ORTEA BLOG

Articles, news and stories from our network

Ortea Next & Data Center

At Ortea Next, we have always paid attention to each step in the production process. Currently, we are finalising the production of the second batch of isolating transformers, which will contribute to the security of an important Data Center located in Indonesia, belonging to an online sales giant.

In particular, these are special isolating transformers, produced with high-quality and high-performance copper winding and grain-oriented sheet metal core. They are also equipped with intermediate sockets, an automatic circuit breaker, a measurement control unit with a communication module for remote monitoring, and they are supplied with an IP31 protection rating cabinet.

The customization of our solutions and close collaboration with the customer allow us to pair the product’s high quality with specific requirements; in fact, the design of these transformers is tied to that of the UPS, to which they must be coupled.

Thanks to its technical innovation and decades-long experience, Ortea Next is able to design and manufacture transformers that are suitable for any type of UPS system. In addition, partnerships with the world's leading manufacturers provide evidence of the high degree of reliability achieved.

Since 1969, the year Ortea Next was founded, low-voltage transformers have been at the heart of its business. The design and production knowledge and experience gained over the years allow us to offer high-quality, optimized and reliable products.

In addition to this, one of Ortea Next’s hallmarks has always been its extreme flexibility, which means it can ensure the quick development of dedicated solutions based on the Customer's technical specifications.

All this is achieved through customised design and our guarantee to maintain the same high levels of quality for standard products.

All design, production and marketing activities are carried out at Ortea Next's headquarters, thus ensuring continuous control and synergy among staff involved.

Ortea Next has manufactured and provided isolating transformers, including high power ones, installed in every continent, in contexts such as data centres, oil & gas, national security sites, and infrastructure.

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Stop wasting energy with Powersines

Power prices continue to rise! Scheduling upgrades immediately is increasingly strategic.

The energy saving device POWERSINES by Ortea Next, ideal for retail sales points, public and private offices, service companies, etc., ensures an immediate reduction in consumption.

At Ortea Next, we’re here to help guide you in making the right choice: fill in the dedicated form at the bottom of the article to be contacted by one of our sales reps!

After purchasing the Powersines assets, Ortea Next completed the technical validation process and re-engineering of the technology purchased according to the quality standards that define it. The equipment has passed all its tests with flying colours and large-scale production has been launched.

Powersines ComEC by Ortea Next is a universal energy controller for commercial applications that enables power bill savings of up to 12% (the savings vary according to the system load types).

Powersines ComEC is installed downstream of the system’s main circuit breaker.

It dynamically controls and stabilises the voltage delivered at all loads, generating an immediate energy saving.

It improves the quality of the power and reduces maintenance costs.

ComEC does not require any change to the power system and, thanks to its small size, it can be easily connected to power switchboards. The sizing is immediate and depends exclusively on the power value of the main circuit breaker.

  • Optimisation of the voltage delivered. The voltage provided by power companies in general oscillates in the range of ±10% and depends on the electricity demands, on the quality of the electricity distribution infrastructure, but also on the site’s distance from the production plant. Power surges, especially overloads, may negatively influence the good operation of the electrical equipment, of outlet points and of all electronic devices.
  • Energy saving. The electrical equipment available on the market is designed to work with a range of nominal voltages from more than 240V to less than 220V. Voltage greater than nominal voltage leads to the inefficient use of the equipment and power wastage. ComEC ensures a rapid return on investment by reducing the voltage to 220V and reducing the reactive power consumed.
  • Technology and Design. The ComEC system was developed and created with a patented technology that makes it possible to dynamically control the voltage provided to electrical circuits. The heart of the technology developed is produced with power transformers controlled by a microprocessor. In contrast to multi-tap transformer systems, ComEC is highly reliable and does not compromise the quality of the power supply.
  • Improvement in energy quality. ComEC is a “Power Quality Friendly” system. In fact, it provides a form of pure sine wave to all the electrical circuits, free of harmonic distortions and with a THD near zero. In addition, it mitigates and filters harmonic and voltage distortions, thus reducing the frequency of damage to electrical equipment. By adjusting the voltage to inductive loads, like air conditioners, compressors and pumps, it also helps to reduce the consumption of reactive power (Kvar) helping protect the environment and minimising the risk of sanctions from the energy provider.
  • High reliability. Unlike systems based on solid-state components that require special thermal management devices, the design of ComEC ensures a high degree of robustness and can tolerate disturbed electrical environments, thanks to integrated protection mechanisms, such as the automatic internal bypass, the manual bypass, and the output protection circuit.
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Ortea Next Training 2022: enrolments are now open!

After the forced break due to the pandemic, Ortea Next's "full immersion" technical training sessions are starting again.

Following the "glocal" strategy, which aims at a "global" action but with a "local" application, Ortea Next continues to invest in the training of technicians from the distribution channel and customers, in order to intervene effectively and promptly on the installed machinery.

The training sessions will be delivered in English, Spanish and French (dates yet to be defined) according to the following schedule:

  • June 13th to 17th 2022: English
  • September 26th to 30th 2022: Spanish.

Enrollments for the English session are now open!

Registering is easy, just fill in the form at this link.

The training session is offered free of charge with a maximum of 12 participants and will be held at Ortea Next's headquarters in Italy. The candidates will be selected by Ortea Next at its sole discretion.

Ortea Next will provide lunch in our canteen and transfers to and from the airport and hotel. Participants will be responsible for the travel costs to Italy and accommodation at a hotel (Euro 78.00 per day including breakfast) located near the venue.

During the training session all the necessary notions will be acquired for:

  • Verification of parameters on site for the choice of suitable equipment.
  • Installation, start-up and commissioning.
  • Troubleshooting.
  • Maintenance and repair.

The agenda is divided into theoretical and practical sessions:

  • in the theoretical sessions the ranges and characteristics of Ortea products will be illustrated with focus on design methodologies, operating principles, electrical diagrams, etc.. This information will allow the participants to learn the technical design "philosophy" in order to improve their propensity to identify the problem and its resolution;
  • the practical sessions will involve actual manual interventions on the equipment to acquire knowledge of the procedures for working on the machines, whether for maintenance or troubleshooting.

At the end of the training session an official certificate will be issued, valid for three years, which is necessary to carry out any service activity on behalf of Ortea.

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Improve your Power Quality with Sirius Advance

The SIRIUS ADVANCE range of voltage stabilisers significantly increases a system’s power quality since it combines the voltage stabilisation function with power factor correction.

Moreover, SIRIUS ADVANCE, top of the range of the Ortea Next series of voltage stabilisers, has a multilingual, 10-inch touch display user interface, and is supplied already equipped with the “total protection kit” that comprises:

  • Input automatic circuit breaker.

  • By-pass switch with interlocked automatic circuit breaker.

  • Output motorised interlocked automatic circuit breaker.

The 200kVA ±30% SIRIUS ADVANCE pictured here is currently on its way to an important bank located in the Democratic Republic of Congo to resolve the customer’s power quality problems.

Our top-of-the-range model SIRIUS ADVANCE is available as standard from 60kVA up to 4000kVA and with different input voltage ranges: ±15%, ±20%, ±25%, ±30% adjustment.

Control and stabilisation, performed on the true RMS value, is carried out by a two-way DSP-microprocessor under the supervision of a second "bodyguard" microprocessor, operating with a software which has been developed specifically for ORTEA.

The columnar variable autotransformer with rollers (ORTEA design - without sliding contacts, which are subject to heavy wear & tear) is solid and very reliable.

The user interface is a multilingual 10” touch panel equipped with RS485 port. The display shows all the electric parameters (voltage, current, active power etc.), the information regarding the operating modes (power on; voltage regulation limits; increase/decrease of voltage regulation etc.) and the alarms (minimum and maximum voltage, maximum current, overtemperature, etc.).

A panel with the reactive power regulator RPC8BGA is installed to manage the power factor correction part. Designed to provide the desired power factor, while minimizing the wear and tear of capacitor banks, the SIRIUS ADVANCE are accurate and reliable in measuring and control and easy to install.

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Ortea Next training starts up again

In line with the glocal vision that distinguishes us: “think globally and act locally”, we strongly believe in the added value that continuously training our employees, our distribution channel, and our customers’ technicians brings to end users of our products and solutions.

For a number of years, in fact, we have organised specific training courses at our headquarters on maintenance and repair operations for our equipment with a calendar of 2-4 annual sessions lasting one week.

The advent of the pandemic put a halt to this activity. The good news we’d like to share is that the decrease in restrictions imposed by governments on the movement of people allowed us to carry out the first training session for a group of maintenance technicians for an important African airport where our voltage stabilisers are installed.

With an eye on the pandemic situation, we’re already working on restarting the usual training activity as soon as possible.

The calendar for our sessions is usually divided into theory and practice:

  • the technical sessions illustrate the Ortea product ranges and features with a focus on design methodologies, operational principles, electrical systems, etc. This information allows students to learn the technical design “philosophy” for improving their ability to identify and resolve problems.
  • the practical sessions involve genuine manual operations on equipment for acquiring knowledge of the machine intervention procedures, both maintenance ones and those relating to resolving problems.

As soon as possible, we will publish a calendar of sessions with an enrolment form.

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Enersolve, tailor-made saving

Final testing phase for this Enersolve machine, tailored to the needs of the customer, a large glass-works located in northern Italy.

75% of the Customer's production derives from the use of recycled glass. To achieve this important result, also from the circular economy and environmental sustainability point of view, it uses a large furnace that works by means of electrodes that cause the fusion of glass through the formation of an electric arc. In addition to being an energy-intensive technology (overall process consumption approx. 7gWh/year), service continuity is very critical and requires a quality power supply that meets well-defined parameters.

This is why the customer chose an Enersolve solution that, in addition to guaranteeing an expected energy saving of between 3% and 4% in this specific case, ensures compliance with the parameters necessary for the proper functioning of the system.

In particular, a 3200kVA Enersolve ESL-10 complete with numerous optionals:

  • 3 x 2500A input switches (to allow the connection of 3 x 1600kVA transformers)
  • 5000A bypass
  • “safety bridge” by-pass
  • direct selection of target output voltage via multi-switch.

The equipment measurements are truly impressive: 7000x1000x2300h mm weighing almost 6000 kg.

The ENERSOLVE range is available in three models:

  • ESL-5 for the retail/small business market.
  • ESL-10 for environments where energy parameters fluctuate within the requirements of the ±10% reference standard.
  • ESL-20 for the most severe cases where fluctuations exceed the requirements of the reference standard.

The added value of the ENERSOLVE solutions is undoubtedly represented by the ENERCLOUD platform, which is essential for displaying and analysing energy parameters and a prerequisite for obtaining the benefits linked to Industry 4.0 plans. The on-board instruments make it possible to read and record the values of all the plant's electrical parameters, hence processing energy-saving data in real time. The method used to process the energy-saving data is based on the principles of the ESPRO protocol approved by ENEA (National Agency for New Technologies, Energy and Economic Development) after 3 years of joint studies.

