Industrial Clean Power

What Happens When a Manufacturing Facility Loses Power?

Tue, 08 Jul 2025 12:47:11 GMT

In highly automated manufacturing environments, maintaining continuous, reliable power is mission-critical. Yet, despite best efforts, power loss events are common and can have far-reaching consequences. Understanding what causes manufacturing power loss and how to protect against it is essential for minimizing operational disruptions and financial impacts.

What Causes Power Loss in Manufacturing Facilities

Manufacturing facilities are vulnerable to power loss for a variety of reasons, many of which are beyond the control of plant managers. Common causes include:

Severe Weather: Storms and lightning strikes can damage utility infrastructure, leading to sudden outages.
Grid Instability: High demand, aging infrastructure, and unexpected faults can disrupt power flow from the utility provider.
Internal Equipment Failures: Faulty machinery, overloaded circuits, or electrical malfunctions can cause localized outages.
Voltage Fluctuations: Voltage sags, surges, and other irregularities can destabilize operations even if full power loss doesn’t occur.

While external threats are difficult to prevent, power quality inside the facility can (and should) be proactively managed.

Consequences of Power Failures

How to Plan Ahead for Power Failures

While no facility can completely eliminate the risk of power loss , proactive strategies can dramatically reduce the impact on operations.

Industrial UPS Systems and Voltage Regulators

Industrial Uninterruptible Power Supply (UPS) Systems provide immediate backup power, keeping critical operations running or allowing for controlled shutdowns in the event of an outage. This helps prevent data loss, equipment damage, and unsafe shutdown scenarios.

Complementing UPS systems, Active Voltage Regulators (AVR) and Active Voltage Conditioners (AVC) stabilize incoming power, correcting voltage sags and surges in real time. These systems protect sensitive manufacturing equipment by ensuring that even when utility power is unstable, your facility’s electrical supply remains consistent and clean.

Together, these solutions create a layered defense that minimizes downtime, protects equipment, and safeguards personnel.

Choose Voltage Correction for Industrial UPS & Voltage Regulators

At Voltage Correction, we specialize in protecting manufacturing facilities against the risks associated with power instability. We offer industrial-grade UPS systems and active voltage regulators designed to maintain power quality and operational continuity in even the most demanding environments.

If you're ready to strengthen your facility’s resilience against power loss, contact Voltage Correction today to schedule a consultation or request a quote. Let us help you stay online, protected, and productive.

Summer Power Spikes: How Voltage Correction Protects Industrial HVAC Systems

Mon, 07 Jul 2025 21:33:54 GMT

What is a Power Spike?

A power spike is a sudden, sharp increase in voltage that typically exceeds the nominal voltage level by 10% or more. Unlike brief surges that affect residential appliances, power spikes can deeply destabilize sensitive industrial systems . Industrial HVAC systems, which rely on finely tuned controls, motors, and variable frequency drives (VFDs), are particularly vulnerable.

In industrial environments, power quality issues extend beyond transient surge events. Power spikes, sags, and fluctuations can cause cumulative damage over time, threatening the integrity and reliability of critical HVAC infrastructure. Recognizing and mitigating these issues is vital for maintaining operational continuity. Addressing these challenges proactively ensures that HVAC systems remain resilient, reducing operational risks and extending the lifespan of expensive assets.

Common Causes of Summer Power Spikes

During the summer months, several factors converge to make power spikes more frequent and damaging:

Utility Grid Instability: High demand from air conditioning systems and industrial cooling operations strains the grid, causing voltage fluctuations and instability. When demand outpaces supply, voltage irregularities spike, often without warning.
Weather-Related Disturbances: Lightning strikes and storm-induced faults can send sudden voltage surges through the grid, affecting industrial facilities. Summer thunderstorms, which are more frequent in many regions, amplify this risk.
Internal Facility Causes: The start-up of large equipment or sudden load shifts within a facility can create localized power spikes. Industrial facilities with heavy machinery must be particularly cautious, as these internal shifts can interact with external grid instability.

Industrial HVAC systems in manufacturing plants, data centers, and healthcare facilities are particularly susceptible. These systems operate continuously and draw significant loads, making them sensitive to even minor voltage anomalies. Given their constant operation, these HVAC systems have little tolerance for inconsistency in power quality, necessitating robust protection strategies.

Risks of Power Spikes on Industrial HVAC Systems

Power spikes pose serious threats to the longevity and reliability of industrial HVAC systems:

Electrical Stress: HVAC compressors, control boards, and VFDs experience immense electrical stress during spikes, leading to premature aging. Repeated incidents cause thermal stress and component fatigue, hastening end-of-life scenarios.
Component Failure: Motors and controllers can suffer from insulation breakdown, overheating, and ultimately, failure. Components subject to electrical overstress may show no immediate signs of malfunction but deteriorate internally, resulting in unexpected breakdowns.
Downtime Risks: Equipment malfunctions can halt critical cooling operations, causing facility-wide disruptions and productivity losses. For industries reliant on temperature control, such as pharmaceuticals and food processing, even brief interruptions can result in compliance issues and product spoilage.

It's important to note that the damage from power spikes isn't always immediately visible. Repeated exposure can gradually weaken HVAC components, leading to expensive repairs and increased maintenance cycles. Over time, this "invisible wear" significantly erodes system reliability and inflates operational costs.

How to Protect HVAC Systems from Power Spikes

Active Voltage Regulation (AVR) Systems

Active Voltage Regulation (AVR) systems are engineered to maintain consistent voltage outputs , even when incoming power is unstable. By stabilizing the voltage, AVRs protect delicate electronic components within HVAC systems, ensuring that control boards and VFDs operate within safe electrical parameters.

Beyond mere stabilization, AVRs are capable of dynamically adjusting to small fluctuations, ensuring that voltage levels stay within optimal operational ranges. This constant balancing act extends the life of critical HVAC system components and reduces instances of unexpected downtime.

Active Voltage Correction (AVC) Systems

For industrial applications, Active Voltage Correction (AVC) systems provide an even more robust solution. AVC systems are designed to handle the dynamic demands of industrial loads, correcting voltage anomalies in real-time. They adapt instantly to grid fluctuations, safeguarding HVAC infrastructure from both spikes and sags.

AVC systems offer an advanced layer of protection by monitoring incoming voltage hundreds of times per second, making micro-adjustments to keep voltage within a tight tolerance band. This real-time correction is especially crucial for industrial HVAC systems, which are sensitive not just to large disturbances but also to minor variations that can cause long-term harm.

Facility Power Studies

Before implementing a correction solution, it’s crucial to understand the specific vulnerabilities of your facility. A Power Study identifies weak points in your electrical system, enabling tailored recommendations. This proactive approach ensures that voltage correction solutions are precisely matched to the needs of your HVAC systems.

Facility power studies analyze load profiles, historical disturbance data, and specific stress points in the system. These insights allow for custom-designed correction strategies that not only prevent damage but also optimize energy efficiency, offering long-term operational savings

Why Surge Protectors Aren't Enough

While basic surge protectors or whole-building suppressors provide minimal defense against transients, they are insufficient for industrial-grade threats. Industrial HVAC systems require sophisticated voltage correction technology to combat the more complex and persistent power quality issues experienced in high-load environments.

Surge protectors primarily guard against very short, high-voltage events, missing the more insidious low-voltage sags and intermediate spikes that cumulatively degrade HVAC system components. Only high-performance AVR and AVC systems are capable of delivering the comprehensive protection industrial environments demand.

Steps to Take After Experiencing Power Quality Issues

If your facility has experienced power quality disturbances, swift action is essential:

Conduct a Power Quality Assessment: Diagnose hidden stresses and detect signs of degradation before catastrophic failures occur. Using advanced diagnostic tools, Voltage Correction can uncover subtle power quality issues invisible to standard monitoring systems.
Partner with Voltage Correction: Our team specializes in power metering, load analysis, and the development of customized correction plans to protect critical infrastructure. We understand that every facility is unique and offer solutions engineered specifically to match your operational profile.
Proactive Maintenance: Continuous monitoring and maintenance of your power quality ensures that your HVAC systems remain efficient, extending equipment life and minimizing costly downtime. Periodic audits and recalibrations ensure that protection systems stay optimized as facility demands evolve.

Why Choose Voltage Correction?

Voltage Correction is a full-service provider offering end-to-end solutions for industrial power quality challenges. From initial consultation and power studies to system design, installation, and post-installation support, we deliver comprehensive protection for critical HVAC systems.

Specializing in manufacturing, healthcare, and data center environments, our Active Voltage Regulators and Correction Systems are engineered to meet the rigorous demands of industrial operations. Our solutions are built on a foundation of technical excellence, reliability, and a deep understanding of the power quality challenges facing modern industrial facilities.

Protect your HVAC and critical systems against summer voltage instability. Schedule a power study with Voltage Correction today and ensure uninterrupted operations even during the most demanding summer months.

The Importance of Surge Protection for Commercial Buildings

Sun, 06 Jul 2025 14:00:49 GMT

What are Power Surges?

At its core, a power surge is an event that happens when a sudden, overwhelming surge of electricity travels through power lines and into a connected device. The amount of power required to run a device is fairly regulated. If the amount of supplied power were to suddenly exceed that range, significant damage can occur as a result. In some cases, a fire may even break out.

Causes of Power Surges

Power surges can be caused by an unfortunately large list of things, from issues with the wiring in a building to sudden and unpredictable lightning strikes. Power surges are even quite common in the immediate aftermath of a power outage. The power suddenly comes back on and a surge of electricity happens as a direct result.

Impact on Commercial Buildings

At a minimum, a power surge will likely result in some type of disruption to a commercial building. Even if the surge doesn't damage the building's wiring or connected devices, it will still likely take them offline until the issue can be fixed. This could result in costly (and equally unpredictable) repair costs.

There's also the chance that a fire could break out, causing even more significant damage. Oftentimes, connected devices are taken permanently offline. If they cannot be repaired, they'll need to be fully replaced, resulting in even more unexpected downtime for your commercial operations.

How Do You Prevent Power Surges?

At a certain point, you have to acknowledge the fact that power surges are not a matter of "if," but "when." You can't control the weather, so even if you were to painstakingly eliminate every other cause of a power surge, something like a lightning strike could still occur.

Of course, there are steps you can take to help avoid significant problems as much as possible. If a storm is rolling through your area, unplug any and all equipment that you can. If you see that trees are growing near power lines around your building, have them professionally trimmed to avoid a potential problem. Even installing a generator is a good idea, as this can act as a backup power source during an outage to prevent the types of surges that usually happen immediately thereafter.

Because of that, you must shift your attention towards surge protection for commercial buildings in particular. Only then will you be able to mitigate the type of risk that comes along with these types of events moving forward.

Role of Surge Protection for Commercial Buildings

Also commonly referred to as surge protection devices or "SPDs" for short, surge protectors divert any excess electricity away from your sensitive equipment. More often than not, that excess electricity goes into the ground, where it is dissipated safely and without issue.

Types of Surge Protection Systems

There are a few different types of surge protection systems that you can choose from for your commercial building. They include the following:

Whole building protection. As the name implies, this type of surge protector is designed to work in tandem with the entire electrical system in a commercial building. So not only will it protect subpanels, but also individual circuits as well.
Point-of-Use systems. This is a slightly more cost-effective solution in that it is intended to protect only specific, particularly sensitive pieces of equipment. You would connect the equipment to the surge protector, and then the surge protector to the electrical system.

Network and data line protection. Here, you're focused on protecting equipment that is connected to either an internal or external network (like the Internet), or some type of data line. This type of system gets installed at the point where the network cabling enters your commercial building.

Type 1 vs Type 2 Surge Protector

The major difference between a Type 1 and a Type 2 surge protector comes by way of the level of protection they offer. To be classified as Type 1, a surge protector must have gone through the lightning test waveform of 10/350us. To meet the requirements of Type 2, that device will need to have a lightning test waveform of 8/20us.

Choosing the Right Surge Protection Solution

Ultimately, there is no "one right way" to choose the right surge protection for commercial buildings. As always, you need to start with exactly what type of protection you need. Your choices become fairly limited at that point.

Are you worried about every last piece of equipment or other electronic device in the building? Whole building surge protection is going to be the most effective way to mitigate that risk. Are there only specific pieces of equipment that, if they were to go offline, would cause significant disruption that you can't afford? Point-of-surge protection is likely the answer.

Always start with your needs and work your way back to the surge protection system that meets them. Don't invest heavily in a system and hope that it meets your requirements.

Choose FGC as your UPS & Voltage Regulator Supplier

At FGC , we understand how important your sensitive equipment is to your continued success as a business. That's why, in addition to a wide range of voltage regulation solutions, we also offer facility asset management software and more - all so that you can rest easy knowing that your needs are being taken care of.

We've been partnering with businesses like yours since 2008. In addition to proudly serving those in the data center market, we've also partnered with organizations in industries as varied as industrial , 3D printing facilities, oil and gas, and more. We always take the time to learn about your business and its unique needs, all so that we can put together the unique solutions required to address any and all concerns that you might have.

If you'd like to find out more information about surge protection for commercial buildings , or if you have any additional questions that you'd like to go over with someone in a bit more detail, please don't delay - contact the team at FGC today .

Choosing the Right Voltage Regulator for Your Design

Thu, 03 Jul 2025 13:29:51 GMT

At its core, a voltage regulator is a device designed to maintain a consistent output voltage level to a connected system, regardless of fluctuations in the input voltage or variations in load current.

There are many reasons why voltage irregularities may occur, most of which are beyond your control. Major storms can disrupt local utility grids, and nearby construction projects can cause electrical disturbances at the worst possible moments.

Regardless, without a voltage regulator, many devices in your area would cease to function. At worst, they would require significant maintenance and might even become permanently damaged.

However, not all voltage regulators are created equal. As with any critical infrastructure component, the right approach is to start by evaluating your application’s specific needs, then select the voltage regulation solution that aligns with those requirements. Here’s what you should know.

What are the Different Types of Voltage Regulators?

Linear Voltage Regulators

Linear voltage regulators are straightforward, cost-effective options known for their low noise operation. However, they generally offer lower power efficiency and are limited to stepping down voltage from one level to another. They are often used in applications where minimal electromagnetic interference is crucial but where efficiency is a secondary concern.

Switch Voltage Regulators

Switching regulators provide higher efficiency and greater flexibility. They can step voltage up or down as needed, making them well-suited for industrial applications with varying load demands. While they do produce more electrical noise than linear regulators, their ability to manage more complex voltage requirements makes them invaluable in many high-performance environments.

Common Applications for Voltage Regulators

Voltage regulators are critical components in a wide range of industrial systems, where reliable, consistent power is non-negotiable. Key applications include:

Industrial control systems, providing stable power to sensors, control circuits, and programmable logic controllers (PLCs).
Healthcare facilities, ensuring the uninterrupted function of medical imaging equipment and other mission-critical devices.
Data centers, where voltage stability is essential to maintain server uptime and protect sensitive IT infrastructure.
Oil and gas operations, protecting complex exploration and refining equipment from damaging voltage fluctuations.
Manufacturing facilities, supporting high-precision processes such as 3D printing, robotic assembly lines, and semiconductor fabrication.
Aerospace and defense industries, where the margin for error is minimal, and system reliability is paramount.

In all these environments, voltage regulators prevent even minor power disturbances from escalating into major operational disruptions or costly equipment failures.

What to Consider When Choosing Your Voltage Regulator

Voltage Correction Has You Covered

At Voltage Correction, we specialize in solving the toughest power quality challenges facing today’s industrial and mission-critical facilities. Our active voltage regulators and correction systems are engineered to provide reliable, consistent power, protecting sensitive equipment from the damaging effects of voltage fluctuations.

We proudly support industries such as 3D printing, oil and gas, mining, healthcare, advanced manufacturing, and critical IT infrastructure. Our expertise ensures that your systems stay operational even when the power grid falters.

If you'd like to learn more about selecting the right voltage regulator for your industrial application, or if you have any specific questions about how voltage correction can safeguard your facility, contact the experts at Voltage Correction today.

Benefits of the TSI Single Phase 1.4 kVA-26.1kVA

Tue, 01 Jul 2025 13:11:45 GMT

About the TSI Single Phase Active Voltage Regulator

In any industrial or mission-critical environment, maintaining continuous, reliable operation of equipment is essential. Yet, utility voltage instability (including voltage sags, surges, and overvoltage events) remains a persistent threat. Even brief voltage anomalies can result in productivity losses, data corruption, or costly equipment damage.

The TSI Single Phase Active Voltage Regulator is engineered specifically to counter these challenges. It continuously monitors incoming utility voltage and automatically adjusts it in real-time, maintaining output within a tight ±3% tolerance. Designed for high-reliability applications, it also incorporates internal surge suppression and load overcurrent protection, making it an ideal investment for industries where power quality cannot be compromised.

TSI Systems Vs. ABB Systems

While ABB Systems are widely recognized for their capabilities in lower voltage correction scenarios, TSI Systems provide solutions tailored for facilities requiring higher precision and broader correction ranges. The TSI Single Phase Active Voltage Regulator offers robust protection against a broader spectrum of voltage anomalies, including under- and overvoltage conditions, that can disrupt operations and damage sensitive systems.

For industries operating high-value equipment such as CNC machinery, robotics, extrusion systems, and medical instrumentation, the superior voltage stabilization capabilities and industrial-grade reliability of TSI Systems make them a preferred choice for critical environments where downtime is not an option.

Why Consider a TSI Single Phase Voltage Regulator

The primary reason to consider a TSI Single Phase Active Voltage Regulator is its ability to stabilize power for sensitive plant and process equipment impacted by unstable voltage. Whether dealing with manufacturing lines, high-speed drives, or precision robotics, voltage irregularities often lead to elevated maintenance costs, PCB failures, and system malfunctions.

Deploying a voltage correction system like the TSI unit protects against these risks, ensuring not only operational continuity but also reducing long-term maintenance expenses and equipment replacement costs.

