Respondents

• B.J. Hanson, Energy Solutions Business Development Lead, Werner Electric Supply, Appleton, Wisconsin
• Lanny Floyd, Owner and Principal Consultant, Electrical Safety Group Inc., Elkton, Maryland
• Lee Ward, Industry Sales Manager – Process, Mining, Cement and Power Generation, Rockwell Automation, Marlborough, Massachusetts

Left to right: B.J. Hanson, energy solutions business development lead, Werner Electric Supply; Lanny Floyd, owner and principal consultant, Electrical Safety Group Inc.; Lee Ward, industry sales manager – process, mining, cement and power generation, Rockwell Automation.

What’s the current trend in electrical and power systems for industrial and manufacturing facilities?

Lee Ward: There are generally two schools of thought: Investment in renewable power generation sources or expansion in the cleaner fossil fuel generation sources. There is ongoing risk discussion around grid reliability vs. investment in self-sufficiency as a risk mitigation strategy. In addition to those topics, the over-arching specter of the cybersecurity challenge and how, if not given the true deference it deserves, cybersecurity risk can have a major impact on the business.

Lanny Floyd: Higher energy density.

What future trends should engineers, plant managers and designers expect for such projects? (Looking ahead one to two years.)

Ward: Regardless of the generation genre, it is essential for them to harden their cybersecurity to reduce system vulnerabilities at the grassroots level, making the facility not only serviceable but also well-defended. My main concern is that when it comes to plant investment, expansion, or greenfield projects, a greater emphasis is often placed on capacity and the overall outcome of the project rather than prioritizing the core control infrastructure, which poses the highest risk.

Floyd: Equipment with reduced exposure to hazardous electrical energy, increased capability for condition monitoring to enhances safety and reliability.

What are the most critical power system maintenance practices that facility managers should prioritize to minimize unplanned downtime and maintain system reliability?

Ward: Asset visibility is the most overlooked practice. Other than routine mechanical operations, the digital information provided by equipment is often overlooked. Condition monitoring typically only occurs when a failure is imminent, but your equipment can be telling a story long before a catastrophic failure occurs. Runtime hours, duty cycles, incremental sensor readings all contribute to this valuable insight. Prioritize new analytics and predictive models to prevent unplanned downtime and avoid catastrophic capital equipment failures.

Are you incorporating electric vehicle charging stations and if so, what power pros and cons have you come across?

B.J. Hanson: Yes, we are incorporating EV charging stations but are not seeing large-scale adoption yet, at least on larger installations. However, we do expect the NEVI initiative to help increase that adoption. Electric vehicle (EV) charging stations and EV’s in general, certainly offer several benefits, including reducing greenhouse gas emissions, supporting the adoption of clean energy and improving air quality. They provide convenience for EV owners and can integrate with renewable energy sources for a sustainable charging option. However, challenges include high installation costs, particularly for fast-charging stations and the need for significant infrastructure upgrades to handle increased demand. In certain locations charging stations can also strain the power grid, especially during peak hours, requiring smart grid solutions. Additionally, the environmental impact of local electricity generation and battery disposal must be considered to ensure overall sustainability.

Is your facility implementing microgrid or renewable power systems? Describe the project.

Ward: Rockwell Automation has a microgrid controller application that is based on its PlantPAx® process controls platform. It is designed to monitor, manage and dispatch generating assets, as well as curtail loads when necessary. In addition, it provides visibility into asset operations and maintenance, equipment availability and performance insights. Notably, PlantPAx® is designed with security as a top priority and offers flexible configuration options along with extensive scaleability.

What techniques have you used to mitigate harmonics in a facility?

Hanson: We have helped customers install line-side power quality products, such as line reactors, passive and active harmonic filters, dc link chokes. In doing so, we aim to help customers meet Institute of Electrical and Electronics Engineers Standard 519 (IEEE-519) for total harmonic distortion within their facility.

Ward: Equipment that tends to create harmonics typically includes devices that modify the regular sine wave, such as inverters or variable frequency drives (VFDs). If such devices are already in use or if we are supplying new equipment, then using active front-end VFDs or 18-pulse VFDs with line reactors and filters can help mitigate these disturbances. For existing equipment, either active or passive line filtering can be used to address the issue.

What are some key trends in power distribution and automation that facility managers should be aware of and how might these trends impact future investments in electrical systems?

Floyd: Equipment with reduced exposure to arc flash and electric shock hazards, enhanced capability of condition-based monitoring.

Ward: The biggest trend in power distribution is twofold: enhancing asset visibility regarding power quality data and critical measurands and protecting the power system from malicious intrusion.

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