltage and frequency tolerances. Without proper power, any electrical device may malfunction, fail prematurely or fail to operate.
Why should I be concerned?
Poor power quality has become one of the most serious issues in industrial facilities – and one of the most untapped areas of cost reduction and economic advantage.
The U.S. plastics industry loses $9.6 billion every year because of poor power quality and utilization. And up to 80% of the $9.6 billion loss is preventable and curable. Poor power quality and utilization problems are common in most factories, ultimately causing machinery and component failure as well as the loss of production while these conditions are being repaired or replaced. Properly addressing power quality issues is the largest cost reduction opportunity in the plastics industry today.
What are the symptoms of poor power quality?
Motor Burnout and Downtime
The windings inside an inductive motor degrade over time. Much of the degradation is caused by poor power quality. The winding insulation burns off and ultimately causes shorts, reducing motor output and increasing internal heat until it fails. All this is not a motor warranty issue, but instead is the fault of poor power quality which can be diagnosed and prevented.
Controls/Displays, Memory Loss and Downtime
PLCs and microprocessors control most production equipment nowadays. And, these devices are ultra-sensitive to power fluctuations which can lead to excessive current and heat or program loss. Very little of this is ever the fault of the controller itself, but instead is the result of poor power quality which can be diagnosed and prevented.
Power Factor Problems and High Utility Penalties
Variable Frequency Drives or VFDs may lower power consumption, but they often result in poor power utilization which prompts penalties on your utility bill. Again, all of this can be easily diagnosed and corrected.
Transformers Failing and Downtime
Just the same as motor windings, transformer internals decay over time and fail because of power fluctuation. This is rarely the fault of the transformer itself, but is the fault of poor power quality which can be diagnosed and prevented.
What can be done?
Grabbing your share of $9.6 billion starts with diagnosing the problems in your plant.
Less than 20% of factories address poor power quality and utilization issues. That’s because most users aren’t electrical engineers and are intimated by electrical jargon and expensive instrumentation which can’t be understood by the vast majority.
Until now, diagnosing these costly events required an army of highly-skilled electrical consultants, expensive specialized instrumentation often limited by 24-hour storage, and capital appropriation through multiple approval levels.
That all changes with the introduction of the MachineSense Power Analyzer. This proven technology has been tested for two years with industrial users just like you. The result is, the first affordable, easy-to-understand, easy-to-install, 24/7 power diagnostic instrument and app for non-electrical manufacturing professionals.
It’s priced thousands less than historic power instrumentation. Consider it an “industrial MRI” that diagnoses under the covers of your wiring, your electrical distribution grid and your powered machinery, so you can easily identify the internal power issues and get them fixed. Like an MRI, with Power Analyzer you’ll know what’s really happening inside…inside your control panels, inside the wires in your walls and inside your drives. But unlike actual MRI diagnostics, you don’t have to be an expert to read the results. For the first time, easy-to-read dashboards tell you exactly what’s going on with your power quality or utilization and provides actionable advice on how to implement the cures.
But unlike actual MRI diagnostics, you don’t have to be an expert to read the results. For the first time, easy-to-read dashboards tell you exactly what’s going on with your power quality or utilization and provides actionable advice on how to implement the cures.
How does it work?
MachineSense electrical toroids are placed directly on incoming power lines or machine power lines to automatically monitor power conditions. This 24/7 collection of data transmits through an internal datahub directly to your router and is analyzed by cloud-based servers. Our Crystalball software automatically translates complicated electrical graphs into intuitive dashboards available on your desktop or handheld devices. You’ll receive text or email message to alert you to possible upcoming problems. Armed with this data, you can put together an action plan to tackle the biggest cost reduction opportunity and productivity enhancer in American industry today.
What’s in it for me?
You’ll conquer poor power quality issues and achieve economic gains through reduced utility bills, lowered downtimes and improved productivity. And you’ll avoid expensive part replacement as well.