TACKLING POWER QUALITY PROBLEMS IN PLASTICS PROCESSING

Posted by messungelectricalengineering on December 3rd, 2021

Imagine this scenario: Operations at a plastics processing plant are on in full swing. Suddenly, there is a power or motor failure during the plastic formulation process. The plastic, in a molten state, quits flowing and instantly solidifies in the pipes. A large amount of costly material is lost, not to mention the manpower needed to disassemble and clear the pipes of the hardened plastic. Let’s not forget the time lost from production while the plant shuts down for cleaning.

The plastics processing industry utilises varied machines and processes for transforming plastic granulates, powders and liquids into a wide range of diverse products. The primary processing methods include injection moulding, blow moulding, extrusion as well as compression and injection moulding. Other processes are rotational moulding, thermoforming, calendaring, coating, casting, cutting, welding, etc.

Undetected and un-solved power quality problems cost the plastic processing industry thousands of rupees each year in preventable equipment failure, unplanned downtime and prohibitive energy costs.

Let’s understand power quality a little better.

What is good power quality?

Good power quality would be one that\'s always available, always within voltage and frequency tolerances, and has a pure sinusoidal wave shape.

Voltage disturbances occur frequently in the grid, as well as on-site. As on-site machinery becomes more sophisticated thanks to the widespread use of microprocessors, the ramifications of poor power quality have grown substantially. For some devices, even a momentary disturbance can cause scrambled data, interrupted communications, system crashes and equipment failure.

Harmonics too are becoming omnipresent, due to the prevalence of power electronics in computer power supplies, energy saving lamps and motor driven systems with variable speed control.

Poor power quality can dramatically increase the cost of doing business, either through investing in solutions for mitigation, or through adaptation to poor power quality.

Such problems in power quality result in

- premature equipment failure

- transformer failure

- additional heat losses in transformers, cables, motors

- derating of equipment, resulting in need for frequent replacement of equipment

What are the symptoms of poor power quality?

Motor burnout and downtime: The windings inside an inductive motor degrade over time, caused by poor power quality. The winding insulation burns off and eventually causes shorts, reducing motor output and increasing internal heat until it fails.

Controls/Displays, memory loss and downtime: PLCs and microprocessors control mostly used in plastics production equipment, and are extremely sensitive to power fluctuations. Power variations lead to excessive current and heat, or program loss.

Power factor problems and high penalties: VFDs may lower power consumption but they often result in poor power utilisation which attracts penalties on your utility bill.

Transformer failure and downtime: Transformer internals decay over time and fail due to power fluctuations.

MONITOR, ANALYSE & CONTROL POWER QUALITY WITH UMG 512-PRO

Trust Janitza’s UMG 512-PRO fixed Class A power quality analyzers for reliable power quality monitoring & analysis in accordance with current standards, e.g. EN 50160, IEEE 519-2014, EN 61000-4-30.

Using Janitza PQA UMG 512-PRO, enterprises in the plastics processing industry can identify voltage and other Power Quality issues such as Harmonics, Transients, Flicker, etc. at the main incomer, so as to address problems in real time.

Janitza\'s UMG 512-PROhelps businesses to fulfil mandatory requirements while they maintain supply stability, ensure power quality, minimise downtime of critical assets, and reduce costs.

Main Features of UMG 512-PRO

  • Class A
  • Power quality
  • Residual Current Monitoring (RCM)
  • Measuring devices homepage
  • Ethernet-Modbus-Gateway
  • BACnet

Applications of UMG 512-PRO

  • Continuous monitoring of the power quality
  • Harmonics analysis with power quality problems
  • Checking the internal supply network according to EN 61000-4-7, EN 61000-4-15, IEC 61000-4-30
  • Fault analysis in case of problems with the energy supply
  • Documentation of the power quality for customers and regulatory authorities
  • Ethernet Gateway for subordinate measurement points
  • Report generator for power quality standards: EN 50160, IEEE 519, EN 61000-2-4
  • Report generator for energy consumptions
  • Energy Dashboard
  • Remote monitoring of critical processes

CONCLUSION

In a plastics processing facility, poor power quality can cause transformers to fail, motors to burn out, controls to suffer memory loss. Due to impure power, the most common and regular problems are IGBT card burn out, and main switch MCB burn out, besides welding errors, cable burning, heating.

Janitza’s UMG 512-PRO can enable reliable plant operation, reduced maintenance costs, longer life of electrical/electronic equipment, energy savings and higher productivity. It also helps your facility achieve compliance with IEEE 519- 2014, IEC 61000-4-30 or any other power quality standards and recommendations.

In India, Janitza\'s advanced energy management products and solutions are brought to you by Messung. For modern energy data management (e.g. ISO 50001), power qualityand residual current monitoring; for power quality analyzers, power quality meters, digital energy meters, software and apps – contact Messung.

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messungelectricalengineering
Joined: February 27th, 2021
Articles Posted: 15

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