Case Studies
Browse successful case stories by industry:
Protection of electronic equipment in Reclosers
Issue
Protection of each recloser with Surge/transient protection and integrated filter (Frequency Attenuation) and sinewave tracking (4th generation technology) – Two levels of protection.
Solution
Electrical utility company presented many issues or flaws in the sub-circuit reclosers stationed at different locations, regardless of the technology and/or the recloser brand.
Results
80% Reduction in Maintenance Operations
Efficiency, improvement and better power quality in Reclosers.
Protection of Inverters and Communication in Solar Systems
Issue
Solar structures and conductors are exposed to impulsive transients and overvoltage induced in direct current conductors. Communication components and inverters presented failures and damages in the AC supply of electronic equipment.
Solution
Cascade protection installed in the substation, AC power inputs of the inverters and the power of communication systems.
Surge/transient filter protection (4th Generation) Sinewave tracking.
Results
ROI: 15 Days
No more damages or failures on Inverters and communication.
Reliability and improvement in equipment and system.
Avoid downtime and losses.
Ellevio Wind Farm – Kville, Sweden
Issue
Industries such as energy production where is high power demand, there is a concurrent need for a powerful power quality solution.
Challenge
Capacitive cables connecting the windmills to the site’s substation. These cables were responsible for producing Reactive Power, so they faced restrictions on how much reactive power they could send to the grid. Additional they needed to implement a solution to be connected on 130KV, avoid issues like overheating, and remote connection.
Solution
ADF Statcom Added inductive current to compensate the reactive power. Easy integration into existing on-site infrastructure. The compensation is done on 690 V, however by using a step-up transformer they were able to connect to 130KV from the turbines.
Results
ADF STATCOM automatically compensates the load actively and dynamically from zero to maximum without any differences.
Offshore Wind Farm – Dantysk, North Sea – Germany
Challenge
Supply reactive power to the generators, which energise the windmills, in an emergency situation, such as losing connection to shore. In order to maintain warranties on valuable equipment, it was essential that the system be running constantly so that each windmill can remain dry and controllable at all times.
Solution
ADF STATCOM units were installed at the offshore substation, which forms the gateway for the onward transport of energy to the mainland vis submarine cables.
Results
Reliable reactive power quality solution that compensates the cable capacities during grid outages and is able to optimise the power supply generated from 80 windmills.
Protection of electronic equipment in water pump systems
Issue
Transients are very high incidence in Mining and generate big issues in submerged pump drives in the ground loop induction like burns in the soft-starters and electronic equipment.
Solution
Protection of each panel with Surge/transient protection with integrated filter (Frequency Attenuation) and sinewave tracking (4th generation technology)
Results
ROI: 3.02 Months
Efficiency and improvement of electronic equipment in water pump systems. No failures in soft-starters. Reliable system to ensure 100% of the operation at the mine.
Protection of VFD, Electro-submersible pumps, progressive cavity pumps, electronic actuator valves, flow meters, PLC, Well monitors, tank sensors, communication systems.
Issue
Damages and failures on electronic cards and components of equipment due to transients (Impulsive & Oscillatory)
Equipment affected:
- Control Wave
- Flow Boss PC
- Transmitters
- Ultrasonic meters
- Communication in SCADA
- Systems
- Affected systems in AC, DC and Data
Solution
Installation of Surge/transient filter protection (4th generation) in cascade system to generate reductions by 95% in damages of electronic components.
Decrease failures, errors and false alarms in the SCADA System.
Protection of electronic equipment in Radio bases
Issue
Huge stock of spare parts, and the replacement cost is high in two years for surge suppressors which had exploded with a risk of fire.
Solution
Change all surge suppressors for transient/surge filter protector (4th Generation) with sinewave tracking and Frequency attenuation.
Results
ROI: 2.5 Years
Saving in annual inventory for replacement of SPDs:
USD $ 40,400
Total savings for 15 years warranty in our solution:
USD $ 606,000
Protection and Improvement of Passenger Boarding Bridge
Issue
The automated bridge presented downtime and damages in electronic equipment. Measurements demonstrated that transients/surges were the reason to affect the normal function of the bridge.