The ESPRO protocol enables dynamic savings measurement: it is not based on measurements before and after the implementation of the energy efficiency implementation but rather enables continuous savings measurement.

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How to measure Power Quality

Today's industrial systems are evaluated in terms of maximising production continuity, a characteristic that is achieved above all by exploiting process automation to the full. As a result, we are witnessing an increasing introduction of electronic and IT equipment in production lines, devices that are very sensitive to Power Quality.

In order to ensure the high production performance required, industrial systems must be supplied with power of excellent quality, both in terms of continuity as well as intrinsic characteristics. In fact, the main causes of unscheduled system downtime, malfunctions, and serious damage to electrical equipment and infrastructure are due to poor power quality.

According to statistical studies, approx. 80% of disturbances due to poor power quality are generated internally at the end-user (downstream) system. Typically, these disturbances are due to non-linear loads (inverters, welding/punching machines, drives, robots, electronic equipment in general) that generate harmonics on the grid, or to the presence of high-power loads (large motors, for example) that can generate disturbances.

The remaining 20% of disturbances come from the Grid (upstream), i.e. the power supplier. Even the most advanced transmission and distribution systems cannot guarantee supply with absolute continuity and perfect quality. In this sense, the recent complexity of the generation world (think of the increasing diffusion of renewables such as solar and wind power) has certainly had and will increasingly have a significant impact on the quality of the power supplied.

Measuring the Power Quality of one’s electrical system is almost never a simple matter. First of all, it is necessary to identify whether any problems are coming from "upstream" or "downstream," and then try to understand where, when, and how they manifest themselves…

In order to collect information and electrical data to be analysed, it is necessary to carry out one or more measurements, or better said, veritable measurement campaigns. To carry out such campaigns, extensive skills are required; it is unlikely that any one person can cover all areas in a given system. It becomes necessary to involve several people: an expert in electrical measurements (often also a system expert), a solution expert (a Power Quality specialist), and the operational personnel in the company, since there is no one better able to provide the right information (even if usually the effect is known but not the cause that generated it).

The measurement campaign is a key point in solving PQ problems. It is the first step in the investigation process and, if it is done in the wrong direction, it will lead to failure.

It is important at this stage to have a comprehensive and in-depth discussion with those who are familiar with the process and the problems encountered, and to determine what is happening, in which system situations, at what times/on which days/in which seasons, and whether the problems started before or after any system changes. If the problems involve a certain piece of equipment, it would also be a good idea to talk to the manufacturer to understand the reason of certain incorrect behaviour.

This phase also includes documentation checks, going over the wiring diagram with verification that it is updated to the current state, since this document is fundamental to be able to identify distorting and sensitive users in order to understand which are the users affected by any malfunctions. Looking at the bills for an entire calendar year is also important, especially for systems that are not in continuous operation. In addition, if there is a supervisory IT system with data logging, it should definitely be consulted, verifying that the measuring instruments used provide truthful data.

Before taking the measurements, it is advisable to carry out an inspection to examine the system. Important information can be gathered from a "sensory" point of view, by sight (state of the machinery, presence of evidence of short circuits, overloads, overheating, presence of pollution of possibly conductive dust, etc), by ear (humming in the cabinet, and their trend as a function of active loads), and by "feel" (cabinet temperature, humidity).

At this point, the picture should be clear and it will be necessary to think about:

  • Where
  • When
  • For how long
  • Which measurements to take and with which instruments

The choice is fundamental and strategic, since the measurements must provide the useful data on which to reflect to solve the problem. Measuring should not be overdone, risking complicating the problem with a volume of data to be analysed and managed that can become unnecessarily embarrassing.

Where: establish in which points of the system the measurements are to be performed: at the terminals of the disturbed loads, at the terminals of the disturbing loads, just downstream of the MV/LV transformer, etc. In systems with complex topology, the choice of where to take the measurement is fundamental; making a mistake in the measurement point means having to "throw away" all the measurements previously taken and starting again from scratch.

When: at full load (or during start-up of the main loads) if the maximum current and voltage harmonic distortion and/or the minimum voltage is to be measured. With minimum load (e.g. evening hours) if possible voltage variations beyond the nominal value are to be evaluated. In the case of problems encountered during certain processes or system states, measurements should be conducted reproducing these conditions.

For how long: measurements aimed at identifying max THDI and max THDV can take less than an hour, if carried out when the system is at maximum load. On the other hand, measurements aimed at voltage or power profiling should be conducted for at least one full week (CEI EN 50160). Statistically based investigations (e.g., voltage gap counts and their duration and depth characteristics) need a continuous measurement of at least a few months.

Which measurements to take and with which instruments: this depends on numerous factors; it is not possible to generalise. It is a case-by-case assessment; the value added lies in the skill of the electrical measurement experts.

Ortea is able to carry out Power Quality measurement services in both industrial and tertiary power systems, aimed at the identification of voltage/current distortion problems or slow/rapid voltage variations, with subsequent identification and technical/commercial proposal of power factor correction, filtering and stabilisation solutions.

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3D design: functional to production

A modernly organised company that wants to keep up with the times and the needs of an increasingly competitive global market must stay aligned and updated with new technologies.

Ortea SpA is constantly looking for advanced technologies and methodologies to develop the best Power Quality solutions, keeping design, development and production costs under control, in order to offer the market the usual quality but at competitive prices.

That is why our design engineers have been using 3D design software for over a decade.

Once the machine has been designed from an electrical performance standpoint, it then becomes necessary to translate calculations and electrical schematics into a hardware application. With the aid of 3D software, it is possible to design equipment down to the smallest details, with enormous advantages that have repercussions on the entire production chain. All this becomes even more significant taking into account that one of the flagships of Ortea SpA is the ability to modify the designs of its standard equipment, adapting them to the specific customer needs, and to produce high power machines with many components.

At this point, to allow workers to assemble the equipment, the designer prints a series of views of the design which, however, are never comprehensive. For this reason, several terminals have been placed in production at Ortea that can be consulted by assembly workers. This solution allows workers, in case of doubts, to view the machine in all its parts and from all angles, with the advantage of avoiding assembly errors and wasting time for both designers and assemblers.

Thanks to the synergy among all departments, Ortea SpA is constantly evolving to provide quality solutions that ensure the peace of mind of its customers.

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Rising energy costs: the storm does not stop

2021 was a year characterized by extraordinarily high energy prices (as you can see from the data published by Iea - International Energy Agency) and numerous studies show that this trend will be confirmed for 2022.

The root causes are the same: skyrocketing commodity prices and the costs of CO2 emissions paid by energy companies and energy-intensive industries, a vicious circle which at the moment shows no signs of trend reversal, despite Governments’ effort to control prices.

At this juncture, it becomes increasingly important and strategic to quickly plan investments to reduce the consumption and the running costs of your electrical system.

Our Power Quality solutions, especially our Icar branded Power Factor Correction Systems and our Enersolve branded Energy Efficiency Smart Devices, guarantee immediate savings.

Ortea is your partner to guide you through the right choice (www.next.ortea.com).

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Corporate culture: we believe in it

We can define the culture of a company as the set of values that characterise the identity of a firm. When we talk about values, we refer to the company mission and vision, to the management of the team, and to all those aspects that define the approach of the company, both within and outside of the organisation.

By referring to these concepts, we can say that:

  • For “company vision” we mean the set of long-term goals that the Top Management wishes to define for its company.
  • For “company mission” we mean, instead, its purpose, the why of its existence.
  • The management of the team includes all those practices for coordinating and listening to employees, their needs, and the protection of workplaces.

The corporate culture is important both for employees and for the company heads. In the first case, the workers are more likely to enjoy their time in the workplace when they adapt to the corporate culture. At the same time, the corporate culture is also important for employers, so that the workers who adapt to this won’t just be happier, but also more productive. When an employee is in harmony with the corporate culture, it’s likely that they will wish to work for the company for longer. This entails a big advantage in terms of productivity and retention on the part of business owners, who can count on a motivated team that wishes to bring value to the organisation.

With this in mind, Ortea has launched the Work Groups Project. To summarise, this is a project in which work groups are formed, which are not homogeneous, within the corporate organisation with the task of proposing projects for improvements focused on two macro-areas:

  1. Qualitative theme: the mission, the vision, and the company values. The purpose of this theme is to obtain a “payoff” to be used as a corporate manifesto.
  2. Measurable theme: which are the areas of potential the company has not yet realised? How can we improve them? The purpose of this theme is to suggest improvements in relation to optimising the production process, perfecting the organisational process, and improvements to equipment and related production activities.

The project is divided into three phases:

• Phase 1: Implementation and definition of the roles of the work groups’ members, collection/processing and presentation of the proposals.

  • Phase 2: Development of the project/proposal.
  • Phase 3: Final presentation.

Currently, we have completed Phase 1. Shortly, the winning project will be voted on; each group will assign their preference to one of the works of the other groups and the project that obtains the most preferences will pass to Phase 2. We’ll see what happens!

A special thanks to the Paolo Cazzaniga Employment Consultancy Studio for its priceless and effective collaboration in implementing and coordinating this project, in particular to Paola Cazzaniga and Luca Riboldi.

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The 2022 Ortea desk calendar: Think Green

The traditional 2022 Ortea desk calendar, which is being distributed to our partners, is dedicated to sustainable development and, as a result, environmental sustainability.

Ortea SpA is sensitive to this issue. Not only does it produce Power Quality solutions, which contribute to reducing energy consumption, and certify the company quality system, which also comprises the ISO 14001 standard (suitable management system for keeping the environmental impact of operations under control and systematically researches improvements thereto in a consistent, effective, and, above all, sustainable way), but Ortea also has scheduled structural works in the pipeline. These works include adopting an energy co-production system with the use of solar panels and “full-electric” vehicles for the company fleet.

And we can’t forget the continuous commitment of our team of engineers dedicated to developing new technologies that may effectively contribute to energy efficiency and, therefore, to the reduction of CO2 emissions in the atmosphere.

The calendar is intended to be a small tool to contribute to reflection, having the 17 Sustainable Development Goals defined by the UN in the 2030 Agenda as its central theme.

1. End poverty in all its forms\ Today, there are still many people living on less than 1.25 dollars a day; it’s unjust in terms of the dignity of any human being and could come to an end with cooperation between countries and the implementation of social systems and measures to protect everyone.

2. End hunger, achieve food security and improved nutrition and promote sustainable agriculture\ Every one of us has the right to enough food throughout the year. This is a basic concept, but one that is still neglected. In any case, it could be sustained, for example, with sustainable food cultivation and production systems and by preserving the ecosystem and diversity of seeds and plants to cultivate.

