Power control system and method

Abstract

A power control system 201 of a processing plant determines power characterisation data of the power supply to one or more loads in the processing plant. A power factor correction system 202 applies a

Description

Field

[0001] The present invention relates to the monitoring of the performance of a system and / or control of the system. Embodiments in particular include the monitoring and / or control of a production process in the food and beverage industry. Background

[0002] In the food and beverage industry, large processing plants are used to produce products such as bottled and canned drinks as well as other contained liquids. The processing plants typically comprise many large interoperating systems, with each system comprising motors and / or transformers for a number of different purposes. For example, motors may be required to drive compressors for refrigeration, ventilation and / or air conditioning. Motors may also be required to drive pumps for liquid flows through equipment as well as for other purposes.

[0003] There is a general need to improve the monitoring of a processing plant to determine if its systems are operating correctly and to control processes so as to improve the overall efficiency of the processing plant. Summary of the invention

[0004] Aspects of the invention are set out in the appended independent claims. Optional aspects are set out in the dependent claims. List of figures

[0005] The invention is described below, by way of example only, with reference to the drawings, in which:

[0006] Figure 1 schematically shows the components of a monitoring and / or control system that may be located in a processing plant according to an embodiment;

[0007] Figure 2 schematically shows an example of the display of data by an operator system; and

[0008] Figure 3 schematically shows the components and configuration of a monitoring and / or control system according to an embodiment.

[0009] The following description is merely exemplary in nature and is not intended to limit the scope of the present invention, which is defined in the claims. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. Description

[0010] Embodiments of the present invention provide a system and method for improving the monitoring and / or control of the operations of a processing plant. In a preferred embodiment, the processing plant is for food and / or beverage production. However, embodiments may also be used to monitor and / or control the performance of processes in other industries.

[0011] In a large processing plant there is substantial power consumption, there are fluid flows, there are vibrations and there are temperature dependent processes. A substantial cause of the power consumption may be inductive loads, such as motors and transformers. A system may comprise motors for a number of different purposes. For example, motors may be required to drive compressors for refrigeration, ventilation and / or air conditioning. Motors may also be required to drive pumps for liquid flows through equipment as well as for other purposes. The cost and environmental impact of operating such inductive loads is directly correlated to their power consumption. It is thus desirable to improve the efficiency of power transmission and consumption of inductive loads.

[0012] The power factor of an AC electric power system is generally considered a measure of efficiency of the system. The power factor is defined as the ratio of real or active power used by the load and apparent power transmitted to the load. An AC electric power system comprising an overall inductive load typically has apparent power greater than real power. This is due to energy that is stored in the inductive load, in the form of a magnetic field required to operate the inductive load, and returned to the source. The power factor of such a system is less than 1 or unity. The “wasted” or useless power lost to energising the magnetic field of the inductive load is also referred to as reactive power. The AC current waveform in such an inductive load is out of phase, and lags, the AC voltage waveform. The reactive power does not contribute to the useful power output of the inductive load, but adds to the power transmitted to the inductive load and thus increases the environmental impact and cost of operating the inductive load.

[0013] A system for correcting power factor may be used to improve the power factor and reduce the reactive power of an AC electric power system. A system for correcting power factor compensates for the lagging current induced by the inductive load by creating a leading current, for example by using capacitive loads. A capacitive load gives rise to a negative reactive power, effectively cancelling the positive reactive power of an inductive load.

[0014] Systems for correcting power factor are disclosed in PCT / GB2019 / 052374 and EP4258502 A2, the entire contents of which are incorporated herein by reference.

[0015] The systems disclosed in PCT / GB2019 / 052374 and EP4258502 A2 allow the monitoring and correction of power factor performance. This may be used to improve the efficiency of the operation of the inductive loads in a processing plant. However, a limitation of these, and all other known systems for correcting power factor, is that they are restricted to the monitoring and correction of only power factor performance. They do not provide an operator with the required data for the monitoring of all of the processes performed in a processing plant. This complicates and increases the cost of the monitoring of the processing plant because independent monitoring systems are required for the different processes that are performed in the processing plant.

[0016] Embodiments improve on known techniques by providing a monitoring system that allows an operator to monitor, in substantial real time, performance data on a plurality of different processes in a processing plant. The monitored performance measures may include the power factor of the overall power supply to the processing plant, the power factor of the power supply to specific loads within the processing plant, vibration levels of one or more systems within the processing plant, the temperatures of one or more systems within the processing plant, and flowrates of fluids in one or more systems within the processing plant. The data may be provided to an operator, who may be remote from the processing plant, over an Ethernet / Internet connection and / or via a wireless communication network, such as 2G or 4G. The operator is thereby able to monitor the operation of the processing plant with a single monitoring system.