The TSI regulator is well-suited for a variety of industrial applications, including but not limited to:

CNC Machinery
Drives
Extrusion Equipment
Medical Devices

Motors and Controls
Robotics
3D Printing Systems

Even if it isn't downtime that you're trying to combat, voltage irregularities often lead to significantly higher maintenance costs. Overvoltages and surges, in particular, can cause PCB and board failures as well. Having a TSI active voltage regulator can dramatically reduce all of these problems, saving you money that can be funneled back into other areas of the business where it can do the most good.

Benefits of the TSI Single Phase Voltage Regulator

Precise Voltage Correction

One of the major advantages that comes with an investment in the TSI active voltage regulator comes down to just how precise this device is. Once the converter accurately measures the incoming voltage, it makes adjustments by either adding or subjecting (also referred to as bucking or boosting) the voltage to within +/- 0 to 3% of the output voltage range.

Operates Automatically

Once it is properly installed, the TSI active voltage regulator is notorious for being something of a "set it and forget it" device. You don't have to watch the weather to switch it on ahead of an upcoming storm. You don't have to tell it to do anything when voltage irregularities are detected. They're identified automatically, the correction happens in milliseconds, and you and your team members can keep right on working.

Quick Response Time

When used with high-speed power electronics, the TSI active voltage regulator has a response time of literally 10 milliseconds. This is the amount of time it takes to switch over from standard power to the voltage regulator and for the correction to take place. During this time, the load current path will not be broken.

Internal Surge Protection

Many people don't realize that situations where overvoltage is present and power surges are two different things, and protection against one doesn't necessarily protect against the other. Thankfully, the TSI active voltage regulator includes internal surge protection that safeguards expensive machines and other equipment (and helps reduce the risk of electrical fires and similar matters).

Noise Filtering

The type of built-in noise filtering offered by the TSI active voltage regulator isn't just one of the most common ways to reduce noise in a power supply–it's also among the most effective as well.

Wide Range of Applications

Beyond heavy manufacturing and robotics, the TSI active voltage regulator is ideal for medical laboratories, high-tech production facilities, and automated industrial systems. Its broad application range ensures all critical devices receive stable, clean power, essential for maintaining operational standards and protecting delicate electronics.

Low Maintenance

Engineered for reliability, the TSI voltage regulator has minimal moving parts, with the only active component being a cooling fan. Unlike systems with servo motors or mechanical relays, this design results in lower wear, reduced maintenance needs, and increased system uptime even in demanding industrial environments.

Get Our Expert Opinion on the Right Voltage Regulator for You

At Voltage Correction, we're proud to offer the high-quality voltage products you need to operate your business without worry. More than anything, we want to help make sure that you can spend less time worrying about your technology so that you can spend more time putting it to good use.

If you'd like to learn more about the TSI Single Phase Active Voltage Regulator or discuss a customized voltage correction strategy for your facility, c ontact Voltage Correction today . Our team is ready to assess your power quality challenges and design a solution that keeps your operations running reliably and efficiently.

Industrial Voltage Regulation: Effective Ways to Stabilize Industrial Voltage

Fri, 27 Jun 2025 20:16:44 GMT

Maintaining stable voltage is a critical component of industrial power management. Without consistent voltage, sensitive equipment is at risk of malfunction, production processes can be interrupted, and downtime can escalate operational costs dramatically. Voltage instability doesn’t just cause immediate disruptions; it shortens the lifespan of machinery and increases maintenance overhead over time.

Industrial facilities are particularly vulnerable due to the scale of their operations and the power demands they face daily. That’s why investing in industrial voltage regulation solutions is essential.

The Importance of Stable Voltage in Industrial Operations

Industrial operations rely on heavy machinery, sensitive automation systems, and complex control equipment, all of which require a steady and reliable flow of power. Even minor voltage deviations can lead to operational inefficiencies, system errors, or complete shutdowns.

Without a stable voltage, motors can overheat, PLCs can fail, and precision manufacturing equipment can lose calibration. The result? Unplanned downtime, increased maintenance costs, and lost productivity. Industrial voltage regulation ensures that power stays within tight tolerances, protecting equipment, reducing energy waste, and keeping production lines running smoothly.

Common Causes of Voltage Instability in Industrial Facilities

Voltage instability in industrial environments doesn’t happen randomly. There are several predictable factors that contribute to the issue. Understanding these root causes can help facilities identify where vulnerabilities exist and take targeted action.

Ways to Regulate Industrial Voltage

Fortunately, there are proven methods to combat voltage instability and protect your operations:

Active Voltage Regulators (AVR/AVC): These systems monitor incoming power and correct voltage sags, swells, and fluctuations in real time, ensuring consistent delivery to critical equipment.
Uninterruptible Power Supply (UPS) Systems: In addition to providing backup during outages, industrial-grade UPS units often include voltage regulation features to smooth out minor inconsistencies.
Power Conditioners: These devices filter electrical noise and correct minor voltage deviations, protecting sensitive electronic components and control systems.
Load Management Systems: Implementing automated load controls can reduce sudden spikes or drops by sequencing machinery startups and managing peak demands intelligently.

Combining these strategies creates a layered defense, ensuring voltage remains within safe operating limits no matter what external or internal factors arise.

What to Look for When Choosing Voltage Regulation Solutions

When evaluating industrial voltage regulation systems, consider the following:

Real-Time Correction Capabilities: Look for systems that monitor and adjust voltage instantly to protect against rapid fluctuations.
Scalability: Solutions should be able to grow alongside your facility’s expanding needs.
Compatibility: Ensure systems integrate seamlessly with your existing electrical infrastructure.
Rugged Design: Industrial environments demand equipment that can withstand temperature extremes, dust, vibration, and other harsh conditions.
Monitoring and Diagnostics: Remote monitoring and detailed diagnostics help detect and address issues before they escalate.
Energy Efficiency: Select solutions that improve power quality without adding significant operational costs.
After-Sales Support: Partner with providers who offer installation, commissioning, and long-term maintenance services.

Carefully weighing these factors ensures you invest in a voltage regulation solution that delivers long-term protection and value.

Choosing the Right Solution

Selecting the best voltage regulation system is not a one-size-fits-all decision. It requires a careful assessment of your facility’s load requirements, operational processes, and growth plans. For complex industrial operations, layering solutions, such as combining a UPS system with an active voltage regulator, often delivers the most comprehensive protection.

Working with an experienced partner like Voltage Correction ensures you get more than just a product; you receive a customized solution backed by industry expertise. Through detailed power studies and site assessments, we tailor systems to your facility’s unique needs, ensuring reliable, long-lasting performance.

Take Control of Voltage Stability – Schedule an On-Site Power Assessment

Voltage instability is a risk you can’t afford to ignore, but it’s also one you don’t have to face alone. Voltage Correction offers comprehensive power quality assessments to identify vulnerabilities and recommend tailored solutions to stabilize your facility’s voltage.

Our team specializes in the installation and support of industry-leading products like the ABB 100 ESS AVC and PCS UPS-1, designed to protect your operations against voltage fluctuations, outages, and power quality issues.

Take control today. Schedule a professional on-site power assessment and find out how we can help you maintain stable, reliable power. Not to mention, safeguarding your equipment, minimizing downtime, and optimizing operational efficiency.

Factors Affecting Power Quality and How to Manage Them

Fri, 27 Jun 2025 19:57:42 GMT

Poor power quality leads to equipment failures, unplanned downtime, and inflated maintenance costs. For industrial, healthcare, and technology-driven facilities, understanding the power quality factors that impact operations is essential to maintaining performance and profitability.

In this blog, we’ll dive into what power quality means, explore the most common factors that affect it, and offer practical strategies to manage and mitigate risks before they escalate.

What Power Quality Is and Why It Matters

Power quality refers to the stability and reliability of the voltage, frequency, and waveform of electrical power supplied to equipment. High-quality power operates within defined parameters, ensuring systems run smoothly without interruption or damage.

When power deviates from these standards, even briefly, it can result in overheating, equipment malfunction, data loss, or complete operational failure. Facilities that depend on automation, sensitive electronics, or continuous uptime must prioritize power quality to avoid significant financial and operational consequences.

Key Factors Affecting Power Quality

Several technical factors can degrade power quality. Let’s explore the most common ones:

Industry-Specific Power Quality Challenges

While all industries must consider power quality, certain sectors face heightened risks:

Manufacturing Facilities: Heavy machinery and robotics are highly sensitive to voltage sags and harmonics.
Data Centers: Even minor transients can corrupt data or damage servers, risking significant financial loss.
Healthcare Facilities: Imaging and diagnostic equipment require highly stable voltage; poor quality can lead to inaccurate results or equipment downtime.
Oil & Gas and Mining Operations: Harsh environments and long distribution lines heighten the risk of voltage instability and phase imbalance.

Each industry’s unique power profile demands tailored solutions to protect assets and ensure operational resilience.

How to Identify Power Quality Issues

Detecting power quality problems early can prevent costly damage. Here are key ways to identify potential issues:

Voltage Monitoring: Track voltage levels continuously to detect sags, swells, and variations.
Harmonic Analysis: Conduct a harmonic distortion assessment to measure waveform integrity.
Thermal Imaging: Identify overheating components that could indicate load imbalances or poor power quality.
Site Power Studies: Comprehensive power audits provide a detailed look into your facility’s power health and highlight vulnerabilities.

Without proper detection, power quality issues can remain hidden, silently eroding your facility’s efficiency and productivity.

Effective Solutions to Manage Power Quality

Once issues are identified, implementing the right solutions is critical:

Active Voltage Regulators (AVRs/AVCs): Correct voltage sags and swells in real time, maintaining stable voltage delivery to systems.
Industrial UPS Systems: Provide backup during outages and smooth minor voltage fluctuations.
Surge Protection Devices (SPDs): Shield systems from damaging transients and surges.
Power Conditioners: Filter out electrical noise and harmonics , protecting sensitive equipment.
Load Balancing Equipment: Distribute loads evenly across phases to prevent imbalances and phase issues.
Frequency Regulation Equipment: Maintain consistent system frequency to safeguard motor-driven and timing-sensitive systems.

Layering these solutions provides comprehensive protection against a wide range of power quality challenges.

Choosing the Right Approach for Your Facility

Choosing the right power quality solution requires a strategic, facility-specific approach:

Assess Load Requirements: Understand the sensitivity and power demands of your equipment.
Consider Scalability: Choose systems that can adapt as your facility grows.
Evaluate Environmental Conditions: Ensure systems are rugged enough for industrial or harsh environments.
Prioritize Monitoring and Diagnostics: Real-time insight into power health enables proactive maintenance.
Partner with Experts: Work with power quality specialists who can perform detailed assessments and recommend tailored solutions.

A one-size-fits-all solution rarely works. Truly, customized strategies yield the best long-term results.

Take Control of Power Quality Before It Costs You

Ignoring power quality issues can lead to mounting repair costs, frequent downtime, and reduced equipment lifespan, all of which hurt your bottom line. Voltage Correction is here to help you identify vulnerabilities and implement effective, industrial-grade solutions.

Our services include comprehensive power studies, site metering, and the installation of trusted solutions like the ABB 100 ESS AVC and PCS UPS-1, products that are designed to deliver stable, reliable power under even the most demanding conditions.

Contact us today, or schedule an on-site assessment with our power quality specialists and protect your facility before hidden problems turn into costly failures.

10 Power Irregularities Every Facility Should Be Aware of

Sun, 22 Jun 2025 20:37:14 GMT

What is a Power Irregularity?

Power irregularities refer to any deviation from the normal, stable delivery of electricity that facilities depend on. These fluctuations, such as a voltage sag, surge, or harmonic distortion, can damage equipment, interrupt operations, and lead to costly downtime. In environments where operational continuity and equipment health are critical, understanding these irregularities is the first step toward prevention.

What Are Common Causes for Power Irregularities?

Power irregularities can stem from a range of external and internal factors. Common causes include:

Utility Grid Instability: Strain on the grid during peak times or extreme weather.
Electrical Faults: Short circuits and ground faults disrupt voltage flow.
Large Equipment Cycling: Motors, compressors, and HVAC systems introduce sudden load changes.
Lightning Strikes: Generate voltage spikes and surges.
Poor Facility Wiring: Outdated or improperly grounded electrical systems invite disturbances.

Recognizing these causes can help facility managers preempt risks before they escalate into serious problems.

Which Facilities Are Most Susceptible to Power Irregularities?

Certain facilities face heightened risks of power irregularities due to either their operational demands or environmental factors:

Manufacturing Plants: Heavy machinery and robotics are sensitive to voltage fluctuations.
Data Centers: Require uninterrupted, clean power for server uptime.
Healthcare Facilities: Imaging and diagnostic equipment must be protected against even minor disruptions.
Mining and Oil & Gas: Remote locations and harsh conditions increase vulnerability.
Facilities in Storm-Prone Areas: Weather-related grid instability introduces added risks.

Understanding your facility's susceptibility is key to designing an effective power protection strategy.

10 Common Types of Power Irregularities

What Are Solutions to Mitigating Power Irregularities at Your Facility?

Combating power irregularities requires a layered approach:

Voltage Regulators: Systems like ABB’s Active Voltage Conditioners (AVC) maintain tight voltage tolerances and correct real-time fluctuations.
Industrial UPS Systems: Provide backup during outages, bridging the gap and preventing abrupt shutdowns.
Power Studies and Site Metering: Identify vulnerabilities and tailor solutions to your facility’s unique profile.
Surge Protection Devices (SPDs): Protect against transient overvoltage caused by surges and spikes.
Proper Grounding Systems: Ensure safe dissipation of excess voltage and minimize risk of stray currents.

By deploying a combination of these solutions, facilities can safeguard operations against even the most unpredictable power events.

What Voltage Correction Offers for Power Irregularities

At Voltage Correction, we specialize in delivering turnkey solutions for power irregularities. From initial site assessments to full system design and installation, we ensure your facility is equipped with the latest in power correction technology.

We offer:

ABB PCS UPS-1 Systems for reliable backup power and efficiency.
ABB 100 ESS AVC Systems for continuous voltage regulation.
Custom Power Studies to identify and address specific vulnerabilities.
Expert Consultation to guide you in selecting the best solution for your environment.

Our focus is on delivering comprehensive protection that maximizes uptime, extends equipment life, and enhances operational efficiency.

Contact Voltage Correction today to schedule a consultation. Let’s build a power strategy that prepares your facility for whatever challenges the grid (or nature) throws your way.

Large Facility Power Protection: High-Performance Voltage Products by ABB

Fri, 13 Jun 2025 20:55:20 GMT

Why Large Facilities Need High-Performance Voltage Products

Power quality is the foundation that large-scale industrial operations rely on for precision, safety, and uptime. Large facilities such as factories, data centers, healthcare institutions, and oil and gas operations depend on uninterrupted, stable power to maintain systems like automation lines, robotics, HVAC infrastructure, and sensitive IT networks. Yet, voltage sags , surges, and outages remain persistent threats, leading to abrupt shutdowns, equipment degradation, and costly production delays.

The financial impact is significant. According to industry reports , unplanned downtime in manufacturing can cost up to $300,000 per hour, highlighting the urgency for effective power protection strategies. Sensitive systems are particularly vulnerable, with unstable voltage accelerating wear on control boards, motors, and precision machinery.

For industries where performance margins are razor-thin, proactive voltage correction means stabilizing power in real time to protect investments, preserve output, and fortify operations against the increasingly unstable grid.

UPS Systems vs. Voltage Regulators: Complementary Solutions

When it comes to protecting critical infrastructure, relying on a single layer of defense is a risk most large facilities can’t afford. UPS systems and voltage regulators (such as ABB’s Active Voltage Conditioners [AVC] and Automatic Voltage Regulators [AVR] ) serve distinct yet complementary roles in a robust power protection strategy.

UPS systems are designed to provide backup power during outages. By instantly bridging the gap between utility failure and generator startup or system shutdown, a UPS prevents abrupt interruptions that could otherwise damage sensitive IT equipment, automation systems, and medical devices. However, UPS systems are primarily reactive, meaning they kick in once a total outage occurs.

In contrast, voltage regulators operate continuously, correcting sags, surges, and voltage swells in real time. These fluctuations may not cause an immediate shutdown, but they steadily degrade sensitive equipment, leading to costly failures over time. Active voltage correction ensures stable, clean power delivery at all times, preserving the lifespan of mission-critical systems.

Importantly, this is not an either-or decision. Layering UPS and voltage regulation together provides comprehensive protection. For example, the UPS safeguards against complete outages, while the voltage regulator maintains day-to-day voltage stability. For facilities serious about uptime and asset protection, both are indispensable parts of a complete power quality solution.

Benefits of the ABB PCS UPS-1

For large facilities, the ABB PCS UPS-1 offers an advanced line of defense against the disruptive effects of outages, surges, and voltage sags. Engineered for high-reliability environments, this UPS system sustains continuous operation during power disturbances, shielding sensitive systems from abrupt shutdowns that can cost both time and capital.

One of the standout features of the PCS UPS-1 is its high energy efficiency. Leveraging cutting-edge inverter technology, it minimizes power losses and reduces operational costs. This is a significant advantage for facilities managing heavy electrical loads and looking to optimize long-term energy spending.

Scalability is another key benefit. The modular design of the PCS UPS-1 allows facilities to expand their power protection as operational demands grow, avoiding costly overhauls or system replacements. This makes it ideal for industries where capacity needs are dynamic, such as data centers, advanced manufacturing, and healthcare systems.

Additionally, the PCS UPS-1 offers advanced monitoring capabilities and a compact footprint. Intelligent diagnostics, remote monitoring, and real-time performance data enable proactive maintenance and efficient space utilization are all factors in environments where floor space is at a premium and reliability is non-negotiable.

Benefits of the ABB 100 ESS AVC

While UPS systems provide backup during outages, the ABB 100 ESS Active Voltage Conditioner (AVC) works constantly to ensure your facility’s power remains stable and within tight tolerances. Designed specifically for industrial and high-demand environments, the 100 ESS AVC protects sensitive systems by correcting voltage sags, surges, and swells in real time, before they can cause measurable damage.