3. Ensure healthy lives and promote well-being for all at all ages\ An essential goal is reducing the global rate of maternal mortality and preventing the death of new-borns and children below 5 years old due to preventable causes. How? For example, by ensuring healthcare for everyone and supporting the research and development of vaccines and medicines for diseases, whether contagious or not.

4. Ensure inclusive and equitable quality education and promote lifelong learning opportunities for all\ Education can truly guarantee all young people a better future. One step forward would be to ensure that everyone, men and women, can read and write, eliminating all forms of gender discrimination and promoting equal access to all levels of education accompanied by high-quality teaching.

5. Achieve gender equality and empower all women and girls\ Still today, women and girls are the target of discrimination. Rooting up any form of violence against women in the private and public spheres, such as their sexual exploitation, is essential.

6. Ensure availability and sustainable management of water and sanitation for all\ Water is the source of life and it is essential that this is accessible to everyone: a statement urging us to ensure universal access to clean, drinkable water by 2030 and suitably hygienic conditions, with special attention to more vulnerable people.

7. Ensure access to affordable, reliable, sustainable and modern energy for all\ Today, energy systems are fundamental to everyone’s daily life. As a result, an important step is that of making them accessible to everyone.

8. Promote sustained, inclusive and sustainable economic growth, full and productive employment and decent work for all\ Work gives us the possibility to live our lives in dignity. Supporting economic growth and attaining high levels of productivity can help our survival.

9. Build resilient infrastructure, promote inclusive and sustainable industrialization and foster innovation\ Both infrastructure and industry are important for supporting all economic development and our well-being; they become sustainable and trustworthy with technological development and research.

10. Reduce inequality within and among countries\ Every country should have equal opportunities and rights at an economic and global level: because of this, it is essential that growth in domestic revenue is achieved and sustained. To move in this direction, it is urgent that, by 2030, tax, salary, and protection policies are promoted that gradually ensure greater equality among the population.

11. Make cities and human settlements inclusive, safe, resilient and sustainable\ The environment that surrounds us can dramatically influence our habits and lifestyles. Because of this, an improvement in terms of the sustainability of our living spaces by 2030 is a goal that cannot be neglected.

12. Ensure sustainable consumption and production patterns\ Our planet needs to be respected and protected. In this regard, by 2030, it is important to reduce waste and chemical substances released, especially by large, multi-national companies, using sustainable policies that are characterised by product recycling.

13. Take urgent action to combat climate change and its impacts\ Climate change is the order of the day and stands out in everyone’s eyes. It’s a situation that can no longer be ignored and must be confronted by 2030, with global, sustainable policies and strategies so as to curb environmental risks and current natural disasters.

14. Conserve and sustainably use the oceans, seas and marine resources for sustainable development\ The conservation and sustainable use of our oceans, seas, and all those resources within them are important to our lives. Reducing marine pollution, along with a sustainable management of the ecosystem and protection of the underwater environment, are essential goals for protecting our health.

15. Protect, restore, and promote sustainable use of terrestrial ecosystems, sustainably manage forests, combat desertification, and halt and reverse land degradation and halt biodiversity loss\ Preserving our planet is a task that is entrusted to every one of us and, for this reason, it is essential that, by 2030, we pursue combined action for protecting, restabilising, and promoting the sustainable use of the earth’s ecosystem.

16. Promote peaceful and inclusive societies for sustainable development, provide access to justice for all and build effective, accountable and inclusive institutions at all levels\ A better future for each of us is possible, but only if there is a drastic reduction in violence and mortality. It’s a vision that seems a long way away today; however, it is feasible with the implementation of peaceful societies, access to justice for everyone, and the existence of responsible institutions by 2030.

17. Strengthen the means of implementation and revitalize the global partnership for sustainable development\ The implementation of the Agenda requires the heavy involvement of all members of society: from companies to the public sector, from civil society to philanthropic institutions, from universities and research centres to media and culture organisations.

All countries are called upon to contribute to the effort to guide the world onto a sustainable path, without distinguishing between developed, emerging, and developing countries any longer. This means that each country must commit to defining its own sustainable development strategy that enables the 2030 Agenda goals to be attained, accounting for the results obtained as part of a process coordinated by the UN.

Download the digital version

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Advantages of power factor correction integrated into the voltage stabilizer

Years of experience in applied development, acquired both in the field of voltage stabilisers and power factor correction, has allowed Ortea technicians to offer (as optional for Orion Plus and Sirius, standard for Sirius Advance) power factor correction banks integrated into the voltage stabiliser enclosure.

Thanks to its expertise in designing and producing both types of equipment, this solution is entirely designed and made by Ortea, with an optimised size for ensuring maximum performance.

From 80kVA to 320kVA, the power factor correction bank is produced using single-phase capacitors made of high-density metallized polypropylene; starting from 400kVA, we use capacitors of the same type, but three-phase, ensuring greater strength.

The advantage is the result of having a load that is fed in a stabilised way and that has a high power factor and, as a result, the maximum active power available. In addition, for the 1000kVA (and above) power stabilisers, the product involves installing a blocking reactance that protects the capacitors from any harmonic distortions generated by non-linear loads, increasing the plant’s power quality even further.

In practice, this product makes it possible to exploit all the power factor correction and voltage stabilisation advantages, without having to manage two separate purchase orders and without having to coordinate the double installation, perhaps at two different times, with a consequent saving in cost.

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More yellow Oxygen…

Two of the four Oxygen sag compensators, intended for an important, international European airport, are in the testing phase. The cabinets, on the customer’s explicit request, have taken on a particular, yellow uniform, and the colour hasn’t gone unnoticed.

As a result of an order at the end of 2019, for which three Oxygens were provided, the customer, happy with the results achieved and engaged in a project for expanding the gates, ordered four more of them.

The supply involves two 500kVA Oxygens and two 320kVA Oxygens, both with ±10% input voltage regulation and coverage for voltage sags of up to -40%, with indoor IP54 protection.

The Oxygens will power and protect the electronics of the underground conveyor belts that sort and carry baggage directly to the gates. These new belts have been devised and designed to speed up the handling of baggage and, therefore, the service offered to travellers. Being activated by sophisticated electronic equipment that is very sensitive to power quality, sophisticated protection devices needed to be installed on them. Oxygen was chosen from among various options on the market.

The more modern the equipment, and the more electronics are required, the more serious are problems caused by voltage sags. With the growing number of renewable energy generation plants, voltage sags, fluctuations, and frequency deviations are on the rise.

Oxygen, thanks to the suitable size of power components and a remarkable response time (<3 milliseconds), is able to resolve voltage sags of a maximum duration of one minute. The energy required is taken directly from the mains.

Current models are able to cover voltage sags of up to 50% of the nominal value (-50%).

The voltage compensation on the buck/boost transformer’s primary winding is performed by IGT static circuit breakers controlled by a micro-controller. The micro-controller system controls the output voltage and determines the opening or closure of the IGBTs, ensuring the best regulation.

The use of double-conversion technology ensures insulation from mains disturbances and distortions and, together with the use of electrolytic capacitors, makes it possible to create machines for high loads.

The range of Oxygen sag compensators:

  • Oxygen 10-40 with input voltage compensation: ±10% continuous and -40% for 1 minute from 200kVA to 2500kVA
  • Oxygen 15-50 with input voltage compensation: ±15% continuous and -50% for 1 minute from 200kVA to 1600kVA
  • OxygenK 10-40 with input voltage compensation: ±10% continuous and -40% for 1 minute from 200kVA to 2500kVA
  • OxygenK 15-50 with input voltage compensation: ±15% continuous and -50% for 1 minute from 200kVA to 1600kVA

Compared to the standard model, the K model is equipped with an input automatic circuit breaker, an output automatic circuit breaker, and a manual by-pass line with interlocked automatic circuit breaker.

To find out more about Oxygen, download the catalogue.

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Taylor made: two truly special voltage stabilisers

Destined for a prestigious project for a grand Hotel in Qatar, two truly special Sirius voltage stabilisers are in the process of being shipped.

Manufactured “off-catalogue”, according to the customer’s specifications, the two voltage stabilisers are top-of-the-range Sirius models and have a power of 1600kVA and extreme input voltage regulation: ±40%.

These specifications led to the production of very large magnetic components; in fact, the total weight of the machines is a good 11,700 kg.

The Sirius range of the highest-performance and most complete voltage stabilisers in our production, is encountering a lot of success on the market.

Sirius is available for powers ranging from 60 to 6000kVA, with ±10%, ±15%, ±20%, ±25%, ±30%, +15/-35%, and +15/-45% adjustment. The control logic is managed by two DSP microprocessors (one that implements the control and the other that manages the measurements) that stabilise the output voltage, adjusting the true-RMS (root mean square) thereof. The whole system is supervised by a third (bodyguard) microprocessor that checks the correct operation of the other microprocessors.

In addition to the generous size and additional protections, which make the equipment very reliable and durable, the user interface is undoubtedly another very important feature.

Consisting of a 10-inch, multilingual touch display (equipped with an RS485 port), it can provide information on the state of the lines upstream and downstream of the voltage stabiliser (voltage, current, power factor, active power, apparent power, reactive power, etc.), the operating state of the stabiliser (it displays all the information relating to each operating mode: on/off, adjustment limit reached, increase/decrease in adjustment, etc.), and any alarms (minimum and maximum voltage, maximum current, excessive temperature, etc.).

If connected to a network via Ethernet with an RJ45 cable, the display can, in addition, be remotely transmitted to a PC using VNC software. It is, in addition, possible to interface with the stabiliser using the Modbus TCP/IP protocol (a standard protocol in communicating between industrial electronic devices). The system is also equipped with two USB ports that can be used to download the data stored and upload software updates from the control card.

The interface possibilities widen with Ortea Cloud, the new Ortea platform for remotely monitoring voltage stabilisers.

To find out more about Ortea Cloud

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Ortea Monitored Rollers: +Monitoring = +reliability

Quality and reliability: two words that have always been key to Ortea SpA’s vision. The R&D department engineers are constantly looking for new solutions and means for improving our products.

As far as electro-mechanical stabilisers go, the various modes for achieving this purpose include increasing the monitoring of the components, going into ever more detail, and choosing a predictive way that generates alarms so as to warn of any failures or disruptions.

Despite rigorous tests performed in the company, extended use, in the absence of suitable maintenance, can sometimes generate issues owing to component wear. Through monitoring and predictive analysis, however, it is possible to avoid any stabiliser disruptions and machine stoppages, with the resulting added costs owing to unproductive personnel, wasted raw materials, damage to/malfunctions of the connected machines, etc.

To this end, the Ortea SpA engineers have developed OMR (Ortea Monitored Rollers), an electronic system capable of monitoring the operation of all the components of the regulator columns: the beating heart, together with the electronics that govern the operation thereof, of the stabiliser.