Solution
Transient/Surge Protection (4th Generation) with sinewave tracking were installed in all boarding bridges at the airport. They were installed in the main control and switchboard.
Protection Injection machines – Automation
Issue
Mains power fluctuation occurred in the facility, and electrical/electronic modules were lost and damage. e.g. PLCs, input-output cards and power supply components. Also huge production wastes and extended downtimes causing loss of production opportunities.
Solution
Installation of Surge/transient filter protection with high technology in the main panel, distribution boards and sensitive equipment like PLCs and power supply modules of injection machines.
Results
- Reduced production wastes by 68%
- Machines now are available for production by more than 73.6 Hours
- Standard protection in all systems and machines to stabilise manufacturing and industrial process infrastructure from dirty power.
Protection and improvement in Robots
Issue
Two robots suffered constant downtime and corrupted programming in the PLCs. These Robots are extremely important because they are responsible to transport 120,000 cans and 30,000 PET Bottles per hour.
Solution
Installation of transient/surge filter protection in power and control (Cascade Protection). After installation, the robots are working with NO interruptions, avoiding downtime and losses.
Results ROI
ROI CAN Robot: 4 Seconds
ROI PET Bottle Robot: 6.5 Seconds
Protection and Improvement of profiling machines in a production line
Issue
The most common issues were damages and deconfiguration or deprogramming of Frequency drives and PLCs. It affected with high downtime and losses for around USD$50 k per month.
Solution
Surge/transient protection were installed in electrical boards of the machine. After installation, the machine has not suffered critical damages or suddenly stops. Now production is more reliable and the machine more efficient.
Issues caused by transients were 100% solved. The solution has been over 2 years and engineers has not recorded similar events that they experienced in the past.
Thanks to this solution, the company decided to protect all equipment in the plant.
Results
ROI: 6 Days
Savings in annual loss: USD$494,000
Protection of electronic equipment in Reclosers
Issue
Protection of each recloser with Surge/transient protection and integrated filter (Frequency Attenuation) and sinewave tracking (4th generation technology) – Two levels of protection.
Solution
Electrical utility company presented many issues or flaws in the sub-circuit reclosers stationed at different locations, regardless of the technology and/or the recloser brand.
Results
80% Reduction in Maintenance Operations
Efficiency, improvement and better power quality in Reclosers.
Protection of Inverters and Communication in Solar Systems
Issue
Solar structures and conductors are exposed to impulsive transients and overvoltage induced in direct current conductors. Communication components and inverters presented failures and damages in the AC supply of electronic equipment.
Solution
Cascade protection installed in the substation, AC power inputs of the inverters and the power of communication systems.
Surge/transient filter protection (4th Generation) Sinewave tracking.
Results
ROI: 15 Days
No more damages or failures on Inverters and communication.
Reliability and improvement in equipment and system.
Avoid downtime and losses.
Ellevio Wind Farm – Kville, Sweden
Issue
Industries such as energy production where is high power demand, there is a concurrent need for a powerful power quality solution.
Challenge
Capacitive cables connecting the windmills to the site’s substation. These cables were responsible for producing Reactive Power, so they faced restrictions on how much reactive power they could send to the grid. Additional they needed to implement a solution to be connected on 130KV, avoid issues like overheating, and remote connection.
Solution
ADF Statcom Added inductive current to compensate the reactive power. Easy integration into existing on-site infrastructure. The compensation is done on 690 V, however by using a step-up transformer they were able to connect to 130KV from the turbines.
Results
ADF STATCOM automatically compensates the load actively and dynamically from zero to maximum without any differences.
Offshore Wind Farm – Dantysk, North Sea – Germany
Challenge
Supply reactive power to the generators, which energise the windmills, in an emergency situation, such as losing connection to shore. In order to maintain warranties on valuable equipment, it was essential that the system be running constantly so that each windmill can remain dry and controllable at all times.
