When a metal manufacturing plant in the northeast was forced to consider a substation upgrade totaling nearly $1 million, information from their PowerLogic system convinced the company to simply switch loads to three other existing substations with sufficient capacity, turning a major capital expense into a very minor project.

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Square D companies such as Juno Lighting Group and TAC, LLC, initiate energy optimization for it’s own plants and facilities, with an ambitious goal of reducing energy consumption per employee by 10 percent from 2004 to 2008.

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When Mercedes-Benz USA International (MBUSI) began building a sophisticated plant to manufacture its M-Class sport utility vehicle, the company was determined to find an equally sophisticated system for monitoring and troubleshooting power quality problems, minimizing downtime, and reducing energy costs. The system they got from Square D paid for itself in two years ? one year ahead of schedule.

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Market growth and frequent product innovations were forcing the facility personnel at Smith and Nephew's Memphis plant to struggle to keep up with the demand for changes in the manufacturing processes. Without a good monitoring system to provide an accurate picture of loading, electricians struggled to determine if particular circuits could handle new loads. After installing a PowerLogic system, the staff soon had accurate peak demand data that allowed them to add new loads to existing circuits and avoid a $2 million expansion.

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A PowerLogic system installed to help keep an eye on costs helps uncover costly errors in the plants utility metering. After reviewing data from PowerLogic System Manager Software, a company executive discovered a major discrepancy between system manager reported data and the utility bill in regards to power factor. Further investigation revealed an uncalibrated utility meter resulting in a $250K credit for past power factor penalty charges.

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A paper mill customer wanted to buy a new 250KVA winder but found out that there was not enough current capacity available in their switchboards to support the new winder. A power system study reveled that power factor correction would reduce the current through his switchboards giving the capacity needed for the new winder.

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Large Steel Mill facilities require relatively large amounts of reactive power to operate. Resultant low network efficiency decreases effective network capacity, creates overloads of network distribution equipment, and inflates Utility bills with low power factor penalties.

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