Currently available as optional for the top range: Sirius and Sirius Advance, OMR is able to:

  • Measure the actual temperature of each column in a selective way (with resulting, quick visual identification thanks to the synoptic representation on the touch display).
  • Measure the average linear distance travelled by each group of rollers (measured in metres).
  • Measure the linear distance travelled by each, individual roller (measured in metres).
  • Measure the linear distance travelled by the rollers in relation to the column temperature (distance travelled with temperature being: normal (green zone), high (yellow zone), or critical (red zone)).
  • Measure the amount of time in operation hours (measured in hours).
  • Measure the amount of time in roller movement hours in relation to the column temperature (time with temperature being: normal (green zone), high (yellow zone), or critical (red zone)).
  • Identify, in a timely way (critical red zone) the overheating of the column and/or the blocking of a roller.

The analysis of these data, displayed on the machine’s touch display, and the generation of alarms in the event of critical conditions make it possible to analyse the stabiliser’s behaviour and anticipate any disruptions with timely interventions.

OMR, an additional device for increasing the already well known reliability of Ortea targeted stabilisers and for improving the consequent peace-of-mind of the customer who installs our products.

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Enersolve: the customer doubles

The manufacturing sector for bicycles and related components is an important one in Italy; it boasts a long tradition and very high level of quality, and has survived global competition. It is a jewel in the crown of Italian manufacturing.

Our customer, always attentive to the environment, is a producer of components for competition bikes, and already had a 1000kVA Enersolve solution operating in the company, which was installed in 2017. Being happy with its results, both in terms of making the electrical system more efficient and in terms of improving Power Quality, the customer decided to install a new 630kVA machine on a new production line.

The ENERSOLVE range is available in three models:

  • ESL-5 for the retail/small business market.
  • ESL-10 for environments where energy parameters fluctuate within the requirements of the ±10% reference standard.
  • ESL-20 for the most severe cases where fluctuations exceed the requirements of the reference standard.

The added value of the ENERSOLVE solutions is undoubtedly represented by the ENERCLOUD platform, which is essential for displaying and analysing energy parameters and a prerequisite for obtaining the benefits linked to Industry 4.0 plans. The on-board instruments make it possible to read and record the values of all the plant's electrical parameters, hence processing energy-saving data in real time. The method used to process the energy-saving data is based on the principles of the ESPRO protocol approved by ENEA (National Agency for New Technologies, Energy and Economic Development) after 3 years of joint studies.

The ESPRO protocol enables dynamic savings measurement: it is not based on measurements before and after the implementation of the energy efficiency implementation but rather enables continuous savings measurement.

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Power outages: transients

In the general context of Power Quality issues, power outages are among the most annoying events.

The CEI EN 50160 Standard defines the supply interruption as “a condition in which the voltage at the supply terminals is lower than 5% of the reference voltage”.

A power outage can be categorized as:

  • Scheduled, when users have previously been notified;
  • Accidental, if it is caused by transient or permanent failures, mainly related to external events, such as equipment failures or third party interference. An accidental interruption is classified as long (>3min), short (<3min) or transient (<1sec).

Scheduled interruptions are typically due to the execution of programmed maintenance works on the power grid. The effects of a scheduled outage can be minimized by the users by taking timely measures.

Accidental interruptions, on the other hand, are unpredictable and largely random events, generally caused by the intervention of operating or protective devices.

Under normal operating conditions, the annual number of outages can vary from a few dozen to several hundred, depending on the characteristics of the network. According to the statistics, 70% of outages last less than a second; accidental long outages usually originate from external causes or events that cannot be predicted by the supplier: this is the reason why it is impossible to state typical values of annual frequency and duration. Nevertheless, the ARERA statistics (Italian Regulatory Authority for Energy, Networks and Environment) are very indicative in this sense: by improving the quality of the network infrastructure, the number of interruptions is dramatically reduced. Under normal conditions, the annual frequency of such interruptions can vary from less than ten to about fifty, depending on the areas.

The effects of interruptions, even temporary, mainly affect the most sensitive users:

  • computers, PLCs, processors;
  • control systems;
  • drives;
  • lighting with gas discharge lamps;
  • electronic devices;
  • protection and control relays.

Power outages typically cause the equipment to stop, in particular the categories listed above, but they can also cause some damage. In particular, the aspect that we want to take into consideration in this article is the voltage recovery transient that takes place immediately after the interruption.

Among the many different network events that can lead to a power outage, we can identify two macrocategories:

  • Tripping of a network overload protection
  • Tripping of a short circuit or earth fault protection

This is the dynamic In the first case (picture 1). The mains voltage drops during the overload due to the voltage drops caused by the current on the line impedances: as a consequence the electromechanical voltage regulation devices (both those located upstream of the delivery point and those possibly present downstream) tend to counteract this lowering by going to the “maximum rise” operating state. However, if the overload persists and a protection is released, it is likely that when the voltage is restored, the regulating elements are still in the condition they were in just before the release. Consequently, if the voltage returns to its nominal value when it is restored, the users can be stressed by a voltage significantly higher than the nominal one.

In the second case (picture 2), the tripping of the protections can be followed by subsequent attempts by the automatic recovery devices of the energy distribution company. In this case the multiple transients due to the different O-CO-CO cycles of the circuit-breakers multiply the stress in a very short time.

In addition, after an interruption the voltage transient may have an initial overshoot. In general, the stress on the most sensitive equipment can cause damage (for example to electronic boards), which in the case of sophisticated industrial users have a great impact in terms of costs for production stops (identification of the fault, replacement of the component, provided that it is available and not to be ordered from the distributor or the manufacturer).

To reduce the stress caused by these events, ORTEA engineers have studied a solution, which is supplied as a standard on ORION PLUS, SIRIUS and SIRIUS ADVANCE, as well as on the largerst ENERSOLVE Energy Efficiency Smart Devices: it is the system of return to the optimal voltage through supercapacitors.

Picture 1: tripping of networt overload protections.

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Picture 2: tripping of a short circuit or earth fault protection and subsequent O-CO-CO maneuvers.

This feature, also called “voltage shock absorber” or “soft-start” (words that make its effect more understandable), intervenes in the event of a power failure.

The special supercapacitors mounted on the electronic board store the energy, which is necessary to drive the motors of the voltage regulator rollers to the position of “minimum” regulation.

Upon restoration of the power supply, the mechanical inertia of the voltage regulators will absorb the transient, thus delivering to the downstream users a voltage with a “tame” transient, much less dangerous than that coming from the network. In fact, the voltage is gradually restored to the load, as it is apparent in pictures 1 and 2.

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Automatic PFC banks: components quality

In the majority of industrial plants the power factor correction system is centralized, with high capacity capacitor banks usually equipped with harmonic blocking reactors to protect capacitors from harmonics in the current.

When choosing a capacitor bank, it is necessary to pay attention not only to the quality of the capacitors inside the cabinet, but also to the quality of the other components and to the different solutions adopted by the manufacturer, in order to choose a device which will be efficient, long-lasting and easy to maintain.

Internal structure\ ORTEA SpA manufactures all ICAR APFC with removable rack. It is preferable to choose a capacitor bank with removable racks: it’s the best way to reduce time and problems during maintenance.

Regulator\ It is the intelligent element, which controls the capacitor bank, so it is very important. The regulators on board the ICAR APFC are all microprocessor-based, with several measuring and alarm functions: they will help you understand how the APFC works and how the electrical system to be rephased behaves. You will appreciate it a lot during the capacitor bank’s life and in particular when there will be problematic situations.

Contactors\ In order to guarantee excellent long life and reliability, ORTEA SpA ORTEA SpA uses only good well-executed contactors. For standard PFC systems, contactors have to be with damping resistors to limit capacitors inrush current (AC6-b). For detuned PFC systems are enough standard contactors (the function of the peak smoothing It is performed by the blocking reactance).

Load break switch\ It is the operation element, the one which has to bear the current of the capacitor bank also in case of overload. According to IEC 60831-1 regulation it has to be dimensioned with a nominal current which is at least 1.43 times the nominal current of the capacitor bank.

Steps\ ORTEA SpA manufactures ICAR APFC with a step-by-step that can ensure good accuracy in the correction of the power factor. Typically ICAR realizes its APFC with linear steps, which allows the optimization of the number of electrical combinations obtainable. Harmonic blocking reactors In detuned APFC, intended for plants with distorted currents and/or resonance risks, the reactors are intended to defend capacitors from harmonic currents, which would damage them. ORTEA SpA designs and builds most of the reactors used in its ICAR APFC, based on the considerable experience gained.

Ventilation\ The ICAR APFC are all made with forced ventilation. This reduces the thermal stress of the on-board capacitors, whether electrically (harmonic overload) and/or ambient (high temperature in the cabin).

Filters for the ventilation system\ They protect the capacitor bank from the entrance of dust and foreign bodies, which could worsen its thermal situation. During the commissioning, especially if with cable arrival from below, it must be carefully placed so that inbound there are no alternative routes for cooling air: this occurs through the opening of cables passage, if it is not sealed appropriately with ad hoc shaped sets or foams.

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Enersolve XXL

The client is a large plastic moulding company located in north-eastern Italy.

The green trend led them to select a monitored energy-saving solution. Not only that, but large fluctuations in the mains supply cause operational problems for the presses… Enersolve is able to solve this problem by guaranteeing a controlled voltage output in case of mains variations in the range of ±10%.

The purchase by the client was made through an ESCO company in EPC (Energy Performance Contract) mode, specialised in this type of intervention. This method will allow the client to reduce the costs of their investment to zero thanks to the monthly savings produced by the ENERSOLVE solution. The savings have been estimated to be about 200,000 kWh per year.

The machine, a 2500-kVA ENERSOLVE ESL-10E (model complete with three electronic, emergency and exclusion by-passes), intercepts the total power of the system, under a Mt/Bt transformer, via a 4000A busbar.

This is an XXL equipment, 5400x1000x2100 mm in size with a weight of approximately 4,900 kg.

The ENERSOLVE range is available in three models:

  • ESL-5 for the retail/small business market.
  • ESL-10 for environments where energy parameters fluctuate within the requirements of the ±10% reference standard.
  • ESL-20 for the most severe cases where fluctuations exceed the requirements of the reference standard.

The added value of the ENERSOLVE solutions is undoubtedly represented by the ENERCLOUD platform, which is essential for displaying and analysing energy parameters and a prerequisite for obtaining the benefits linked to Industry 4.0 plans. The on-board instruments make it possible to read and record the values of all the plant's electrical parameters, hence processing energy-saving data in real time. The method used to process the energy-saving data is based on the principles of the ESPRO protocol approved by ENEA (National Agency for New Technologies, Energy and Economic Development) after 3 years of joint studies.

