Measuring Power with CompactRIO

NI Week 2012
Brett Burger: Sr. Product Manager
National Instruments

Why Measure Power?

Facilities/Utilities

Machine Health

White Goods Testing

Why Measure Power and Power Quality

Measurement

Action

Cost Savings Through

Total energy consumption

Verify with bill from utility

Overpayment elimination

Sub-metering of energy

Assign to cost center

Focus on largest energy consumers

Demand prediction

Run machines in shifts or alter

process control algorithm

Avoid peak usage fees

Power factor

Run machines in shifts or alter

process control algorithm

Avoiding fines from utility

Unbalance, RMS
trend/level, harmonics,
SAG/SWELL

Machine health monitoring

Energy efficiency and predictive maintenance

(machine life, minimize downtime)

Power Quality Events

Sag

Swell

Interruption

Voltage Level (% of nominal)

10%<sag<90%*

Voltage Level (% of nominal)

110%<sag<180%*

Voltage Level (% of nominal)

110%<sag<180%*

Duration
Instantaneous 0.5-30 Cycles
Momentary 30 Cycles 3 seconds
Temporary 3 seconds 1 minute

Duration
Instantaneous 0.5-30 Cycles
Momentary 30 Cycles 3 seconds
Temporary 3 seconds 1 minute

Duration
Momentary 30 Cycles 3 seconds
Temporary 3 seconds 1 minute

*Levels differ based on duration. Data pulled from IEEE 1159:1995 See standard for full data.

What do we think of when we think

of measuring power?

Two Measurements Needed for Power

Voltage

Current

P V *I

Instrumentation Considerations
Simultaneous acquisition
Resolution
Sample rate

Synchronization

Resolution
16-Bit versus 3-Bit Resolution
(5 kHz Sine Wave)

10.00
8.75
7.50

111

6.25

101
100

Amplitude
5.00
(Volts)
3.75
2.50
1.25
0 |
0

16-bit

110

3-bit

011
010
001
000
|
50

|
100
Time (ms)

|
150

|
200

Measuring Waveform Data

Turbine Generators

Power Transmission

Power Quality Demo

The Grid

The power strip represents a small grid.

NI PQA Demo
CompactRIO Components

cRIO-9024 (800 MHz)

cRIO-9113 (LX 50)

NI 9227
5 ARMS

NI 9225
300 VRMS

LabVIEW Electrical Power Suite

For CompactRIO Hardware

Measure power quality and energy

features to IEC, EN, and IEEE standards
Harmonics (IEC 61000-4-7)
Flicker (IEC 61000-4-15)
Sag/swell/interruption with standard or
custom levels (IEC 61000-4-30)
Compatibility with the COMTRADE (IEEE
37.111) file format

Download the Evaluation Version: Search for Electrical Power Suite at ni.com
PN: 782071-35

NI PQA Demo
Non cRIO Components

Demo Case

PS-15

WIFI Router

Software Components

Client Application

File Viewer

Data Dashboard

Voltage Measurement
Black wire
White wire

NI 9225
Connection made using spliced power cord

Grid

Current Measurement

NI 9227*

Transformers & Transducers

Current or Voltage

Output voltage or current

DC or high frequency
Split or solid core
Mount or handheld

Current Measurement

Exposed B,W,G wires

Black wire passes thru

CT

NI 9239

CompactRIO Getting Started

You have waveforms, now what?

Features
Voltage, Current, Power

Instantaneous
RMS

Peak-Peak
Crest Factor
Fundamental Frequency
Power Factor
Power (reactive, apparent, real)

Events
Sag
Swell
Interruption
Flicker

RMS (Root Mean Square)

AC Equivalent of DC
3 Common Ways to Calculate
True RMS
Peak
Average

Equation (True)

Types of Electrical Loads

Resistive

Inductive

Capacitive

In Phase

Lagging Phase

Leading Phase

Power Quality Events

Typical PQ problems

The Power Triangle

Mathematical Analogy
Real Power (Watts) = V * I cos ()
()

Reactive Power
(VAR)

The Power Triangle

Mechanical Analogy

Real Power
Power Factor =
Apparent Power

PFC
Circuit Connection

Contactors Relays

Bank of Capacitors

Example Power Monitors

ENA460
ENA450

All PQA are compliant wit IEC 61000-4-30 class A

ENA440

Up to Date Portable PQ Analyzers

ENA330

All PQA are compliant wit IEC 61000-4-30 class A

ENA500

Power Monitoring Software

ENA-Touch, ENA450 User Interface

Single Board RIO Technology

Case Study: Nucor Steel Corporation

One of the largest steel producers in
the US, and the largest recycler
Implemented grid power monitoring
Acted on grid power information
Saved money and pollution

Monetary fines can be significant.

Nucor Power Monitoring Station

Thanks for Attending!