With its precise voltage regulation capabilities, the ABB 100 ESS AVC safeguards equipment like CNC machinery, robotics, and advanced automation systems against gradual degradation. By maintaining a stable voltage profile, it extends the lifespan of motors, drives, and control boards, reducing maintenance costs and minimizing unexpected downtime.

Built for rugged use, the 100 ESS AVC is engineered to thrive in challenging industrial conditions. Its robust design promotes reliable performance even in environments with high temperature fluctuations, dust, and vibration. All of which are common challenges in manufacturing, mining, and energy sectors.

As far as integration goes, it’s seamless. The 100 ESS AVC fits into existing power infrastructures without major overhauls, offering facilities a scalable, plug-and-protect solution. Whether protecting a data center’s server racks or a production line’s PLC controls, the 100 ESS AVC delivers consistent voltage regulation, keeping processes online and efficient.

How to Choose the Right Power Quality System

Selecting the right power quality system starts with a thorough assessment of your facility’s vulnerabilities. Are you experiencing frequent outages, or is unstable voltage the more pressing issue? Each facility faces unique challenges. For example, data centers may battle voltage fluctuations that threaten server integrity, while manufacturing plants might encounter voltage sags that interrupt precision production lines. Identifying the specific risks is critical to tailoring the right solution.

Equally important is sizing your system correctly. Every facility has distinct equipment load requirements, from robotics and PLCs to HVAC and imaging systems. Undersized systems can fail under peak demand, while oversized systems waste capital and energy. Precise load calculations ensure that your power protection is both efficient and effective.

Future-proofing is also essential. As facilities expand or add new technologies, power demands increase. Choosing systems like the ABB PCS UPS-1 and 100 ESS AVC with scalable, modular designs allows you to grow without costly infrastructure changes, ensuring your investment remains viable for years to come.

This is where Voltage Correction’s expertise is invaluable. Our team conducts comprehensive power studies, site metering, and needs analysis to provide data-driven recommendations. By evaluating your existing electrical environment and forecasting future needs, we help design a layered protection strategy that minimizes risk, enhances uptime, and keeps a resilient operational framework.

Industries that Benefit from ABB Power Quality Systems

ABB’s high-performance voltage products, supported by Voltage Correction’s full-service expertise, deliver protection across a range of industries where uptime and equipment integrity are non-negotiable.

Partner with Voltage Correction for ABB Voltage Solutions

Selecting the right voltage protection products is only the beginning…successful implementation requires deep technical expertise and a full-service approach. That’s where Voltage Correction excels. As a trusted partner, we don’t just supply ABB’s high-performance voltage solutions; we provide end-to-end support to ensure they’re integrated seamlessly and perform reliably in your environment.

Our services begin with consultation and site evaluation, where we conduct detailed power studies and metering to diagnose existing vulnerabilities. From there, we design tailored power quality solutions based on your facility’s load requirements, operational needs, and future growth plans.

Unlike distributors that focus solely on product sales, Voltage Correction offers turnkey installation services, ensuring that every UPS system and voltage regulator is correctly configured and optimized for your specific application. Post-installation, we provide ongoing support and maintenance, helping extend equipment life and maintain optimal performance over the long term.

Request a Quote for Your ABB Voltage Product

Power reliability isn’t something to leave to chance. Whether you’re looking to protect advanced manufacturing lines, safeguard sensitive healthcare equipment, or ensure seamless data center operations, Voltage Correction is here to help you build a power protection strategy you can trust.

Our team is ready to guide you through every step, from initial consultation and site evaluation to system design, installation, and long-term support. With ABB’s high-performance voltage products and our expertise, you’ll have the layered protection your facility needs to minimize downtime and protect your infrastructure.

Get in touch today to schedule a consultation with our power quality specialists. Let’s discuss your facility’s unique challenges and design a tailored solution that ensures stable, reliable power for years to come.

What is Medium Voltage? Understanding Voltage Types.

Thu, 20 Feb 2025 22:35:11 GMT

Using Medium Voltage (MV) with Power Distribution for Industry provides an efficient delivery of High Capacity Power to Manufacturing Facility and Industrial Production Floors.

A higher voltage provides a more “efficient” path for “AC Current” to travel to equipment. Large Motors and high inrush starter loads require much more Startup Current, medium voltage power distribution within a plant will provide an efficient capacity of Amperage for this high demand equipment.

If production equipment in a Plant operates at lower voltage (LV), the delivery mechanism of higher voltage, closer to the equipment seeking the higher amperage, makes for more capacity available to the loads. This is achieved by the installation of step down function transformers, allowing the medium voltage (MV) to deliver higher capacity amperage “near” the loads. Then step down voltage at or near the equipment to the usable voltage.

Benefits of Medium Voltage in a Facility

-Higher Amperage Capacity delivered closer to Equipment Seeking Current (Amps).

-Less “Current” loss during distribution through plant to various loads.

-Lower “Pipe and Wire” costs as higher voltage requires smaller wire size to transmit.

-More reliability in overall plant equipment: ie. Affects of power anomalies from lower voltage, sags, surges, failure of Machine Equipment Components.

Disadvantages of Medium Voltage in a Facility

-Higher cost to Utility for setup

-Specialized Maintenance at higher voltage levels

-Potential first costs higher for substation and distribution equipment up front, but lower cost of ownership over time.

Low Voltage for Industrial Loads

Low voltage distribution in a Plant can be installed successfully with a very constant load profile and demand. If there is larger equipment such as motors and processing that cycle on and off with large inrush current demand, this will affect the other areas of the Plant.

These “surges” in demand for Current in these high demand inrush devices, can starve or pull down overall voltage in the other areas in the plant electrical distribution, or the entire plant. This will cause Power Supply failures in other equipment which seeks a constant voltage, or will burn components of other equipment due to variable voltage events. Over time this greatly affects a Plant’s Maintenance budget.

Benefits of Low Voltage in a Facility

-More Familiar Installation and Voltages for most Electrical Contractors.

-Immediately available equipment, shorter lead times.

-Simpler design and operation of electrical distribution and Electrical One Line.

-Less step-down transformers within Facility and Electrical One Line

Disadvantages of Low Voltage in a Facility

-Exposed to more “Load” created anomalies that may affect other equipment

-Limited amperage “Choke Points” for distribution and installation of larger equipment

-Current loss from LV distribution through plant.

-Susceptible to Inrush Current affect on immediate area or entire facility.

-Higher “Pipe and Wire” costs as lower voltage requires higher amperage and larger wiring.

Description and Uses of Low (LV) and Medium Voltages (MV)

Low Voltage: 1kV - 15kV

Typical City Use Power Grid Activities

-Residential Use: (120v, 240v)

-Commercial Building Use: (120/240v Single/Three Phase, 480v Three Phase)

-Manufacturing and Industry: (480v Three Phase)

-Localized Utility Distribution: Transformer to Load

Medium Voltage: 13.8kV-34.5kV

-High Density Data Center Uses

-Large Manufacturing, Semiconductor

-Motors, Compressors, Large Use Industrial Process

-Electrical Utility Distribution, Long and Short Line distances

High Voltage: 35kV and larger, 138kV

-Long Transmission Lines Substation supply lines from Power Utility Sources

-Industrial Processing Facilities, Steel, Mining.

-Large transit requirements such as Railways and Commuter trains

See your Voltage Correction Specialist to discuss Medium Voltage Power Distribution Options and Corrective Measures for your Facility Power Issues.

Medium Voltage UPS Systems in High Density AI Data Centers

Thu, 20 Feb 2025 22:35:07 GMT

High Density AI compute performance chips like Nvidia Geoforce and now Blackwell B200 chips are requiring up to 300 watt, 400 watt, and 1200 watts. New rounds of chip development are considering up to 3000 watts of power per chip and requiring MEP Engineering design to consider bringing higher voltage closer to the Rack Loads.

Why Medium Voltage UPS Systems

Higher voltage carried over distances is more efficient than lower voltages carried over the same distance. Medium Voltage (13.8kV, 34.5kV) requires lower current (amps) to achieve the same capacities as low voltage (480v/208v), which exponentially changes the amount of power you can move from Point A to Point B, point B being the Rack loads.

480V Power Distribution for Data Centers

In a legacy data center, medium voltage would be delivered to a substation or switchboard on-site. Transformers then step down medium voltage to 480V, which is widely used in data centers for the last 35 years.

The typical legacy larger data center delivers 480 volts through the input switchgear, Uninterruptible Power System (UPS) via it’s Maintenance Bypass Switchboard route, and on to a Floor Power Distribution Unit (PDU). At the PDU, the load is stepped down via a internal PDU Transformer to usable 120/208V and 120/240V, which panels of breakers, or sub-feed breakers on the PDU support the actual breakers for servers. Low Voltage UPS Systems are limited to certain capacities to accumulate kW output for larger 2500kW or 5000kVA capacities.

See Diagram 1.1

Medium Voltage UPS Systems in High Density Data Halls

For new high density Rack layouts of 100kW – 300kW per rack load, the most efficient way to deliver the smallest wire, highest voltage, and most capacity closest to the load is to deliver medium voltage directly to the PDU at the rack row. Major issue, most OEM’s have been set up to build most all capacity of Uninterruptible Power Systems in the 480 Voltage.

Medium Voltage UPS Systems are now being made available to New High Density Data Centers. In much the same routing of power from Utility, Substation, Switchgear, UPS Gear, and ultimately to a Medium Voltage Power Distribution Unit (PDU) neat the high-density rack loads. 13.8kV or 34.5kV delivered closer to the loads provides major benefits to large megawatt installations.

See Diagram 1.2

Benefits of Medium Voltage UPS Systems

-Higher Voltage at Longer Distances = Efficient Power flow and less effective power loss in amperage. (More Real Current (kw) Delivered to Loads)

-Medium Voltage vs Low Voltage uses smaller wire sizes and less connections points resulting in lower material costs per kW during installation. (Less Pipe and Wire)

-Medium Voltage vs Low Voltage uses less connection points resulting in lower Labor Costs per kW during equipment installation. (Lower Installation Labor Hours)

-Medium Voltage UPS Systems provide higher kW capacity in a smaller footprint over legacy 480V low voltage designs. (Higher kW Density psf)

-Installing less components in the delivery line to rack loads lowers total Facility Points of Failure (Less Single Points of Failure)

As an overall guide, you can pack more kW into a smaller footprint using Medium Voltage UPS Systems in your high density Data Hall Design. Using the same concepts of High Density chip computing and direct to chip cooling, bringing more directed high capacity kW power to Rack Loads achieves an increased kW per PSF design, and a lower cost per kW ownership.

See your Voltage Correction Specialist to discuss Medium Voltage UPS Systems and Power Distribution Options. https://www.voltagecorrection.com/medium-voltage-ups-systems

Backup Power Requirements for Bitcoin Mining Industry

Mon, 12 Aug 2024 21:19:51 GMT

When considering the electrical requirements for a bitcoin mining operation you must weigh several factors to install an efficient delivery of power. Also considering the risks of power failures, sags and interruptions to choose the correct technologies for your bitcoin mining farm.

By implementing an effective electrical power strategy can determine the success of your bitcoin mining operation.

Power Utility Options for Bitcoin Mining

Bitcoin mining has captured interest in locations that provide renewable resources. Not only for the cost of input (electricity), but also to lessen the impact on climate change. Many farms are seeking to locate in areas such as Texas that provide much renewable resource by way of wind farms. Others seek cost savings by expending less cooling dollars by locating in Greenland, or northern climates. A large portion of cost to produce bitcoin is expended cooling the bitcoin mining operations. These types of climates provide lower PUE (Power Usage Effectiveness) or more output vs. the electrical input cost. All of these choices, however, put the facility in the crosshairs of variable power disruptions. The mining owner will have to decide if spending capital dollars on the front end is worth it to eliminate power interruptions during operation.

Ways to Correct Power Interruptions for Bitcoin Mining

As discussed, the type of power input or source of power has much to do with how much protection is needed from variable voltage swings, or power outages. Bitcoin operations will need to weigh the cost to correct power in capital expenditures vs. the operational effects it will have on uptime in operations. The following are several ways to correct power issues.

Industrial Uninterruptible Power System (UPS)

A fully industrial UPS system with transformer-based technology would be a full isolation of the utility power source and the bitcoin mining loads. A choice of Pure Lead, VRLA, or Lithium-Ion batteries can be installed for specified runtimes. Typically a system will be sized for 10-20 minutes of backup battery runtime. This would correct 98% of normal voltage sag, and momentary interruption scenarios. Also provide for sequential load shedding upon an outage event, which runtime could be extended longer for more critical components. UPS Systems of this type also protect and extend the life of bitcoin mining components. Constant voltage swings provide wear and tear on expensive bitcoin mining equipment causing premature failures, and higher operational expenses over time. The UPS provides a clean, sterilized power output for the mining operation.

Industrial UPS and Generator

A UPS described above with a shorter duration battery yet combined with a backup generator with automatic transfer switch. This combination would provide for extended, or unlimited runtime provided there is fuel available for the generator. The UPS will isolate all the voltage variations and sags with it’s power sterilization technology. When an outage occurs the backup generator system will automatically switch over via the (ATS) and be the main source of power.

Voltage Correction or Conditioning

If the utility power source is reliable and relatively free of power outages and interruptions. You can correct or stabilize power without battery storage or backup generation. Voltage Correction and/or Conditioning can provide for the regulated voltage output that will provide clean corrected power for your bitcoin mining components, without the higher cap ex cost for the additional storage or runtime. This option at a minimum would be suggested for all bitcoin mining applications.

PUE Efficiency and Backup Power Choices for Bitcoin Mining

Choosing a backup power system, whether it be a UPS Systems, Voltage Correction System, or emergency backup generator should not materially impact your PUE (Power Usage Effectiveness) in your mining operations. UPS systems today provide up to 99% efficiency to operate 100% of the time. During occasional battery charging periods there will be additional amperage draw on the system, but is very minimal. Most if not all of the UPS, Generator, Switching, and distribution is standby in nature. Therefore, the upfront Capital Expenditure will be the cost outlay and the operational PUE will not be affected by these systems. Your choice for backup would be to weigh the operational downtime effects of outages vs the upfront cost to prevent them. The larger effect on PUE would be the choices made for cooling options.

Should you Backup Bitcoin Mining?

The operational efficiencies that you gain long term and the quality of output from your mining equipment says you should invest at a minimum in a voltage stabilizing system. Should you want to completely avoid downtime scenarios, re-boots, and general labor costs to manage your site, then the investment into fully backed up bitcoin operations is extremely justified.

Voltage Correction is experienced in designing and installing electrical systems for the Bitcoin mining industry. We can help you choose the right system for your project. Please contact your representative to discuss opportunities to build out your electrical and mechanical systems for your Bitcoin Mining Operation.

Rolling Utility Brownouts and the Northeast Heat Dome

Fri, 21 Jun 2024 21:19:24 GMT

With the Heat Index reaching record levels in the Northeast part of the country. Rolling brownouts due to continuous tax on the utility grid are a continuous risk to industry.

A rolling brownout is a drop or sag in voltage along the grid distribution. Typically, due to the increased demand on the system. Rolling brownouts are escalating drains on the utility infrastructure which the supply side of the utility power cannot catch up and maintain constant nominal voltage. The result is a continual reduction of voltage power, or a sag condition. Which most manufacturing environments cannot operate in.

Washington, Oregon, and Idaho Power at Risk

Regions and facilities operating in ultra-high heat conditions run the risk of utility power failure or utility voltage sag conditions. A voltage sag sometimes is as impactful as an outright power outage. A sag will lower the voltage below operative levels for equipment. Sometimes doing more damage than an actual power outage. Washington, Oregon, and Idaho affected by the heat dome may experience continuous exposure to power anomalies throughout the weather event.

Brownouts and Sags worse than an outage

Due to the continuous exposure of low voltage conditions, equipment is more likely to “burn out” or receive a spike in amperage that causes failure. Rather than a power outage that eliminates the power voltage altogether. A sag or drop in voltage over a period of time such in a brownout will likely cause more serious damage to equipment and sensitive components.

Global Warming and the Future of Power Distribution

As city landscapes keep heating up, and requirements for HVAC systems keep increasing the electrical grid will keep being challenged by sag and brownout scenarios. City “heat islands” are expanding. Industries requiring constant clean power that operates from the general distribution grid will continue to experience these brownout scenarios. New commitments to energy infrastructure, clean energy systems, solar, wind, geo and other clean power producing processes will assist in overcoming the source demand that is placed on the electrical utilities today.

For information on power outages check the U.S National Grid Power Outage Tracker Map.

Voltage Correction

Voltage Correction is a provider of services to industry to install voltage correction devices , monitor incoming power to facility for solutions, and provide customers with comprehensive power solutions. Contact us today to talk to your Voltage Correction Technical Representative .

UPS Backup Systems for Plastic Extrusion Power Issues

Mon, 10 Jun 2024 14:41:00 GMT

The plastics industry has a history of complicated manufacturing processes. The procedure to melt plastic stock, transfer it to a die, then hardens to form the product is a process that cannot really be paused or interrupted.

This article discusses ways to correct power interruptions for plastic extrusion manufacturing processes.

Power Issues Affecting the Plastic Extrusion Process

Various power anomalies affect the plastic extrusion process in different ways. Below are some different power issues affecting today’s plastic extrusion facilities.

Power Outages

A complete power outage will absolutely interrupt the plastic molding process. Regardless of which state the mold is in, once it is past melting should you interrupt the power, your process material will harden and will need to be cleaned and re-started. These are major events for plastic extrusion companies. A company will spend many hours if not shifts cleaning out the faulted process, and ready it to re-start.

