Electrical power is omnipresent in industrial settings and is used to drive machinery, production belts, lighting, and HVAC systems and to connect the various sensors, PLCs, and oversight systems that keep processes running smoothly. Electrical energy is thus an extremely core consideration for industrial design (i.e., from where and how power will get to where it needs to go) and administrators (i.e., how much it costs and its various impacts, such as environmental).
Considering its presence and importance, it is also critical to understand how electrical power works and is used in industrial settings. In this blog, we’ll look at some key principles and concepts around electrical power and its industrial applications, with examples of how they apply in real-world situations.
AC/DC Power
Alternating Current (AC): Alternating current alternates the flow of electrons moving back and forth at different intervals, helping to minimize loss while transmitting electricity over long distances. AC is the most common form of electrical power in industrial settings and is used to power all kinds of equipment, such as large motors, HVAC systems, and conveyor systems. In industrial settings, AC power is often delivered through a three-phase supply.
Direct Current (DC): DC power is unidirectional, with the flow of charge and amperes always the same. In industrial settings, DC power is used in specialized applications such as electroplating, precision control systems, and battery storage. Robotics used in manufacturing facilities are often DC-powered as they allow for more accurate and consistent operations.
Electrical Circuits
An electrical circuit is the pathway that electrons use to flow from the source, such as a battery or generator, to its endpoint, such as a motor, computer, or anything that’s powered by electricity. Wiring is the most common feature of a circuit, and it’s what the current of electrons flows on, but other components include capacitors, resistors, and inductors.
Current
Current describes the flow of electrical charge and is measured in amperes (A). In industrial settings the current used depends on the needs of the premises or processes. Low current is used in signal processing systems, programmable logic controllers (PLCs), sensors, and control circuits that monitor and manage production lines and similar processes. High current is used for heavy-duty processes that require high loads of electrical power, including machinery, welding equipment, and heating systems. Electrical engineers use conductors, breakers, and fuses to control and make the current safe.
Volts
Voltage (V) refers to the potential difference or pressure that pushes charged electrons (i.e., electrical current) through a circuit. It is a core parameter used in defining the requirements of industrial equipment (and all electrical equipment). High-voltage applications (400V+) include the power grids used to transmit electricity around industrial premises. This voltage is then stepped down at a transformer to be used by the given equipment. Low-voltage applications (<240V) include electrical equipment like sensors or controllers or equipment you might also find in a home, such as lights or computers.
Electrical Resistance and Conductance
Electrical resistance, which is measured in ohms (Ω), measures how much a material opposes the flow of electric current. Electrical conductance is the ease with which it moves through an object. This has considerable importance for safety and efficiency in industrial settings.
High resistance can lead to excessive heat generation, energy loss, and reduced equipment efficiency. Additionally, the monetary cost of energy loss through overheating can also lead to equipment damage and subsequent downtime. Low resistance (or high conductivity) allows for better current flow, such as high-quality copper wiring used in critical systems like data centers.
Electrical resistance is built on the foundational principle of Ohm’s Law, which gives mathematical equations for how current, voltage, and resistance relate to each other in an electrical circuit. Electrical engineers in industrial settings use these to calculate and design circuits that meet specific voltage, current, and resistance requirements.
Watts
Watts (W) measure power consumption. They measure the rate of energy transfer in an electrical system, that is the change from electrical energy to kinetic or heat energy. In industrial settings, for example, a motor rated at 10,000 watts (10kW) means that 10kW of electrical energy passes from the source to the motor, where it is used to drive the motor’s driveshaft. Understanding watts and energy usage allows electrical engineers to improve the efficiency of industrial processes and premises.
Electrocution and Industrial Electrical Safety
Electrocution is when a fatal flow of electricity passes through a person and is the extreme consequence of coming in contact with electrical power in industrial settings. There are also non-fatal outcomes, such as electric shock (a non-fatal flow through the body) and arc flash, which can cause severe burning.
Electricity, especially high-voltage systems like in industrial spaces, is very dangerous and great caution should always be taken around it. Common safety practices include regular equipment inspection for damaged insulation or faulty wiring, ground fault circuit interrupters that cut off power immediately when a ground fault occurs, ongoing maintenance, and training and safety drills about recognizing and responding to hazards.
Conclusion
Understanding electrical engineering and the underlying core concepts benefits everyone in an industrial setting, even those without direct contact with electricity. Decision-makers can get a better idea of what changes need to be made to improve efficiencies or save on costs while operators and other personnel understand better the processes at play in the work they’re involved in and the safety precautions necessary to minimize harm to humans and equipment.
To find out more about Enercon’s work in building electrical grids and control panels, contact us here.
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