Power Quality Metering / Monitoring Solutions

Like any troubleshooting task, you want the right tools to get the job done. When it comes to power quality, finding, troubleshooting and removing problems with dips and swells, harmonics, imbalance, along with other power quality problems can be difficult. Capturing the information needed to analyze and diagnose is the initial step in solving these power quality issues. MachineSense Power Quality Meters and analyzers can help you identify and trace anomalies and harmonic distortion problems - even the ones which are the most difficult to find.

MachineSense three-phase power quality meters are ideal for logging, and generating detailed reports in combination with the easy-to use CrystalBall cloud-based analytics software.

Why is Power Quality Monitoring Essential?

Power Quality Monitoring has several advantages, like enhancing performance and quality. A PQM System will gather, examine, and interpret raw energy measurement information into useful information. A typical monitoring system measures voltage and electric current, but ground quality might also be measured if dispersed loads or harmonics are found. There are a number various reasons to use power quality monitoring. It helps plants to do energy management, preventative maintenance, quality control and save money. Today, many end users have telecommunications or computer equipment that do not utilize PQM. This makes them susceptible to power quality problems. If you understand the implications of power fluctuations then you will realize the importance of power quality monitoring.

It is projected that power outages account for up to 40 percent of all business downtime. To monitor their power, modern power plants use digital error recorders, smart relays, voltage recorders, in-plant power monitors, and specific purpose power quality equipment. Consumers of power, such as buildings and factories use power quality meters from manufacturers such as MachineSense to prevent equipment damage and fire.

If you are interested in power quality monitoring for your factory or building, please contact us for a free consultation with our sales engineer.

How MachineSense Power Quality Meter Works

Power Quality Analyzer
  1. Vibration Analyzer
  2. MachineSense Power Toroid
  3. MachineSense Power Analyzer
  4. MachineSense Data Hub
  5. Router
  6. Cloud-Based Servers
  7. MachineSense CrystalBallTM Predictive Software
  8. Actionable Maintenance Advice

MachineSenseTM Power Analyzer toroids are placed directly on incoming power lines to automatically monitor power conditions and detect power anomalies. The sensor data transmits through a self-contained data hub directly to your router and onto cloud-based servers running powerful analytic software. Results are then transmitted from the server to either a desktop or user friendly app where you will view power conditions with helpful advice to correct power anomalies.


Download Datasheet Quick Start Guide Installation Guide

How is Power Quality Determined?

Individual Waveform Capture – Allowing engineers and executives to track slowly changing variation in electrical waveforms to root out the cause of mechanical failures well before they happen which can be isolated, recorded and graphically displayed while using the Acuvim IIW.

Harmonic Distortion

Power Quality Monitoring provides an analysis of non-linear loads connected to the distribution system, all of which affect electrical frequencies and cause problems such as misfiring, over-heating and voltage spikes. Individual harmonic measurement can be read on all of the MachineSense power quality meters.

Sag & Swell Monitoring

Voltage Sags and Swells are a decrease and increase in voltage over a brief time. Voltage sags are the most typical events that lead to affect the quality of energy and are usually the most pricey. They affect gear which range from PLCs, relays, controllers and everything else. When the sag happens, the power source within the device overcompensates which when the sag is reduced enough can harm the internal circuits of the device causing malfunctions.

Though these are generally blamed on the utility company, the reality is that these are usually caused inside the site or building and includes grounding, bonding, and other problems or from powering different equipment through the same power supply.

Frequency Variations

The deviation of the frequency at which electric current is supplied may confuse logic systems and affect the operating speed of machinery. These deviations in frequency can be effectively monitored using any MachineSense Power Quality Meter.

Power Factor

The ratio of the real power flowing to the load that it can be used for; this 0-1 figure is a most accurate depiction of how viable the electricity supplied is. Low power factor ( usually called “dirty power” ) affects devices and causes inefficiencies in their functioning. All of the MachineSense power quality meters allow users to keep track of this ratio and users can track the historical power factor.