The ESPRO protocol enables dynamic savings measurement: it is not based on measurements before and after the implementation of the energy efficiency implementation but rather enables continuous savings measurement.

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Remote monitoring: the Ortea Cloud solution

The remote monitoring of equipment functions and parameters is a requirement of an increasingly IOT-oriented market.

This is how Ortea Cloud, Ortea's new platform for remote voltage stabiliser monitoring, was born. It replaces and surpasses "Stabimon", the first monitoring software designed and developed more than ten years ago by Ortea. In addition to the Sirius range, Ortea Cloud is also available for the Orion Plus range.

The system consists of the Edge component, an ARM Linux gateway installed on board the machine, and the Cloud platform.

The Edge component communicates with the unit via industrial protocols, constantly acquiring operating parameters and generating telemetry via an intelligence that can vary the sampling rate according to the status of the machine. The collected information is immediately saved on the gateway, which is able to store it locally for a period of two months in case of loss of connectivity with the cloud. When connectivity is re-established, the information is immediately sent all together.

The on-board gateway application can generate alarms:

  • on the status of the connection to the cloud
  • on the status of the connection to the stabiliser
  • based on the values of the alarm measurements collected.

The data received from the cloud platform is processed by a rules engine capable of generating Real Time alarms based on dynamic rules, sending email notifications and storing telemetry and alarms in the database.

The cloud platform is able to show the telemetry of the measurements collected by each machine as a time series. In this way, the user can analyse their behaviour by comparing even different measurements on the same graph, thus highlighting any anomalies.

The platform manages the entire lifecycle of the machine and gateway, from installation to replacement in the event of failure. Data is stored on databases specifically designed for logging time series, allowing rapid retrieval for dashboard display or export to spreadsheets.

Ortea Cloud therefore makes it possible to:

  • Remotely monitor (via PC, Tablet or Smartphone) electrical and temperature values, display active alarms/archived alarms and produce multifunctional graphs, allowing the operator to produce accurate and well-defined analyses of the operation of their plant.
  • Download the data directly from the platform by selecting values and time intervals using filters.
  • In the event of alarm activation/termination, the system sends an e-mail alert, allowing a quick verification and subsequent resolution of the problem.
  • Activate any maintenance in real time.

The platform is available both to the end customer and, with different access credentials, to any person in charge of running the plant. Ortea offers a direct monitoring service on demand, by interacting with the relevant technical team.

Once logged in with the parameters provided by Ortea, an intuitive and easy-to-use dashboard appears, with the stabiliser or stabilisers, if more than one, active in the cloud.

Ortea Cloud is offered in two versions: the basic version (Ethernet) or the basic version + modem (should it not be possible to connect the stabiliser to a network). Access to the platform is free for the first year and there are no additional costs for software licences and updates. Thereafter, an annual or three-year renewal fee is required.

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Tailor-made: 2 Sirius in 1

The customer is a large Italian pasta company that has implemented a new project for two production lines located in North Africa. The plant is powered by four transformers split between the two lines. Each transformer has a parallel emergency line fed by generators to be used in the event of a power failure. For logistical reasons, the customer wanted a single piece of equipment for each line, which, in addition to stabilising the voltage for both transformers with the relevant circuit breakers, would also have the motorised drive part on board for switching from mains power to emergency-line power, using the ATS (Automatic Transfer Switch) system.

The solution designed by Ortea's engineers is an equipment assembled in a single cabinet consisting of two 1600 kVA Sirius stabilisers, with ±15% input regulation, including all the drives.

Ortea’s production then created the “Sirius two-in-one” to be installed on each of the two lines. To facilitate shipping, handling and installation they were shipped in multiple parts.

Ortea has always been able to design and build special equipment to meet customer's requirements, often helping them in the design phase and adapting its solutions to any plant and logistics situation.

The Sirius range is available for powers ranging from 60 to 6000kVA, with ±10%, ±15%, ±20%, ±25%, ±30%, +15/-35%, and +15/-45% adjustment. The control logic is managed by two DSP microprocessors (one that implements the control and the other that manages the measurements) that stabilise the output voltage, adjusting the true-RMS (root mean square) thereof. The whole system is supervised by a third (bodyguard) microprocessor that checks the correct operation of the other microprocessors

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New forces in Ortea's sales team

Ortea is pleased to announce that from June 2021 the Ortea Spa sales team will be joined by two new members, the engineers Davide Cuppari and Petio Dimitrov.

Davide Cuppari, who has an extensive experience in the world of critical power and business development skills, including international ones, is assigned the role of Italy Sales Manager.

“The Power Quality solutions and services offered by Ortea are very wide-ranging and the company's technical expertise is of great depth. In the near future, also thanks to the path taken by ARERA with the latest TIQE, there will be a lot of attention on the issue of energy quality: we are ready”, says Davide Cuppari.

Petio Dimitrov, who was born in Bulgaria and grew up in Morocco, graduated in Electronic Engineering in Milan and has many years of experience in B2B sales in the plant engineering sector with a focus on foreign countries due to his extensive language skills. Petio will join and enrich our international sales team.

“In order to achieve the targets set by the various states in terms of energy transition, the world needs to change rapidly. This will intensify the existing challenges for electrical networks across the world in terms of continuity of power supply, longevity of equipment and its safety. My professional goal is to be close to customers to overcome these challenges that are particularly dear to me; Ortea, with its organisation and expertise, has provided me with the ideal environment to accomplish this”, says Petio Dimitrov.

“I am confident that Davide and Petio’s experience and professional background will be of great help to our company. Our expectations are to ensure Ortea's continued growth, that would not be possible without an efficient customer service and a mutual relationship with our partners", states our CEO Massimilano Scarpellini.

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Odyssey: static voltage stabilizer for data centers

Odyssey, ORTEA's high-power static voltage stabilizers: ideal when a high regulation speed is a must, as in the case of data centers located in areas where poor voltage quality jeopardizes their smooth operation.

3 high-power static voltage stabilizers Odyssey with ±20% input voltage range are currently being put into operation (2 of 2000kVA and 1 of 2500kVA): they will improve the power quality of a large data center located in the Persian Gulf region.

In the Odyssey static stabilisers, the compensation of the input voltage fluctuation is managed by exploiting the double-conversion technology. The traditional regulating system is replaced by the converters that generate the necessary voltage once the control system has detected an incorrect situation.

The main feature of such configuration is the fast response (<3msecs), which guarantees real-time correction and voltage steadiness on the load side.

The double conversion technology also ensures insulation from disturbances and distortions in the grid. Thanks to suitable electrolytic capacitors, high power loads demands can be met.

Odyssey maintains the usual operational features: the regulation is performed on each phase independently, the load can vary between 0 and 100% on each phase and the operation is not affected by the load power factor. The unit can operate with or without the neutral wire.

Standard units cover a wide power range and offer a double input connection so that with the same unit two different input variations (±15/±20% or ±25/±30%) can be dealt with.

A 10” multilingual touchscreen on the front door works as user interface. By surfing the available menus, the electrical measures can be read and setting parameters adjusted. The interface is fitted with an Ethernet communication port, which, via dedicated «client», allows remote monitoring. Communication with the control system can be established also via RS485 serial bus and Modbus TCP/IP protocol.

The standard unit is housed in an IP2X metallic enclosure with RAL9005 finish for indoor installation.

Extracting fans ensure losses dissipation and unit cooling.

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4 reasons to have power factor corrections

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ENERcloud: savings always monitored

ENERcloud is the cloud platform for our ENERSOLVE “Intelligent energy efficiency devices”.

The tools on board enable the reading and recording of values for all the plant’s electric parameters, processing, in real time, the energy-saving data. The method used for processing the energy-saving data is based on ESPRO protocol principles approved by ENEA (Italy's National Agency for New Technologies, Energy and Sustainable Economic Development) after three years of joint research.

The ESPRO protocol enables savings to be measured dynamically. In fact, the protocol isn’t based on the measurement before and after implementing the energy efficiency measures; instead, it enables energy savings to be measured continuously.

In developing the ESPRO protocol, we started out from a quote of Galileo Galilei: "Measure what can be measured, and make measurable what cannot be measured.” In fact, it involved identifying a method that took account of the continuous variations in the two principal elements that contribute to the final result: the supply source and the combination of load mix moment by moment. Only continuous, not one-off, measurements of these quantities, which constantly and significantly vary, make it possible to determine, with certainty, the efficacy of the measures.

We began with the IPMVP (International Performance Measurement and Verification Protocol), the protocol for checking the results of energy efficiency, water efficiency and renewable energy projects in any field, from civil engineering to industrial sites. This method involves comparing energy consumption before and after the installation of an energy efficiency system. The limitation is that it adapts very well to systems in which the trend of the two parameters cited above is almost constant. However, in a real plant the situation is quite different, the trend in supply voltage, power, and load mix used is very different in each moment.

We added the analysis of the VDE-AR-E 2055-1 method: a standard that VDE created and that adapts IPMVP in the area of energy efficiency. It introduces the concept of variable energy saving depending on the type of load and the classification - in three categories - depending on their sensitivity to voltage variation. The limitation is in identifying the load mix installed in the plant, a piece of data that must be accurately known and must not, subsequently, vary.

The ESPRO protocol involves continuous measurement. The measurements are carried out every 15 minutes and, during a 30-second measuring window, the saving is frozen for 10 seconds, thus obtaining an actual difference between the instantaneous power and what the system would have used without the Enersolve installation. The measurement is repeated for the machine’s entire service life.

The total energy saved during the day is the sum of the individual measurements that repeat the method involved in the IPMVP protocol 96 times per day and exceed the VDE standard requirements, intercepting, sample by sample, the change in load mix.

The guarantee provided by Enersolve, thanks to this ESPRO functionality, refers to the total savings in kWh.

In practice, however, what is the effect when Enersolve is assembled in the plant?

The graphic below, downloaded from ENERcloud, shows the active power absorbed by an actual plant. The lower part shows the power value for the plant with the Enersolve system installed. The upper part, instead, shows the power that the plant would have used without the Enersolve system installed.

In this graphic, instead, the consumption of the system can be seen, day by day, with (green bar) or without (red bar) the Enersolve system.

ENERcloud, all the information in your hands…wherever you are.

The latest-generation electronics installed in the ENERSOLVE equipment makes it possible to measure, send, and store all the sensitive measurements, the energy saving, and the state of the machine in the cloud.

Thanks to the intuitive, Web-based software, it is possible to obtain all the necessary information in real time, in any part of the world and with any device.

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Instruments compared: test ok

The quality and reliability of our products has always been a principal feature, a goal that our project engineers pursue every day with controls and tests performed continuously.

In this case, we wanted to check the reliability of some readings of the tools on board the Oxygen by comparison with class A tools, according to the CEI EN 61000-4-30 standard. One was mounted at the input stage and one at the output stage of an Oxygen 500-10-40 that was installed and operating perfectly in our production plant. There are two tools for comparison: LINETRAXX PEM735 of Bender; the clocks of each are synchronised with that of the Oxygen panel.

