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The Power to Manage Your Power

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Topics:
  • Reliability News - Streamlined Reliability Centered Maintenance
  • TechKnowledgy - The Latest in Data Acquisition and Sampling Techniques
  • Case Study - Blurry X-Rays
  • PQ Tip of the Month - Cap Switching Transients
  • PQ Waveform Analysis - Voltage Unbalance
  • Promotion of the Month - Vote for Dranetz-BMI as Product of the Year

    Reliability News - Streamlined Reliability Centered Maintenance

    A recent article in Plant Services magazine brings the topic of predictive maintenance back to the forefront of best industrial practices. The article talks about how years of cost- and staff-cutting, as well as attrition have taken their toll on system reliability. It further discusses the hierarchy of maintenance problems (see figure below) and the drive toward Streamlined Reliability Centered Maintenance.


    A definitive hierarchy of progressively more efficient maintenance practices has been established over time.

    Reliability centered maintenance (RCM) is the maintenance approach used when following a process that assesses equipment condition and determines the maintenance requirements of any physical asset in its operating context.

    Basically, the RCM methodology addresses key issues not dealt with by other maintenance programs. This approach recognizes that all equipment in a facility is not of equal importance - to either the process or to facility needs and safety. A reliability-focused approach will mean structuring a maintenance program based upon the understanding of equipment needs and priorities, as well as limited financial and personnel resources, to plan activities such that equipment maintenance is prioritized while operations are optimized.

    The following maintenance program breakdowns of continually top-performing facilities echo the RCM approach, which utilizes all available maintenance tactics. As is shown, all maintenance approaches are used, but the predominant strategy used is predictive.




    In developing a streamlined RCM program for your facility, understanding the importance of reliable power quality and its impact on key equipment is crucial.

    Power monitoring provides a continual health check-up for a facility's power system, giving data center managers the ability to see, diagnose and avert looming problems. It is a key component of an effective SCRM. Much like the squeaky brakes on your car, there are leading indicators of impending problems that can be seen through these systems. Or like the black box on an airplane, the data from a power monitoring system will tell you what, when and where the event occurred, to prevent it from recurring. Among the benefits:

    • A continuous evaluation of the electric supply system to first benchmark, and then identify disturbances and power quality variations that could cause disruption of data center operations or impact the operation of power conditioning equipment. This information is invaluable to proper sizing and testing of that equipment.
    • The monitoring of power quality characteristics of computers, servers and other key equipment within the facility. Important examples can include harmonic interactions between loads and power conditioning equipment, inrush characteristics for loads that can impact backup generator operations, transients associated with switching events within the facility, and many others.
    • For proactive management, the continuous capture of all events enable users to establish trend lines and algorithms to maintain real time illustrations of infrastructure performance and improve reliability, while automated alerting sends alarms to power managers before problems occur.
    • Identifying pattern changes and trends allow for "just-in-time" maintenance programs, as well as the planning for new capital investment-to decide from a power reliability and energy cost perspective where and how to add new computers, chillers or other equipment.

    TechKnowledgy - The Latest in Data Acquisition and Sampling Techniques

    The Dranetz-BMI PowerGuide 4400 and PowerXplorer PX5 are the first in a new class of instruments that fully comply with the latest international and US standards on power quality, as listed below:
    • IEC61000-4-30 Class A, Electromagnetic Compatibility (Emc) Part 4-30: Testing And Measurement Techniques - Power Quality Measurement Methods
    • IEC61000-4-7 Second Edition Class I, Basic Standard On Harmonics And Interharmonics Measurements And Instrumentation, For Power Supply Systems And Equipment Connected Thereto
    • IEC61000-4-15, Flickermeter - Functional and design specifications
    • EN50160, Voltage Characteristics Of Electricity Supplied By Public Distribution Systems
    • IEEE1159, Guide for Recorder and Data Acquisition Requirements for Characterization of Power Quality Events
    • IEEE1453, Recommended Practice for Measurement and Limits of Voltage Flicker on AC Power Systems
    • IEEE519, IEEE Standard Practices and Requirements for Harmonic Control in Electrical Power Systems
    • IEEE1459, Trial-Use Standard for the Measurement of Electric Power Quantities Under Sinusoidal, Nonsinusoidal, Balanced, or Unbalanced Conditions (PX5 only).

    PQ disturbances can affect the power line waveform in different ways. Therefore, different events may require different triggering mechanisms. The most common method of triggering, RMS sampling will not capture every type of disturbance even if the sampling rate is greatly increased. As a result, Dranetz-BMI has developed advanced methods to capture the various types of events.

