Reliable and efficient warehouse operation via power quality improvements

Power quality improvements reduced harmonic distortion to below 5%, increased power factor to 0.98, and helped ensure reliable operation of a highly automated 44,000 m² warehouse.

Segment background

Sortation centers and warehouses are places where various products can be safely stored before shipping to another location. The nature of these facilities varies greatly depending on what kind of storage conditions the products require. The electricity needs can be big or small with numerous different pieces of equipment that need a continuous power supply.

The electrical equipment directly affects the reliability of sortation centers and warehouses. Many of these devices are fed by non-linear loads such as Variable Frequency Drives (VFDs). While VFDs provide motor efficiency, they also cause severe power quality issues like harmonic distortion. This can lead to power outages, overheating, malfunctions, and premature failures that affect for example lighting, air conditioning, cold storage, warm storage, and the operation of conveyors.

It is possible to effectively prevent serious electrical disturbances and maintain a high-quality and reliable service in sortation centers and warehouses by improving power quality.

Challenges at the customer’s facility

Our customer’s 44,000 m² temperature-controlled warehouse in West Melbourne is a state-of-the-art facility, boasting advanced technology including AGVs (Automated Guide Vehicles) to assist workers in moving pallets efficiently. However, due to the extensive use of modern automated logistics and electronic equipment, the warehouse faces significant power quality issues. These issues, particularly harmonic currents and poor power factor have led to frequent disruptions in operations and increased costs.

For example, Variable Frequency Drive-controlled devices, such as conveyor systems, have introduced harmonic currents, resulting in overheating and equipment malfunctions. Additionally, inductive loads have contributed to a poor power factor, leading to inefficient energy consumption and higher electricity bills.

To mitigate these challenges, the warehouse operator decided to invest in power quality solutions for harmonics mitigation and power factor correction. These measures were considered to ensure a stable electrical supply, reduce maintenance expenses, and optimize equipment performance. In today’s competitive logistics landscape, addressing power quality issues is essential to maintain efficiency and reliability in automated warehouse operations.

Our Merus^® Solution

Merus Power’s local partner, Ampcontrol, delivered a hybrid power quality -solution to the site. Merus^® HPQ-Hybrid Power Quality Compensator is a modular solution that consists of a detuned capacitor bank and a Merus^® Active Harmonic Filter module. It provides the warehouse an economical solution of dynamic reactive power compensation and harmonic mitigation. The smart control software of Merus^® HPQ monitors the system parameters and provides adaptable and flexible power quality control, ensuring that all the equipment operate efficiently and reliably at all times.

Results after installation

After the Merus^® HPQ system was installed on the site, Total Harmonic Distortion (THDi) reached the target <5% on average, and power factor improved to 0.98. The installation of the Merus^® HPQ was executed with minimal disruption to the daily operations of the warehouse, ensuring that the customer could continue business activities with only minimal interruption.

Merus^® HPQ solution significantly decreases the risk of interruptions caused by the nuisance of relay tripping and power system equipment failures. This innovative hybrid solution addresses multiple power quality issues, resulting in cost savings and increased efficiency.