[0017] Embodiments may also allow the remote control of processes in the processing plant by the operator.

[0018] Embodiments may also allow the automatic detection of problems and / or performance gains in the processing plant.

[0019] Figure 1 schematically shows the components of a monitoring system that may be located in a processing plant according to an embodiment. In a preferred embodiment, the processing plant is for food and / or beverage production. However, embodiments may be used to monitor the performance of processes in other industries. The monitoring system may comprise further components that are not shown in Figure 1, such as a remote operator system.

[0020] The monitoring system comprises a power factor system 102, a vibration sensor system 103, a flowrate sensor system 104 and a communications system 101. Although not shown in Figure 1, the monitoring system may comprise further measurement systems such as temperature and humidity measurement systems. The further measurement systems may be standalone systems or alternatively integrated with the other systems. For example, the vibration sensor system 103 may comprise both vibration and temperature sensors and be a source of both vibration and temperature data.

[0021] The power factor system 102 may be a power factor measurement system for measuring the power characteristics of the power supply to one or more loads in the processing plant. The power factor system 102 determines power characteristics from received current measurements 105 and voltage measurements 106. The power factor system 102 is arranged to generate and communicate power characterisation data to the communications system 101.

[0022] The power factor system 102 may comprise the RI-F550 Series module as sold by Rayleigh Instruments (see https: / / www.rayleigh.com / rayleigh-instruments-ri-f550-multifunction-analyser-single-three-phase.html, as viewed on 12th August 2024).

[0023] The power factor system 102 is preferably a system for both measuring the power characteristics and applying a correction to the power supply to one or more loads in the processing plant. For example, the power factor system 102 may be the central control unit 130 as disclosed in Figure 2 of PCT / GB2019 / 0523 74, or the central control unit 130 as disclosed in EP4258502 A2, adapted to have the additional functionality of communicating the determined power characteristics to the communications system 101. Accordingly, although not shown in Figure 1, there may be one or more arrangements of capacitive modules for applying a power factor correction to one or more inductive loads.

[0024] The vibration sensor system 103 may comprise one or more vibration sensors for measuring the vibration at one or more locations, such as on systems, within the processing plant. The vibration sensor system 103 is arranged to communicate the vibration data to the communications system 101.

[0025] The vibration sensor system 103 may comprise the QM30VT2 combined vibration and temperature sensor as sold by TURCK (see https: / / www.turckbanner.co.uk / en / product / 3806276, as viewed on 12th August 2024).

[0026] The flowrate sensor system 104 may comprise one or more flowrate sensors for measuring the flowrate of fluid in one or more fluid conduits within the processing plant. The fluids may a number of different types of liquid and gas. The flowrate sensor system 104 is arranged to communicate the flowrate data to the communications system 101. The types of flowrate sensors that are used may be determined in dependence on parameters specific to the performed processes, such as the type of liquid, the type of gas and conduit diameters.

[0027] The communications system 101 is arranged to receive power characterisation data from the power factor system 102, vibration data from the vibration sensor system 103 and flowrate data from the flowrate sensor system 104. The communications system 101 is arranged to communicate the received data to an operator system. The operator system, which is not shown in Figure 1, is a computing system that may be used by an operator of the processing plant. The communications system 101 may communicate the received data to the operator system over the Internet. The communications system 101 may communicate the received data over a wired Ethernet connection and / or via a wireless communication network, such as 2G or 4G.

[0028] The communications system 101 may also comprise a wired communications interface, that may be an RJ45 communications interface, that allows control over further devices. In particular, the wired communications interface may be used to control the capacitive modules as disclosed in PCT / GB2019 / 052374 and EP4258502 A2.

[0029] The communications system 101 may comprise the RI-EC-PRO Series as sold by Rayleigh Instruments (see https: / / www.rayleigh.com / ri-ec-pro-gsm-or-gsm-ethernet-control-and-communication-gateways-rayleighconnect.html, as viewed on 12th August 2024).

[0030] The communications system 101 may provide data on the power characteristics, vibration, flowrate and other measurable performance measures of the processing plant to the operator system in substantial real time. The operator system may be located at the processing plant or in a remote location from the processing plant.

[0031] The communications system 101 may transmit the power characterisation data, vibration data and flowrate data to the operator system as the data is received from each data source. In this implementation, the frequency at which the operator system receives the power characterisation data, vibration data and flowrate data may be substantially the same as the rate at which the respective power factor system 102, a vibration sensor system 103 and a flowrate sensor system 104 generate and communicate data to the communications system 101.

