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European Power Quality Survey

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Leonardo ENERGY
Leonardo ENERGY

- A study surveyed 68 organizations across 8 EU nations to analyze the impact of poor power quality on industry. - It estimated that poor power quality costs EU industry €150 billion annually due to issues like downtime, equipment damage, and raw material/sales losses. - The main sources of power quality issues were reported to be UPS systems, variable speed drives, processing equipment, electric motors, and electronic equipment. Common consequences included tripped relays/contactors and damaged motors/equipment.

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Why EU industry annually loses €150bn Pan-European Power Quality Survey
Belgium - Katholieke Universiteit Leuven Poland – AGH University of Science and Technology in Cracov Portugal – Universidade de COIMBRA Slovenia - University of Ljubljana Spain - Universidad Politécnica de Madrid – Escuela Técnica Superior de Ingenieros Industriales Spain - Universidad Politécnica de Catalunya – Centre d’ Innovació Tecnològica en Convertidors Estàtics i Accionaments UK - University of Manchester (formerly UMIST) Power Quality Survey – 68 respondent organisations + 15 project partners Academic Industrial Bovis LendLease España Corporate Risks Associates (UK) ECD Italy Edu Watt, France EPRI USA, Laborelec (Belgium) APC-MGE (EU) Schneider Electric (EU and Spain)
A study into the impact of power quality on energy critical industrial sectors Why industry loses €150bn annually Industry – 16 key industrial sectors 70% of the EU-25’s financial outputs 74% of the final non-residential energy demand The costs Down time Equipment damage Irrevocable raw material & sales losses Various penalties.
A study into the impact of power quality on energy critical industria sectors Industry – the sectors Pharmaceutical - Pulp paper - Oil chemical - Continuous manufacturing – Semiconductor Food beverage – Metallurgy - Newspaper publishing – Manufacturing – Hospitals – Banks Hotels – Telecom – Retail – Transport – Services & transport Major research project 68 face to face interviews 8 EU nation states Questionnaire 5 sections data gathering 6 th section comprising 11 case scenarios
Sources of power quality issues Capacitors Contacts and relays Electric motors Electronic equipment Lighting equipment Processing equipment UPS uninterruptible power supplies VSD and other static converters Welding and smelting equipment
Main sources of power quality issues UPS 29 UPS 24 VSD – static converters 29 Processing equipment 29 Electric motors 33 Electronic equipment 37 Lighting equipment 38 VSD – static converters 61 Electronic equipment 57 Electric motors 63 Services & Transport % responses Industry % responses
Main consequences experienced from power quality issues Circuit breakers Computers lock up Computers / other electronics damaged Data loss Electric shocks Lights flicker or dim Loss of synchronization of processing equipment Motors /other process equipment malfunction Motors /process equipment damaged Noise interference to telecom lines Relays /contactors nuisance tripping Transformers/ cables overheating
Main consequences experienced from power quality issues Relays & Contacts tripping 19 Motors / process equipment damaged 37 Transformers / cables overheating 33 Motors / other process equipment malfunction 51 Computers / other electronic equipment damaged 38 Data loss 51 Computers lock up 43 Computers / other electronic equipment malfunction 51 Lights flicker 43 Computers lock up 54 Data loss 48 Relays & Contacts tripping 54 Circuit breakers tripping 57 Loss of synchronisation 61 Services & Transport Group % re s ponses Industry Group % responses
Power Quality Solutions adopted Backup generator Dynamic voltage restorers Harmonic filter Isolation transformers Line conditioners or active filters Multiple independent feeder Oversizing equipment Shielding and grounding Site generation capable of substituting supply Static transfer switches Static Var Compensator Surge protectors on key pieces of equipment Uninterruptible Power Supply UPS devices Voltage stabilisers
Power Quality Solutions adopted Overall – most common solutions: Back up generation Multiple independent feeds Shielding & grounding UPS Services: Redundancy Security of supply Industry: More reacting to events Ad hoc solutions
Power Quality Solutions adopted “ Services” sectors tend to invest more into original designs “ Industry” sectors often have to adapt existing possibly older installations to cope with current demands Sectors that cannot allow for power interruptions tend to design reliability & resilience into their systems. Annual investment into power quality “solutions” measured by this investigation - €298 million. An EU-25 equivalent of ~ €50bn pa.
Measuring Power Quality Measurement should be fundamental and key to all these industrial sectors Measurement is the starting point to ensure that everything works correctly This investigation addressed How respondents measured and … What they were measuring.
Measuring Power Quality – how respondents measured 38% of the “Services” group undertook no measurement 46% of the “Industry” group undertook no measurement
Measuring Power Quality – how respondents measured
Measuring Power Quality – how respondents measured Industry RMS voltage – 57% of the 54% that measure anything Other parameters reactive power voltage unbalance harmonics – [THD] & specific orders 5 th & 3 rd Services Reactive power – 71% of the 62% that measure anything Other parameters same precedence Flicker – 17%
Power Quality Survey – data confidence Are these data representative? Application of the data to a pan EU-25 scenario. “Industry” & “Services” sub-samples.
Power Quality Survey – data confidence “ Industry” R Sq Linear = 0.942 In both cases
Power Quality Survey – data confidence “ Services” R Sq Linear = 0.809
Power Quality Survey Assessing the impact through 11 key case scenarios Voltage dip Short interruptions Long interruptions 4 x Harmonics Additional energy losses and related problems Overheating N conductor Nuisance tripping protective devices Malfunctioning PLC devices & other control systems Surges & transients Flicker Unbalance Earthing & EMC
Power Quality costs EU-25 €150bn pa Labour losses WIP Process slow down Equipment damage Other costs Dips & SIs LIs Harmonics Surges & transients Flicker, unbalance & earthing
Power Quality Survey – what does €150bn represent? 5% of a notional 15% net profit margin The €300 million invested into power quality solutions is:  33% of these annual EU-25 losses < 3% of the net profit These data consistent with other studies in other regions eg EPRI CEIDS USA [2000]
Power Quality Survey – what does €150bn represent? Electrical energy >70% of final electrical energy consumed by these sectors 1½ times EU-25 2020 annual reduction in energy consumption targets of €100bn pa … NOW! 115% pa of predicted cumulative cost of 110GW installed wind power by 2012 [DEWI 2007] +10 times current carbon credits in circulation
Power Quality Survey – what does €150bn represent? Social costs 4 months to repay the World Bank’s highly indebted countries’ debt of €54bn 2 hurricane Katrinas .. every year And all this is just the EU-25
Power Quality Survey – what does €150bn represent? Business efficiency 47% of the EU-25 annual investment into R&D 187% of the EU-25 annual investment into Life Long Learning ~ 5% of the reviewed sectors’ annual profit margin
Conclusions and actions to be taken Power quality costs EU-25 significantly End users’ own installations are the main source of this wastage It lies within their gift to do something about it. Driving these lessons home – including end users presenting and applying data within their own organisations Intention to put this data to work: For the benefit of EU as a whole, For industrial competitiveness And for our environmental objectives.
Specific 2008 actions to date Confederation of Paper industries - CPI Process Issues Committee Chemicals industry Association [possibly inc. CEFIC] – June 10 th
Why EU industry annually loses €150bn Pan-European Power Quality Survey http://www.leonardo-energy.org

