Motors and Drives

Motor Research spurs development of new product capable of reducing the large economic impacts resulting from momentary power interruptions in industrial facilities

Testing in Advanced Energy’s nationally accredited motor test laboratory has allowed an Ohio-based company to ensure critical loads driven by AC induction motors to ride through momentary power interruptions.

Background

Bay Controls Inc., Maumee, Ohio, has more than 20 years of experience engineering and supplying advanced control solutions for industrial and process compressor systems. A strategic alliance partner and exclusive control system supplier of Cooper Turbocompressor, the company manufactures a line of control systems for any brand and type of compressor, providing optimized operation that results in lower life cycle costs.

Problem

Electric power is delivered where it is needed across a complex utility network or grid. The grid is specifically designed to reduce power outages that can come from a variety of sources outside of the control of the electric utilities. When a problem is detected the grid quickly responds using circuit breakers to control the flow of power to try to clear faults. Most of the time this works with little to no effect on manufacturing facilities. You might notice this at home when you have to reset your VCR or alarm clock. What actually is happening is a complete loss of power for a fraction of a second, called a momentary interruption. A momentary loss of power can create unplanned shutdowns costing manufacturers significantly. Some specific industries are highly sensitive to any loss of power and they either end up paying millions of dollars to site themselves in close proximity to very stable transmission lines or pay additional monies to have power supplied by two transmission lines.

Assistance

With support from Progress Energy, Duke Energy, and Dominion Resources, Advanced Energy started researching this phenomenon in 2001. The goal of the research was to create momentary outages in the lab and determine if it was safe for motor driven equipment to “ride through” these short events. Before the research began enough hard evidence had not been produced to convince equipment manufacturers that riding through momentary power interruptions was possible without damage to their equipment; thus they were skeptical of any add-on device with such claims. Consequently, utilities often are blamed for momentary interruptions that, for the most part, are out of their control.

One of the advantages of working with Advanced Energy is testing capabilities made available using the mobile point on wave [POW] switch. This has proven to be a valuable tool in the field and in the lab. Bay Controls currently is using the POW switch with a 250 hp centrifugal air compressor to create momentary power interruptions to test the operation of their device.

Impact in the marketplace

After two rounds of testing in Advanced Energy's lab, Bay has demonstrated a device showing great promise. In a recent interview with Tom Reed, Executive Vice President and Chief Technical Officer of Bay Controls, we captured this about the device's impact on the marketplace.

Q   How has working with Advanced Energy helped your product development process?
A   It's been incredibly beneficial to us. From the outset, Advanced Energy has provided complete access to the research already done, equipment we do not have, and a staff that has been very helpful. They have shortened our product development life cycle dramatically. We will have a device on the market like no other very soon and we could not have done it without the cooperation of Advanced Energy.

Q   How does the controller work, and how do you see it fitting into your products?
A   The momentary outage ride through device monitors the supply power and motor back EMF actuating the motor starter as necessary during a momentary outage to prevent torque and current spikes from occurring. We plan on integrating this capability with our existing compressor control systems and also creating stand alone products for other AC induction motor applications.

Q   How will your customers benefit from this new technology?
A   Plain and simple — increased process reliability and productivity. Being able to run air and gas compressors through momentary power interruptions will give our customers a competitive advantage they had no access to before. Compressed air is a critical resource to many and not having it when you need it can be costly. Our new controller will provide immediate and tangible benefits in the air and gas compressor market.

Q   What are the next steps to bring this technology to market?
A   We are working with Advanced Energy and utility partners to conduct field testing and evaluation of the momentary outage device with compressor and other equipment applications. We anticipate completing initial field testing by late 2004. If all goes well we should be able to bring this new device to market in early 2005.

For details on how Advanced Energy can assist you, contact Kitt Butler at 919-857-9017 or kbutler@advancedenergy.org.