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Successful Power Monitoring is a Process Michael Daish Vice President Sales Summit Technology Inc. Power Monitoring is a Process • • • • • • • • Introduction Why is monitoring a process? What are the tasks? Why studies go wrong Choosing instrumentation Data collection, retrieval, & analysis Documentation & reports Conclusions Why is Power Monitoring a Process • • • • • • Power studies have a beginning, middle, and end. Connecting and set-up, correctly, safely Measurement over time, logging Analysis and Reports – the “end game” Monitor is central to the process – data collection tool Software tools complete the process, analysis, report What do we want to accomplish? • Define the problem you want to solve, examples: “I need to add more loads – will my panels and circuits support the new additions?” “We need to reduce energy consumption – I need to perform an energy audit to evaluate energy savings opportunities.” “How are the energy savings measures we have implemented performing?” “This transformer is very hot – is it overloaded, or are high harmonics the cause?” “My (machine/process) is operating erratically – is power quality the cause?” “When the HVAC (or motor or other equipment) turns on the breaker trips.” “I’m commissioning a UPS and need to verify it’s performance.” “I want to perform regular diagnostics on our motors as part of a predictive maintenance program.” etc. Power Study Tasks • • • • • • • Log V & I Power & Energy Power Quality – sags/swells Power Quality – high-speed transients Harmonics Frequency Flicker Frequency High-speed 5% Flicker 0.2% transients 8% Log V&I Harmonics 34% 10% Sag/swell events 19% Power & Energy 25% Choosing Right Instrument Frequency High-speed 5% Flicker 0.2% transients 8% Log V&I Harmonics 34% 10% Sag/swell events 19% Power & Energy 25% Instrument Types and Trends • • • • • • • • Multiple vendors = choice difficult Microelectronics progress = lower cost More processing power Lower cost memory = more storage Variety of communications methods Black-box, tablet, hand-held PQ features added to permanently installed meters Standards based or trouble-shooting Instrument Types Instrument Types Instrument Types – Present Hand-Held Size Tablet Black-Box smallest medium biggest Weight lowest medium heaviest Display LCD LCD/Graphics none Ease of Connection Good Good Good Ease of set up Easy Less Easy Easiest Medium - High Medium - High Highest Good Very Good Very Good Very Good Very Good Very Good Lowest $1.5K - $5K Medium $4.5K - $ 9K Highest $10K - $15K Breadth of Measurements Software Reports Cost Why power studies go wrong! • • • • • Bad planning Incorrect connections Wrong set-up Power cord or leads come off Tampering To Display or Not Display • Unattended long-term monitoring and logging does not require a display For long monitoring periods no one is looking at the monitor Analysis done off line Use PC as display for analysis and reports Good security – small size, less conspicuous • Attended short-term monitoring sometimes requires oscilloscope display Witness conditions as they occur Forcing events, changing of waveforms Usually during commissioning and set-up of equipment Poor security – video game Safety Categories Overvoltage Protection Categories CAT II 600V Overvoltage withstand capability 4000V CAT III 300V CAT III 600V 6000V CAT IV 300V CAT III 1000V 8000V CAT IV 600V CAT IV 1000V 12000V Safety: Connecting Safely • CAT IV rating - highest level of transient overvoltage (8,000 V over voltage at 600 Vrms service) • Verifying connections by experience • Indicator lights – go, no go • Display – phasors, rotation, polarity, waveform • CT’s self-identify • Intelligence – SureStart checks all conditions Waveform Capture Spot Checks • • • LCD Meter display Labeled buttons Instant readings Connection Check List Types of Errors that may be present One, two, or three voltages not connected One, two, or three currents not connected to source One, two, or three currents not connected to measuring system Two or three connections to the same voltage Two or three connections to the same current Voltages misidentified Currents misidentified One, two, or three current sensors backwards Two voltage connections switched Two current sensors switched All voltages rotated one position left All voltages rotated one position right All currents rotated one position left All currents rotated one position right One phase not present Two phases not present Three phases not present One phase offered as two or three phases One phase shorted to neutral or ground Two phases shorted to neutral or ground Neutral not connected to ground Non-standard voltage due to improper loading Non-standard voltage due to power system problem Non-standard frequency due to power system problem Non-standard phase shift between phases due to power system problem Combinations of the above listed errors ™ SureStart For Successful Studies • Algorithms check