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 are the key factors influencing electrical system efficiency?

Ward: Key factors influencing electrical system efficiency include understanding how to manage loads in relation to operating conditions and selecting the appropriate generation source at any given time.

Modern technologies, such as artificial intelligence, can help in the decision-making process, as there are multiple dynamic factors at play.

Floyd: Managing power quality, which includes harmonics and voltage balance.

How does power factor correction impact overall system efficiency?

Hanson: Power factor (PF) correction improves system efficiency by reducing the reactive power, which does not contribute to useful work. Power factors closer to 1.0, lowers the total current flowing through electrical systems, thus reducing energy losses in transmission lines, transformers and equipment. By improving the PF, there is less heat generation from the equipment, as well as less stress and wear. It also helps optimize capacity, allowing for better use of existing infrastructure without overloading. Additionally, some utilities impose penalties or charges when PF drops below 0.90, therefore, correction of PF may reduce demand charges or penalties from utilities leading to cost savings. Overall, PF correction enhances voltage stability, improves power quality and ensures more effective use of electrical resources, increasing overall system efficiency.

Floyd: It improves efficiency by reducing nonproductive losses in power distribution equipment.

Can you explain the concept of demand-side management and its role in improving system efficiency?

Hanson: Demand-side management (DSM) refers to strategies that encourage consumers to adjust their energy usage to improve system efficiency. This can include reducing overall consumption, shifting energy use to off-peak times, or using more efficient equipment. DSM helps balance demand with supply, reducing the need for additional generation capacity and lowering peak demand. By optimizing energy use, it also minimizes system losses, reduces strain on infrastructure and lowers operational costs. DSM improves grid stability, reduces emissions and lowers consumer energy costs, playing a crucial role in enhancing the overall efficiency and sustainability of the energy system.

In what ways can we optimize the efficiency of electrical motors in industrial applications?

Hanson: The first and easiest way to optimize the efficiency of electrical motors in industrial applications is to ensure they only run when needed. Additional controls can monitor motors and shut them down motors when they’re not needed. Utilizing variable frequency drives (VFDs) can adjust motor speed based on demand, reducing energy consumption.

Regular maintenance, such as cleaning and lubrication, ensures smooth operation and reduces friction losses. Use high-efficiency motors with better insulation and cooling designs to minimize energy waste.

Additionally, optimize motor control systems and improve load management by avoiding motor overloading. Finally, ensure proper alignment and balance of motor-driven equipment to reduce mechanical losses and enhance overall motor performance.

Ward: Using intelligent motor control with modern devices, such as electronic overloads, soft starters and VFDs, provides operational and situational data that can deliver real-time motor conditions and therefore encourage efficiencies and awareness of anomalies.

How can predictive maintenance and advanced monitoring systems enhance the efficiency of power systems?

Hanson: Advanced monitoring systems, like steam trap and compressed air leak monitoring, enhance power system efficiency by detecting inefficiencies and enabling timely maintenance. Steam trap monitoring identifies failed traps, preventing steam loss and optimizing heat recovery. Compressed air leak monitoring detects leaks that waste energy, ensuring the system operates at peak efficiency. These systems provide real-time data, allowing for proactive repairs and minimizing energy waste. By improving system reliability, reducing energy consumption and lowering operational costs, advanced monitoring systems help maintain optimal performance, extend equipment life and contribute to overall energy efficiency in power systems.

Ward: This trend uses intelligent devices to enhance operations. It is much more cost-effective and efficient to plan and manage asset outages, making sure the right parts and resources are available for maintenance activities, rather than responding reactively to unexpected downtime events.

What are the current trends or emerging technologies that hold promise for significantly increasing electrical system efficiency?

Ward: Using artificial intelligence in decision-making processes provides owners and operators with valuable insights into plant and equipment operation. This leads to better management of profits and costs, as well as enhanced efficiency and, in many instances, extending an asset’s operating lifecycle.

Hanson: Emerging technologies like artificial intelligence (AI), machine learning and advanced system controls are poised to significantly boost electrical system efficiency. AI-powered monitoring systems can analyze vast amounts of real-time data to predict and optimize energy consumption, identify inefficiencies and enhance decision-making. Smart grids enable dynamic load balancing, demand response and integration of renewable energy sources, improving system flexibility. IoT-based sensors offer continuous performance insights, while automation and predictive maintenance reduce downtime and optimize asset management. These technologies enhance grid stability, reduce losses and improve operational efficiency, leading to a more sustainable, cost-effective and responsive electrical system. At Werner Electric, we are showing our customers how these technologies work in our Innovation Center and implementing cutting edge solutions such as these with our industrial customers.

Do you have experience and expertise with the topics mentioned in this content? You should consider contributing to our WTWH Media editorial team and getting the recognition you and your company deserve. Click here to start this process.