More Related Content

European Power Quality Survey

  • 1. Why EU industry annually loses €150bn Pan-European Power Quality Survey
  • 2. Belgium - Katholieke Universiteit Leuven Poland – AGH University of Science and Technology in Cracov Portugal – Universidade de COIMBRA Slovenia - University of Ljubljana Spain - Universidad Politécnica de Madrid – Escuela Técnica Superior de Ingenieros Industriales Spain - Universidad Politécnica de Catalunya – Centre d’ Innovació Tecnològica en Convertidors Estàtics i Accionaments UK - University of Manchester (formerly UMIST) Power Quality Survey – 68 respondent organisations + 15 project partners Academic Industrial Bovis LendLease España Corporate Risks Associates (UK) ECD Italy Edu Watt, France EPRI USA, Laborelec (Belgium) APC-MGE (EU) Schneider Electric (EU and Spain)
  • 3. A study into the impact of power quality on energy critical industrial sectors Why industry loses €150bn annually Industry – 16 key industrial sectors 70% of the EU-25’s financial outputs 74% of the final non-residential energy demand The costs Down time Equipment damage Irrevocable raw material & sales losses Various penalties.
  • 4. A study into the impact of power quality on energy critical industria sectors Industry – the sectors Pharmaceutical - Pulp paper - Oil chemical - Continuous manufacturing – Semiconductor Food beverage – Metallurgy - Newspaper publishing – Manufacturing – Hospitals – Banks Hotels – Telecom – Retail – Transport – Services & transport Major research project 68 face to face interviews 8 EU nation states Questionnaire 5 sections data gathering 6 th section comprising 11 case scenarios
  • 5. Sources of power quality issues Capacitors Contacts and relays Electric motors Electronic equipment Lighting equipment Processing equipment UPS uninterruptible power supplies VSD and other static converters Welding and smelting equipment
  • 6. Main sources of power quality issues UPS 29 UPS 24 VSD – static converters 29 Processing equipment 29 Electric motors 33 Electronic equipment 37 Lighting equipment 38 VSD – static converters 61 Electronic equipment 57 Electric motors 63 Services & Transport % responses Industry % responses
  • 7. Main consequences experienced from power quality issues Circuit breakers Computers lock up Computers / other electronics damaged Data loss Electric shocks Lights flicker or dim Loss of synchronization of processing equipment Motors /other process equipment malfunction Motors /process equipment damaged Noise interference to telecom lines Relays /contactors nuisance tripping Transformers/ cables overheating
  • 8. Main consequences experienced from power quality issues Relays & Contacts tripping 19 Motors / process equipment damaged 37 Transformers / cables overheating 33 Motors / other process equipment malfunction 51 Computers / other electronic equipment damaged 38 Data loss 51 Computers lock up 43 Computers / other electronic equipment malfunction 51 Lights flicker 43 Computers lock up 54 Data loss 48 Relays & Contacts tripping 54 Circuit breakers tripping 57 Loss of synchronisation 61 Services & Transport Group % re s ponses Industry Group % responses
  • 9. Power Quality Solutions adopted Backup generator Dynamic voltage restorers Harmonic filter Isolation transformers Line conditioners or active filters Multiple independent feeder Oversizing equipment Shielding and grounding Site generation capable of substituting supply Static transfer switches Static Var Compensator Surge protectors on key pieces of equipment Uninterruptible Power Supply UPS devices Voltage stabilisers
  • 10. Power Quality Solutions adopted Overall – most common solutions: Back up generation Multiple independent feeds Shielding & grounding UPS Services: Redundancy Security of supply Industry: More reacting to events Ad hoc solutions
