Increase production efficiency, increase voltage and improve power quality

An ethanol plant recently faced significant challenges with low and fluctuating voltage, which led to frequent failures of sensitive electronic equipment, such as PLCs, computers, and smart sensors. These issues caused substantial economic losses due to equipment downtime and production disruptions. To resolve this problem, the plant turned to Strong Power for a solution.

Problem Analysis:

Under the expert guidance of Strong Power, the plant conducted a comprehensive power quality analysis using a power quality analyzer with continuous waveform recording capabilities and PQSCADA power management software. This analysis helped to identify the root causes of the power quality issues, allowing Strong Power to propose a tailored solution.

Proposed Solution: Real-Time Reactive Power Compensation

After analyzing the power quality data, we recommended the installation of a Static VAR Generator (SVG). The SVG is a high-performance, real-time power quality solution that leverages power electronics technology to:

– Compensate for reactive power

– Eliminate voltage drops

– Filter harmonics

– Reduce voltage flicker and fluctuations (less than 1 cycle)

This solution is designed to stabilize the voltage and improve the overall efficiency of the plant’s electrical system.

Results:

The installation of the SVG led to the following improvements:

Voltage Stabilization: The SVG increased and stabilized the voltage to a normal level, addressing the fluctuations and ensuring reliable power supply.

Reactive Power Compensation: The system met the plant’s reactive power requirements, improving overall power quality.

Reduced Demand on the Power Grid: The SVG reduced the reactive power demand by approximately 400 kVA, eliminating the need to upgrade the upstream transformer or increase the total kVA capacity.

Power Factor Improvement: The power factor improved significantly from **0.71 to 0.99**, leading to reduced energy costs and eliminating electricity fines.

Increased Equipment Reliability: The SVG effectively prevented the frequent failures of sensitive electronic loads, ensuring smooth operation and reducing maintenance costs.

Conclusion:

The installation of the SVG not only resolved the voltage instability and reactive power issues but also enhanced the overall efficiency of the factory’s electrical system. This solution minimized energy losses, lowered operational costs, and significantly improved the reliability of sensitive electronic equipment, thereby preventing costly downtimes and enhancing production efficiency.