all voltage and current connections • Advises user of connection errors, setup SafeConnect • • • • • • • • • • ™ Monitor power without exposure to high voltages No need to wear special gloves, eyeprotection, or flame-retardant clothing. No need to power down. No need to put up protective barriers or warnings. Quick setup and teardown of monitoring sessions on live power. No need to remove panels. No need to deal with hooking up current probes in tight or inaccessible spaces. Periodic maintenance measurements. No switched phases, reversed probes, or dead channels. Permanent connections means the data is right when you return 1 month later. “The Mighty Hand-Held” • • • • Power Logger Power and Energy Analyzer Power Quality and Harmonics Motor Diagnostics PS250 PS2500 PS3000 PS3500 PS4000 PS4500 “The Mighty Hand-Held” Frequency High-speed 5% transients 8% Harmonics 10% Log V&I 34% Sag/swell events 19% Power & Energy 25% • • Power Logger Harmonics optional “The Mighty Hand-Held” Frequency High-speed 5% transients 8% Harmonics 10% Log V&I 34% Sag/swell events 19% Power & Energy 25% • • Power Logger Power and Energy Analyzer “The Mighty Hand-Held” Frequency High-speed 5% transients 8% Harmonics 10% Log V&I 34% Sag/swell events 19% Power & Energy 25% • • • Power Logger Power and Energy Analyzer Power Quality and Harmonics Data Retrieval Methods • • • • • Serial cable RS 232 Ethernet via serial-to-Ethernet converter USB via serial-to-USB converter Wireless - Bluetooth SD Memory card (256KB – 2 GB) Log V and I Log Tabular Data – Export to Excel • * Start • * Date • 7/18/2002 • 7/18/2002 • 7/18/2002 • 7/18/2002 • 7/18/2002 • 7/18/2002 • 7/18/2002 • 7/18/2002 • 7/18/2002 • 7/18/2002 • 7/18/2002 • 7/18/2002 • 7/18/2002 • 7/18/2002 Start Wb Freq Time Avg Avg 11:33:57 2995 60 11:33:58 3222 59.9 11:33:59 3050 60 11:34:00 3139 60 11:34:01 3115 60 11:34:02 3173 60 11:34:03 3226 59.9 11:34:04 3178 60 11:34:05 2996 60 11:34:06 2987 59.9 11:34:07 3087 60 11:34:08 3007 60 11:34:09 3185 59.9 11:34:10 3256 60.1 Van Wc Vbn VAa Vcn VAb Ia VAc Ib PFa Ic PFb Wa PFc Avg Avg Avg Avg Avg Avg Avg Avg Avg Avg Avg Avg Avg Avg 270.5 2980 268.2 6346.4 270.3 6080 23.448 6401.6 22.664 0.45 23.672 0.49 2835 0.47 270.7 3238 268.2 6675.2 270.1 6204 24.656 6566.4 23.128 0.51 24.32 0.52 3433 0.49 270.3 3235 268 6668.8 270.5 6139.2 24.688 6553.6 22.904 0.52 24.232 0.5 3473 0.49 270.7 3097 268.1 6630.4 270.7 6184 24.504 6505.6 23.064 0.5 24.032 0.51 3339 0.48 270.5 2939 268 6566.4 269.9 6154.4 24.28 6433.6 22.96 0.49 23.832 0.51 3217 0.46 270.4 3062 268.1 6611.2 269.9 6197.6 24.456 6486.4 23.112 0.51 24.024 0.51 3346 0.47 270.8 3019 267.9 6649.6 270.5 6230.4 24.544 6492 23.248 0.51 24 0.52 3365 0.47 270.4 3033 268.4 6700.8 270.7 6272 24.776 6536 23.36 0.51 24.136 0.51 3408 0.46 270.7 3146 268.6 6668.8 270.8 6187.2 24.624 6553.6 23.032 0.51 24.2 0.48 3403 0.48 270.4 3156 268.2 6643.2 269.9 6144 24.56 6529.6 22.904 0.5 24.184 0.49 3351 0.48 269.6 3033 267.5 6566.4 269.9 6114.4 24.352 6514.4 22.856 0.5 24.136 0.5 3262 0.47 270.3 2890 267.3 6518.4 269.9 6028 24.112 6385.6 22.544 0.49 23.656 0.5 3212 0.45 270.2 2900 268.3 6604.8 270.7 6228.8 24.448 6449.6 23.208 0.5 23.816 0.51 3277 0.45 271.1 3013 268.5 6617.6 271 6285.6 24.416 6503.2 23.4 0.5 23.992 0.52 3289 0.46 Power and Energy KWh Harmonics Harmonics RMS Events Sags/Swells Waveform Sags/Swells RMS Events Current Inrush High-Speed Transients High voltage probes • High voltage probes for 5KV or 15 KV Motor Current Signature Analysis • Evaluate motors while running • Rotor/armature health • Stator mechanical/electrical health • Field coil faults • Bearing health • Eccentricity • Loose connection problems • Induction, synchronous, DC, wound rotor and induction with VFD type motors. Reports and Documentation • The “end game”! • Print individual graphs • Highlight peaks and behavior • Tabulate results – minimums, maximums, and averages • Filter results • Edit text and graphs • Wizard to compare two results surveys – “before and after!” • Save as pdf, doc etc. Reports and Documentation Add labels to draw attention to behavior Reports and Documentation Tables and graphs compiled automatically Reports and Documentation Filter report Reports and Documentation Comparing two studies Reports and Documentation Comparing two studies Safety: NFPA 70E Arc Flash Hazards CAT IV and Bluetooth for Safety Safety: Remote PDA Operation Safety: Leaving monitor behind unattended Conclusion • • • • • • • • • • • • Power monitoring is a process Connect correctly and safely V & I data logging most common study Energy analyzer addresses 60% of studies Sags/swells are most common PQ problem Harmonics and high-speed transients less significant Display need depends on attended/unattended operation New hand-held analyzers pack high performance Options for high voltage, high freq noise, motor diagnostics Report writer completes the job NFPA 70E has changed electrical maintenance & testing Bluetooth for remote control by PC or PDA