Voltage Spikes

Uneven voltage situations, sags on the grid and voltage swells or spikes can also affect the plastic extrusion process in the same way a power outage can. Voltage spikes whether from lightning, stray voltage, or ramping up and down of larger equipment loads can also wreak havoc on plastic forming processes. Each time the voltage spikes the amperage will dip, and vice versa when the voltage sags the amperage spikes. This will wear on all pieces and parts of mechanical equipment, also very much wears process controls equipment until failure. You will not always see these event with the naked eye.

Voltage Sags

The increasing tax on our electrical grid and power demand continues to cause brownouts and sags . Rolling brownouts and sags are not derived at the electrical utility, however, they come about along the distribution line. You are always subject to the affects of these power issues, and it is not that the utility company can necessarily do anything about it for you. Sags can be quite long in durations, again not visible to the naked eye. But pro-longed voltage sagging will directly raise amperage and burn on equipment, boards, processors, and controls. Sags and spikes may not always knock equipment offline, however, the changes in voltage directly affect the operation and life of your plastic extrusion process equipment and controls.

Ways to Correct Power Interruptions for Plastic Extrusion

The following are different technologies that may correct or “fix” facility issues that are facing power related problems in the plastics industry. There is no magic bullet, but there are definitely measures that can be taken to prevent downtime.

Industrial UPS Systems

An Industrial UPS System is specifically made for mechanical environments such as plastics industry. Typically made with internal transformers and capacitors sized for taking on larger industrial or high inrush current loads. A typical data center or IGBT type UPS system built for computer processors is not usually a good fit for the harsh environment of a plastic extrusion plant or other manufacturing loads.

(AVC) Active Voltage Correction System

99% of power issues affecting process controls and manufacturing are associated with sags, surge and spiking voltage events. A properly designed AVC – Active Voltage Correction System can provide 100% protection against all these issues. An AVC system can correct a single-phase sag that may dip 30% of nominal voltage. It can correct all 3 phase sags up to 30% of nominal. It is an absolute must for plastic extrusion process environments.

(AVR) Active Voltage Regulator

Much like an AVC system, the AVR holds a tighter input voltage window it is willing to accept. Much like a Voltage Conditioner, the AVR system will take a varying voltage and tighten it up to within +/- 5% nominal voltage. It will not take care of larger sags or swells. If power in your facility is not the worst, but you wish to tighten the voltage and operational window for all your plastic process controls and equipment, then and AVR is an inexpensive solution to provide that type of operational integrity.

About Voltage Correction

Voltage Correction is a provider of power correction services globally. Please contact your Voltage Correction representative to discuss power correction options for your facility and plastics operation. Call 855-240-6776

New ABB PCS 100 to Correct Today’s Industry Voltage Problems

Thu, 23 May 2024 21:17:42 GMT

Today’s Industry and environment is elevating the demand for Voltage Correction Solutions. ABB remains at the top of the food chain with the ABB PCS 100 line of Active Voltage Conditioners. The new ABB PCS 100 Systems can provide constant sag protection down to 50% remaining voltage on al three phases. The system can correct and maintain 100% voltage stabilization on the output.

Wide Range of Sizes and Voltages in New PCS 100

Now more sizes and voltages to choose from! In addition to 480V models widely available, the new system can accept and correct 380V, 400V, and 415V voltage input variations.

The high efficiency and compact Design of the PCS 100 is an excellent choice to fit into tight electrical rooms, and on the floor of production manufacturing environments. ABB systems are the choice for large industrial plants and environments experiencing large voltage variations that disrupt operations.

ABB PCS 100 models can be configured in a wider range of size options. 150kVA, 300kVA, 450kVA, 600kVA, 750kVA, 1000kVA, 1500kVA, 2000kVA, 3000kVA, and up to 12MVA.

The PCS100 AVC 400V application can be used in a wide variety of countries such as South America, Mexico, and Malaysia. Frequency adjustable systems also provide more flexibility.

ABB PCS 100 Corrects Large Voltage Sags

Unreliable and unstable power is a growing issue in large commercial and industrial environments. Unstable voltage provides undue stress on critical mechanical and control components. This constant variation in voltage can decrease the life of PLC’s, control boards, and system electronics. PCS100 constant voltage regulation holds the output voltage to 100% nominal target voltage through large and small sags and surges in utility power. These swings can be up to 40% drop in voltage and maintain constant output power.

Voltage Issues Affecting Industry

The electrical grid in all countries is taxed in today’s world. Climate change, demand on supply, natural disasters, and distance of power distribution, all contribute to the constant suspect power delivered to end user plants. All industry’s must take power regulation into their own hands. Utility Power Suppliers are not going to anytime soon start correcting power along the distribution lines. Power conditioning and voltage regulation is something that each industry , and company at it’s plant level needs to address.

Prepare for Power Sags and Outages with Industrial Clean Power

Thera are many Voltage Correction Solutions you can do at your site level to mitigate any and all of the affects of voltage sags and surges .

If you have any questions or would like to receive additional information about our products and services, our team is available for Technical Review of power information, Utility Bill and Performance Review, Sizing assistance, and Voltage Correction Systems selection. Contact Us today to explore your Voltage Correction Solutions !

The Importance of Voltage Regulation

Mon, 15 Apr 2024 18:09:18 GMT

What is Voltage Regulation?

Although the principles of voltage regulation may be inherently complex, the concept at the heart of it is straightforward. You're talking about the ability of any electrical system to provide the constant (or near constant) voltage necessary to successfully and safely operate in a wide range of load conditions.

Voltage Regulators

A voltage regulator is a circuit that both generates and manages a secure, fixed output of voltage in whatever power system it is installed in. Essentially, it's making sure that the voltage coming from the power supply is always in whatever range necessary to be compatible with other components.

To that end, there are a few different types of voltage regulators to concern yourself with. One of these is called a linear voltage regulator, which is commonly used in many commercial devices in particular. It employs a "series pass transistor" to make sure that the output voltage stays consistent. It is simple, has low output noise, and offers excellent line regulation. It does have a limited voltage range, however, making it unacceptable for certain types of applications.

Another type is called a switching voltage regulator, which is inherently more complicated but highly efficient. These types of regulators can sometimes cause electromagnetic interference, however, so you must also be careful when using them.

Finally, there is a shunt voltage regulator, which controls the output voltage via a low-resistance path for excess current to bypass the load. It's simple and highly precise, but has limited load current handling.

Typically, the end application will dictate which type of voltage regulator should be used.

Factors Affecting Voltage Regulation

The number one factor that affects voltage regulation is the variation of the load in question. If that load is increased, it will sometimes cause a voltage drop. This refers to the amount of voltage loss that occurs as a result of resistance. That voltage regulator will then need to make up the difference to preserve the safe operation of not only the electrical system but whatever component it is connected to.

There are other factors that affect voltage regulation as well, with temperature being chief among them. If a voltage regulator is suddenly subject to extreme conditions like intense heat, it could change properties like line resistance. This would change how hard the voltage regulator had to work to maintain that consistent voltage, or if it was even able to do so at all.

Obviously, the tolerances of any component attached to the system would also impact voltage regulation. The tighter the tolerances, the more effective the voltage regulator will be at performing its primary function.

As is true with other types of mechanical components, wear-and-tear and maintenance (or a lack thereof) can also impact voltage regulation. As a voltage regulator ages after periods of heavy use, it will naturally become less effective. Its performance may suffer and its ability to accurately regulate voltage may be negatively impacted. At that point, it would either need to be repaired or fully replaced depending on the specifics of the situation.

Why is Voltage Regulation Important?

Ensures Equipment Safety . Proper voltage regulation always helps to minimize the possibility of dangerous conditions like an arc flash. This can cause not only severe burns to anyone in the immediate area, but long-term injuries and even fatalities due to a catastrophe like a fire as well.
Improves Productivity & Efficiency . Without proper voltage regulation, you're likely looking at a lot of equipment and systems that malfunction in unpredictable ways. This leads to unplanned downtime, which isn't just frustrating - it's also massively expensive. Voltage regulation keeps power systems running as consistently and as efficiently as possible, meaning that your workers are spending less time dealing with issues and more time being productive.

Prevents Damage to Electronics . Another core reason why voltage regulation is so important is because it helps to prevent damage to mission-critical equipment and other components. Proper voltage levels help prevent thermal stress, which reduces the risk of a failure. It also helps to maximize the lifespan of your equipment as well, all while cutting down on unnecessary maintenance costs.
Enhances System Reliability . Equipment that constantly cycles on and off due to inconsistent loads goes through an incredible amount of unnecessary stress over time. This requires downtime for maintenance that, even if it is planned, is still costly. It also reduces the lifespan of the equipment as well. Voltage regulation helps enhance system reliability in a way that prevents all this from happening.
Prevents Data Corruption . Voltage irregularities can lead to sudden system shutdowns, which can lead to corrupt and otherwise lost data. Proper voltage regulation helps make sure this isn't something that you or your own customers have to spend time worrying about.

FGC Industrial Voltage Regulation & Correction Systems

As a division of FGC Equipment, Voltage Correction is proud to offer a wide range of industrial voltage regulation and correction systems for you to choose from depending on your needs. Since 2008, we've proudly offered high-quality solutions to clients in just about every industry you can think of , from industrial organizations to 3D printing facilities to those in oil and gas, mining, commercial/retail, emergency lighting, and more.

In addition to our 24/7/365 emergency service response capabilities , clients have also come to trust us over the years thanks to our robust preventative maintenance plans. We can keep all your systems free from downtime so that you can focus all your attention on running the most successful business you can. Also available is our FGC Asset Management software , which allows you to log all historical maintenance and repair data in one easy-to-manage location. You can also view your current calendar of maintenance activities, dive deep into information pertaining to budgeting, and more - all to give you complete control over the asset lifecycle for critical components like voltage regulation and correction systems.

If you'd like to find out more information about the importance of voltage regulation, or if you'd just like to discuss your own needs with a team of professionals in a bit more detail, please don't delay - contact Voltage Correction today and request a quote.

Brownout vs Blackout: Causes and Solutions Explained

Mon, 26 Feb 2024 14:32:54 GMT

What is a Brownout?

A "brownout" involves a partial loss of power coming from a utility company. Electricity is still flowing from a provider, through the grid, and to end users like homes or businesses. It's just that the voltage being supplied is reduced anywhere from 10% to 25% in many situations.

What is a Blackout?

"Blackout" is simply the term used to describe any power outage, whether it is planned or unplanned, that results in a total loss of electricity via the utility grid. These outages are temporary, but absolutely no electricity is being transmitted through the grid to the end user.

A blackout could happen for a wide range of different reasons. Planned ones, which are also sometimes called "rolling outages," happen when the utility company is shutting off power to specific areas in an attempt to protect the integrity of the grid. Usually, customers get warned in advance. Unplanned blackouts can happen due to situations like extreme heat or even a sudden storm that rolls through an area at the worst possible moment.

Blackout vs Brownout

The major difference between the two terms is that a blackout refers to a total loss of power, while a brownout is talking specifically about a partial loss of power.

Again, brownouts tend to be both temporary and planned in advance by a utility provider. During this period, electricity is still reaching a home or business, but voltage levels have been reduced. This can still cause issues with very sensitive electronics, but most people likely won't realize something is happening at all. The vast majority of brownouts last for a precise period of time that is known in advance.

Blackouts are unplanned in more ways than one. Not only are you unexpectedly losing total power for whatever reason, but they can also last anywhere from minutes to days or more. Even in the event of a "planned" blackout, the situation is still likely happening for reasons beyond anyone's control. Utility officials may be taking the power offline in a specific attempt to protect the integrity of the grid, but exactly how long that will be required quickly becomes anyone's guess.

What Can Happen If a Business Has a Brownout?

As stated, there is a chance that your business could experience a brownout, and you might not realize that it's even happening at all. You may see the lights dim periodically, but if it happens on a day when you're busy enough, you probably won't give it too much attention.

Unfortunately, there will be situations where even a brownout can cause a major disruption to your organization. Just a few of the potential effects include but are not limited to ones like the following.

Equipment Damage . Because voltage suddenly fluctuates during a brownout, certain types of equipment - notably appliances - won't just stop working. They could be permanently damaged.

Data Loss. A power interruption that you weren't planning for likely means that your computers and workstations will turn off - resulting in the immediate loss of any data that hadn't been previously saved.

Productivity Loss . To put it simply, if your business relies on technology to function, it relies on electricity. Every minute that you don't have access to critical computers or machinery is a minute that you and your employees cannot be productive at all.

Downtime . Every minute of downtime also has a very real dollar value attached to it. Not only do you immediately start to fall behind on work, but that could push up against deadlines or other deliverables for clients - thus causing potential damage to your reputation as well.

Safety Risks . Especially if you're talking about a business environment like a warehouse or manufacturing space, suddenly losing electricity creates very real safety risks. People could get trapped in elevators, emergency lights could fail to come on, or someone could be in the middle of using a machine when they suddenly lose control over it.

Supply Chain Disruptions . The events of the last few years have taught us just how connected every link in the supply chain truly is. A disruption for you or one of your partners instantly starts to create a ripple effect that begins to delay businesses that were in no way affected by the initial brownout.

What Machinery is Vulnerable to Power Fails?

Any piece of machinery that is vulnerable to voltage sags, surges, impulses, or failures is vulnerable to a brownout - which means the vast majority of the equipment your organization depends on daily. Examples include things like

Computers.
Computer equipment like printers or scanners.
Industrial machinery.
Manufacturing equipment.

How to Protect Equipment and Machinery From Brownouts?

One of the most important things you can do to protect your equipment and machinery from a brownout involves using a generator, if possible. Generators are a source of backup power that can allow you to continue to use certain assets even if the main power is unreliable or is disrupted altogether.

In the case of something like a computer, a generator can buy you precious minutes to become aware that there is a problem and take corrective action. You can properly save all work and shut down your machines to avoid long-term damage from power spikes, for example. You may still lose productivity due to an unplanned outage, but you won't have to worry about surges, and you certainly won't be dealing with anything like data loss.

Another step you'll want to take to protect your equipment and machinery from brownouts involves unplugging everything until the situation is stable once again. This will help you avoid power over consumption, which is one of the major causes for brownouts to begin with. You should also sign up for alerts from your utility provider so that you know exactly when the situation is resolved.

Choose FGC as your UPS & Voltage Regulator Supplier

At FGC Equipment , we understand just how stressful brownouts and blackouts can be - which is why we want to make sure you have all the resources you need to mitigate risk from these situations as much as possible. We provide uninterruptible power supply (UPS) and voltage regulator solutions to clients in many industries , including but not limited to oil and gas, 3D printing facilities, industrial organizations, and more.

If nothing else, we want you to be able to rest easy knowing that even if the unexpected does happen, you're still covered in more ways than one.

If you'd like to find out more information about the major differences between brownouts and blackouts, or if you're looking for additional assistance about ways to prepare yourself for times when your electricity may be interrupted unexpectedly, please don't delay - contact the FGC team today .

Voltage Sags: What They Are and How to Avoid Them

Mon, 29 Jan 2024 22:21:41 GMT

What is a Voltage Sag (Voltage Dip)?

A voltage sag , otherwise known as a voltage dip, is defined as a situation where electricity voltage dips 10% or more below either normal or recommended usage. If a 120-volt outlet is suddenly only providing 90 volts of power, for example, that would classify as a voltage dip.

National Power Outage Map: PowerOutage.US

What is a Voltage Surge?

A voltage surge , on the other hand, is a scenario where the voltage flowing through a power line is suddenly increased by 10% or more. This might only last for a minute or less, but that unexpected increase in power could permanently damage sensitive equipment and electronic components in particular.

To make things easier, think of a voltage surge as a power overload. In that context, a voltage sag would be something of a "power underload." Both are bad situations to find yourself in, but for slightly different reasons.

Causes of Voltage Sags

Many people don't realize just how sensitive the power grid is until they start to experience issues. That is to say, voltage sags can be caused by a surprisingly long list of reasons. Maybe the most common of them is the weather. When a lightning strike happens nearby, for example, it actually draws a significant amount of power from the local power supply. This will put a lot of strain on the local grid, which can cause voltage sags to anyone in the vicinity.

The same is true of the wind. Sustained periods of intense wind might knock down power lines during a particularly bad storm. Or, they might cause a tree to fall onto the power line. Regardless, the effect is the same - the remaining, functional power lines are strained, and voltage sags occur until the issue is corrected.

Even something like a nearby construction project could cause voltage sags to occur. While a lot of power lines in an area are above ground, some are below. If construction crews are digging, and they happen to accidentally cut an underground power cable, it will cause voltage sags to happen almost instantly in the surrounding area.

How Do Voltage Sags Impact Business Operations?

Some people assume that a voltage sag is just a "minor inconvenience." Yes, you're temporarily unable to get important work done, but the situation seems to resolve itself fairly quickly. Unfortunately, the reality of the situation is quite different. Voltage sags create an almost immediate negative ripple effect across your entire organization, including in ways like the following.

Equipment Damage . Any piece of equipment that is susceptible to sudden changes in voltage, like computers, appliances, or even a lot of industrial machines, could be permanently damaged by even a single voltage sag.
Downtime. Every minute that your operations are down unexpectedly is a minute you're losing money. In a manufacturing environment, some studies put the average cost of unplanned downtime at as high as $260,000 per hour.
Data Loss. If a computer shuts off unexpectedly due to a voltage sag, you will instantly lose any data that hadn't been previously saved. This could result in hours of lost productivity in an instant.
Reduced Efficiency. Productivity isn't just lost due to the voltage sag itself. You also need time to properly recovery - which only delays your ability to pick back up and keep moving as if nothing had happened.
Increased Costs. Those employees who can't work due to a voltage sag still need to be paid. That work that evaporated due to data loss will need to be redone. Damaged equipment needs to be replaced. All these add to costs during a time when your profit margins are likely already razor-thin.
Risk to Reputation. Unexpected productivity delays due to voltage sags could cause clients to see you in a negative light as their deliverables are delayed as well.
Compliance Issues. If critical safety systems fail due to voltage dips, it could instantly cause compliance issues for your entire organization.
Employee Frustration . Even if you set aside the frustration due to the fact that employees can't work and are thus falling behind on what is expected of them, voltage sags can also cause dangerous situations with faulty equipment or other systems that suddenly aren't working properly. They're not going to be mad at the utility company - they're going to grow frustrated with you, which will negatively impact morale if it happens often enough.

