Power analytics increases resilience, reduces costs

As organizations become more reliant on electrical power – and the cost of downtime becomes more menacing to their bottom lines – they are scrambling to find ways to maximize resilience and minimize energy costs.

07/15/2008


As organizations become more reliant on electrical power %%MDASSML%% and the cost of downtime becomes more menacing to their bottom lines %%MDASSML%% they are scrambling to find ways to maximize resilience and minimize energy costs. But these factors are working against them:

  • The national power systems infrastructure is overtaxed

  • Internal power systems designs are not well-documented

  • New equipment tends to be designed for output instead of energy efficiency

  • Utility costs are going through the roof.

    • Recently, a technology called “power analytics” has been helping organizations to optimally design, diagnose and manage their power infrastructure. The technology protects operations, increases energy efficiency and predicts when and where power system anomalies could occur in real time.

      Power analytics defined

      Power analytics is similar to “business analytics,” which is the technology that provides statistical analysis of credit scores. As the credit score relies on real-time measurements such as income, outstanding debt and payment history to reflect personal financial health, power analytics determines the operational health of a facility’s electrical power infrastructure based on the answers to questions that include:

      • How stable is my power infrastructure?

      • How much gross capacity do I have?

      • How much is my capacity loaded?

      • Historically, is my infrastructure reliable?

      • Why have we experienced overvoltage and undervoltage problems the past 30 minutes?

      • How would my power systems integrity be affected if I lost utility power?

      • How does the installation of new equipment impact system integrity?

      • How much capacity would I gain if I modernized my facility?

        • How this technology works

          When an electrical power system is designed, it is routinely created by a power systems engineer using modeling programs. Available from a number of specialized CAD vendors, these programs allow engineers to not only design complex electrical power systems, but to simulate how they will perform in live operation. They can simulate and help resolve issues such as arc flash, power flow, power quality, protective device coordination and dozens of other power considerations. This process enables engineers to produce a model that is “perfect on paper.”

          Once the design is completed and accepted, electrical system engineers have a decision to make. Historically, the CAD model is printed out as an electrical one-line diagram and “thrown over the wall” to a construction firm who, at the completion of the project, archives the drawings. But with power analytics, the CAD model remains in electronic form and is redeployed in an on-line mode. As a result, all of the components and their specifications “go live,” to provide a benchmark for how the system should be performing an its ideal state, and what variations may exist between the “ideal” and “actual” states.

          Impact on energy management, costs

          How can the information divulged by a power analytics system help organizations lower their energy costs? If you are trying to increase the energy efficiency of a plant, the power analytics system will tell you how efficiently each piece of equipment is performing, what can be done to optimize its performance and how to accomplish needed modifications without taking the entire system offline.

          Once a facility is optimized for energy efficiency, power analytics can report accurate, real-time energy usage. These data can be compared to the “as-designed” energy usage to give insight into system unbalances, capacity restraints or overloads. The results of virtualization and other energy efficiency measures can be followed and assimilated. The system can then suggest scenarios for improved energy use based on its predictive diagnostics ability and by “what-if” simulation. At the current energy costs (based on $0.089/kWh), a nominal realized annual savings of 10% for even a relatively small facility is significant: greater than $100,000.


          Author Information
          Mark A. Ascolese is chairman and CEO of


          The benefits of power analytics

          Benefits of a power analytics system include:

          The design model codifies an immense amount of very detailed information about the power infrastructure at a component-level, which contributes to a global view of the entire interrelated power ecosystem

          Variations anywhere in the infrastructure are instantaneously isolated and assessed for the “ripple effect” they theoretically pose to the entire system, and potential threats and their resolution are immediately calculated and presented

           



Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
June 2018
2018 Lubrication Guide, Motor and maintenance management, Control system migration
May 2018
Electrical standards, robots and Lean manufacturing, and how an aluminum packaging plant is helping community growth.
April 2018
2017 Product of the Year winners, retrofitting a press, IMTS and Hannover Messe preview, natural refrigerants, testing steam traps
June 2018
Machine learning, produced water benefits, programming cavity pumps
April 2018
ROVs, rigs, and the real time; wellsite valve manifolds; AI on a chip; analytics use for pipelines
February 2018
Focus on power systems, process safety, electrical and power systems, edge computing in the oil & gas industry
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
April 2018
Implementing a DCS, stepper motors, intelligent motion control, remote monitoring of irrigation systems
February 2018
Setting internal automation standards

Annual Salary Survey

After two years of economic concerns, manufacturing leaders once again have homed in on the single biggest issue facing their operations:

It's the workers—or more specifically, the lack of workers.

The 2017 Plant Engineering Salary Survey looks at not just what plant managers make, but what they think. As they look across their plants today, plant managers say they don’t have the operational depth to take on the new technologies and new challenges of global manufacturing.

Read more: 2017 Salary Survey

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Electrical Safety Update
This digital report explains how plant engineers need to take greater care when it comes to electrical safety incidents on the plant floor.
Maintenance & Safety
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me