    RMS Triggers
    RMS measurements are made over one AC cycle. In accordance with IEC standards RMS measurements are over once cycle but incremented in ½ cycle steps. The IEC standards refer to this as Urms(1/2). It's important to note that the measurement window for PQ triggers is still always 1 cycle but the ½ cycle increment allows for more detailed event detection. Any one cycle exceeding the instruments limits will trigger an RMS event, regardless if it's detected on a ½ cycle boundary.




    If a trigger occurs data is stored to memory in accordance with the RMS Summary and Waveform (# of cycles recorded) settings entered during setup. This tells the instrument how many cycles of data to record if an event occurs. In addition to PQ triggers the Urms(1/2) data is used as the basis for all voltage and current min, max and average measurements which therefore have a 1 cycle resolution with ½ cycle steps.

    Transient Triggers

  • Instantaneous Peak (Low/Medium Frequency): This trigger uses the RMS sampled data and looks for any one of the 256 samples to exceed the Instantaneous Peak limit. If at least one sample exceeds the limit data is recorded to memory based upon the users pre/post waveform settings. Applications for this trigger are events such as peak over voltage (or current), lightning strikes, etc…




  • Waveshape Triggers (Low/Medium Frequency):
    Waveshape triggers look for changes in the waveform on a cycle by cycle basis. These are important triggers as many types of transients do not affect the waveform enough to change the RMS significantly. Therefore, traditional RMS triggers will not detect these events. There are two waveform trigger methods available; cycle to cycle waveshape and RMS distortion (or difference) waveshape. If the difference exceeds the user's limits an event is recorded.
  • Cycle to cycle Waveshape:
    This method breaks down the present AC waveform being measured into user-defined windows of time (shown below in the circle) that represent a percentage of the overall waveform. Each window is compared to the same window of time in the previous waveform and if the difference exceeds the user's limits an event is recorded. In the picture below the duration (width of the window) is 10% (1.67ms), which means the waveform is broken down into 10 consecutive windows with each representing 10% of the overall waveform. If the duration were 50% the waveform would be broken down into 2 windows with each representing 50% (8.3ms) of the overall waveform.




  • RMS distortion (or difference) waveshape:
    This method computes a (sample) point by point subtraction of the previous waveform from the present waveform. If the waveforms are the same the difference will be zero, otherwise the difference will be the change in waveshape from the previous to present waveform. If the difference exceeds the customers' limits an event is recorded.




  • High Speed Transient (High Frequency):
    The Dranetz-BMI PowerXplorer PX5 adds high speed transient detection and recording circuitry. Details are described in the Digitization section above. This additional circuitry works in addition to and in parallel with the other triggering methods described above to capture high speed events that cannot be detected using transitional RMS (256 samples per cycle) triggering methods.

    The PX5 samples high-speed transients at a sampling rate of 1Mhz for voltage and 0.5Mhz for current. Both voltage and current are digitized using a 14 bit Analog to Digital (A/D) converter. Therefore, the PX5 can detect and record virtually any high- speed transient in a power system.

    High-speed (HS) transient data is stored in 80us windows with a minimum of 4 windows (320us) of data being recorded on any HS transient event. The 4 windows are comprised of 1 fault, 1 pre, and 2 post windows of data. HS triggers are detected using an energy/area under the curve method. Each 80us window is compared to the previous window for a change in area under the curve relative to the users settings. If a change exists that exceeds the thresholds the data is stored to memory. Data is continuously recorded until an 80us window goes below the threshold, or reaches a total duration of 16/20ms (60/50Hz), whichever comes first. The PX5 HS transient circuitry always works in a worst-case mode continually recording the information with data stored to memory only if thresholds are exceeded.





    Case Study - Blurry X-Rays

    This hospital has an older X-ray system that has a motor driven autotransformer to provide power to produce the high voltage (typically 100 kV) needed by the tube. The hospital facility engineer wanted to correct any voltage deviation, whether it is line or load induced because he is contemplating adding additional load to the circuit that feeds the X-ray system. We were brought in to determine the kind of voltage regulator that the facility engineer should buy?

    A power quality analyzer was used to characterize the operation of the X-ray machine. Figure 1 shows the voltage sag that occurs during exposure due to the large amount of current needed. Figure 2 illustrates the short (100 msec) high magnitude (170 amps) current requirement that is needed for a radiographic exposure. The voltage sag does not affect the X-ray machine, but it could effect the proposed equipment to be added to the circuit.


