Process industries, such as food processing and foundries, require an uninterrupted flow of production for successful operation. This continuous mode of operation requires significant power, which places a heavy load on the energy grid.
Specific applications may include food processing, packaging, plastic fabrication, pulp and paper production, metal processing, manufacturing, foundries, refineries and automotive production.
Power quality and common issues
The highly-advanced machinery and equipment used in process operations represents a significant capital investment. The sensitive nature of such machines makes them vulnerable to power disturbances and other related problems, including trips, unplanned stops, equipment failure, reduced equipment lifetime, and flicker.
Also, while energy consumption, and therefore cost, is a main concern for those in process industries, safety and sanitation is the highest priority. This is why it is crucial to have a reliable power quality solution to strengthen the electrical system overall and avoid unplanned stops—which is the scenario most likely to contribute to a safety or sanitation risk.
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Five advantages for you
ADF can monitor and compensate electrical disturbances at very high speeds. It improves the plant’s overall energy network, minimizes stoppages, protects sensitive electronics as well as non-electronic equipment parts, and lowers electricity costs.
1. Optimize your network
ADF makes it possible to compensate all power available in the grid. This enables secured network stability, even with demands from lighting, computers, etc.
2. Prevent surges and transients with improved power quality
ADF monitors and compensates imperfect power in the grid at lightning speed to prevent power surges and transients that can damage monitoring or control systems in automated plants. Thanks to this active and dynamic monitoring, production can continue smoothly.
3. Eliminate facility “ghost” problems
Have you ever experienced a mechanical or operational problem that seemed to have no apparent cause? Poor power quality is often the cause. ADF technology eliminates and prevents “ghost” problems that are really due to unseen electrical problems in the grid (improving power quality).
4. Achieve compliance
This low harmonic solution minimizes the effect that the facility’s heavy energy load will have on the grid—thereby helping you avoid fines or other legal repercussions due to non-compliance with electrical standards, such as IEEE.
5. Decrease power consumption
Sustained high power quality means more efficient, problem-free production. Due to its ability to reduce losses (heat energy) in the transformer, ADF helps you simultaneously conserve energy and lower your energy costs.
Explore our case stories
Muraplast is very satisfied with the whole solution, especially with the reliability, and would like to continue implementing ADF solutions through its production halls.
After installing the ADF Active Harmonic Filters Henrad has managed to keep their Pst value below 0,63, regardless of how many welding lines that are running.
WDI (Westfälische Drahtindustrie) is a german industry group founded in 1856 and is the margest steel wire producer in Europe. The company produces steel reinforcement mesh grids at the Salzgitter plant in Germany.
As the Mercedes-Benz factory continues to expand and develop, they have requested additional ADF modules to support new product lines within the facility.
Within a major leading edge manufacturing company, a test bed put extreme demands on the power supply network. In this case study, an ADF installation results in significant reduction of notching.
REWE Dortmund Großhandel eG is a federation of over 300 independent retail dealer and supplies approx. 540 grocery stores. REWE decided to use a Comsys ADF Active Dynamic Filter to eliminate the problems in the power supply.
After experiencing sudden unplanned production stops, and worried about the risk of increased total voltage harmonic distortion on production, UNILIN explored implementing a power quality solution.
With ADF Power Tuning, the amount of energy needed to melt the steel decreased, the overall melting time was shorted, and Sandvik experienced reduced wear and tear on the furnace, especially the electrodes.
The ADF P300 active filters were supplied in late 2015 and commissioned early 2016. The new and improved TiZir Tyssedal plant is successfully up and running, and is fully compliant with the demands of the electrical grid company.