Tired of Experiencing Poor Power Quality in Your Industrial Systems?

Transformers are Failing Leading to Downtime.

Efficient and reliable service is available at SUIN.

Motor Burnout Causes Significant Downtime.

Controls/Displays Experience Memory Loss Resulting in Downtime.

VFD Drives Fail Leading to Downtime.

Research indicates that 80% of electrical system failures such as air conditioner, elevator, and machinery breakdowns in industrial facilities are attributed to poor power supply quality, which can seamlessly be identified and rectified via our power quality monitoring system.

Importance of Power Quality Measurement & Audit in Manufacturing Units

Electrical challenges are common for manufacturers, directly impacting productivity, machinery efficiency, and energy costs. Many plant engineers and managers often prioritize mechanical issues, possibly due to a lack of understanding of electrical problems and diagnostics. When machinery, equipment, elevators, and air conditioning systems falter, the usual recourse is to engage expensive consultants to diagnose the issue, leading to a cycle of component replacements without addressing root causes.

Many plant managers avoid investigating deeper electrical issues and resort to merely replacing defective parts or resetting PLC systems without grasping the underlying electrical anomalies. Efficient insights into internal electrical distribution concerns—including power factor, harmonics, swells, and sags—are often missing, leading to suboptimal productivity.

Our innovative Power Analyzer technology is adept at capturing, diagnosing, and interpreting vital data from electrical components and internal distribution networks. MachineSense products empower plant management to identify common electrical issues and present findings in an easily understandable format, irrespective of their electrical background.

Operation of Our Electrical Power Analyzer

1. Vibration Analyzer 2. MachineSense Power Toroid 3. MachineSense Power Analyzer 4. MachineSense Data Hub 5. Router 6. Cloud-Based Servers 7. MachineSense CrystalBall™ Predictive Analysis Software 8. Actionable Maintenance Advice

MachineSense™ Power Analyzer toroids are stationed directly on incoming power lines for continuous monitoring of power conditions and detection of anomalies. Data captured by the sensors is relayed to a dedicated data hub, then transmitted to cloud-based servers running advanced power quality analysis software. The outcomes are sent to users via a desktop interface or user-friendly application, showcasing power-related conditions along with corrective recommendations.

Top 3-Phase Portable Power Quality Analyzers for Monitoring Electrical Systems

Utilizing Power Analyzers for Voltage Anomalies & Harmonic Distortion Identification in Industrial Units:

Installation Guides for Power Analyzer Meter

Download Datasheet Quick Start Guide Installation Guide

Electric Power Quality Evaluation Parameters

Our Power Analyzer meticulously measures and tracks multiple parameters using proprietary cloud analytics to diagnose potential failures in motors, stator, bearing, heating elements, and recognises common line issues such as sags, swells, harmonics, surges, etc.

• Average 3 Phase Voltage
• Average 3 Phase Current
• Power Factor
• Active 'Working' Power
• Reactive 'Non-Working' Power

• Cumulative Active Energy
• Cumulative Reactive Energy
• Power Quality Harmonic Distortion for Current & Voltage
• All Values Needed for Energy Optimization
• Reports Phase Imbalance

Key Features & Advantages of Our Power Analysis Devices

1. Affordable, low investment, and easy to install on existing equipment.
2. Clear diagnostic advice via simple text or messages on handheld or desktop dashboards, eliminating the need for manual analysis.
3. Dedicated power supply negates the need for sensor battery replacements.
4. Continuous automatic monitoring around the clock, without manual data gathering.
5. Accurate assessments of potential machine and component failures, minimizing unplanned downtimes.
6. Access to real-time and historical electrical power consumption data.

The expanding range of MachineSense Power Analyzers has been specifically designed for various industrial applications, aimed at uncovering significant electrical issues and addressing potential financial implications due to looming failures in motors, drives, and heating elements.

Historically, probing into power quality issues has been a last resort due to a deficiency in electrical knowledge among many plant management personnel. However, studies reveal that numerous machinery failures stem from electrical power quality deficiencies. Proactively assessing power quality should be a priority for most process manufacturers.

Poor power quality manifests in numerous ways, adversely affecting machinery control systems, which operate as computers today. Furthermore, it compromises the lifespan and performance of essential components such as heaters and motors. A stunning $188 billion annual loss is attributed to businesses in the US due to internal power quality problems that frequently go unrecognized or mistakenly diagnosed, leading to recurrent issues.

Most industrial facilities were established long before computerization. Electrical systems were designed to accommodate specific motors running at optimal speeds, ignoring the rise of computerization with each machine control. This oversight led to minimal concern about harmonics, transients, and power factor struggles. Consequently, internal plant power often represents a major undiagnosed hurdle that constrains productivity, escalates utility expenses, and incites failures in electrical or computer systems. Motor failures, for example, are often misattributed to the motor or machinery supplier, when in actuality, they predominantly result from power quality shortcomings.

