Electro Integra's specialized engineers have more than 20 years of experience in power systems analysis and consulting in Peru and globally. Since the year 2000, the EISAC engineering group members who oversee and/or conduct studies use the ETAP software to solve electrical problems in the Mining and Oil Industry. Listed below are our main areas of specialization and expertise.
Comprehensive studies of electrical systems focused on energy optimization
Electricity is one of the highest costs in the operations of most industries. Optimizing energy consumption brings immediate benefits to the company’s P&L. Using powerful ETAP optimization algorithms such as Optimal Power Flow, Optimal Capacitor Placement and Transformer Tap Optimization and with the extensive experience of its engineers, Electro Integra offers its specialized services to optimize the energy use for medium and large industrial electrical systems.
With detailed models of the electrical system, validated with field measurements taken in strategic locations, Electro Integra analyzes energy losses in the different components of the electrical system and determines the optimal locations to install equipment for reactive compensation and optimal operating voltages.
Harmonic, Parallel Resonance and Power Quality Studies
The use of nonlinear loads such as VFDs, cycloconverters and rectifiers introduces harmonics to the electrical system. To counteract the negative effects of these harmonics, the use of Active Front (AFE) VFDs, harmonic filters, and VFDs with a higher number of pulses (18 Pulses, 24 pulses) has increased dramatically.
However, uncoordinated application of these equipment to an electrical system can correct the problem in one area of the electrical system, but create problems in another area of the same system. Problems such as transformer and electronic cards damage, untimely trips of protective relays, or burning of neutral-to-ground resistors can cause large losses of production and money for industries. Early detection with the use of power quality measurements, analyses and simulations can prevent premature deterioration of some electrical system elements.
Electro Integra has engineers with extensive global experience who have analyzed and solved harmonic resonance and parallel resonance problems in various industries in Peru and the world.
Motor acceleration studies for mining mills and very large motors (2,000 hp to 30,000 hp)
Mining operations require the use of very high HP engines (2,000 hp to 30,000 hp) for the grinding process. The use of SAG and HPGR mills provide optimal solutions for grinding mining operations, but the start-up and operation of these large loads can severely affect the stability of the rest of the electrical system of mining operations.
Catastrophic failures such as motor damage due to lack of acceleration torque, untimely trips of other loads during start-up and electronic card failures on adjacent equipment can cause severe production loss in mining operations.
Electro Integra's extensive experience in mining electrical systems enables us to develop the appropriate mathematical models to be able to simulate the electrical starting parameters and determine the optimal protection settings in the very high HP equipment in mining operations.
Arcflash Studies according to the latest NFPA 70E-2018 and IEEE 1584-2018 standards
The objective of an Arcflash study is to determine the incident energy in cal/cm2 on each equipment of the customer's Electrical System, thus establishing the safety distances, correct working methods, specific procedures, the PPE necessary for a safe operation and the safety warning labels that must be displayed.
Electro Integra studies are carried out in accordance with the latest international standards (NFPA 70E-2018 and IEEE 1584-2018).
Preventive studies to minimize failures due to severe voltage drops during mining operations
Electro Integra has conducted several studies of mining electrical systems where nonlinear electrical loads originating in the shovels and drills have caused production stops and/or severe electromechanical failures.
Catastrophic failures such as VFD damage, failures in the mine shovels control equipment and electro mechanical equipment can result in severe production losses.
The application of AC motors controlled by VFDs or the use of DC motors in the new shovels and the precariousness of the interconnected electrical system requires a preventive study as soon as the mine electrical system grid that feeds the shovels and drills is put into operation.
Electro Integra's extensive experience in mining electrical systems enables a detailed analysis of the quality of the power supply, the impact of nonlinear loads on mining operations, and provide viable solutions to minimize or eliminate production losses caused by power supply quality problems at the mine.
Pre-feasibility studies for PPA Electricity Contracts (Power Purchase Agreements)
For any mining or industrial company, the Power Purchase Agreement (PPA) is of vital importance in establishing the cost of production. Electro Integra has technical staff with 25 years of experience in the Peruvian electrical market and in the regulatory framework established between agents of the Economic System Operation Committee (COES). Our company has participated as an advisor in 3 PPA contracts for the Peruvian Mining Industry.