Recommended Implementation

An effective Power Quality Audit using MachineSense power quality monitoring systems can be achieved using MachineSense Power Quality Meters as a permanently installed power quality meter for proactive and comprehensive power quality measurement. The meter can be read remotely via our proprietary cloud-based software and app.

Features & Benefits

  1. Affordable, low investment and easy to install on existing equipment
  2. Easy to understand diagnostic advice via text or email messages and handheld or desktop dashboards, no manual data analysis
  3. Dedicated power supply, no need to change sensor batteries
  4. 24/7/365 constant automatic monitoring, no manual measurements
  5. Accurate reporting of potential machine and component failures, to reduce unscheduled machine downtime
  6. Real time and historic electrical power consumption data

The growing line of MachineSense Power Analyzers has been designed for many industrial electrical applications—to help identify key electrical issues and possible pricing concerns as well as to help identify looming failure issues in motors, drives and heaters.

In the past, looking for power quality issues has typically only been a last resort because most plant management personnel are not fully educated in electrical issues. However, research has shown that many equipment issues are founded on electrical power quality problems. Instead of making power quality a review of last resort, it should be used as a first survey by most process manufacturers.

Poor power quality shows up in many ways and can absolutely affect the performance of machine controls which are essentially computers nowadays. In addition, it can affect the performance and life of components such as heaters and motors. A recent survey indicated that US businesses lost a staggering $188 billion a year just because of internal power quality issues that are often not diagnosed or misdiagnosed and happen again and again and again.

Most industrial factories in the US were set up long before the age of computerization, computer controls and sophisticated variable frequency drives. Electrical building contractors designed facilities without thinking that computers would be on every desk, let alone every machine controller. Furthermore, they designed only for motors running at their design speed and lighting that emitted low harmonic output. All of this led electrical contractors and electrical engineers in the past to have little reason to be concerned about harmonics, transients and other power factor issues. As a result, internal plant power is often a major undiagnosed problem that constrains productivity, increases utility charges and often causes electrical or computer failures. For example, most plant personnel assume that motor failures are the fault of the motor or the machinery supplier and just replace the motor. However, the vast majority of motor failures are due to power quality problems.

MachineSense Power Analyzers are the first series of economically priced instrumentation designed by and for manufacturers to help them understand electrical issues and act on them so they avoid the continuation of undiagnosed electrical issues occurring on an ongoing basis. Some of the diagnostic tools that can be used include the following:

Energy Analytics Using MachineSense™ Power Quality Meter

Electric submersible pumps (ESP) are used in a wide-range of applications from onshore to complex offshore, deep water, or subsea applications. Premature failures during well drilling can lead to high financial loss. It is also well known additional harmonics currents are generated when the ESPs near failure threshold. MachineSense Power Analyzer can detect ESP failures ahead of time. It is also reported, due to overworking of these Pumps during drilling, 10% of the pumps die much before finishing their assigned task in the field. MotorSense can send SMS/email much before ESP pumps develop its fatigue and thus prevents unplanned failure in field which may disrupt production.

Power Quality Analyzer

Sags are the foremost power quality problem encountered in Industrial applications because they frequently cause the interruption of manufacturing processes, which can result in a significant economic loss due to rejected products . To resolve these problems, industrial consumers often install voltage sag compensators in critical industrial applications. However, these compensating techniques are expensive and at a time ineffective if not designed with proper understanding of the nature of the Sag. The transformer, which is usually mounted in front of the critical load, is likely to be exposed to voltage Sag. As a result, when the compensator reinstates the load voltage, a serious magnitude of transient current begins to flow toward the sensitive load. This inrush current can either damage the equipment or activate the protection devices. In either case, the compensation will eventually fail. MachineSense Power Analyzer tracks both sag and Inrush currents. Industrial operators should be able to monitor both Sag and Inrush current to make sure, neither is affecting their production line.