Normal Physical Results of Above Sag Activity

10% +/- sag/surge: Continuous wear on PLC’s, boards, line equipment, motors, lasers, process equipment
20% - drop in voltage: Considerable spike in amperage due to the low voltage, may see long term or immediate damage to equipment
50% - drop in voltage: Will appear to be outage, flicker or drop of lights. Considerable amperage spike to all loads, damaging.
80% drop in voltage: Power loss occurs, may be gradual sag if on one phase. Damaging to all Electronic Equipment.

How to Prevent Voltage Sags?

The number one thing you can do to prevent voltage sags involves making sure you know when they're happening in the first place . Sometimes, the voltage sags a minimal amount, and you won't immediately realize you have a problem. That can still cause long-term issues with sensitive equipment, however, which is why you should always have a power quality monitor at-the-ready .

You'll also want to employ an uninterruptible power supply (UPS) and similar types of devices to protect equipment that is particularly sensitive. This can provide you with enough time to either ride out the voltage sag or shut down and disconnect sensitive equipment, so it doesn't get damaged unexpectedly.

How Do I Correct Voltage Sags?

The following is what an AVC (Active Voltage Correction) System can provide for sag activity.
Voltage Correction Chart (95%+ Sags occur in a single phase of power)

10% +/- sag/surge 10% +/- sag/surge regulation AVC corrects to nominal power voltage
20% - drop in voltage (Sag to 80%nv) AVC corrects to 100%, 3 phase for 3+ minutes, 1 phase Continuous
50% - drop in voltage (Sag to 50%nv) AVC corrects to 90% 3 phase for 1 minute, 1 phase 100% continuous
80% drop in voltage (Sag to 20% nv) AVC corrects 1 Phase 100% continuous

3 phase Sag more than 70% is considered outage. Unit will still correct, but not in acceptable voltage output window.

FGC Industrial Voltage Regulation & Correction Systems

At FGC, we're proud of the reputation we've been able to earn over the years as a leading voltage regulation and correction systems partner for organizations in just about every industry you can think of. In addition to industrial and manufacturing businesses, we've also partnered with organizations in mining, commercial/retail, oil and gas, and more . We offer the electrical power solutions that can help regulate power, correct sag events, and most importantly eliminate disruptions - all so that you can rest easy knowing that voltage sags are not something you have to spend time worrying about any longer.

Transformer-Based vs Transformerless UPS for Industrial Applications

Mon, 29 Jan 2024 22:08:45 GMT

A transformer-based ups system provides an isolation mechanism. There are inrush currents from all the mechanical equipment. This is not the place for a traditional computer UPS system.

Why a Transformer-based UPS System?

Back in the 1970’s, 1980’s and 1990’s, most UPS systems all had transformers. One of today’s 3kVA UPS systems that sits next to your computer in your office would be 6’ wide and the size of a chest freezer. The componentry was larger, transformers were used on the input and output side of the UPS system.

The output of the UPS was controlled by transformer power. When the industry started converting to higher technology inverter systems. More recently the IGBT (Insulated Gate Bipolar Transistorized Inverter), things changed. Footprints got much smaller; energy efficiency went up. The weight of the system became much less.

Where do I Use a Transformer Based UPS System?

Enter a harsh environment such as a manufacturing plant, a plastic extruder, or 3d Printing facility. The loads are dynamic. There are inrush currents from all the mechanical equipment. This is not the place for a traditional computer UPS system. A transformer-based ups system provides an isolation mechanism for the incoming power against the inductive, or high tax loads on the output of the UPS.

Transformerless UPS Systems: Understanding the Limitations in Industrial Environments

Transformerless UPS systems have become more common in commercial settings, primarily because of their compact size and energy efficiency. However, in the context of industrial applications, these systems often fall short of the protection and performance needed to maintain stable power under heavy load conditions.

Why Transformerless UPS Systems Are Often Less Effective in Industrial Environments

Industrial facilities face unique power challenges, including high inrush currents and frequent power surges, which transformerless systems are not built to handle effectively. Here’s how transformerless UPS systems compare to transformer-based UPS systems:

Surge Protection and Isolation : Unlike transformer-based systems, transformerless UPS systems do not offer the same level of isolation from electrical noise and surges. In an industrial setting where machines generate significant power fluctuations, this leaves equipment more exposed to potential damage.
Handling Inrush Currents : Many industrial machines, such as plastic extruders and manufacturing equipment, require significant inrush currents at start-up. Transformerless UPS systems struggle to manage these high currents, while transformer-based systems are specifically designed to protect sensitive equipment in such environments.
Space Efficiency vs. Durability : While transformerless UPS systems are smaller and may save space, they lack the robust build needed to endure the harsh conditions of industrial operations. Transformer-based systems, with their stronger construction, are far more reliable in dynamic industrial settings.

Importance of Understanding Transformerless UPS Systems

Even though transformerless UPS systems are generally less effective in industrial environments, understanding their operation helps illustrate why transformer-based systems remain the gold standard for industrial applications. Transformerless UPS systems may have a role in facilities with lighter, more stable loads, but for complex industrial demands, transformer-based systems provide the necessary protection.

Transformer Based UPS Systems for Industrial Applications

A traditional UPS system that originally was design for data centers will perform well to support those computer processes intricate to the manufacturing process. It will not do a good job supporting the mechanical and physical process type loads, or high inrush loads such as cooling systems. There will be a combination of systems to properly support all the loads deemed critical in the facility.

Today’s Industrial UPS System

Today’s industrial ups looks much like the older transformer-based ups system of the 1980’s and 1990’s. However more modern componentry, inverter systems, as well as the transformer provide for a robust system. These products can withstand he dynamic load environments such as a manufacturing process facility. They can backup runtime via flywheel systems, ultra-capacitors, and a variety of battery systems.

Choosing the Right UPS System for Your Industrial Facility

When selecting a UPS system, it’s crucial to consider your facility’s specific power needs:

Transformer-Based UPS Systems are essential for environments with high inrush currents, dynamic mechanical loads, and frequent power disturbances. These systems are built for industries like manufacturing, where protecting equipment from voltage dips, surges, and electrical noise is paramount.
Transformerless UPS Systems may be considered in smaller industrial environments with more predictable power conditions and lighter loads. However, they are often less effective in heavy-duty applications and do not offer the same long-term protection that transformer-based systems provide.

At Voltage Correction, we can help guide you through the decision-making process and determine which system best fits your industrial application’s needs. Contact our technical representatives today for assistance.

Which Transformer-based UPS do I choose?

Ferrrups Ferroresonant UPS System 500VA-18kVA

One of the first widely used transformer-based UPS systems was the Ferrups Ferroresonant UPS system by Best Power. This UPS System is still being made and used today. Eaton now owns the Ferroresonant line of Ferrups UPS Systems. It is now called the FX Series Ferrups UPS. It is built from 500VA to 18kVA. It is widely used on manufacturing environments. It can withstand hot environments. It is a bulletproof protector of loads in harsh environments.

3-Phase Large Transformer-based UPS Systems 100kVA – 3000kVA

Your Power Quality Specialist at Voltage Correction can provide you a quote for a Transformer based UPS System. For inquiries on Transformer-based UPS systems contact Voltage Correction today for a consultation on how we can help you protect your equipment and business from damaging voltage fluctuations.

Or Call 855-240-6776.

Have a site survey done to survey your facility and install a power metering device.

When you install equipment that will correct power and hold voltage within your facility, you will be providing your facility with protection against all outside influences of power. Halting wear and tear on other equipment in the facility by having stable voltage and power factor is the goal. The long term positives are lowered operations and maintenance costs by limiting voltage and amperage anomalies inside the facility. It is common to vet these issues by installing a monitoring device at the service entrance of the facility utility power. This is a low-cost method to really understand these issues and to make a proper diagnosis.

We are available to review electrical one-lines, Power Reports, Demand Usage, and any other data on your facility power.

Call your Voltage Correction Technical Representative today to discuss options to increase efficiency in your facility and correct our facility power issues!

Industrial UPS System: How to Choose the Right Solution

tmarks@facilitygateway.com (Tyler Marks) — Mon, 29 Jan 2024 21:26:57 GMT

What is an Industrial UPS System?

This is different than sizing a UPS for a data center load. The sizing and tolerance of an Industrial UPS System vs. sizing a Voltage Correction device is different. Both require an analysis of the load center and the incoming power to determine the best choice. This is done with an FGC certified meter to capture the load characteristics and power data. This monitoring will specifically pick up issues in the plant affecting equipment. Our national team of installation professionals can provide a turn-key installation proposal that includes delivery, installation, and electrical interconnection.

Why not a Traditional Data Center UPS?

Not all UPS Systems are created equal. Many customers seek out a traditional data center built UPS to quickly solve a problem in their plant or process facility. Not a good idea. Many expensive capital projects have had to be reversed and replaced for this issue. In general, not all consumers are informed, nor are the resellers of the product. An Industrial UPS System is much more expensive and careful thought must go into the sizing of runtime storage and what form to avoid large Cap Ex and Op Ex costs in the future.

The traditional IGBT or transformer based UPS used in a data center application is used to support loads that are constant and have little effect on the output sine wave of the UPS. It is not built for those loads disrupting the output sine wave of the UPS. In a typical industrial environment, those typical UPS units will bounce in and out of static bypass because it feels things are out of tolerance. This constant “banging” into the bypass circuity will eventually cause it to fail. The whole time this is happening, the load is at risk should the power fail because the unit is not on inverter and connected to the batteries. It is also bouncing on and off of inverter, therefore there isn’t power sterilization happening. So the very reason you installed the UPS to isolate the power and be ready for battery, it is not.

These types of occurrences operationally and failures are not warranted by the manufacturer. Eventually the static bypass fails and or the inverter section. This is not the fault of the OEM of equipment. They are not built for this type of environment. Types of Manufacturers of Data Center UPS Systems are Eaton, Liebert, Vertiv, Toshiba, MGE, APC, Mitsubishi and General Electric/ABB. Some of these models are inverter based UPS systems and can be used in harsher environments such as MRI applications. You will want to discuss this with your power quality consultant to choose the best Industrial UPS for your need. Some of the manufacturers of Industrial UPS Systems are Controlled Power, SE, and Ametek. Many of the large megawatt Industrial UPS Systems are contract manufactured by ABB and the like for special projects. Voltage Correction Consultants can assist in the specification development and project management of this type of project.

Which UPS do I choose for my Facility?

There are three categories of UPS Systems to choose from:

Traditional IGBT Data Center UPS

The Insulated Gate Bipolar Transistorized Inverter system is the standard for today’s data center UPS system. It provides a smaller footprint than its predecessor “Transformer Based UPS”. It is more efficient and gives off less heat. Therefore, your traditional UPS system solution will use this technology. And is specifically designed for computer-based loads.

Transformer Based UPS System

A transformer-based ups system will provide a more robust tolerance for harsh loads on the output. Back in the day, all UPS Systems had internal transformers. The transformer was the basis for scrubbing power and isolating the loads from the power utility.

Industrial UPS System

Today’s industrial ups looks much like the older transformer-based ups system of the 1980’s and 1990’s. However more modern componentry, inverter systems, as well as the transformer provide for a robust system. These products can withstand he dynamic load environments such as a manufacturing por process facility. They can backup runtime via flywheel systems, ultra-capacitors, and a variety of battery systems.

What type of batteries for an Industrial UPS System?

A traditional UPS System will use (VRLA) Valve Regulated Lead Acid batteries. An Industrial UPS System can use similar batteries. Many times it will need to tolerate higher temperatures. Facilities do not seek to invest capital expenditure similar to a Data Center UPS. A longer term battery can be installed such as a 10 year Pure Lead Battery. Ultracapacitors are an option for very short cycle runtime solutions. An Industrial UPS System may be properly sized to work in tandem with a standby generator system for long runtime solutions. There is a line between correcting voltage properly with Active Voltage Conditioning, and making the additional investment into storage battery runtime for short cycle power interruptions. Adding the battery storage will make the solution much more costly.

Voltage Correction has Solutions for short and long term power events.

Sub-cycle or multiple cycle events can be corrected by properly sizing an AVC to the load level. Most equipment damaging events are less than 3 seconds long. They are either a sag in voltage or momentary flicker. Power affected equipment can easily be preserved by properly installing a Voltage Corrective Device either at the equipment location in a facility, or choose a large distribution point for proper installation.

Mid-duration requirements up to 30 seconds can be specifically designed with a ultra-capacitor system, battery system, or flywheels. These correct not only the persistent sags, but also correct those longer duration outages which may occur in certain parts of the country. The seasonal effects on power from lightning, wind, and all mother nature events in certain times of the year usually justify this protection.

For installations requiring longer than 30 seconds, a Voltage Correction System may be a combination of voltage regulation, battery system, and/or emergency backup generator system. All need to be properly sized and coordinated to work efficiency and quickly during an event. But it is entirely possible to set up a system that can be sophisticated enough to correct short and long term power issues. Contact your VC consultant today to discuss these options for your facility.

Have a site survey done to survey your facility and install a power metering device.

We are available to review electrical one-lines, Power Reports, Demand Usage, and any other data on your facility power.

Call your Voltage Correction Technical Representative today to discuss options to increase efficiency in your facility and correct our facility power issues!

The Difference Between a Power Surge vs. Power Outage

Mon, 18 Dec 2023 21:40:38 GMT

Industrial facilities face significant risks from power surges, sags, and outages, which can disrupt operations and damage equipment. Understanding the differences between these events and how to protect your facility is essential.

There is a difference between a power outage and a power sag. Although the flicker of lights or temporary power interruption may seem like an outage. Many times a sag can dip to a level that appears to be an outage. This is a major difference in how to correct these problems.

90% of industry power problems are due to sags , either internally derived or externally created. You do not need a transformer to blow up to create a sag. Taxing loads on the utility grids, particularly in the summer, can create rolling sags or brownouts. These sags on the voltage will dip so far that lights will flicker or flash out. These dips in voltage have a direct offsetting effect on amperage, causing a spike of amperage throughout your facility. For these reasons, all industries should install some form of voltage regulation or protection.

Power is not perfect and rarely holds at nominal voltage. Therefore, there is a constant change in voltage, which means a constant change in amperage. This constant change is always working at the power supplies of all equipment. With much process control equipment (PLCs) now integrated into the assembly and production process, it is imperative to extend the life of this expensive equipment through simple voltage regulation or correction .

What is a Power Surge?

Power and voltage surges only last for a millisecond, but they are very damaging to electronic equipment. These affect the electronic circuit by raising the voltage a few hundred or even a few thousand volts. Understanding the causes of power surges and how to reduce the risk helps save businesses from downtime and unexpected costs.

Common Causes of Power Surges

The following are two common causes of power surges within an industrial facility:

Internal Surges

Internal surges occur from the day-to-day operation of many devices within the facility. Those devices include:

Variable speed drives
Generators
Air conditioners
Electric motors
Elevators
Other electrical equipment.
Power surges also result from internal circuit breakers and fuses from within the equipment or at the electrical panel

External Surges

Weather events cause external power surges, such as lightning. That is by no means the only reason why they take place. Other possibilities include:

Electrostatic discharge
Switching on or off capacitor banks
Power line disconnection and reconnection
Utility load switching
Turning transformers on and off
Poor quality within the distribution grid

The Difference Between a Power Surge vs Power Outage

A power surge and a power outage have very different effects on your facility, though both can cause major disruptions. A power outage is a complete loss of electrical power. When an outage occurs, the entire system shuts down. Outages are generally caused by external factors, such as severe weather, equipment failures in the grid, or utility grid issues. Outages can last for seconds, minutes, or even hours, depending on the cause.

In contrast, a power surge is a sudden and brief spike in electrical voltage. This surge lasts only milliseconds but can have devastating effects on sensitive electronics and equipment. Surges can originate from internal sources, like machinery within your facility, or external sources like lightning or grid fluctuations. While outages are often noticeable and disruptive, surges may go unnoticed but gradually degrade your equipment over time.

Understanding the difference between surges and outages is crucial for industrial facilities. While both can lead to downtime, surges have the additional risk of causing permanent damage to critical systems like PLCs, drives, and motors. This makes surge protection and voltage regulation essential in industrial environments.

Direct Benefits to Active Voltage Correction for Short and Long-Term Sags

Implementing active voltage correction in your facility can provide the following benefits:

Reduce DOWNTIME
Reduce/ Eliminate voltage/amperage fluctuation events wearing all computer components
Reduce/ Eliminate voltage/amperage fluctuation events wearing all drives, PLC’s, and control equipment.
Lower Maintenance and replacement parts cost
Constant Voltage Environment for all facility equipment
Ability to monitor and understand load dynamics and incoming power

A Power Surge is Caused by Both Internal and External Factors

A power surge is caused by an event or issue within the facility or from outside the facility. A higher percentage of power surges tend to occur as a result of problems within the facility, including within the electronic equipment itself. Both external and internal events leading to power surges cause significant problems.

A power surge occurs when there is a sudden change in the electrical conditions within the circuit. This change leads to larger amounts of energy released to the electrical system.

The Need for Industrial Surge Protection

Today’s industrial and professional equipment is dependent upon microprocessors and other sensitive electronic equipment, increasing the world’s need for greater protection from Power Sags and Surges.

Microprocessors, programmable logic controls (PLCs) and other electronic circuitry that is used to automate industrial machine programming, tool changes, motor speed and other processes within sophisticated manufacturing systems is especially vulnerable. At industrial sites, power surges wreak havoc on equipment, causing catastrophic failures, interrupting processes and causing equipment to prematurely age, leading to failure.