The purpose of the test is to check the correctness and precision of the voltage sag readings. Contrary to what you might think, voltage sags often occur on electric lines considered to be of good quality, such as Italian ones.

We have identified a single-phase voltage sag entering the second phase as can be seen from the screen-shot of the tool:

In this case, the second phase has a residual tension of 88.54%.

Here, we’d like to recall that the definition of a voltage sag is a change in voltage starting at -10% of the nominal voltage up to -95% (i.e. residual voltage of 5%) with a duration of 10ms to 1 minute.

We detect the event, accurately, in the operator’s panel mounted on board the Oxygen:

At this point, Oxygen intervenes to compensate for the sag; in fact, in the period of time in which the event occurred, the tool does not detect any voltage sag on output:

An additional confirmation of Oxygen’s performance.

Oxygen is available in two models:

Oxygen 10-40 (from 200 to 3200kVA) with input voltage compensation ±10% (continuous) and compensation for voltage sags of up to -40% of the nominal voltage per 1 minute.

Oxygen 15-50 (from 200 to 2000kVA) with input voltage compensation ±15% (continuous) and compensation for voltage sags of up to -50% of the nominal voltage per 1 minute.

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Sirius: the top voltage stabiliser!

The Sirius range of the highest-performance and most complete voltage stabilisers in our production, is encountering a lot of success on the market. In recent months, in fact, we have manufactured and delivered a significant amount of equipment destined for customers spread across every part of the globe.

The Sirius range is available for powers ranging from 60 to 6000kVA, with ±10%, ±15%, ±20%, ±25%, ±30%, +15/-35%, and +15/-45% adjustment. The control logic is managed by two DSP microprocessors (one that implements the control and the other that manages the measurements) that stabilise the output voltage, adjusting the true-RMS (root mean square) thereof. The whole system is supervised by a third (bodyguard) microprocessor that checks the correct operation of the other microprocessors.

In addition to the generous size and additional protections, which make the equipment very reliable and durable, the user interface is undoubtedly another very important feature.

Consisting of a 10-inch, multilingual touch display (equipped with an RS485 port), it can provide information on the state of the lines upstream and downstream of the voltage stabiliser (voltage, current, power factor, active power, apparent power, reactive power, etc.), the operating state of the stabiliser (it displays all the information relating to each operating mode: on/off, adjustment limit reached, increase/decrease in adjustment, etc.), and any alarms (minimum and maximum voltage, maximum current, excessive temperature, etc.).

If connected to a network via Ethernet with an RJ45 cable, the display can, in addition, be remotely transmitted to a PC using VNC software. It is, in addition, possible to interface with the stabiliser using the Modbus TCP/IP protocol (a standard protocol in communicating between industrial electronic devices). The system is also equipped with two USB ports that can be used to download the data stored and upload software updates from the control card.

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Blocking reactors XXL size

The first batch of a supply of reactors (55 units in total) to be installed inside fixed, 5 MVAR power factor correction systems, in order to block harmonic currents, is on its way.

Their function is to compensate the reactive power on 24 kV networks with an IGBT insertion system, thus a very fast - practically real-time - compensation system.

Although the application of these systems is horizontal for all those customers who use electricity with a medium-voltage connection, in this case the final customer is a producer of electronic parts for consumer electronic goods: computers, mobile phones, and peripherals.

Since 1969, the year in which ORTEA was founded, the magnetic parts (transformers and reactors) have been at the centre of its business and, thanks to vast experience and close collaboration with customers, the company has developed specific knowledge that allows them to produce reactors to respond to various problems that may derive from their great variety of uses.

In addition to this, one of ORTEA SpA’s hallmarks has always been its extreme flexibility, which enables the quick development of dedicated solutions based on the Customer's technical specifications.

In particular, we produce the following for both indoor and outdoor use:

  • Three-phase and single-phase reactors
  • Reactors with iron or air core
  • Detuning reactors
  • Smoothing reactors
  • Blocking reactance
  • Inrush current limiting reactors.

All design, production and marketing activities are carried out at ORTEA SpA's headquarters, thus ensuring continuous control and synergy among personnel involved.

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MULTImatic FH20 and ORC turbogeneration

The 960Kvar MULTImatic FH20 system, designed for the power factor correction of an ORC (Organic Rankine Cycle) thermodynamic cycle turbogenerator, is ready for dispatch.

The Rankine cycle developed for this application is similar to that used by a traditional steam turbine except that the working fluid, in this case, is an organic fluid with a high molecular mass. This enables the effective production of electricity in a wide power range, beginning with a low-temperature heat source both from renewable sources (biomass, solar heating) and from residual heat sources from primary industrial thermal processes (exhaust fumes, fluid leaving gas turbines).

The system is a special version: single cable arrival from above with an automatic switch as requested by the customer for their plant connection requirements.

The FH20 range, with blocking inductors, is a solution that is used when a current with a high harmonic content (THD) and/or with high risk of resonance with the MT/bt transformer circulates in the electrical system.

In these cases, the installation of “normal” power factor correction equipment, without barrier inductors, can cause the rapid degeneration of the capacitors and instigate dangerous electrical and mechanical stresses in the system power components (cables, busbars, switches, transformers).

The barrier inductors protect the capacitors from the harmonic distortions and, at the same time, exclude the risk of resonances, but they leave the harmonic content of the plant current unaltered (if you wish to reduce the system harmonic content, you need to install active filters. Consult us).

ORTEA SpA offers two types of power factor correction solutions with barrier inductors: one with 180Hz blocking frequency (detuned to 3.6 times the line frequency) and a second with 135Hz (2.7 times).

It’s worth underlining that the lower the detuning frequency, the more robust the system, since the inductors must have a larger iron core.

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UPS and voltage stabilisers: unpredictable synergies

The voltage supplied by the electrical network to the user’s terminals should be perfectly sinusoidal, at a constant frequency and without interruptions. Actually, the mains voltage usually presents several anomalies, as shown by the measurements carried out on site, and as taught by the CEI EN 50160 standard, a guiding document in the world of power quality fundamentals.

Non-continuity is among the major problems afflicting the power supply: this can be caused by the tripping of circuit breakers, interruption of the conductors, maintenance or works on the grid, atmospheric events, etc. Voltage sags are another big issue: they can be considered as close relatives of voltage interruptions when they are short and deep; instead, they are more similar to voltage variations when they have limited depth and long duration. Another problem is the voltage fluctuation, which can be fast or slow, usually due to network maneuvers, difficulties of adjustment by the energy distributor, disconnection or starting of large loads, etc. The duration of a voltage fluctuation can be several hours.

A "classic" solution to slow voltage variations is the voltage stabiliser, which can be electromechanical or electronic. LV voltage stabilisers for large powers, let's say >100kVA, typically operate thanks to a “buck-boost” transformer connected in series to the line and suitably piloted by voltage regulators. They are available in a wide range of sizes: from the smallest ones capable of handling an apparent power of a few kVA, up to those managing several MVA. They guarantee an excellent output voltage accuracy, up to ±0.5% of the nominal value, provided the input voltage variation remains within the range shown on the data label. In the most recent versions, the voltage regulation is obtained through electronic actuators, whose performances allow a higher reaction speed: the voltage regulation is completed within 20ms.

When equipped with appropriate accessories, voltage stabilisers become very complete solutions and can significantly improve the power quality of the systems installed downstream.

Voltage stabilisers can be equipped with the following options:

  • Interruption and protection devices.
  • Protection of the load against over/undervoltage, with automatic release if the output voltage exceeds the pre-adjusted threshold: this is a very useful protection for very sensitive loads.
  • By-pass line made with disconnectors, changeover switches or circuit breakers.
  • Input isolation transformer.
  • Fixed or automatic power factor correction system.
  • Surge arresters.
  • EMI/RFI filters, to detect and reduce high frequency disturbances conducted along the lines.
  • Active filtering system to reduce the current harmonic content.

When enriched with these optional features, a voltage stabiliser is called "line conditioner", like 3200kVA Sirius Advance shown in the picture.

Since voltage stabilisers are not equipped with any energy storage system, of course they cannot cover interruptions. Short ones have traditionally been solved by means of expensive and sophisticated equipment, such as the flywheel UPS, usually dedicated to special systems. Generators are the right solution for long-lasting interruptions.

More recently, the development of power electronics and the spread of batteries has led to the emergence of UPS as the solution for a large part of the voltage problems, which is especially true for the more complete versions ("online” or “VFI" types):

  • Interruptions
  • Slow and fast voltage variations
  • Sags
  • Frenquency variations

Therefore, it would look like the voltage stabiliser is destined to be inexorably replaced by the UPS. It would seem that when the designer or the person in charge of the plant decides to use a UPS, the stabiliser will automatically be discarded. But this is not always the case.

First of all, the perfect equipment without "weak points" does not exist: in the case of UPS, the most expensive and delicate aspect is the cost of the batteries on board and the fact that they have a limited useful life, after which they must be replaced, otherwise the UPS will prove ineffective.

The batteries must be carefully managed and maintained in order to optimize their life: attention must be paid to their operating temperature, but other aspects can also be annoying, for example the operation of the UPS with too low mains voltage. In fact, if the mains voltage exceeds a certain range, the UPS goes into battery operation even if the mains is on. For these reasons, some UPS are equipped with a stabilisation stage to preserve the batteries.

In Ortea we have come across many examples of synergy between stabilisers and UPS, especially when it comes to large installed power, and when the user loads include sophisticated machinery, sensitive to power quality issues. This is particularly true in those Countries, where large and technically advanced industrial plants are supplied by much less robust and solid electrical networks.

Let's see the three most typical situations.

In series

As already understood in the previous paragraph, a rather frequent synergistic use of stabiliser and UPS is to install the two units in cascade, with the voltage stabiliser immediately upstream of the UPS. In power grids where large and frequent voltage fluctuations are expected, the stabiliser in series with the UPS preventes the wear and tear of the batteries, which would normally be required to work overtime, with a significant reduction in their useful life. In this case, the stabiliser and the UPS necessarily have the same size. The stabiliser is designed to manage very large voltage fluctuations, which differ even up to 30% from the nominal value. For such situations we have supplied voltage stabilisers up to 1.5MVA.

In parallel

To ensure continuity of operation to the powered systems in the event of the UPS being out of order for maintenance or failure, a by-pass line is very often provided. If the network is unstable, but the customer does not want to add a redundant UPS, a good solution is to install a voltage stabiliser or a line conditioner on the by-pass line, thus raising the power quality at a reasonable cost for the limited period of time in which it will be called to operate. The stabiliser/line conditioner is an excellent solution for this kind of application, as it requires very limited maintenance during inactivity periods. Also in this case the two units are substantially the same size.