Power Quality Analyzer

Data center evolved to become large power consumers. Its supporting infrastructure, such as cooling and power distribution, consumes resources e.g. electric power. Power conditioning and cooling systems constitute largest proportion of Opex for any data center. Therefore, the efficiency of cooling system and power quality are extremely important. There are several designs of cooling and power efficiency but given the infinite permutation of possibility of optimization techniques, Data centers need EnergySense to track several Energy optimization techniques in play at different part of their center and select the best possibility. In addition, if some of the techniques fail to work effectively over the time, EnergySense data can help them sorting out easily as a large of number of EnergySense can be deployed to track the different parts and systems of the Datacenter.

Power Quality Analyzer

BioTech and pharmaceuticals production is guided by the Federal Drug Administration (FDA) regulations which demand high level of product excellence. High power quality is indispensable in the pursuit of the level demanded by the FDA. Poor power quality and related disturbances can lead to reducing the quality standard and loss of production. Pumps, mixers and motors have to run flawlessly to ensure that the ingredients are mixed in the correct proportions and in the case of capsules, filled properly. Pills cannot be misshapen and high-speed packaging lines must run smoothly. Any glitch in the power quality can result in production losses and even lawsuits. Power Analyzers can be placed at strategic points in the factory to diagnose and record a wide variety of electrical characteristics and automatically report issues to the factory managers or stake holders via SMS and email so corrective actions can be taken.

Power Quality Analyzer

In recent years, microgrid technologies have captured global interests among governments, industries, and academic institutions due to their potential benefits in improving energy efficiency and reliability, and reducing carbon emissions. A microgrid system should be a single controllable entity that operates in both grid-connected and standalone modes of operation. The total generation capacity, operational capabilities, and network boundary of a microgrid system can vary, depending on types of loads. Microgrid systems have been built on university campuses, military installations, and other industrial sites, for supporting both demonstration and mission-critical activities. One of the primary operational challenges in a building microgrid is associated with power quality management when the microgrid is in standalone operation. Due to the small generation capacity, the physical operating characteristics of building equipment and appliances can considerably affect the microgrid voltage, current, and frequency, and result in harmful harmonic distortions. Therefore, the device operating characteristics must be adequately modeled in both the fast time scales associated with local controls and the longer time scales relevant to energy scheduling. EnergySense cloud provides load/current/harmonics/energy data of the microgrid with easy interface for studying them off-line and real time.

Power Quality Analyzer

There is a very high usage of power converters in the modern power system because of their high efficiency. Solid state drives are extensively used in industries like textile plastic extrusion for flexible control of power and to reduce the power loss. Unfortunately, solid state drives produce different types of power quality problems. Waveform distortion, particularly harmonics generated by power converters is one of the power quality issues that affect the power system operation. These converter systems generate not only characteristic harmonics but also non- characteristic harmonics like inter harmonics. Power Analyzer measures all kinds of harmonics and current imbalance and if harmonics cross a threshold amount, it sends SMS/Email alerts to the stake holders.

Power Quality Analyzer

Refrigeration constitutes 20-50% of the operating cost of the food processing Industry. Effective refrigeration or energy efficient cooling is done via 3 major optimizations – thermal shielding, convection of cool air flow and using energy efficient compressors so that least amount of heat is generated. To track effective cooling, one needs to track ambient temperature in all areas of the room and energy efficiency of its cooling compressor. Less efficient compressor will dissipate heat and thus will make system less efficient. Therefore effective tracking of cold storage will need a MachineSense for tracking temperature of cold storage and EnergySense for monitoring compressors for its energy efficiency.

Power Quality Analyzer

Power factor compensation and harmonic suppression are two important issues in industrial plants because of the installation of a huge number of inductive loads such as electric motors and non-linear power electronic devices that produce harmonic disturbances. Harmonics can shorten the life of industrial equipment and cause transformer overheating, motor failures, fuse blowing, capacitor failures, and malfunction of control systems. In heavy industry plants, an attempt to compensate for low power factor has commonly resulted in installation of medium and low voltage capacitor banks which also help customers avoid penalties from the utility, reducing extra losses in transformers, overhead lines and cables. However, banks of capacitors and industrial inductors, when placed together, can create a lot of undesired frequencies due to resonance. That’s why optimization of configuration and values of capacitor banks is of utmost importance. This can be automatically discovered from harmonics levels and Power Analyzer provides the total harmonics distortion information automatically with a SMS/Email alarm system.