In addition to externally generated surge events, such as lightning and grid switching, industrial equipment is also susceptible to damage by internally generated surges. The offending surges can be utility-generated overvoltage events, or power fluctuations created by machinery operating in adjacent areas of the plant. All will have the same adverse effect on both the machinery and shop productivity. Internally-generated surges reinforce the necessity for facility-wide surge protection applied at all stages of the electrical distribution system, from the electrical service entrance down to the single-phase loads.

What This Means for Industrial Facilities

For industrial-sized facilities, power surges, sags, and outages can result in significant operational disruptions. The downtime caused by these events can halt production, leading to missed deadlines and increased costs. Equipment failure due to surges and sags can also cause long-term damage to essential machinery, such as PLCs, drives, motors, and other critical systems, ultimately reducing their lifespan.

While power outages are often resolved by backup generators or UPS systems, power surges and sags require more proactive solutions. Voltage fluctuations caused by sags and surges can degrade your equipment over time, even if the effect isn’t immediately apparent.

Solutions for Industrial Facilities: On-Site Power Assessment

To safeguard your facility from costly downtime and equipment failure caused by power surges, sags, and outages, the first step is conducting an on-site power assessment . This assessment will help identify vulnerabilities and allow you to implement proactive solutions such as voltage correction and surge protection.

When you install equipment that corrects power and stabilizes voltage within your facility, you protect your equipment from outside influences of power, reduce wear and tear, and lower operational costs over time. Installing a monitoring device at the service entrance of your facility's utility power is a low-cost, effective way to diagnose these issues and take corrective action.

We are available to review electrical one-lines, Power Reports, Demand Usage, and any other data related to your facility’s power.

Call your Voltage Correction Technical Representative today to discuss options to increase efficiency in your facility and correct your facility power issues!

Avoid Downtime in Methane Digesters for Dairy Operations

Mon, 12 Jun 2023 16:16:00 GMT

The onset of “LCFS” Low Carbon Fuel Credits spiked demand for power created from the Dairy Industry in the form of Methane Digester Systems as a Distributed Energy Resource, or DER. Low Carbon Energy Credits, which are derived by having a low carbon impact in the production of the power created, can be purchased by large Power Conglomerates to offset the high carbon impact is systems like drilling or fracking for natural gas. Dairy Farm Methane Digester Systems in operation all over the country now can not only produce valuable resource at a premium, but also satisfy demand for these High-Value LCFS Credits on the West Coast. As the trend continues for State, Municipal, and general Government Mandates, and incentives for a cleaner, carbon neutral supply, these Digester farms, Solar, and Wind Farms will likely see an increase in price demand per kW.

High Dollar Digester Natural Gas to West Coast Instead of Electricity

As Methane Digester production was introduced a couple of decades ago, it was a process framed at converting the by-product of Dairy Farms manure supply into a usable form of gas that could be burned in a very local gas generator and alternator producing power which would assist in running operations at the farm, and if efficient enough, sell some of the power back to the utility. The incentive on the value of that power was minimal other than the direct benefits of creating a kW out of something you would otherwise spread on a field. As the digester systems have become more evolved and efficient the natural gas by-product of the process can be directly loaded into a distribution truck, taken, and contributed into a pipeline, and shipped to a western state. A Dairy and Digester Farm in WI can now efficiently sell LCFS creditable power units to a larger gas and petroleum supplier to offset otherwise high carbon production. This is why there is a demand premium put on the digester produced gas.

Points of Interconnection POI for Methane Digesters

Whereas the Point of Interconnection of a Solar Grid may consist of connecting to a substation at various voltages, integrating it’s power capacity at that point in the power grid, then having the local utility manage the distribution of that power. The new ability for natural gas to be produced in states far away by a methane digester and trucked over to a distribution pipeline and connected into a regional pipeline for distribution, opens up a whole opportunity for interconnected clean power. The space needed to operate facilities such as widespread Dairy Operations, the requirement for feed stock, and the proper environment for the cows requires vast and variable resources. This gives a very different look to the future of Methane Digestor processing and the Dairy Industry of the future.

Process Interruptions and Voltage Stabilization in Methane Digester Processes

For proper execution of the digester process, the voltage supporting the processing equipment, pumps, boards, and equipment must have good stable voltage. This really has nothing to do with the output product of the digester, but what electrical supply is available for use at the site. Usually this is a rural farm environment without the most reliable voltage. Because of the relationship between a change in voltage and changes in amperage used by equipment. Any drop or sag in voltage will derive a direct and offsetting spike in amperage. Vice versa, a surge in voltage will provide a direct offsetting sag in amperage used by the equipment it is supporting. All of this means that the equipment using the imperfect voltage at these sites gets a pretty harsh environment to operate.

Solutions to Methane Digester Process Interruptions

The maintenance budget to operate a Methane Digester is a direct influence on its output and success. If control boards to the operating systems are constantly burning out due to stray voltage problems, this is easily correctible. If a shut down is directly attributed to a sag or interruption in power, this also is easily correctible. Many digester farms have backup generator systems to make sure that the processes do not ever stop. This does not, however, correct the ever-variable voltages that happen in an operation with pumps and large equipment cycling on and off. Voltage Stabilization and Correction Systems can be installed at point of controls, or around the entire process electrical supply to thwart off these damaging effects.

Prepare for Voltage Issues with Voltage Correction

We understand that finding the right solution for all industrial power issues is important for maintaining the operation of your business. At Voltage Correction, a Division of Facility Gateway Corporation, we pride ourselves on quality customer service, and overall industry experience in the mission critical electrical power solutions market. Our team members are available to assist you throughout the system selection process and will review the specifications and concerns you address. Voltage Correction is a provider of power correction services globally. Please contact your Voltage Correction representative to discuss power correction options for your facility and plastics operation. Call 855-240-6776.

Why are Utilities Rejecting Solar Farm Power?

Sat, 10 Jun 2023 13:04:00 GMT

With current Government and Municipal Mandates, Solar Farm DER (Distributed Energy Resource), connect to a specific POI (Point of Interconnection), on the electrical grid. The POI connections change at different capacity outputs and voltages. Where the POI connection is, the level of Voltage at which it connects, and how far a distance all matter. As a function of all of those factors, the quality of the DER-made power, at the Point of Interconnection may matter the most. The utility may reject the planned Solar DER, or worse, reject the power after the plan has been constructed. These are new challenges for the Solar Power Industry today. There are some answers.

Utility Rejected Solar DER Interconnect Power at Point of Connection

The Electrical Utility, who is tasked with collecting and distributing all power generated by Solar DER’s, reserves the right to reject the power generated at the connection point POI. The Utility will maintain strict guidelines as to what voltage parameters, ampacities, resonances, and disturbances it will tolerate into the electrical utility grid system. It may review a plan for a specific DER in a location at a specific voltage, once testing is done, require the DER connect at a different point on the grid miles away and at a different voltage. This is costly to the project and its original expected payback.

Solar Projects Stopped in their Tracks by Reactive Voltage Control RVC

As a developing issue unrecognized largely by the industry, Reactive Voltage Control RVC , and Reactive Power Control RPC , are now straight in the crosshairs of the utility transmission administrators. Reactive voltage generated by Solar DER systems are an intently measured data point by the utility. Reactive Power is damaging to distribution systems, lowering real power capacity and efficiency. Reactive power will increase equipment replacement and maintenance costs to manage not only the utility transmission, but everything receiving the so-called contaminated energy.

What Amount of Solar Reactive Power will Utilities Accept?

Power Lines absorb and provide reactive power on a normal basis. Devices absorb reactive energy depending on the power factor. When a generative load starts in the factory it uses a percentage of reactive power and creates heat. The lower the power factor, the higher the reactive power consumption. Reactive Power does not travel well over electrical lines. Therefore, a requirement to collect more “real power” by the utility is a prudent policy. The Solar Industry, at this time is guessing what the utility will require for RVC Reactive Voltage Control long term. DER’s are relying on single case examples, and Plan Review’s by the utility to find out this feedback after design. Again, convoluting the project budgeting process.

Are There Solutions?

As the RVC and Reactive Power conversation is developing as a major trending topic for Solar Farm installations. There are ways to mange RVC and RPC. Current options to mitigate the reactive power issue area available depending on the size and scale of the operation and distribution requirements.

Review your RVC and RPC issues with Voltage Correction

Why is Utility Power in Mexico So Bad?

Fri, 09 Jun 2023 16:21:00 GMT

Many industries have moved manufacturing operations to Mexico for various reasons. Plastic Extrusion operations, steel making, wire manufacturing and general assembly plants.

In today’s manufacturing environment with the complicated controls systems and robotics running many of the processes, an unstable voltage situation provides much disruption to continuous operation. Therefore, the power related problems with Mexico’s Power Utility distribution can affect almost all manufacturing installations.

Power Sags in Mexico

Not only are seasonal brownouts very common, general sags and surges in the electrical voltage are constant. Whether it is aged electrical distribution lines, or the amount of distance that voltage has to travel to get to it’s ultimate customer, many factors contribute to the degradation of Mexico’s Utility power as it transits it’s lines. The fact that there is more and more demand being placed on the already taxed electrical grid is an indication these issues are not going to fix themselves or go away anytime soon.

What causes Voltage Sags in Mexico?

Voltage as it leaves the utility distribution point is always very constant. As it travels along the electrical distribution path to all of the customers it runs into the various issues that end up affecting the stabilization of the voltage. The more commercial customers creating demand along the distribution line all contribute to the overall fluctuation in voltage. The heat from the environment cause hvac systems to cycle on and off. These demand variations on the electrical grid contribute to the burden put on the lines.

What can be done to Correct Mexico’s Power?

There isn’t a commercially available technology to “re-align” the voltage as it travels down the distribution path. The larger the transmission line, the more power (voltage and amperage) you can move across a single path to a destination. That electrical distribution must always be split up and voltage stepped-down to a usable product at all site levels. Like a body with main arteries, then smaller blood vessels, then to capillaries, all of the paths affect the ones after.

What Types of Power Outages happen in Mexico?

As discussed, there are various causes to the power related issues that are affecting industry in Mexico. The following are some of the main causes:

Power Sags cause by Demand

The amount of customer demand, and the variation of use by all the customers along the electrical distribution path all contribute to Sag activity. Manufacturing and industry have large loads ramping up at different times of the day. Daily levels of HVAC systems across the grid coming to a peak mid-day contribute and pull on the entire system at once.

Substation Switching

Not just in Mexico, but all Electrical Utilities and Transmission companies are required to maintain distribution by doing electrical switching at the substation level. This switching, though measured in milliseconds, provides in some cases daily issues for customers. This is not something you can do anything about other than install protection at your site level.

Weather Related Sags and Outages

Weather related power issues are a prevalent culprit in power events. Lighting strikes, Electrical Storms, hot high-demand days, are a constant contributor to the relative instability of all electrical distribution grids.

Nature

Tree’s, animals, birds, water, ultraviolet rays, wind, plus any and all aspects of nature are constantly interacting with the above, and below ground Utility Grid. There is no end to the amount of influence here. Only that it is constant and that will never change.

Industries Affected

All industries in the manufacturing space use much electricity. Robotics, PLC Controls, Computer guided assembly lines, all use and require sterilized power to properly operate. Some of the largest manufacturers in the world have located plants in Mexico’s region.

-Plastic Extrusion Companies

-Wire and Steel Manufacturing Plants

-Automotive, Aerospace, and Medical Manufacturing

-Appliances and Electronics

-Textiles

Solutions to the Problem

Voltage concerns should be dealt with at the site level. As mentioned earlier, going back to the distribution point (Utility Source), does not provide an answer to things that affect the distribution grid after that point. Mexico’s Utility providers, if metered at point of distribution, can control what happens at that point. There is very little they can do after it leaves the distribution point beyond repairing interrupted lines.

All customers should do an internal site review of power usage. Customers should get meter data of the power anomalies at the site level, then choose the proper technology to correct those issues.

Some of the existing technologies to correct these issues are Active Voltage Regulation , Active Voltage Correction , Power Conditioning , and Power Factor Correction Solutions. All of these help various degrees of power sag and surge activity. There are also systems that can carry across Sub-station transition switching interims with a runtime. These systems use Ultra-capacitors, Batteries, Integrated Zinc Bromide Systems, and other technologies to ride through low sag and power outage events.

Prepare for Power Sags and Outages with Voltage Correction.

Thera are many Voltage Correction Solutions you can do at your site level to mitigate any and all of the affects of voltage sags and surges.

Nashville Power Outages due to Tornado Event

Sat, 11 Dec 2021 17:10:00 GMT

See current power outages in the Nashville metro area via our Power Outage Tracker site linking to NES Nashville Electric Service.

Power Outage Tracker on Industrial Clean Power

Please see link below to connect to NES Power Outage Map

Power Outage Tracker Links | Current U.S Power Grid Problems (industrialcleanpower.com)

Contact Industrial Clean Power

ICP is experienced in installing voltage protection systems for industries. We can help you choose the right system for your project. Please contact your representative to discuss opportunities to correct voltage or power sag issues in your facility.

www.industrialcleanpower.com , (844) 501-1887.

The post Nashville Power Outages due to Tornado Event appeared first on Industrial Clean Power .

The Difference Between a Brownout vs. Power Outage

Tue, 29 Jun 2021 15:07:00 GMT

A sag in voltage or brownout condition can represent a major issue for most equipment. The longer the brownout, the more impact this event will have on equipment components. Depending on a situation, an outright power outage may be a better scenario than extended brownouts for equipment.

How are Brownouts Caused?

A brownout is a drop or sag in voltage along the electrical grid distribution. This is caused by increased demand on the utility grid. In high heat, summer conditions the increased demand of hvac systems over a large area will outweigh the supply of power. Therefore, causing a nominal drop in voltage across systems. Since there is not a disruption in service, this “over-demand” will cause the overall voltage to sag for an extended period of time. Causing rolling or regional brownouts.

Why are Brownouts Bad for Equipment?

Under normal power conditions, electrical grid distribution voltage is maintained within a certain nominal range. A variance in voltage of 5-10% is not unusual due to local equipment start/stop, or different events affecting the grid daily. Components are not made to endure long periods of low voltage. In fact, when low voltage is applied to power supplies a higher amperage event takes place to compensate for the decreased voltage. This spike in amperage is what causes heat and “burns out” equipment. Much like when a circuit in your house trips when amperage spikes over the breaker rating. When amperage is elevated for periods of time it can cause permanent damage to components, wiring, and mechanical equipment.

Why are Power Outages better than Brownouts?

Well, no one likes a power outage. As for equipment that is sensitive to amperage spikes such as controls systems or manufacturing processes, some would say it would be better for that equipment to just shut off rather than endure extended voltage sags and amperage spikes. Re-booting production lines, cleaning out extrusion systems vs failed equipment parts replacements are the trade-off.

Avoiding Brownouts

These days there is equipment which can be installed that will perform against voltage sags and brownouts. Rather than installing an expensive UPS system and batteries that intercept and replace the voltage, an Active Voltage Regulator may be installed to correct these temporary brownout scenarios. Boosting the voltage sag back to normal. Even a considerable single-phase voltage sagging to 30% of normal a Voltage Correction Device can boost that back to nominal. This is the best protection against this type of disturbance.

Voltage Correction

Voltage Correction is a provider of services to industry to install voltage correction devices, monitor incoming power to facility for solutions, and provide customers with comprehensive power solutions. 855-240-6776

How do I Size a UPS for a 3D Printer?

Tue, 04 May 2021 14:57:00 GMT

The industry of 3d printing has become increasingly integrated into our society’s products and services. As voltage problems exist in our electrical distribution systems, 3d printing facilities face issues with power outages, downtime, shutdowns, repair, and re-starts. Here we discuss the options available to defend against downtime with 3d printers due to electrical power outages, sages, or surges.

Can I use a UPS System for 3D Printing?

Yes you can. 3D printers are not a typical UPS load such as a computer server. 3d printers have cooling mechanisms or chillers attached. They also have blowers, and sometimes heating elements. You cannot always support a 3D printer with a traditional UPS System . You can, however, oversize a UPS System for the inrush current. You will need a proper sizing calculation for this design. You can make a mistake by sizing the UPS system to the running load amps. Then when it comes time for the UPS system to operate, it may fail due to the inrush current provided by the different systems on the 3D printer.

What is Inrush Current when sizing a UPS System?

Inrush is the step up in current or demand of a load that happens when equipment cycles on. Many mechanical loads, chillers, and cooling systems have inrush currents many times that of their actual running load. Therefore a mismatch can occur when sizing a UPS System for complicated system such as 3D Printers. The magnitude of the inrush must be calculated for properly sizing a UPS System.

Common Power Related Causes of 3D Printer Downtime

Voltage: Voltage swings, power sags, and surges can affect the operation of your 3d printing facility. Any voltage fluctuations outside the normal acceptable window can cause disruptions in work in process. These can be fixed with a properly sized UPS System or Voltage Regulation device.

Power Outage: Complete power outages are obvious threats. Having a UPS System with a backup power runtime allows for seamless operation. If you have a generator installed this will provide a transition to emergency back up generator power and potentially unlimited uptime.

3D Printer Voltage Requirements: Many 3D printers operate from different voltage than the facility general power. Many times, a transformer is required to convert the power to the required voltage a 3d printer needs. Many of today’s 3d printers are manufactured overseas where voltage is different than in the U.S. This makes for some complicated electrical distribution scenarios, step-down transformers, more heat generating activities, and complicated to properly size a UPS or voltage correction system.

Voltage Correction

Your power quality consultants at Voltage Correction are ready to assist in your sizing of a UPS or Voltage Correction system to provide maximum runtime of your 3d Printing facility. Please call us at 855-240-6776.

What is a Rolling Brownout?

Sun, 02 May 2021 05:02:00 GMT

A rolling brownout is a continual sag in voltage in the utility grid distribution. Rolling brownouts are cascading drains on the utility infrastructure that do not allow the supply side of the utility power to catch up and maintain a constant nominal voltage. The result is a continual reduction of voltage power, or sag condition.