  • 11. Power Quality Solutions adopted “ Services” sectors tend to invest more into original designs “ Industry” sectors often have to adapt existing possibly older installations to cope with current demands Sectors that cannot allow for power interruptions tend to design reliability & resilience into their systems. Annual investment into power quality “solutions” measured by this investigation - €298 million. An EU-25 equivalent of ~ €50bn pa.
  • 12. Measuring Power Quality Measurement should be fundamental and key to all these industrial sectors Measurement is the starting point to ensure that everything works correctly This investigation addressed How respondents measured and … What they were measuring.
  • 13. Measuring Power Quality – how respondents measured 38% of the “Services” group undertook no measurement 46% of the “Industry” group undertook no measurement
  • 14. Measuring Power Quality – how respondents measured
  • 15. Measuring Power Quality – how respondents measured Industry RMS voltage – 57% of the 54% that measure anything Other parameters reactive power voltage unbalance harmonics – [THD] & specific orders 5 th & 3 rd Services Reactive power – 71% of the 62% that measure anything Other parameters same precedence Flicker – 17%
  • 16. Power Quality Survey – data confidence Are these data representative? Application of the data to a pan EU-25 scenario. “Industry” & “Services” sub-samples.
  • 17. Power Quality Survey – data confidence “ Industry” R Sq Linear = 0.942 In both cases
  • 18. Power Quality Survey – data confidence “ Services” R Sq Linear = 0.809
  • 19. Power Quality Survey Assessing the impact through 11 key case scenarios Voltage dip Short interruptions Long interruptions 4 x Harmonics Additional energy losses and related problems Overheating N conductor Nuisance tripping protective devices Malfunctioning PLC devices & other control systems Surges & transients Flicker Unbalance Earthing & EMC
  • 20. Power Quality costs EU-25 €150bn pa Labour losses WIP Process slow down Equipment damage Other costs Dips & SIs LIs Harmonics Surges & transients Flicker, unbalance & earthing
  • 21. Power Quality Survey – what does €150bn represent? 5% of a notional 15% net profit margin The €300 million invested into power quality solutions is:  33% of these annual EU-25 losses < 3% of the net profit These data consistent with other studies in other regions eg EPRI CEIDS USA [2000]
  • 22. Power Quality Survey – what does €150bn represent? Electrical energy >70% of final electrical energy consumed by these sectors 1½ times EU-25 2020 annual reduction in energy consumption targets of €100bn pa … NOW! 115% pa of predicted cumulative cost of 110GW installed wind power by 2012 [DEWI 2007] +10 times current carbon credits in circulation
  • 23. Power Quality Survey – what does €150bn represent? Social costs 4 months to repay the World Bank’s highly indebted countries’ debt of €54bn 2 hurricane Katrinas .. every year And all this is just the EU-25
  • 24. Power Quality Survey – what does €150bn represent? Business efficiency 47% of the EU-25 annual investment into R&D 187% of the EU-25 annual investment into Life Long Learning ~ 5% of the reviewed sectors’ annual profit margin
  • 25. Conclusions and actions to be taken Power quality costs EU-25 significantly End users’ own installations are the main source of this wastage It lies within their gift to do something about it. Driving these lessons home – including end users presenting and applying data within their own organisations Intention to put this data to work: For the benefit of EU as a whole, For industrial competitiveness And for our environmental objectives.
  • 26. Specific 2008 actions to date Confederation of Paper industries - CPI Process Issues Committee Chemicals industry Association [possibly inc. CEFIC] – June 10 th
  • 27. Why EU industry annually loses €150bn Pan-European Power Quality Survey http://www.leonardo-energy.org

Editor's Notes

  1. Today I want to talk about why EU industry is losing some €150bn annually in a way which we believe is both unnecessary and cost effectively avoidable. These are very vague terms so let us look into what each of them mean in more detail.