Power Quality Analyzer

Drying reduces the water content of a product or material. There are various kinds of industrial drying- for example spray drying is particularly used in the dairy industry to increase the shelf-life of a product as well as reduce the cost of transportation. The main challenge in controlling the dryer is to minimize energy (hot air) to bring the residual moisture in the material below the recommended level. Drying accounts for a large proportion of energy bill in the plastic and dairy industry. Now, since several optimization techniques are known for efficiently re-using the hot air for regeneration, it is important to track heat regeneration process for energy efficiency. Dryers can use all the variants of the Power Analyzer analytics packages - EnergySense, MotorSense (tracking the failure of the blower) and HeaterSense (tracking the failure of the heating elements) for predictive maintenance and increasing energy efficiency.

Power Quality Analyzer

Chemical processing plants need an uninterrupted, high quality, power supply for every part of the process. For example, in hydrocarbon processing, production starts with cracking; the breakdown of large hydrocarbon chains into smaller ones. High pressure steam is superheated, and several general pumps are used to bring water and reactants to the furnace. If a pump fails, the flow of substances in the process will be disturbed. MachineSense Vacuum Pump Analyzer is recommended for such applications. The quencher pump is important to refill the water reservoir of the quencher. The quencher prevents the products from further reaction after the proper temperature has been reached in the furnace or reactor. Long interruptions will lead to unscheduled process downtime, damaging the system. During scheduled downtime, steam is used to de-coke and clean the lines of the furnace to improve reaction efficiency and yield. A five-stage compression process is generally used to dry and compress the products to be separated. During the third stage, the acid gas scrubber uses a pump to spray the gas with a caustic wash, under high pressure, to remove any carbon dioxide and Sulphur. Finally, the dried cracked gas is put through a complex separation process. If a pump or compressor failure occurs, the separation process is affected and the product purity is significantly reduced while lowering the efficiency of the entire process. Thus, in all stages in a refinery plant, pumps play a critical role, failure of which will damage the downstream production. Failure of most of these pumps is caused by higher harmonics and imbalanced powerline fed to those pumps. The Component Analyer can monitor the health of the pumps and compressors 24x7 and any potential risk of the pump or compressor failure will be alarmed. Meanwhile, Power Analyzer can monitor harmonics and line imbalance so you can take corrective actions to minimize damage to these mission-critical pumps.

Power Quality Analyzer

Power AnalyzerTM Single-Port (with isolation) Specifications

Current IEC60059 0-50/100/300 amp per phase ± 0.3% Full Scale Span 0.01
Voltage IEC60038 0-600 V ± 1.2% Full Scale Span 0.01
Apparent power n/a up to 310 kVA 1% (0.25 Kw MAX) 0.01
Total harmonic distortion (V) IEC 61000-4-7 0-10% upto 5th harmonics (Published)/Upto 27th for THD ±2.5% 0.01
Total harmonic distortion (I) IEC 61000-4-7 0-10% upto 5th harmonics (Published)/Upto 27th for THD ± 2.5% 0.01
Voltage sag/swell IEC 61000-4-30 Vsag< 0.8*Vnom, Vswell>1.2 * Vnom
Energy IEC 62052-11, IEC 62053-21 n/a ± 2%, - under steady loads.
Display Connected Mobile / Desktop Android/iOS
Power supply 110-270V AC or 24 VDC
Dimension length x width x depth 10.0 in X 7.4 in X 2.0 in (255.4 mm X 189.2 mm X 51.7 mm)
Weight 1.35 KG without current sensors
Safety IEC60950-1
Operating temperature 14° F to 149°F (- 10° C to 65° C)
Operating humidity <= 90%
Electromagnetic Compatibility IEC 61326-1
Number of inputs 3-phase current input
Number of inputs 3-phase voltage input
Voltage 0-600V (L-L)
FREQUENCY 47.5-63 Hz
Resolution 24-bit ADC sampling
Sampling frequency 1.024 MHz
Input signal frequency 47.5-63 Hz
Data storage internal flash memory (not user replaceable) 4 GB for local data storage during disconnection
Data rate to cloud 1 regular dataset per second. (voltage, current and power factor)
Length 2M
Weight 2.1 oz (60 g)
Clamp type Crocodile clamp with banana adapter
Cable specification PTFE Insulated 0.40 Sq.mm - Silver Plated Copper - 600 V - 6 Core - Shielded Cable Description: Awg.22/19/34 - SPC - E - 6 Core - TEF / SPC / TEF Cable OD : 4.50 mm + / - 0.50 mm
Shielding 90% shielding with silver plated copper
Connector PG-9 cable gland
Length 2M
Weight (including sensor) 5.3 oz (150 g)
Sensor type Split core CT
Cable specification PTFE Insulated 0.40 Sq.mm - Silver Plated Copper - 600 V - 6 Core - Shielded Cable Description: Awg.22/19/34 - SPC - E - 6 Core - TEF / SPC / TEF Cable OD : 4.50 mm + / - 0.50 mm
Shielding 90% shielding with silver plated copper
Connector PG-9 cable gland