What Causes a Rolling Brownout?

Can a Rolling Brownout be Avoided?

Avoiding a brownout scenario in the future is not possible as we are all at the mercy of the utility distribution grid. Customers can install voltage correction equipment that will provide support for a rolling brownout event. Emergency Generators, Uninterruptible Power Systems with batteries, and Active Voltage Regulators can be used to combat voltage issues in a facility.

Rolling Brownouts and the Future of Power Distribution

As metropolitan areas keep expanding there is a continuous additional tax on America’s electrical grid system. Industry that is continuously improving its efficiency in processes and pollutants, still needs much electricity to exist. Commitments to clean energy programs, solar, wind, geo and other clean power producing processes will assist in overcoming the source demand that is placed on the electrical utilities today.

For information on power outages check the U.S National Grid Power Outage Tracker Map.

Voltage Correction

Voltage Correction is a provider of services to industry to install voltage correction devices, monitor incoming power to facility for solutions, and provide customers with comprehensive power solutions. Call us at 855--240-6776

What is a Voltage Regulator?

Sat, 01 May 2021 21:47:00 GMT

A Voltage regulator is a component that that provides a consistent voltage output, set to a voltage nominal position to hold. A voltage regulator can provide a stabilization of voltage that is preset, and can hold that voltage to avoid certain swings and disruptions to the components it is supporting.

Where are Voltage Regulators Used?

Voltage regulators can be found in power supplies for all kinds of personal use object. Computers use a voltage regulator on board to maintain a proper consistent voltage to computer components to avoid damage. Because in most computers the voltage is converted to DC (Direct Current) for use by the processors and internal components. The voltage regulator will maintain that voltage and stabilize it against fluctuations. Again, a variation in the voltage or a fluctuation will damage componentry.

What Does a Voltage Regulator Do?

It has to do with the inverse effect of voltage and amperage. While voltage is steady say 120v at 2 amps. The equipment will constantly draw the 2 amps needed to operate. If the voltage were to drop say by 10%, the equipment would seek to compensate by pulling an inverse amount more amperage. Should there be a 50% sag in voltage, the inverse effect of the amperage is quite extreme. Therefore, the spike in amperage which can burn out equipment components. In the case tripping a breaker in an electrical distribution panel, the breaker received a amperage load that exceeds its rating. Hence why breakers trip due to a spike in amperage when there is a power outage, sag, or brownout.

What Size are Voltage Regulators?

As in the above example they can be quite small to fit inside of a laptop computer. Others are quite large. Voltage regulators are used inside large power generation facilities to control the output of the power. A voltage regulation system may be installed into power generating dam system to regulate the output voltage of the large aqua power producing systems. Many manufacturing and plant facilities will install (AVR) or Active Voltage Regulation Systems on the front end of the facilities or specific equipment that will provide a consistent voltage into its important processes.

What types of Companies use Voltage Regulation?

Robotics, plastic extrusion, 3d printing, CNC machines, all have critical processes that cannot be disrupted. Almost all plant facilities use (VFD) or variable frequency drives to control some sort of process or mechanical system. Stray voltage, sags, or surges all affect the operations of these systems. Voltage sags over time will wear on the components and cause failures.

What are the Dangers of not using Voltage Regulators?

Large enough swings in voltage will knock processes offline. 3D printing processes and form processes such as plastic extrusion require a consistent voltage input to properly complete the task. A voltage event can knock these systems offline and cause considerable downtime and reset. It is difficult for a facility to stop mid process and reset the production line. Many times, the raw materials need to be thrown away and start over as the process has been disrupted.

Choosing the Correct Voltage Regulator with Voltage Correction

Voltage and current are constantly changing in distribution systems, wreaking havoc on your drives, boards, and controls. At Voltage Correction, we want to help you correct and hold voltage to avoid deviations that slowly wear out control and process equipment. If you require professional assistance to protect your facility’s devices, ask our team about our Active Voltage Regulation (AVR) technologies and our other voltage stability solutions.

We are also able to provide you with product solutions, metering, and site visits to any customer site in the contiguous U.S. We are focused on providing quality solutions specific to industrial customers, such as transportation, plastics, process industry, and others dealing with harsh electrical environments.

We encourage you to contact us online today or give us a call at 855-240-6776. In either case, we look forward to helping you find the best clean power solution for your industrial needs.

UPS vs AVR – Which Do I Choose?

Sat, 01 May 2021 10:55:00 GMT

Because more than 90% of power related problems for industry are related to voltage sags. It is important to analyze the power prior to choosing a corrective method. There is more up-front capital cost related to an Industrial UPS system, as well as recurring costs. Most of the ups system equipment built for Data Centers does not qualify to correct harsh environment voltage. For that matter, the nature of the loads in a facility requires a totally different sizing method for UPS systems in an industrial setting. For these reasons it is imperative to measure and analyze the loads in the facility, as well as the power to determine the best course of action.

How to Choose Between UPS and an AVR

The Harsh environment in a plant facility requires a robust Industrial UPS solution or an (AVR) Active Voltage Correction Device. The sizing and tolerance of an Industrial UPS System vs. sizing an AVR Voltage Correction device is different. Both require an analysis of the load center and the incoming power to determine the best choice. This is done with a FGC certified meter to capture the load characteristics and power data. This monitoring will specifically pick up issues in the plant affecting equipment. Our national team of installation professionals can provide a turn-key installation proposal that reflect delivery, installation, and electrical inter-connection.

It is not that you should oversize a UPS System for Industrial type loads. It is more that it may not work all together based on the technology. Seek out a qualified contractor to assist in measuring loads. Contact your ICP Representative to discuss the sizing and load calculations for a proper AVR, AVC, or Industrial UPS System.

Pifalls to Installing UPS vs AVR

-Overlooking Inrush currents on mechanical loads leading to overloads

-Expecting a UPS System to support facility loads like a data center

-Not considering temperature environment

-Not considering Air Quality issues for UPS

-Overall technology: inverter-based UPS vs transformer-based UPS

Industrial Clean Power Ready to Assist

Voltage Correction is here to help review your power consumption and issues in order to increase efficiency in your facility and correct facility power issues with real solutions. If you’re ready for a product solution, metering, or want to request a site visit, contact our team today and let us know how we can help Phone 855-240-6776

AVC vs AVR: Active Voltage Correction vs. Active Voltage Regulation

Thu, 08 Apr 2021 19:26:00 GMT

Power outages and power sags across the United States frequently occur due to outdated power grids and weather related events. These power events are costing businesses and consumers billions of dollars. Some American power lines date back to the 1880s, and the ever-increasing demands for power are pushing capacity to the limit with no signs of slowing down.

You might think there is little you can do to combat process downtime, power outages, sags, spikes and surges; however, you can protect your facility’s supply. Consider the differences between Active Voltage Correction vs. Active Voltage Regulators.

What is Active Voltage Correction (AVC)?

An Active Voltage Conditioner (AVC) is an inverter-based system that protects sensitive industrial and commercial loads from voltage disturbances. It provides fast, accurate voltage sag correction plus continuous voltage regulation and load voltage compensation. The AVC is a flexible device that can be used in multiple applications. It has an operating efficiency exceeding 98% and provides extremely fast response to three-phase sags down to 50% nominal voltage, and single-phase sags down to 25% nominal voltage. Standard models are optimized for sag correction, voltage balance, and flicker reduction. This truly will correct most, if not all of your power related issues up until a total outage. Systems can be installed at the Electrical Service of a Facility, or at the Point-of-Use equipment needing the protection.

What is an Active Voltage Regulator (AVR)?

In the context of protecting industrial or manufacturing equipment the (AVR) or Active Voltage Regulation option is the most inexpensive to correct simple line voltage. The AVR provides consistent nominal output voltage based on a limited input voltage window. It does not provide the wide swing correction an AVC system will in the event of a major sag, surge, or power anomaly. The size and technology choice for a customer specific option will depend on the voltage window they are trying to correct. Many times a voltage regulator along with a transformer to isolate incoming anomalies is chosen. In smaller applications a ferroresonant transformer based system can provide voltage regulation with battery storage backup. Such as the traditional Ferrups UPS System from Eaton for manufacturing or process control environments. The larger Medium Voltage AVC is an ideal solution for complete facility protection. Its standard outdoor enclosure saves valuable indoor floor space. While the low voltage units can be applied to a process line or a specific critical load. Outdoor or enclosed models may be provided per site requirements.

The Case for AVC Active Voltage Correction vs AVR Active Voltage Regulation

Best used for large power conditioning in harsh electrical environments, AVC and AVR are similar in function, but have major differences in performance.

If you regularly experience voltage fluctuations such as sags, power swells , spikes, transients, or electrical noise , (AVC) Active Voltage Correction can truly make a difference in protecting sensitive loads by delivering pure and clean power. It is going to be a garbage eater for bad voltage up until an actual outage. Many consider a flicker of lights, or quick off/on in power to be an outage. 90% of short-term electrical events affecting facilities are sags , and many of those sags in a single phase of power. An AVC can correct most all of those issues by boosting the line voltage of the lagging phase up to an operative level. This pays off big in manufacturing, and process environments that work stoppage can get expensive.

Conversely, a voltage regulator (AVR) protects equipment against surges or small drop offs in power, but will not correct major swings, sags, or variations in power.

Why Not an Industrial UPS?

Active Voltage Correction is different than sizing a UPS for a data center load. The sizing and tolerance of an Industrial UPS System vs. sizing a Voltage Correction device is different. Both require an analysis of the load center and the incoming power to determine the best choice.

Keep Your Power Clean with Voltage Correction

Want to find out more about an Active Voltage Correction (AVC) or Active Voltage Regulator (AVR) for your facility? Voltage Correction will work with you to understand your needs and keep your business and equipment always safe & running.

Contact Voltage Correction today for a consultation on how we can help you protect your equipment and business from damaging voltage fluctuations. Phone 855-240-6776 .

Power Conditioner vs Stabilizer: An Overview

Thu, 25 Mar 2021 16:40:00 GMT

Power outages across the United States frequently occur due to outdated power grids. These outages are costing businesses and consumers billions of dollars. Some American power lines date back to the 1880s, and the ever-increasing demands for power are pushing capacity to the limit with no signs of slowing down.

You might think there is little you can do to combat power outages; however, you can protect your facility’s supply. Consider the differences between a power conditioner vs. a stabilizer and the roles they perform in ensuring a steady supply of power.

What are Power Conditioners?

A power conditioner is also known as a power line conditioner or a line conditioner. These devices are intended to improve the quality of power delivered to any equipment that is supplied via an electrical load.

Most businesses are familiar with surge protectors as a defense of protecting computers and other electronic devices against damaging voltage spikes. A power conditioner operates in a similar way to offer additional protection for components of home office devices. What causes your devices’ damage is that voltage fluctuations surge through the electrical lines, phone lines, LAN connections, and COAX TV inputs. These power surges degrade the performance of the device and lead to system failure.

A power conditioner acts as a buffer between the outlet in the wall and the system that smooths out voltage fluctuations. Because radio and electromagnetic interference affect system performance, a power conditioner can ward off these fluctuations.

Strengths & Weaknesses of Power Conditioners

Pros

Cons

A balanced transformer offers noise reduction that is superior to passive-types. It balances the AC power feed better suited to audio and video devices. In addition to being more costly than passive type filters, power conditioners are larger, noisier, heavier and offer limited power delivery in industrial and commercial settings.

The AC regenerative types also tend to be larger and pricier. They tend to throw off a lot of heat; however, they are much better at addressing noise problems found on the audio and video spectrum.

Passive-type filters are the least expensive and offer fundamental noise-reduction capabilities. When it comes to the quality of your power and the optimal performance of your equipment, keep in mind the rule of thumb: you get what you pay for.

What are Power Stabilizers?

A Power System Stabilizer (PSS) is the generator equipment used to produce high quality and stable power supply in the event of a disruption to electrical services that produce a significant deviation of the main voltage. Modern stabilizers use high-performance control circuits to set voltage requirements through digital control circuitry.

Power stabilizers are a solution to optimize power to electronic appliances that are sensitive to voltage fluctuations. They deliver a constant voltage to an electrical load regardless of voltage fluctuations. They also work on many different devices such as air conditioners, televisions, monitors, medical equipment, computers, CNC machines, and telecommunication equipment, to name a few.

Strengths & Weaknesses of Power Stabilizers

Pros

Power stabilizers are used in industrial applications such as laboratory equipment, industrial machines, medical apparatus, and offset printing machines. Voltage stabilizers are often preferred to using costly electrical equipment to protect against harmful low/high voltage fluctuations.

Cons

Voltage stabilizers are mostly used for low rating appliances in residential, commercial, and industrial applications. This is because they are low weight and low cost. They have limitations when it comes to slow voltage correction speed. They tend to be less durable, less reliable, and with interruption to power, cannot withstand high voltage surges.

Power Conditioners vs. Stabilizers – Which One Is Best For Your Needs?

Best used for large power swings in harsh electrical environments, power conditioners and stabilizers both are similar in function, but have their best use case scenarios. If you regularly experience voltage fluctuations such as spikes , transients, or electrical noise, a power conditioner can truly make a difference in protecting sensitive loads by delivering pure and clean power. Conversely, a voltage stabilizer protects equipment against surges or drop offs without causing changes to incoming voltage. To decide which is best for your needs, carefully weigh the pros and cons of each system outlined above and compare them to your power demands.

Keep Your Power Clean with Voltage Correction

Want to find out more about the power conditioner vs. stabilizer you need for your specific business? Voltage Correction will work with you to understand your needs and keep your business and equipment always safe & running.

Contact Voltage Correction today for a consultation on how we can help you protect your equipment and business from damaging voltage fluctuations. Call 855-240-6776

AVR vs UPS: Active Voltage Regulator (AVR) vs Industrial UPS System

Thu, 04 Feb 2021 15:29:00 GMT

As the electrical equipment market continues to become heavily saturated with a wide range of products, the need for clarity is becoming increasingly important. Today, the range of available Active Voltage Regulation (AVR ) and Uninterruptible Power Supply (UPS) system products are expanding even further, leading many to believe that the two are similar, even redundant in function. However, despite this popular belief, these two devices are actually very different in terms of the functions they perform for your facility and the ways in which they work. Below, we explore the differences in function between an AVR vs Industrial UPS System , and including AVC Active Voltage Correction with battery , to provide guidance on which of these products may be best suited to cater to your voltage regulation requirements.

Uninterruptible Power Supplies (How They Work)

Acting as a backup power supply, a UPS System is designed to deliver power during short or extended power outages long enough for equipment to be shut down properly. Or work in tandem with an emergency generator to keep continuous supported load until utility returns. By doing so, a UPS System helps to prevent important data losses while simultaneously minimizing damage that a hard shutdown can have on electronics. A correctly sized UPS system, integrated properly, is an invaluable piece of support equipment for data centers, hospitals, telecommunications, and various industrial spaces. Smaller UPS systems are also available which cater to your office or home needs. Those seeking Industrial Applications for Industrial UPS Systems should seek out a specialized inverter based system that can handle the rigors of the facility. There is a point where an AVC plus battery solution exceeds the quality of an Industrial UPS System for plant or process environments. See page AVC or Industrial UPS System .

Outside of a complete blackout or power outage, abnormal voltage, such as a surge or sag , can also damage electronics in terms of life span and performance. To counteract this fact, one additional function of a UPS system is surge protection. UPS systems work to correct voltage before it reaches your equipment, protecting connected devices from power problems of many types.

Active Voltage Regulators (How They Work)

Normal utility power can vary, in some cases dramatically enough to cause damage or decrease the performance of your devices. The purpose of an AVR is solely to maintain constantly acceptable voltage levels for the benefit and health of your electrical equipment. Because of their ability to stabilize the voltage in a reliable way, an AVR is often the preferred device for this particular application.

When it comes to protecting industrial or manufacturing equipment, Active Voltage Regulation is often the most inexpensive and simplest way to correct voltage. Generating a fixed output voltage as these devices act as a buffer to protect components from sustaining damage. However they are limited to a certain voltage window at which they can correct to nominal voltage.

The size and technology choice for a customer specific option will depend on the voltage window they are trying to correct. In many instances, a voltage regulator is incorporated with a transformer to isolate incoming anomalies. In smaller applications, a ferro resonant transformer-based system can provide voltage regulation with battery storage backup, much like a Ferrups UPS system from Eaton.

However, because Active Voltage Regulators do not have a backup power supply of their own, the extra cost of an external battery will be required in order to provide uninterruptible power in the event of a blackout. Additionally, some voltage regulators can also automatically cut off the power supply if the input voltage becomes to low, or high for the regulator to do its job properly.

AVR vs UPS – Which is Right For You?

Now that you know a little more about each of the devices in question, how can you choose the one that most appropriately meets your voltage and power needs?

If continuous power is an absolute requirement, even during a blackout, a UPSs functionality should always be your first choice. Even if you experience a wide range of power issues, if your equipment requires a steady power supply, or the ability to shut off properly in the event of an outage, a UPS will be the best option for your needs.

However, if your equipment does not require uninterruptible power and you are searching for a more cost-effective method of protecting your devices from fluctuations in power, and active voltage regulator may be just as beneficial.

Get Your Site Surveyed with Voltage Correction

At Voltage Correction, we specialize in Voltage Regulation Solutions for your industry. All industries dealing with harsh electrical environments required a different approach to power quality management, and our team is ready to provide corrective solutions that match. If you would like more information on what voltage regulation solution is best for your site or want to know more about which specific type of product you should choose to implement, our team is just a call, click, or email away.

The national team is here to help you with product solutions, metering, and site visits to any customer site in the contiguous U.S. We encourage you to contact us today and have your voltage regulation solutions delivered. Call 855-240-6776.