Solution
ADF STATCOM units were installed at the offshore substation, which forms the gateway for the onward transport of energy to the mainland vis submarine cables.
Results
Reliable reactive power quality solution that compensates the cable capacities during grid outages and is able to optimise the power supply generated from 80 windmills.
Protection of electronic equipment in water pump systems
Issue
Transients are very high incidence in Mining and generate big issues in submerged pump drives in the ground loop induction like burns in the soft-starters and electronic equipment.
Solution
Protection of each panel with Surge/transient protection with integrated filter (Frequency Attenuation) and sinewave tracking (4th generation technology)
Results
ROI: 3.02 Months
Efficiency and improvement of electronic equipment in water pump systems. No failures in soft-starters. Reliable system to ensure 100% of the operation at the mine.
Protection of VFD, Electro-submersible pumps, progressive cavity pumps, electronic actuator valves, flow meters, PLC, Well monitors, tank sensors, communication systems.
Issue
Damages and failures on electronic cards and components of equipment due to transients (Impulsive & Oscillatory)
Equipment affected:
- Control Wave
- Flow Boss PC
- Transmitters
- Ultrasonic meters
- Communication in SCADA
- Systems
- Affected systems in AC, DC and Data
Solution
Installation of Surge/transient filter protection (4th generation) in cascade system to generate reductions by 95% in damages of electronic components.
Decrease failures, errors and false alarms in the SCADA System.
Protection of electronic equipment in Radio bases
Issue
Huge stock of spare parts, and the replacement cost is high in two years for surge suppressors which had exploded with a risk of fire.
Solution
Change all surge suppressors for transient/surge filter protector (4th Generation) with sinewave tracking and Frequency attenuation.
Results
ROI: 2.5 Years
Saving in annual inventory for replacement of SPDs:
USD $ 40,400
Total savings for 15 years warranty in our solution:
USD $ 606,000
Protection and Improvement of Passenger Boarding Bridge
Issue
The automated bridge presented downtime and damages in electronic equipment. Measurements demonstrated that transients/surges were the reason to affect the normal function of the bridge.
Solution
Transient/Surge Protection (4th Generation) with sinewave tracking were installed in all boarding bridges at the airport. They were installed in the main control and switchboard.
Protection Injection machines – Automation
Issue
Mains power fluctuation occurred in the facility, and electrical/electronic modules were lost and damage. e.g. PLCs, input-output cards and power supply components. Also huge production wastes and extended downtimes causing loss of production opportunities.
Solution
Installation of Surge/transient filter protection with high technology in the main panel, distribution boards and sensitive equipment like PLCs and power supply modules of injection machines.
Results
- Reduced production wastes by 68%
- Machines now are available for production by more than 73.6 Hours
- Standard protection in all systems and machines to stabilise manufacturing and industrial process infrastructure from dirty power.
Protection and improvement in Robots
Issue
Two robots suffered constant downtime and corrupted programming in the PLCs. These Robots are extremely important because they are responsible to transport 120,000 cans and 30,000 PET Bottles per hour.
Solution
Installation of transient/surge filter protection in power and control (Cascade Protection). After installation, the robots are working with NO interruptions, avoiding downtime and losses.
Results ROI
ROI CAN Robot: 4 Seconds
ROI PET Bottle Robot: 6.5 Seconds
Protection and Improvement of profiling machines in a production line
Issue
The most common issues were damages and deconfiguration or deprogramming of Frequency drives and PLCs. It affected with high downtime and losses for around USD$50 k per month.
Solution
Surge/transient protection were installed in electrical boards of the machine. After installation, the machine has not suffered critical damages or suddenly stops. Now production is more reliable and the machine more efficient.
Issues caused by transients were 100% solved. The solution has been over 2 years and engineers has not recorded similar events that they experienced in the past.
Thanks to this solution, the company decided to protect all equipment in the plant.
Results
ROI: 6 Days
Savings in annual loss: USD$494,000
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