Core Challenge and Project Objectives
This project was initiated to provide a Tanzanian modern beverage factory with a continuous, stable, and highly efficient electrical supply system. Production lines—such as filling, fermentation, and refrigeration—demand extremely high power continuity. Power outages or voltage fluctuations can cause product spoilage and significant financial loss. Furthermore, the factory's numerous inductive loads (compressors, motors) resulted in low power factor and high energy costs.
Our objective was to design and deliver a comprehensive power distribution solution integrating Automatic Transfer Switching (ATS), Reactive Power Compensation, and Precise Load Distribution to achieve the two core goals: "Continuous Power Supply" and "Energy Saving and Consumption Reduction."
Solution and Technical Architecture
We customized a three-tier collaborative power distribution system for the client, consisting of the ATS Panel (Automatic Transfer Switch), Capacitor Compensation Panel, and Feeder Panel:
Energy Inlet (ATS Panel): Implements a dual-source automatic switching mechanism. In the event of a utility power failure, the system automatically switches to the standby generator source within $\le 10$ seconds, ensuring the uninterrupted operation of critical loads like fermentation tanks and filling lines.
Power Optimization (Capacitor Compensation Panel): Continuously monitors system reactive power and automatically switches capacitor banks, elevating the overall power factor from $0.8$ to above $0.95$. This measure is projected to save the factory up to 15% to 20% on annual electricity bills.
Load Distribution (Feeder Panel): Features a "main busbar + multi-branch circuit breaker" structure, utilizing breakers like the Schneider EZD series. This provides "branch-level protection," ensuring that a fault in a single piece of equipment does not cause a factory-wide outage.
Results and Customer Value
The commissioned power distribution system has delivered significant value and operational improvements to the beverage factory:
Production Continuity Guarantee: The rapid ATS switching mechanism ($\le 10$ seconds) effectively eliminates the impact of utility interruptions on production, ensuring fermentation and filling processes are unbroken, thereby maximizing production line output.
Substantial Reduction in Energy Costs: The significant optimization of the power factor not only eliminates potential utility penalty fees but also reduces line current and copper losses, leading to long-term green and efficient energy savings.
High-Reliability Design: The panels are built with an IP54 protection rating and customized anti-corrosion/moisture-proof design, fully adapting to the humid and potentially corrosive environment of a beverage factory. Combined with smart SCADA remote monitoring, the system achieves highly reliable and intelligent operation.
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