Power Analyzer sensors

Power Analyzer sensors

Power Analyzer single port

Power Analyzer single port

FAQ's on Power Quality Meter and Monitoring

Electrical power runs almost every machinery in the world. As clean unadulterated food is important for the healthy lifestyle of human beings, machines need clean power for longevity and uninterrupted operations. Therefore, high-quality power is absolutely required for the successful operation of the factories and the buildings. IEEE 1159 standard defines the international standard for clean power by limiting the maximum limits allowed for over/under voltage/current conditions, Sag/Swell, poor grounding/earthing, level of different current and voltage harmonics, etc. Power distribution companies maintain this standard while feeding to the transformers at the input to the factories and the buildings. However, power distribution inside the factory or the building may not comply with IEEE 1159 standards since within the factories/buildings power quality degrades due to uneven tapping of single-phase load from 3-phase lines, DC loads like LEDs, UPS, Mobile/Laptop charges, etc. Poor quality is not only responsible for immature death/downtime of the machines/controllers, it also threatens basic fire safety issues since power surges or imbalance may lead to the burning of the wires. In addition, harmonic contents of the power are normally wasted and thus contribute to energy inefficiencies.

Power Quality Meters had wide range of applications - most notable among them are:

  • Check the compliance with IEEE 1159 power standards to make sure Power fed to the factories/buildings/machines are clean.
  • Additional algorithms available to monitor predictive health of the Motors, Heaters, Drives 24x7 continuously in the cloud and in the edge system.
  • Compare energy usages between different machines within a factory.
  • Calculate the utilization and productivity of the machines.
  • Measure energy usage per unit of productivity.
  • Estimate the actual cost of electricity by an accurate cost model of energy usage that depends on time of the day, time of the year, etc.
  • Capture surge or small duration electrical event in detail using the event capture mechanism.

Power Quality Meter has one hardware and 4 software components.

  • Its hardware captures the voltage and current data of a machine or electrical line. Its hardware supports up to 6.6 kV and 0-4000A range.
  • Voltage, Current and Power Factor data then fed to sensor system software ( Software-1) which extracts all the useful information ( metadata) of power quality ( harmonics, over-voltage, RMS, etc.) in real-time and with a sampling rate required for the application
  • Then power quality metadata is ingested into an analytic module ( Software-2) which does analytical modeling for power quality. All the metadata and analytic results are continually stored into a database system ( Software-3) which stores the data for 6 months. In MachineSense system, Software 2 and 3 can be deployed both locally within the factory ( edge cloud) as well as in the public cloud ( MachineSense offers a fully-featured SaaS for that).
  • Final results of analytics, metadata and database can be displayed/accessed using two different visualization software systems ( Software-4). One type of visualization known as data monitor is for plant engineers /maintenance crew. This version of visualization is fully automated. Another type of visualization is for expert electrical engineers which allows the engineers to play with data and algorithms in an open platform.

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