“Dan, We Have a Problem”: Tales From A Power Supply Sleuth

When the phone rings, it’s often because there’s an unsolved mystery on the other end, that while undiscovered, is usually related to variances or weaknesses in power quality.  Production has probably come to a standstill, millions of dollars are at risk; elevators, motors, assembly lines and finely tuned electronics are unresponsive.  In other words, it’s urgent. 

The first words I hear on those calls is always, “Dan, we have a problem.”

And just like the lunar drama with Lovell, Swigert, and Haise of Apollo 13, there are options for assessing and tackling the dilemma remotely, by employing experience, creativity, and the right hardware/software.  However, an on-site investigation always proves fruitful as the power supply breadcrumbs present obvious clues to the trained eye.

One of the first steps is to monitor power quality using a specialized meter that allows the collection of streams of valuable data.  Of course, you always, always ask if any new equipment has been added and installed as part of an upgrade, modernization or regular maintenance cycles.

But there are often ghosts in the machine that require meticulous and creative sleuthing, be it within a pharmaceutical operation, a plastics extrusion plant, any manufacturing facility, or any place that’s connected to a power supply.

It’s imperative to understand that what happens on the grid has a direct relationship to production, efficiency, wastage of product, lost labour, and even safety.  There is an intricate interplay among voltage, current, and frequency that underpins reliable and efficiency power distribution. The power quality imbalances now surging through our electricity grid have consequences far beyond minor disruptions and annoyances.

In today’s unpredictable power quality environment, you must develop strategies to address these challenges in their broader business strategies.  It’s not just about rectifying the immediate issues; it’s about foreseeing and preventing them, understanding their deeper implications, and innovating solutions to protect your operations and your bottom line.

So when the call comes in and the stressed voice on the other end says “Dan, we have a problem” - the stakes are usually high, while the solution lies in the domain of science…and experience. 

As industry leaders, our task is to not only resolve today’s challenges but also anticipate and mitigate those of tomorrow.  And always make sure you know who to call when the emergency arises.