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The client is a prominent player in the manufacturing industry, specializing in the production of high-tech electronic components. Located in an industrial zone known for its dense concentration of precision manufacturing facilities, the client’s operations are integral to the electronic manufacturing sector of the region.
PROBLEM STATEMENT
The client was encountering persistent issues with power quality, which were significantly affecting their production line. Key challenges included voltage fluctuations, harmonics, transients, and interruptions, primarily due to the extensive use of advanced electrical and electronic equipment and automation systems. These power disturbances were not only disrupting production but also leading to equipment damage, increased maintenance costs, and reduced profitability.
SOLUTION PROVIDED BY 3PHTECH
Three Phase Techno Solutions was engaged to conduct an exhaustive Power Quality (PQ) Analysis. The solution included:
1. Assessment and Setup:
Determination of critical measurement points at the facility’s Point of Common Coupling (PCC) based on the Single Line Diagram (SLD), followed by the installation and calibration of current and voltage probes.
2. Monitoring and Data Collection:
Continuous recording of voltage and current waveforms over a 24-hour period, focusing on capturing data related to harmonics, flicker, unbalance, transients, and frequency variations.
3. Analysis and Implementation:
Detailed analysis of the collected data against IEEE 519-2014 and EN50160 standards. Based on the findings, custom solutions such as harmonic filtering and strategic equipment upgrades were implemented to stabilize power quality.
CLIENT BENEFITS
The solutions provided by Three Phase Techno Solutions led to substantial improvements in the manufacturing facility’s operational efficiency and system reliability:
Increased Equipment Longevity
Enhanced power quality significantly reduced maintenance frequency and extended the lifespan of sensitive manufacturing equipment.
Operational Efficiency
The more consistent power supply minimized production interruptions, thereby increasing output quality and reducing process variability.
Cost Efficiency
The overall energy consumption was reduced, and the occurrence of equipment failures decreased, leading to significant cost savings in operational expenses.
CONCLUSION
This engagement highlights the critical importance of targeted power quality management in maintaining competitive and sustainable manufacturing operations. Through its strategic interventions, Three Phase Techno Solutions not only resolved the client’s immediate power quality issues but also bolstered the long-term sustainability and competitiveness of their manufacturing processes.