    Figure 1: Voltage sag caused by X-ray machine operation




    Figure 2: Radiographic exposure current requirements

    An electronic tap switching voltage regulator was brought in to regulate the voltage to the X-ray machine. The regulator has a plus/minus 3% voltage regulation, and as seen by the previous measurements, the X-ray machine can easily cause a 5-10% drop in voltage. Therefore switching of taps during and exposure is likely. Figure 3 illustrates the performance of the regulator.

    Approximately one cycle into the exposure the regulator corrects the voltage back to normal. In addition, after the end of the exposure, there is a slight voltage rise followed by regulator compensation one cycle later. The consequence of the voltage compensation is an unpredictable, blurry X-ray exposure.


    Figure 3 - Regulator Output Voltage during Exposure

    A magnetic power synthesizer was brought in next to regulate X-ray machine voltage. The magnetic synthesizer is an electromagnetic device that takes incoming power and regenerates a clean, three- phase ac output waveform, regardless of input power quality. A block diagram of the process is shown in Figure 4.


    Figure 4 - Block Diagram of Magnetic Synthesizer

    The synthesizer doesn't regulate voltage in steps, but it does ring for up to 100 msec when a large step load is applied as shown in Figure 5. Because the X-ray exposure takes only 100 msec, the output voltage is unstable throughout exposure, causing blurry X-rays. Unfortunately, older X-ray systems expect to see a voltage drop and can't compensate for fast voltage changes during exposure. In this case it is better to leave the X-ray machine alone on its own dedicated circuit and feed the proposed loads with a different circuit.


    Figure 5 - Power Synthesizer Output during Exposure


    PQ Tip of the Month - Cap Switching Transients

    Transients are very short duration disturbances, less than ¼ cycle of power frequency and more often, measured in microseconds. The most prevalent of these is the PF cap switching transient. These capacitors are used to correct for the power factor shift caused by large inductive loads, such as motors, that typically come on line each morning as businesses start up. An uncharged capacitor will absorb a large amount of energy in a very short time, producing a negative impulsive transient. Since the feeder wires are mostly inductive and resistive, this suddenly-added capacitance causes a brief resonant period, so the negative transient is followed by a oscillatory or ringing transient with a frequency typically between 400 and 2000 Hz, lasting less than ¼ cycle. The positive peak that immediately follows the initial negative peak can have a magnitude double the normal peak voltage. This type of transient can confuse overcurrent protection circuits in some equipment, and cause them to trip off line.





    PQ Waveform Analysis - Voltage Unbalance

    Voltage unbalance is a steady-state quantity defined as the maximum deviation from the average of the three phase voltages or currents, divided by the average of the three phase voltages or currents, expressed in percent. Unbalance can also be quantified using symmetrical components. The ratio of the negative sequence (or zero sequence) component to the positive sequence component is used to specify the percent unbalance. The negative sequence (or zero sequence) voltages in a power system generally result from unbalanced loads causing negative sequence (or zero sequence) currents to flow. Unbalance can be characterized by a trend of the unbalance magnitude in percent vs. time or can be summarized using statistics of the unbalance magnitude over some period.

    The primary source of voltage unbalance less than two percent is unbalanced single-phase loads on a three-phase circuit. Voltage unbalance can also be the result of capacitor bank anomalies, such as a blown fuse on one phase of a three-phase bank. Severe voltage unbalance (greater than 5%) can result from single-phasing conditions. Voltage unbalance is most important for three phase motor loads. ANSI Std. C84.1-1989 recommends that the maximum voltage unbalance measured at the service entrance under no load conditions should be 3%. Unbalance greater than this can result in significant motor heating & failure if there are not unbalance protection circuits to protect the motor


    The above waveform, measured using a Signature System 5530 DataNodẻ shows a trend of the the voltage unbalance on a 12kV feeder during a three month period.


    Promotion of the Month - Vote for Dranetz-BMI as Product of the Year

    We're pleased to announce that the PowerXplorer PX5 has been selected as a finalist in the Plant Engineering Product of the Year contest. The reasons for this selection are many, so we'll just highlight a few:

    • It's the only 3-phase, 8 channel instrument with an intuitive color touch screen, "super smart" setups and an annunciator report card that instantly characterizes power quality events into color-coded categories so that you can immediately take action on items of concern.
    • The unique measurement capabilities of the PowerXplorer include capture of low-medium-high frequency transients (sub-microsecond) through peak, waveshape, rms duration and adaptive high-speed sampling, as well as power measurements to clearly characterize non-sinusoidal and unbalanced systems.
    • It collects data at 256 samples/cycle/channel for both voltage and current; AC and DC, and complies with IEEE 1159, EN50160 and IEC 61000-4-30 Class A standards.
    Help Dranetz-BMI win by entering the contest at
    www.plantengineering.com (you need to be a subscriber). Thanks







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