Centralized stabilizer, distributed UPS

A "centralized" stabiliser/line conditioner of great power associated with small "local" UPS only on the loads that really need them is an excellent solution for those systems, which are characterized by a large installed power, in order to avoid installing a huge UPS or many of them when the loads are numerous. In this case, the stabiliser brings the general power quality of the system to a good level, preserving the batteries of the individual peripheral UPS "pampering" particularly sensitive loads. On large systems this philosophy can lead to significant savings also in terms of battery maintenance/replacement. The stabiliser must be large enough to support the power of the entire system, whereas the UPS will be suited to the individual loads, to which they are dedicated. For this kind of application, we have supplied power stabilisers up to 4MVA.

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Master-slave 2x1: the power has doubled

The manufacturing of 6 special detuned power factor correction systems MULTImatic FH20 for a large grain milling plant in Pakistan has been completed.

Each unit has a rated power of 685kvar/415V. They will be coupled in a master-slave configuration, to create three 1370kvar power factor correction systems for the 2500kVA MV/LV transformers powering the production plant.

The plant includes numerous inverter motors, which means high current harmonics . But thanks to the robust detuning chokes on board the MULTImatic FH20 (Fd = 180Hz), there will be no overload problems on the capacitors, nor of resonance in the LV power grid.

It is interesting to underline that, in addition to the "classic" power factor control and management functions, the RPC8BGA regulator on board the MULTImatic system performs several additional advanced functions, such as the measurement of the electrical parameters and of the Power Quality (calculation of the current and voltage THD and the relevant graphic representation). These functions can be remotely monitored through MODbus protocol (on RS485 or via TCP/IP) or with Profibus protocol. The regulator can also be connected to the system in the configuration with 3 current transformers: in this case it is an "additional" multimeter. Moreover, it can monitor the hours of operation and issue warnings that recall the execution of maintenance: an important feature to keep the power factor correction system always efficient and in perfect running order

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ENERSOLVE: outdoor? No problem!

Industrial electrical systems have their own life: after they are born, they usually grow with substantial changes compared to the initial project.

The reasons can be many:

  • The Company is successful on the market and increases production.
  • The Company adds new production lines or modifies the existing ones, in order to adapt them to new market needs.
  • Regulatory evolution of electrical systems.
  • Technological evolution of machinery and processes.
  • Introduction of new systems to optimize the plant (e.g.: energy optimization, generation from renewable sources, improvement of Power Quality).

Therefore, it becomes sometimes necessary to modernize/replace/expand the power equipment located in the electrical substation, where spaces are rarely abundant and do not always allow for the installation of new heavy and big machinery.

Sometimes companies are forced to renounce interventions that would be profitable, simply because there is not enough space in the electrical room. Sometimes expensive extension works must be planned, perhaps over a long period, losing precious time in terms of efficiency and savings.

The customer is a large industrial laundry, specialized in sanitizing workwear also in the health sector, a subject of great sensitivity and urgency in this particular moment.

To improve the energy efficiency and Power Quality of their system, a 315kVA ENERSOLVE equipment was proposed and selected, but there was not enough space in the electrical room. Energy efficiency is a rather recent technology and existing electrical systems are often unprepared for housing them.

Ortea engineers have found a solution to this critical issue by proposing the equipment in IP55 configuration for outdoor installation, giving the customer the possibility to install it outside the room under a canopy.

In addition, since the power factor correction system of the laundly was obsolete, the ENERSOLVE equipment has also been equipped with an integrated 70kvar automatic power factor correction system.

The entire intervention benefits from the reduced taxation of Industry 4.0.

The whole ENERSOLVE range can be equipped with an integrated power factor correction system and it can be supplied in IP54/55 configuration for either indoor installation, for “difficult” internal environments, or for outdoor installation.

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Isolation transformer: monitoring and maximum safety

The isolation transformer is an important element for the power quality of a LV system.

Installing an isolation transformer upstream of your network allows you to galvanically isolate the loads connected downstream of the transformer from everything upstream and, consequently, to protect them from disturbances affecting the mains, in particular transient overvoltages and conducted disturbances.

Isolation transformers are used in telecommunication systems, data centers, sensitive applications in terms of security for the community, such as military bases.

In those cases where the continuity of operation of the isolation transformer is a decisive factor, monitoring and, consequently, the communication of the parameters allowing to evaluate its state of "health" become relevant.

The following example relates to a transformer supplied to a State agency in the Gulf area.

We proposed and built a transformer equipped with:

  • Temperature measurement and control instrument with communication functions.
  • Probes for reading the temperatures inside the transformer and the ambient temperature.
  • Data transmission with Modbus protocol via RS485 port.
  • Protection by circuit breaker.
  • Monitoring of fan operation and status.

This solution will allow the customer to monitor the status of the transformer and to receive real-time information on the status of its accessories and alarms, in the event of phenomena outside its operating range.

A solution by Ortea for a very demanding customer!

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ODYSSEY: Hyper-Fast response

The production of static stabilisers ODYSSEY is proceeding apace. The ODYSSEY has been in production for some years now and it is establishing itself on the world markets, thanks to its outstanding technical characteristics and quality, which have always distinguished all our products.

When response speed becomes an essential requirement, for example for computers, laboratory equipment, test benches, medical instruments, CNC machines, etc., the static stabiliser is a must.

Our static stabilisers ODYSSEY are available for powers from 80kVA to 4000kVA, with input voltage range ±15%, ±20%, ±25% and ±30%.

The compensation of the input voltage fluctuation is managed by exploiting the double-conversion technology. The traditional regulating system is replaced by the converters, that generate the necessary voltage once the control system has detected an incorrect situation.

The main feature of such configuration is its fast response (<3msecs), which guarantees real-time correction and voltage steadiness on the load side.

The double conversion technology also ensures insulation from disturbances and distortions in the grid. Thanks to suitable electrolytic capacitors, high power loads demands can be met.

A 10” multilingual touchscreen on the front door works as user interface. By surfing the available menus, all electrical data can be monitored and setting parameters can be adjusted.

The interface is equipped with an Ethernet communication port, allowing remote monitoring via a dedicated «client» (on request). Communication with the control system can be established also via RS485 serial bus and Modbus TCP/IP protocol.

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Sirius Advance… simply the top!

Two voltage stabilizers SIRIUS ADVANCE 3200kVA ±20% are now ready to be packed. These two units will be installed in Ghana, downstream of the MV/LV transformers of a power distribution project with generation by hydroelectric power plants.

The SIRIUS ADVANCE significantly increase the #powerquality of a system, as they combines a voltage stabilizer with a power factor correction system. Moreover, they are equipped with our total protection kit, which includes an automatic input circuit breaker, a manual by-pass with interlocked automatic circuit breaker and an output motorized interlocked output circuit breaker. All in a single device!

Everyone says they know how to make them… Ortea really makes them!

Our top-of-the-range model SIRIUS ADVANCE is available as standard from 60kVA up to 4000kVA and with different input voltage ranges: ±15%, ±20%, ±25%, ±30% adjustment.

Control and stabilisation, performed on the true RMS value, is carried out by a two-way DSP-microprocessor under the supervision of a second "bodyguard" microprocessor, operating with a software which has been developed specifically for ORTEA.

The columnar variable autotransformer with rollers (ORTEA design - without sliding contacts, which are subject to heavy wear & tear) is solid and very reliable.

The user interface is a multilingual 10” touch panel equipped with RS485 port. The display shows all the electric parameters (voltage, current, active power etc.), the information regarding the operating modes (power on; voltage regulation limits; increase/decrease of voltage regulation etc.) and the alarms (minimum and maximum voltage, maximum current, overtemperature, etc.).

A panel with the reactive power regulator RPC8BGA is installed to manage the power factor correction part. Designed to provide the desired power factor, while minimizing the wear and tear of capacitor banks, the SIRIUS ADVANCE are accurate and reliable in measuring and control and easy to install.

Here are some numbers:

  • Power rating: 3200kVA
  • Input voltage: 415V ±20%
  • Output voltage: 415V ±0,5%
  • Rated current: 4452A
  • Max input current: 5565A
  • Dimensions: 7400x2000x2400mm
  • Weight: 14.000kg
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MULTImatic FD25: tailor-made!

The manufacturing of 2 special detuned power factor correction systems MULTImatic FD25 has finally been completed. The two units will be installed in a large automotive plant in Southern Europe, where research and development activities for special tires are carried out.

The systems, each with a power of 750kvar/400V, have been fully tailor-made, in order to faithfully reproduce the two previously installed units they will replace.

Thanks to the indestructible bimetallized paper capacitors and the robust detuning reactors on board the MULTImatic FD25 (Fd = 180Hz), the harmonic currents of the system will not be a problem!

In fact, current is often affected by distortion in industrial plants. This can cause two types of problems:

  • stress on the capacitors on board, which tend to overheat due to the harmonic currents flowing through them, on account of their progressively lower impedance as harmonic currents increase
  • resonance with the MV/LV transformer powering the system. Resonance becomes more probable as the ratio between the reactive power (kvar) of the power factor correction system and the apparent power (kVA) of the transformer increases

To overcome these problems, detuned power factor correction systems are used. The detuning reactors installed on board must also be of excellent quality, as well as the capacitors. Our reactors are designed and manufactured by ORTEA, to guarantee the quality and reliability of the finished product. The reactors are calculated to obtain a detuning frequency of 180Hz.

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Big stabilizers? Big loading operations!

When dealing with "big" stabilizers, such as these two 3200kVA SIRIUS, also their dimensions and weights are "big": each box measures 6500x2160x2770mm and weighs 14.600kg. As a consequence, also the loading operations require the use of extra-large cranes.

Since we are talking about numbers, here are those relating to these two 3200kVA SIRIUS with ± 20% input voltage range:

• Power rating: 3200kVA \ • Input voltage: 400V ± 20% \ • Output voltage: 400V ± 0.5% \ • Rated current: 4619A \ • Max input current: 5774A \ • Dimensions: 6200x2000x2400 mm \ • Weight: 12.600 kg

Our top-of-the-range model SIRIUS is available from 60kVA up to 6000kVA and with different input voltage ranges: ±10%, ±15%, ±20%, ±25%, ±30%, +15/-35% and +15/-45%.

The stabilization, performed on the true RMS value, is carried out by a two-way DSP-microprocessor under the supervision of a second "bodyguard" microprocessor, operating with a software which has been developed specifically for ORTEA.

The columnar variable autotransformer with rollers (ORTEA design - without sliding contacts, which are subject to heavy wear & tear) is solid and very reliable.

The user interface is a multilingual 10” touch panel equipped with RS485 port. The display shows all the electric parameters (voltage, current, active power etc.), the information regarding the operating modes (power on; voltage regulation limits; increase/decrease of voltage regulation etc.) and the alarms (minimum and maximum voltage, maximum current, overtemperature, etc.).

