Enhancing Industrial Electrical Systems: Process and Standards

Enhancing industrial electrical systems ensures meeting load demands, optimizing efficiency, and maintaining safety, addressing the increasing production needs.

Importance of Upgrading Industrial Electrical Systems

Upgrading industrial electrical systems is essential to accommodate increased equipment and production capacities while minimizing risks such as outdated wiring leading to potential fires and inefficiencies.

It is not just an optimal choice but a necessary requirement for safe and efficient plant operations.

• Ensure Safety and Reduce Risks: Replacing outdated equipment, enhancing insulation, and installing advanced protection systems like smart relays helps prevent hazards like fires and electrical shocks.
• Boost Performance and Energy Savings: Adoption of new technologies like next-generation inverters and industrial LEDs results in more efficient systems. Additionally, automated energy management systems optimize energy usage, reducing operational costs.
• Meet Expanded Production Requirements: Technological advancements such as IoT and industrial robots demand higher power capacity, necessitating upgrades to maintain stable power supply.
• Comply with New Standards: Adhering to electrical safety and environmental standards like IEC and ISO 50001 ensures legal compliance, preventing unnecessary legal risks.
• Facilitate Digital Transformation and Automation: Systems like SCADA and real-time monitoring serve as the foundation for modern digital plants, allowing seamless integration of IoT sensors and data analysis.
• Minimize Downtime: Modern electrical systems can reduce downtime by 30-50% owing to their stability and reliability.
• Environmental Protection: Newer technologies not only conserve energy but also cut CO₂ emissions, aligning with global sustainable development trends.

Highlighted Upgrade Trends (2023-2025)

• Smart Lighting Systems: Automatically adjust brightness according to production needs, optimizing light resources.
• GIS Substations: Reduce installation space by up to 40% compared to traditional stations, optimizing factory space.
• Surge Protection Systems: Safeguard sensitive equipment, ensuring safety in industrial environments.

Technical Process for Upgrading Industrial Electrical Systems

The upgrade process involves assessing the current situation, designing high and low voltage networks, and implementing upgrades. Replacing conductors and equipment to meet IEC/TCVN standards and installing energy monitoring systems like SCADA, IoT is necessary for load management.

Amid industrial modernization, upgrading industrial electrical systems is crucial to meet the growing electrical load demand. This article details the electrical construction process, applying the latest electrical IEC standards and monitoring systems.

1. Construction and Upgrade Process

• Survey and Design: Begin with a detailed assessment of existing electrical systems and determining new load requirements. Detailed design drawings must consider elements like cable distance, electrical cabinet layout, and load distribution adhering to current technical standards.
• Material Preparation: Carefully select equipment like transformers from reputable brands such as ABB, Mitsubishi, Schneider, and essential materials like Cadivi cables meeting IEC and TCVN quality standards.
• Installation Implementation: Includes medium voltage cable laying, electrical cabinet installation, circuit breakers, and industrial lighting systems. This process requires strict adherence to technical and safety requirements to ensure maximum effectiveness and safety.

1. Testing and Trial Operation

• Operational Testing: Conduct detailed checks on actual power capacity and voltage stability post-upgrade. Load capacity and potential problems need close monitoring through IoT-based remote monitoring systems.
• Safety Evaluation: Ensure electrical leakage, grounding, and insulation comply with TCVN 5699-1:2010 standards for operational safety.

1. Post-Upgrade Maintenance and Optimization

• Regular Maintenance: The maintenance process should include device status monitoring and frequent measurement of electrical parameters such as insulation resistance and leakage current to detect issues early.
• System Optimization: Employ energy-saving solutions like industrial LED lights and variable speed drives to enhance energy efficiency.

1. Applied Technical Standards

• International Standards: Apply IEC standards such as IEC 61000-4-2 for interference immunity and IEC 61439 for electrical cabinets to ensure quality and safety.
• Vietnamese Standards: National standards like TCVN 8241-4-2 and TCVN 1983:2013 are widely applied in the installation and maintenance of electrical systems to ensure maximum safety.

1. New Technologies in Industrial Electrical Upgrades

• Remote Monitoring Systems: IoT becomes a powerful tool in monitoring operational parameters like temperature, load current, and resource coordination. This supports failure prediction and maintenance optimization.
• Advanced Insulating Materials: The use of LSZH cables exemplifies reduced fire hazards and enhanced environmental safety.

The upgrade process demands close coordination from design, execution to operational monitoring, always adhering to standards and new technologies for optimal outcomes.

Technology Trends in Upgrading Industrial Electrical Systems

Advancements include smart electrical system integration with IoT sensors, using renewable energy solutions like rooftop solar, and employing premium insulating materials like XLPE, CSR to optimize electrical systems.

Today, the importance of upgrading industrial electrical systems is undeniable, crucial for sustainable development. In the face of advancing technology, integrating IoT solutions and smart electrical systems revolutionizes these upgrades.

Advanced AI has evolved to perform the role of Agentic AI, making autonomous decisions and optimizing electrical system operations without manual intervention. This not only effectively manages electrical loads but also helps with demand forecasting and rapid fault detection. AI plays a crucial role in analyzing large datasets from IoT sensors, aiding businesses in energy-saving strategies and reducing operational costs.

Moreover, smart IoT sensors have been widely implemented for monitoring device performance, environmental factors like temperature and humidity, and real-time electricity consumption. Alongside the development of 5G connectivity, data from millions of devices can be transmitted quickly and efficiently, laying the groundwork for highly automated industrial electrical systems. This is truly a major boost for the trend towards smart electrical systems.

Additionally, the need for clean and energy-efficient technologies is gaining focus. The management of refrigerants has shifted towards environmentally friendly options like CO2, ammonia, and propane, replacing HCFC and HFC to reduce greenhouse gas emissions. Inverter technology also demonstrates its efficiency by allowing flexible power adjustments, reducing energy consumption by 30-50% compared to traditional systems.

Automation is becoming more robust with integrated control systems combined with IoT and AI technology, automating production processes, reducing errors, and increasing accuracy. Predictive maintenance is widely applied, using AI to analyze equipment data to forecast failures and plan proactive maintenance.

Furthermore, to ensure energy security and fluctuation management, the development of energy storage systems such as industrial batteries and thermal storage technology is being actively promoted. Microgrid, an innovative solution, combined with renewable energy, helps continuously supply power to industrial zones.

In Vietnam, with commitments to green transformation, international standards like ISO 50001 are being applied to energy management and reducing carbon emissions in industrial operations. Heat recovery technology is being fully exploited to utilize waste heat for electricity generation or heating, enhancing overall efficiency.

Upgrading industrial electrical systems offers numerous benefits in technology and investment, enhancing performance and responsiveness, contributing to sustainable industry development.

Contact QuangAnhcons via Hotline: +84 9 1975 8191 for optimizing your industrial electrical systems.

QuangAnhcons specializes in consulting and implementing industrial electrical system upgrades, ensuring international standards and high effectiveness.