Power Outages are Increasing Across the Nation – Here’s How to Protect Your Facility’s Supply

Wed, 09 Dec 2020 16:58:00 GMT

According to Popular Science , the United States experiences more power outages than any other developed country. Due to a severely outdated power grid, (the oldest American power line date backs to the 1880s) the ever-increasing demand for power is pushing our system to the absolute limit.

Climate Central , an independent nonprofit scientific news source, found that major power outages affecting more than 50,000 homes or businesses became ten times more common from the mid-1980’s to 2012. On average, these outages cost $18 to $33 billion per year for businesses in lost wages, spoiled inventory, missed business opportunities, and more.

So how can we increase our power outage prevention protocols in order to protect ourselves and our businesses? In this article, we will take a look at a few of the most common causes behind the influx of power outages, and how you can manage your power supply with the latest technology to ensure a healthy and uninterrupted stream of power.

What is Causing These Increased Power Outages?

Currently, there are two main causes behind the onset of increased power outages: increased inclement weather and an aging power grid. A report conducted by the US Department of Energy found increased weather events across the nation to be the leading cause of power outages in the United States. As the weather continues to worsen, we can expect our aging infrastructure to be continually battered, which will in turn lead to even further, and more rampant outages.

Additionally, the weak infrastructure associated with our power supply is extremely vulnerable to cyber-attack. Many sources suggest that one well-timed and well-executed attack on our power supply could cause widespread damage for many users.

What is the Best Solution for Preventing Outages at My Facility?

Initially, it would appear as though upgrading our power supply infrastructure would be the best course of option. Not only would an updated power grid provide better protection from weather and cyber-attacks, but it would also help boost power outage prevention by making the entire grid significantly more efficient. Unfortunately, such updates are estimated to cost more than 4.5 trillion dollars for the United States. That large price tag has discouraged efforts to replace equipment and both industry leaders and the US Government are unlikely to change their stance on this issue any time soon.

For business leaders, the smartest solution is to invest in onsite power outage prevention solutions of their own. Fortunately, with onsite power generation costing less than utility for the first time in US history, there has perhaps never been a better time for such a transition. Below, we will take a look at a few of the most effective and efficient methods of power outage prevention.

Power Outage Prevention Methods

Short Term Power Outages

Frequently, people mistake short term power sags as a power outage. While the lights may flicker and your power supply may be temporarily interrupted, these sags are much easier to correct than long term outages. Fortunately, 90% of industry power problems are due to sags that were either internally derived or externally created.

The best way to combat these types of outages is to install some form of voltage regulation or protection. Active Voltage Correction (AVC) can be achieved in several different ways for short term utility outages.

Active Voltage Correction with Ultracapacitors

As the most expensive solution, ultracapacitors are capable of providing long term static solutions with little attention or maintenance required. Those high up-front expenses will quickly pay off with a low, annual maintenance for 15-20 years. With a reliable run time, ultracapacitors store energy in the form of static charge, as opposed to the electrochemical reactions of batteries.

Other benefits of ultracapacitors include their high-power density, nearly instantaneous charging and discharging, impressive reliability, and extended lifetimes.

Active Voltage Correction with Batteries

Alternatively, AVC with batteries can be equally effective. Performing the same function as ultracapacitors, a battery-operated system will come with lower up-front capital requirements countered by more regular maintenance for your batteries. While this maintenance is less taxing than alternative methods, batteries typically require replacement every seven to ten years in order to keep your system running at full capacity.

Long Runtime Solutions

If you are interested in investing in a power outage prevention system with a longer runtime, the best option is a generator system with an automatic transfer switch. These generators provide constant voltage sterilization via regulation for complete control of your power supply. Available in diesel or natural-gas powered choices, they are the ideal long-term runtime power supply solution for most facilities.

By coordinating and properly sizing your voltage regulator , battery system, and emergency backup generator, your entire system will be poised to work efficiently and quickly during an outage event. Similarly for data center’s, systems such as Eaton UPS Systems may be used for Industrial UPS Applications.

Have an ICP Site Survey Conducted

When you install power correcting equipment, you are providing your facility with protection against all outside influences on power supply. Having that stable voltage and power reduces wear and tear on your facility as well, adding up to a wide array of long-term benefits and lowered operation costs.

An effective voltage regulation solution controls the voltage of a system, so it remains within a practical and safe range of voltage tolerances under all design loads. Voltage at any utilization equipment should be within the guaranteed operative range of the equipment.

Several models of voltage regulators, either automatic or manual, are available to work with all load sizes and types, from independent electronic devices to the equipment for an entire facility.

Benefits of Voltage Regulation

Voltage Correction provides voltage stability by correcting and holding the voltage to avoid deviations that slowly wear out your control and process equipment. This is accomplished by implementing either an Active Voltage Correction (AVC) or an Active Voltage Regulation (AVR) device.

By doing so, you can reduce time spent in recurring maintenance tasks involving the replacement of boards, capacitors, and other parts. Additionally, an AVC or AVR reduces your downtime spent to reset equipment and processes.

Additional benefits include:

Acting as a buffer for protecting components from damages
Generating a fixed output voltage that remains constant for any change in an input voltage or load conditions
Functioning as the most affordable option to correct simple line voltage
Correcting and holding the voltage to avoid deviations that slowly wearing out control and all process equipment
Reducing the frequency of performing maintenance to replace boards, capacitors, and other parts
Reducing downtime spent resetting equipment and processes

Power Factor Correction vs Voltage Regulation: Which Do You Need?

Are you facing penalties from your utility provider that derive from a volatile voltage from other equipment in your facility? Have you experienced an ongoing decreased capacity in your electrical and breaker distribution system? When your electrical loads generate a poor power factor, you need to use a power factor correction device to boost the power factor to an optimal level.

Does your facility need voltage stabilization? When a steady, reliable voltage is needed, then voltage regulation is the preferred method of choice. Doing so generates a fixed output voltage that remains constant for any changes in an input voltage or load conditions. Therefore, voltage regulation acts as a buffer for protecting components from damages caused by voltage swells and sags.

Power Factor Correction and Voltage Regulation Maintenance with Voltage Correction

At Voltage Correction, our electrical engineering experts know which power correction and voltage regulation solutions will best maintain your industry and reduce the occurrence of voltage sags or swells. By analyzing your current power output and monitoring the electrical environments in your facility, we can capture nominal voltage, sags, surges, and events that would otherwise wear down your equipment.

Our Voltage Correction experts can complete a site survey, assess your facility, and install a power metering device. When you install equipment that corrects power and holds voltage within your facility, you will have the proper protection in place to defend against all outside influences of power. Halt the wear-and-tear on equipment in your facility by implementing a stable voltage and power factor.

Contact us today to learn more about our voltage sag correction and metering services or to schedule a site visit. Call 855-240-6776.

Voltage Sags Affecting Manufacturing Processes: What They Are and What to Do About Them

Thu, 06 Aug 2020 19:53:00 GMT

The most common event that affects power output and quality is a voltage sag . Does your industry rely on industrial equipment, including process controllers, PLCs, adjustable speed drives, and robots? Do you notice their heightened sensitivity to voltage sags? In the content below, we discuss voltage sags in terms of what they are, what to do about them, and how to prevent them from happening.

Voltage Sags: What Are They?

Also referred to as voltage dips, voltage sags are brief reductions in electrical voltage by at least 10%. As defined by the IEC 61000-4-30 standard, the voltage sag lasts for less than one minute yet longer than eight milliseconds. The magnitude of a sag ranges between 10% and 90% of the normal Root Mean Square (RMS) voltage at 60Gz.

As voltage sags are a common power quality event, they can occur up to several times annually, yet appear more frequently at equipment terminals. In recent years, it became required that electrical equipment be manufactured with the capability of riding through brief voltage sags. This requirement of using IEEE 1668 for power quality varies on the sag characteristics and the equipment application.

Voltage Sag: What Causes Them?

Voltage sags are caused by abrupt increases in electrical loads such as short circuits, faults, motors starting, or electric heaters turning on. Alternatively, they can derive from abrupt increases in source impedance, typically caused by a loose connection.

Often, sags create a minimal disturbance among disturb incandescent or fluorescent lighting, motors, or heaters. However, some of your electronic equipment may lack the sufficient internal energy storage necessary to effectively ride through sags in the supply voltage. Your other equipment may be able to go unphased through very brief, deep sags, or it may be able to ride through longer, shallower sags.

Below, we explore the most common voltage drop causes.

Voltage Sag: What Causes Them?

Although most would suspect the local utility to be responsible for a voltage sag, it is often derived in the transmission of power between the utility distribution point and your electrical service. Taxed electrical grid, totality of different facility’s impact on the power supply, heat, and weather events can all contribute to creating sag activity. It is something the utility will not be able to control or affect. It is up to the consumer to correct the effects of sag activities.

Power quality problems can occur from either side of the electric meter. However, it is sometimes difficult to determine the source of voltage sags or other power quality problems.

Natural Events

Did you know that a voltage sag on the power grid can affect users in greater than a 100-mile radius from the causing event? Voltage drops that occur on the utility side of the power meter can either stem from natural events or human-created scenarios. Common human-created events are switching operations.

The most common natural events include:

Lighting
Wind
Trees falling onto power lines
Construction workers digging into buried cables
Squirrels and rodents
Equipment failures
Traffic accidents

Voltage Sags recently occurring in the Northeast have been caused by excessive heat. An irregular weather pattern located over that part of the country has been a considerable tax on the electrical grid system.

Physical Results of Voltage Sag Activity

The chart below explores what physical results occur amid voltage sag activity.

10% +/- sag/surge: Continual wear on PLC’s, boards, line equipment, motors, lasers, and process equipment.
20% – drop in voltage: Considerable spike in amperage due to the low voltage. You may see long-term or immediate damage to equipment.
50% – drop in voltage: Will appear to be an outage, flicker, or drop of light output. There will be a considerable amperage spike to all loads that will result in damaged equipment.
80% drop in voltage: Power loss occurs and there may be a gradual sag if on one phase. Visibly damaging to all electronic equipment.

What Can You Do About Voltage Sags?

The most effective solution to voltage sags is determining if a piece of equipment is more sensitive to voltage dips and implementing Active Voltage Correction.

Identify Sensitive Equipment

To prevent any further damage or wear to your equipment, it is crucial to detect and isolate individual pieces of equipment that appear more sensitive to voltage sags. Doing so allows you to better determine where to deploy sag correction devices. Sag correction devices can be installed at various locations, including control panels, machine levels, bus levels, and even at the plant service entrance.

To best determine where to implement the correction devices, you must evaluate the percent of sensitive loads within the plant, ease of installation, downtime cost, solution cost, and return on investment. Additionally, if your plant works with a larger load, it will be necessary to install a three-phase solution.

Implement Active Voltage Correction

The following is what an AVC (Active Voltage Correction ) System can provide for sag activity:

10% +/- sag/surge: 10% +/- sag/surge regulation AVC corrects to nominal power voltage

20% – drop in voltage (Sag to 80%nv): AVC corrects to 100%, 3 phase for 3+ minutes, 1 phase Continuous

50% – drop in voltage (Sag to 50%nc): AVC corrects to 90% 3 phase for 1 minute, 1 phase 100% continuous

80% drop in voltage (Sag to 20%nv): AVC corrects 1 Phase 100% continuous

Voltage Sags: Correction and Maintenance with Voltage Correction

At Voltage Correction, our electrical engineering experts know which voltage regulation solutions will best maintain your industry and reduce the occurrence of voltage sags or swells. By analyzing your current power output and monitoring the electrical environments in your facility, we can capture nominal voltage, sags, surges, and events that would otherwise wear down your equipment.

Contact us today to learn more about our voltage sag correction and metering services or to schedule a site visit. Call 855-240-6776.

Power Quality Impact of Distributed Generation: Effect on Steady State Voltage Regulation

Fri, 22 May 2020 18:42:03 GMT

With the advent of deregulation, distributed generation will play an increasing role in electric distribution systems. Various new types of Distributed Generation (DG), such as micro-turbines and fuel cells, are now being developed in addition to the more traditional solar and wind power. A common belief among developers is that DR will improve power quality, and this potential for better quality is cited as one of the value attributes of installing distributed generators. In some cases distributed generation and storage are being promoted as an answer to the premium-quality power requirements of high technology or sensitive end-use customers. Whether or not this value-attribute of DG is valid will depend on the specific technologies, site conditions and potential interaction with the existing electric power system.

The objective of this paper is to provide a technical assessment of the impact of distributed generation technologies on the power quality of the power distribution system. Power quality is a broad term covering a wide range of operating parameters including both steady state and dynamic conditions. The full range of power quality conditions are described in IEEE Std. 1159-1995 Recommended Practice for Monitoring Electric Power Quality. This paper focuses on steady-state voltage regulation impacts of DG and is the first of several papers covering the various power quality impacts of DG. The guidelines provided in this paper will help utility engineers evaluate the impact of distributed generation on voltage regulation and identify methods to mitigate problems that arise. The paper also makes recommendations for voltage trip thresholds to be used for DG interconnection that will help reduce the susceptibility of DG to nuisance trips but still provide utility system protection against sustained overvoltage.

View the full paper here .

Microgrid Effects and Opportunities for Utilities to Stabilize Power

Fri, 22 May 2020 18:39:41 GMT

Many large utility customers, including military installations, hospital campuses and universities, are considering microgrids to better manage energy usage and enhance power quality and system reliability. In addition to greater energy security, microgrids offer a variety of economic benefits ranging from greater efficiency of operation to the ability to facilitate participation in demand response and interruptible rate programs provided by the local utility.

There are many scenarios and environments where a utility can benefit from a customer’s implementation of a microgrid. This paper explores the drivers behind microgrids, the benefits to end-use customers, and the mutual benefits of microgrids to the utility that provides or supports them.

View the full paper here .

The History and Evolution of the U.S. Electricity Industry

Fri, 22 May 2020 18:36:59 GMT

THE FULL COST OF ELECTRICITY is an interdisciplinary initiative of the Energy Institute of the University of Texas to identify and quantify the full-system cost of electric power generation and delivery – from the power plant to the wall socket. The purpose is to inform public policy discourse with comprehensive, rigorous and impartial analysis.

The generation of electric power and the infrastructure that delivers it is in the midst of dramatic and rapid change. Since 2000, declining renewable energy costs, stringent emissions standards, low-priced natural gas (post-2008), competitive electricity markets, and a host of technological innovations promise to forever change the landscape of an industry that has remained static for decades. Heightened awareness of newfound options available to consumers has injected yet another element to the policy debate surrounding these transformative changes, moving it beyond utility boardrooms and legislative hearing rooms to everyday living rooms.

The Full Cost of Electricity (FCe-) study employs a holistic approach to thoroughly examine the key factors affecting the total direct and indirect costs of generating and delivering electricity. As an interdisciplinary project, the FCe- synthesizes the expert analysis and different perspectives of faculty across the UT Austin campus, from engineering, economics, law, and policy. In addition to producing authoritative white papers that provide comprehensive assessment and analysis of various electric power system options, the study team developed online calculators that allow policymakers and other stakeholders, including the public, to estimate the cost implications of potential policy actions. A framework of the research initiative, and a list of research participants and project sponsors are also available on the Energy Institute website .

All authors abide by the disclosure policies of the University of Texas at Austin. The University of Texas at Austin is committed to transparency and disclosure of all potential conflicts of interest. All UT investigators involved with this research have filed their required financial disclosure forms with the university. Through this process the university has determined that there are neither conflicts of interest nor the appearance of such conflicts.

View the full paper here .

A Digital Energy Network: The Internet of Things & the Smart Grid

Fri, 22 May 2020 18:33:54 GMT

Executive Summary

Driven by new regulation, new market structures and new energy sources the smart grid is the response to profound changes in the way that electricity is generated, distributed, managed and consumed. What makes the challenge particularly acute, is the essential role that energy production plays in modern democracies. Keeping the lights on is a political, economic and social imperative.

Enabled by current and future developments in technology, smart grids will better enable electricity companies to meet rising demand, increase the reliability and quality of power supplies, improve energy efficiency, and integrate low-carbon energy sources into power networks.

This paper looks at the environment in which the smart grid is being developed, based on industry standards and how a newly intelligent, interconnected and interoperable grid can be seen as a leading example of the Internet of Things in action.

View the full paper here .

Electrical Transmission Planning White Paper

Fri, 22 May 2020 18:28:59 GMT

The U.S. electric transmission system is an engineering marvel critical to our economy and way of life. The details can be complex, but the basics are not—the transmission system is designed to reliably and efficiently deliver electricity from where it is generated to where it is distributed to customers. This Transmission Planning White Paper is designed to help policymakers understand the basic technology, economics, and regulations that underlie the planning of today’s electric transmission system.

In the 1830s, a seemingly simple discovery was made that would profoundly change everyday life. Moving a magnet through a coil of wire generated electricity, the flow of electrons, in the wire.1 Nearly all of today’s electricity power plants use this same concept. Wind, water flowing in a river, and boiling water to create steam are some of the various means used by today’s power plants to turn turbines that spin magnets within coils of wire to generate electricity. This is the generation of electricity. Electricity is difficult to store economically; thus, it needs to be generated when it is needed. When you turn on your light switch, a power plant must respond and increase its generation of electricity instantly.

Historically, it has been less expensive to generate electricity at large, centralized power plants, which can be hundreds of miles from where the electricity is used, than with small local generators. The electricity generated at these power plants is transmitted through the transmission system, a network of interconnected high-voltage lines. Transmission lines are designed to transmit a large amount of electricity while minimizing the amount of lost energy, and are interconnected with each other to make the system more reliable. The U.S. interstate highway system is analogous to the transmission system.

In an interconnected network, if a line or power plant goes out of service, another pathway or power plant can take its place. Lower-voltage lines are connected via substations to the high-voltage transmission system to distribute electricity to the exact location where it is needed, such as homes, offices, stores, and factories. These lower-voltage lines form the electric distribution system. Local roads and streets are analogous to the electric distribution system.

View the full paper here .