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Everybody boasts they can do it… ORTEA really manufactures them!

Big currents (max input current 5774A) involve the production of extra-large components: big bars, big transformers, big regulators… ultimately: big voltage stabilizers.

Like these two 3200kVA SIRIUS with ± 20% input voltage range, intended to improve the power quality of a large Nigerian bank.

These are some numbers:

  • Power rating: 3200kVA
  • Input voltage: 400V ± 20%
  • Output voltage: 400V ± 0.5%
  • Rated current: 4619A
  • Max input current: 5774A
  • Dimensions: 6200x2000x2400 mm
  • Weight: 12.600 kg

The SIRIUS, ORTEA’s top-of-the-range model, is available from 60kVA up to 6000kVA and with different input voltage ranges: ±10%, ±15%, ±20%, ±25%, ±30%, +15/-35% and +15/-45%.

The control and stabilisation, performed on the true RMS value, are carried out by a two-way DSP-microprocessor under the supervision of a second "bodyguard" microprocessor, operating with a software specifically developed for ORTEA.

The columnar variable autotransformer with rollers (ORTEA design - without brushes, which are subject to heavy wear & tear) is solid and very reliable.

The user interface is a multilingual 10” touch panel equipped with RS485 port. The display shows all the electric parameters (voltage, current, active power etc.), the information regarding the operating modes (power on; voltage regulation limits; increase/decrease of voltage regulation etc.) and the alarms (minimum and maximum voltage, maximum current, overtemperature, etc.).

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Ortea SpA and Covid-19: informations

With reference to the global health emergency caused by Covid-19, ORTEA SpA has immediately reacted in order to install and adjust preventively protective measures according to the indications provided by the national Health authorities. Such measures aim at preserving and safeguarding ORTEA’s employees, avoiding the virus spreading among the population and ensuring business continuity for ORTEA’s esteemed Customers.

At the moment, although not spared by difficulties in provisioning components and raw materials, there are no indications whatsoever that might negatively affect ORTEA’s business continuity.

At the same time, we are confident we are protecting at the best the health of whoever might get in contact with ORTEA SpA, such as internal and external partners, Customers and Suppliers.

One of ORTEA SpA peculiarities has always been the attempt to offer efficiency to Customers and partners and to establish a network of consolidated relations, in which human rapport plays an important role.

In the immediate future, travelling will not be a possibility, but this emergency is teaching all of us a different working pattern by exploiting digital technologies.

To this purpose, ORTEA SPA is acquiring all the necessary knowhow to carry on these relations even from a distance by means of training initiatives and commercial and technical updating sessions.

Looking forward to shake hands once again as soon as possible, we would like to grasp the opportunity to pay tribute to the resilience of our partners and suppliers throughout these difficult weeks and we also thank them already for the their future support which will allow us to carry on with designing, manufacture and trade innovative solutions.

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ORTEA SpA press release: new CEO appointed

Ortea Spa, a global provider of advanced, high quality electrical systems and mission critical power quality solutions, is pleased to announce the appointment of Massimiliano Scarpellini as Chief Executive Officer (CEO).

Ortea Spa and its distinguished collection of portfolio brands, including Ortea, Icar, Enersolve and Italfarad, serve customers in over 90 countries and across six continents via a global footprint in several segments as PFC, voltage stabilizers, SAG compensators, transformers, active filters and energy efficiency smart devices.

Mr. Scarpellini has served as executive across multiple industries and sectors, with a focus on technology, innovation and multinational operations. He most recently served as Vice president Operations, Vice president Business development and Chief Operating Officer of leading manufacturers of electronic components.

“Ortea brands and operations have tremendous market credibility, unique flexibility and the right offerings with leading innovations and operational expertise” said Mr. Scarpellini. “I am thrilled to join the Ortea team and look forward to working with our employees, customers and other partners worldwide to build on our strengths and drive the company to even greater levels of success”.

Ortea offers a new, innovative approach to the power quality sector, providing premium products and innovative solutions globally. Ortea is committed to growth through customer collaboration, innovative product development, and delivery of premium, mission-critical power quality solutions globally.

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Voltage sag: the most significant of all Power Quality issues

Modern industry is becoming more automated and the sensitivity of processes to power quality events is increasing.

It is generally recognized that quality is an important aspect of the electricity service. Not only low prices are important, also high-quality matters to customers. Price and quality are often complementary aspects; together they define the value that customers derive from consuming electricity.

Companies are more and more sensitive to Power Quality issues because they can cause troubles and damages to equipment, up to interrupting the production cycle.The most significant of all Power Quality phenomena is the voltage sag: more than 60% of poor Power Quality costs are consequence of Voltage SAGs. SAG cost is normally lower than a Voltage Supply Interruption one, but the first is by far more frequent. Troubles increase with sophisticated and electronic appliances.

WHAT ARE VOLTAGE SAGs

Temporary reduction of the Voltage RMS below a specific threshold at an electrical supply line point.

Voltage SAGs are generally caused by faults in the public network or in the installations of network users, in few cases by transient overloads due to the gearing up of large motors or the switching on of large loads. Voltage SAGs are unpredictable and random.

SAG starts when Voltage goes lower than 90% of nominal value and ends when voltages resume above 90%. Voltage SAG duration is considered within 10ms up to 1min.

The great deal of Voltage SAG has a duration lower than 1 second and a residual voltage higher than 40% of the rated value.

The voltage SAG propagates from the higher voltage levels to the lower ones, the load is often connected to a voltage level lower than the point of failure. Faults in the network cause deep voltage SAGs if they occur near loads. The incidence of voltage SAGs is much greater in the case of an aerial MV network than with underground cables.

RELEVANCE OF VOLTAGE SAGs

The more modern the equipment is and the more electronics is required, the more serious are the problems caused through voltage SAG. With the increasing number of regenerative energy sources, energy sags, fluctuations and frequency deviations also increase.

Example of costs due to voltage SAGs:

  • Costs for unproductive personnel due to the sudden termination of the production cycle.
  • Costs for raw materials and production lost.
  • Costs for damages and/or malfunctions of machineries (repairs to them, temporary hire of new ones).
  • Penalties caused by contractual shortcomings.
  • Sanctions for damage to the environment. Increase in general insurance costs.

VOLTAGE SAG SOLUTION

Many businesses require immunity to voltage SAGs and voltage conditioning rather than battery back-up power, provided by UPS system. In those cases where back-up power is unnecessary, a sag compensator provides superior protection and additional power quality functions, such as protecting against SAGs, over/under voltage, voltage fluctuations.

Moreover protecting a whole plant by UPS, which can guarantee SAGs immunity, may be very costly, due to battery and maintenance costs.

The right solution is the sag compensator, that permits SAGs correction up to -50% for 1 min.

It’s an economical solution: no maintenance and operation costs: no battery energy storage required and efficiency >98% at nominal power.

LEARN MORE

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The 3 main causes of low Power Quality

Power Quality is gaining increasing attention in the electric power industry. The consumer of electrical energy requires electric power with a certain quality, but loads can have a negative impact on the electrical system and are thus also subject to an assessment in terms of quality. Power quality is therefore intrinsically linked to the interaction between the electrical system and loads and must take into account both the voltage quality and power quality.

Possible consequences of low power quality that affect business costs are:

  • Power failures (Release switches, fuses blowing).
  • Breakdowns or malfunctions of machines.
  • Overheating of machines (transformers, motors, etc.) leading to reduced useful life.
  • Damage to sensitive equipment (computers, production line control systems, etc.).
  • Electronic communication interference.
  • Increased distribution system losses.
  • The need to oversize systems to cope with additional electric stress, resulting in higher installation and operational costs.
  • Luminosity flickering

Interruption of production due to these impacts of low power quality entails high costs due to production loss and the associated waste. For the Industrial sector, the estimated costs due to poor power quality represent 4% of turnover (Source: Studio Leonardo Energy). The impact of production interruptions is greatest in companies with continuous production.

Among the main causes of poor power quality in low voltage are:

  • Voltage sags, because equipment operates less efficiently and can stop.
  • Harmonic pollution, which causes additional stress on the networks and systems, causing them to operate less efficiently.
  • Excessive reactive power, because it charges useless power to the system.

The solutions vary for each cause. The voltage sags can be eliminated with a sag compensator, which ensures a voltage output at a nominal value. Reduced productivity, loss of data, loss of security, and machine breakdowns are only some of the problems caused by an unstable power supply that can be solved with a voltage sag compensator.

Harmonic pollution is caused by large amounts of non-linear consumption (from inverters, soft starters, rectifiers, power electronics, non-filament lighting, presses, etc.). Such devices deform the electrical current causing disturbances and problems to the system. Harmonic pollution is solved by active filters that are capable of eliminating the current harmonics in the system by measuring and injecting the same current, but in the opposite phase.

Excessive reactive power is regulated by a power factor correction system, which not only avoids any penalties due to excessive reactive energy, but reduces the “unnecessary” electrical current that flows into the lines and power components, yielding substantial benefits, such as reducing voltage drops along the lines and leakages due to the Joule effect.

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Harmonics: active or passive filter?

Loads operated by electronic devices are increasingly adopted in more and more industrial and commercial applications such as: Variable Speed Drives, rectifiers, UPS systems, DC power supplies, welding machines, computers, TV, energy efficient lamps, photocopiers.

These loads generate waveform distortions that become threat for network components.

In particular voltage and current harmonics, where the latter is the more dangerous, generate a series of problems, like:

  • Cable overheating
  • Undue tripping of circuit breakers
  • Blowing of fuses
  • Capacitor overloading and network resonance
  • Neutral cable overload
  • Transformer premature ageing
  • Electronic appliances disturbance.

These effects are seldom related to harmonic current and voltage distortion, while effective remedy for harmonics are passive and active filters. Active filters achieve much higher levels of efficiency in harmonics cleaning the first does not:

ACTIVE FILTER

  • it can compensate many harmonic currents simultaneously (ICAR FA40 up to the 50°)
  • It does not saturate or overload
  • It is uninfluenced by the network conditions (capacitance/Inductances)
  • it hasn’t capacitance
  • it is extremely flexible, it can target few harmonic currents
  • It can compensate power factor, even at high speed
  • it can compensate unbalanced loads
  • it attenuates voltage flicker
  • it can be set in parallel with other filters, even at later stages
  • it automatically and semalessly adjustes to the load

PASSIVE FILTER

  • it can compensate only one or very few harmonic current
  • it is extremely difficult to compensate few harmonics at the same time.
  • it can saturate or be overloaded
  • it is influenced by the network as for the existing capacitance and inductance
  • it is a capacitive load, hence improve power factor.
  • it is fix and not adjustable
  • it can be ON/OFF, or in steps.
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