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From Milliwatts to Megawatts: Measuring Power with LabVIEW

NI Week 2014

Mounzer Saleh, Senior AE

National Instruments

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What do we think of when we

think of measuring power?

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Two Measurements Needed for Power

Voltage

IVP *

Current

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Power Quality Demo

The power strip represents a small grid.

The Grid

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NI PQA Demo CompactRIO Components

cRIO-9068

(Dual-Core ARM 667 MHz,

Xilinx 7 Series FPGA)

NI 9227

5 ARMS

NI 9225

300 VRMS

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High-Voltage Analog Input C Series Modules NI 9242 & 9244, 3-Ch, 50 kS/s, 250 Vrms L-N or 400 Vrms L-N

• Both Modules • 3 AI Ch + 1 Neutral Ch

• 50 kS/s

• 12 AWG

• Delta or WYE 3-phase measurements

• NI 9242 • 250 Vrms L-N, 400 Vrms L-L CAT III

• Ideal for standard output level PTs

• NI 9244 • 400 Vrms L-N, 800 Vrms L-L CAT III

• Ideal for industrial level machine monitoring up to the standard 690 Vrms L-L

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Current Shunt Input Module NI 9238, 4-Ch, 50 kS/s, ± 0.5 V

• Synchronize with NI 9225,

NI 9242 and NI 9244 for

power measurements

• Measure external current

shunts and transducers

• ± 30V overvoltage

protection

• 250 Vrms CAT II Ch-Ch

isolation

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Voltage Measurement

NI 9225 “Grid”

White wire

Black wire

Connection made using spliced power cord

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Current Measurement

NI 9227*

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Transformers & Transducers

Current or

Voltage

• Output voltage or current

• DC or high frequency

• Split or solid core

• Mount or handheld

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Current Measurement

NI 9238

Exposed wires

Black wire passes

thru CT

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LabVIEW Electrical Power Suite 2014

New Features

• Measurement of variable frequency

networks [Full] • Ramp up/down tests for generators/motors

• Aircraft frequencies (400Hz, variable)

• Similar to benchtop PQA functionality

• New example programs • SAR modules (like the NI 9215, NI 9222/23)

• New HV Module Example Programs (NI

9242/44)

• Compliance to the latest PMU standard

(M&P class support) [Pro]

Search for “Electrical Power Suite” at ni.com

Demo

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Turbine Generators

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Power Transmission

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Types of Electrical Loads

Resistive Inductive Capacitive

In Phase Lagging Phase Leading Phase

Demo

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Interruption Swell Sag

Voltage Level (% of nominal)

10%<sag<90%*

Duration

Instantaneous 0.5-30 Cycles

Momentary 30 Cycles – 3

seconds

Temporary 3 seconds – 1

minute

Voltage Level (% of nominal)

110%<swell<180%*

Duration

Instantaneous 0.5-30 Cycles

Momentary 30 Cycles – 3

seconds

Temporary 3 seconds – 1

minute

Voltage Level (% of nominal)

Interruption<10%

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.

Power Quality Events

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Power Quality Events

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Problems Caused by Poor Power

• Computer Equipment • Lock-ups

• Lost data

• Damage to media storage (disk drives)

• Damage to power supplies

• Occupant comfort and productivity • Flicker (can trigger migraines)

• Lost productivity due to system reboots or outages

• Direct Monetary Loss • Fines from utility company for low power factor

• Process manufacturing losses • Power issues can lead to wasted material and time (scrap and

rework/restart) o Most common in silicon and bio/pharmaceutical industries

• Premature Machine Failure • Insulation breakdown

• Inefficient operation (excess heat, less usable work)

Photo by Florian Hirzinger

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Application for Power Measurement

Utility Distribution

White Goods Testing

Machine Health

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Instrumentation Considerations Synchronization

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Instrumentation Considerations Resolution

Time (ms) 100 200 150 50 0

0

1.25

5.00

2.50

3.75

6.25

7.50

8.75

10.00

Amplitude

(Volts)

16-Bit versus 3-Bit Resolution

(5 Hz Sine Wave)

16-bit

3-bit

000

001

010

011

100

101

110

111

| | | | |

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Calculations are Based on Waveform Data

Features

• Voltage, Current, Power

• Instantaneous

• RMS

• Peak-Peak

• Crest Factor

• Fundamental Frequency

• Power Factor

• Power (reactive, apparent,

real)

Events

• Sag

• Swell

• Interruption

• Flicker

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RMS (Root Mean Square)

AC Equivalent of DC

3 Common Ways to

Calculate

• True RMS

• Peak

• Average

Equation (True)

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Measuring Waveform Data

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Calculations are Based on Waveform Data

Features

• Voltage, Current, Power

• Instantaneous

• RMS

• Peak-Peak

• Crest Factor

• Fundamental Frequency

• Power Factor

• Power (reactive, apparent,

real)

Events

• Sag

• Swell

• Interruption

• Flicker

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Types of Electrical Loads

Resistive Inductive Capacitive

In Phase Lagging Phase Leading Phase

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The Power Triangle Mathematical Analogy

()

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

Reactive Power (VAR)

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The Power Triangle Mechanical Analogy

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Power Factor = Real Power

Apparent Power

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Power Factor Correction

Circuit Connection

Contactors “Relays”

Bank of Capacitors

Demo

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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.

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Nucor Power Monitoring Station

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Example Power Monitoring Solutions from Elcom

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

ENA440

ENA460

ENA450

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Power Monitoring Software from Elcom

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Build Your Own and Power it with LabVIEW Demo

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• Power

• RMS current trending

• Power factor

• Load

• Voltage/Current unbalance

• Mechanical

• Bearing vibrations

• Shaft alignment

• Shaft speed

• Thermal

• Temperature

Machine Health

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Floor Demo’s

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• Power

• Energy efficiency

• Power factor

• Load

• Mechanical

• Sound

• Vibration

• Motor speeds

• Flow rate

• Thermal

White Goods Testing

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Power Quality Monitoring

• Electrical

Power

Suite

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Benefits of Power Measurement with LabVIEW

Feature Benefit

Select only the analysis required Easier user interface, less extraneous

information

Custom analysis Ideal for research or installations with

unique power features

Access to raw data Capture and store full waveform data

for post processing with almost any

SW package

Fully programmable Automated reporting and web hosting

to suit specific requirements

Open communication Integrate with existing systems

Expandable I/O Add more voltage/current lines, OR

mix with measurements such as temp,

pressure, vibration etc.

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Thanks for Attending!

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