MachineSense Power Analyzers comprise the first series of economical instrumentation crafted by manufacturers, helping them swiftly comprehend and rectify electrical issues to prevent ongoing electrical complications.

Power Factor

Industries utilize inductive loads predominantly, including motors, transformers, and induction furnaces—all of which require magnetic fields to function. Inductive loads use both working power (kW) for operational tasks and reactive power (kVAR) to maintain these magnetic fields. The power factor, indicating the effectiveness of electricity usage, is calculated by the ratio of working power to apparent power. A high power factor signifies efficient electricity usage, while a low power factor suggests inefficiencies, commonly produced by inductive loads from electric motors, transformers, and other devices.

MachineSense can evaluate power factors for specific machines or internal distributions. As utilities often impose penalties for poor power factors, identifying these issues can mitigate energy costs, thus justifying the investment in MachineSense equipment. Maximizing power factor measurement serves as a critical step in comprehending your plant's electrical structure.

Harmonics

Historically, industrial facilities could rely on a steady power supply with minimal distortion; however, today's conditions often reveal 'dirty power' exacerbated by the growing prevalence of variable frequency drives and solid-state switching components. Harmonic distortions can disrupt normal operations, leading to blown fuses, diminished component lifespan, and potential equipment malfunctions.

MachineSense monitors and logs harmonic distortions, measuring both true-RMS values and instantaneous peak values, which allows identification and tracking of these issues throughout the facility.

Sag

Sags represent a temporary reduction in AC voltage ranging from 0.5 cycles to 1 minute, often triggered by the startup of heavy loads such as motors or HVAC systems. These conditions can disrupt manufacturing processes and lead to costly errors, prompting industrial users to install voltage sag compensators—frequently a costly and inefficient solution.

MachineSense tracks both sag and inrush currents so operators can monitor factors impacting production lines effectively.

Swells

Swells are increased AC voltage levels for a brief duration, primarily resulting from sudden large load reductions or fault conditions. These can result in catastrophic failures of electronic components, which necessitate detection capabilities to allow for timely interventions.

MachineSense identifies and addresses swells, enabling users to understand the causes behind the circuit issues and implement appropriate solutions swiftly.

Power Usage

As energy costs rise, understanding and tracking power usage is essential in an industrial setting. MachineSense enables accurate assessments and allows for critical energy-saving strategies to be employed.

Solid State Drives

Power converters are widely used today for their efficiency. However, their operation often leads to significant power quality issues, particularly harmonics, which can hinder system performance. Electrosense delivers comprehensive measurement capabilities to monitor these anomalies and ensures alerts are issued upon exceeding threshold levels.

Power Factor Suppression & Harmonic Compensation Using Capacitor Banks

Implementing power factor compensation and harmonic suppression are crucial in industrial plants, especially regarding numerous inductive loads. The optimization of capacitor banks is vital to avoid resonance and so ensure sustainable operational efficiency.

Request Report on Energy & Productivity Analysis Using Our Power Analyzer

Utilization Load (24 hrs)

Voltage Imbalance

Current Imbalance

Voltage Sag

Voltage Swell

Motor Winding (Stator)

Motor Bearing

Machine Utilization (24 hours)

VRMS

IRMS

Power Factor

Active Power

Voltage Harmonic Distortion

Current Harmonic Distortion

Heater Bank

Oil & Gas

Electric submersible pumps (ESPs) are utilized across a broad spectrum of applications, and premature failures can incur substantial financial ramifications. MachineSense Power Analyzer effectively anticipates potential failures by monitoring EPS performance, aiding in proactive maintenance.

Current & Sag-Powering Transformer-Coupled Loads

Monitoring sag and inrush currents ensures that manufacturing processes aren't adversely affected, addressing loss of productivity and associated costs.

Energy Optimization in Data Centers

Data centers can greatly benefit from rigorous power quality management, with MachineSense tracking systems providing vital analyses for maintaining peak efficiency.

Solid State Drives & High Harmonics in Industrial Lines

Power Quality monitoring addresses challenges posed by modern solid-state drives and other electronic devices, making it imperative to monitor harmonic distortion closely.

Refrigeration in Food Storage & Processing

Effective refrigeration mechanisms require precise tracking of energy efficiency and ambient conditions, wherein MachineSense systems facilitate ongoing monitoring.

Power Factor Suppression & Harmonic Compensation Using Capacitor Banks

Power factor compensation using capacitors and inductors must be optimized to mitigate harmful resonance and other potential power quality issues, a task efficiently managed by MachineSense systems.

Energy Optimization of Drying in Plastic, Dairy & Food Processing

Energy efficiency in drying processes is critical for minimizing operational costs, where MachineSense solutions provide comprehensive asset tracking per production requirements.

Oil Refineries & Chemical Processing

Ensuring high-quality power supply is vital in chemical processing plants, where utilities underpin all crucial operations. MachineSense can monitor operational health and avert failures.

Power Analyzer™ Single-Port (with isolation) Specifications

Power Quality Metering / Monitoring Solutions