[0032] In an alternative implementation, the communications system 101 may temporarily store the received power characterisation data, vibration data and flowrate data, and periodically transmit the stored data to the operator system.

[0033] The operator system preferably receives power characterisation data, vibration data and flowrate data, within less than an hour, preferably less than 30 minutes, and more preferably, less than 10 minutes, further preferably less than one minute, of the data being generated by the respective power factor system 102, a vibration sensor system 103 and a flowrate sensor system 104. The operator system may be considered to receive data in substantial real time if the operator system receives the data within less than an hour of the data being generated at its source.

[0034] The operator system may process the received data to generate a combined display of the received data. Figure 2 schematically shows an example of the display of the received data by the operator system. The display simultaneously provides an operator with data on all of power factor performance, flowrate, vibration and temperatures within the processing plant. The greatly aids the monitoring of the performance of the processing plant by the operator.

[0035] Embodiments may also include the remote control of processes in the processing plant by the operator system. For example, in response to the received data, an operator may determine that a flowrate in a conduit needs to be changed. The operator may input an instruction to change the flowrate into the operator system. The operator system may communicate the instruction to the communications system 101, or other communications system within the processing plant, that controls the systems of the processing plant to perform the instructed change of flowrate. The control of processes may also be performed automatically by the operator system in dependence on the power characterisation data, vibration data and flowrate data.

[0036] In a preferred embodiment, the operator system processes the received data and automatically detects problems and / or performance gains in the processing plant. The operator system may automatically detect problems / faults and / or actions that may be taken to achieve a performance gain in dependence on determinations from data on more than one performance measure. The detected problems and / or actions that may be taken may be automatically displayed to an operator.

[0037] From the monitoring of only a single performance measure, it may not be possible to determine that a specific problem has occurred or if a specific performance gain may be made. For example, if a blockage occurs in a conduit of the processing plant, then the blockage may cause a load change of a motor that drives a pump of fluid through a conduit. The load change may cause a sudden change in the measured power characteristics. From the power characteristic data alone, the sudden change in power characteristics may be detected but it may not be possible to determine the cause of this and what action needs to be taken. For example, the sudden change in power characteristics could have been caused by a failure of a motor or other piece of equipment within the processing plant, a glitch in the national grid or a number of other potential causes. However, if the flowrate data indicates that a blockage has occurred within a conduit of the processing plant, a determination may be made that the sudden change in power characteristics has been caused by the blockage causing a load change of a motor. Accordingly, by automatically monitoring both the power characterisation data and the flowrate data, the operator system may automatically determine the cause of the problem. The operator system may automatically determine and display both that there is a blockage in the system and that no fault is expected with the motors of the processing plant, despite the detected sudden change in power characteristics.

[0038] A further embodiment is described below with reference to Figure 3.

[0039] Figure 3 schematically shows the components and configuration of a monitoring and / or control system according to the present embodiment. A preferred implementation of the present embodiment is as a power control system.

[0040] The power control system comprises a control system 201, a power factor correction system 202, a vibration sensor system 103, a flowrate sensor system 104 and Measuring Instruments Directive (MID) meter 203.

[0041] The control system 201 and power factor correction system 202 may between them perform at least the same functions as the earlier described power factor system 102 and communication system 101.

[0042] The control system 201 may coinprise a power factor measurement system for measuring the power characteristics of the power supply to one or more loads in the processing plant. The control system 201 may determine power characteristics from received current measurements 105 and voltage measurements 106. The determined power characteristics may be referred to as power characterisation data and comprise a power factor measurement. The control system 201 is arranged to generate and communicate power characterisation data to an operator system. The control system 201 may comprise the RI-F550 Series module as sold by Rayleigh Instruments (see https: / / www.rayleigh.com / rayleigh-instruments-ri-f550-multifunction-analyser-single-three-phase.html, as viewed on 12th August 2024). The control system 201 may determine corrections to be applied to the power supply for improving the power factor performance. The control system 201 may communicate the power characterisation data and / or instructions for determined corrections to be applied to the power supply to the power factor correction system 202.

[0043] The power factor correction system 202 may generate control signals 206 for switching one or more capacitor banks for improving the power factor performance of the power supply. The power factor correction system 202 may receive instructions from the control system 201 and generate the control signals 206 for switching one or more capacitor banks in dependence on the received instructions. Alternatively, the power factor correction system 202 may receive power characterisation data from the control system 201 and generate the control signals 206 for switching one or more capacitor banks in dependence on the received power characterisation data. The power factor correction system 202 may comprise harmonic reactors. The harmonic reactors protect the one or more capacitor banks from resonance that may occur due to the amplification of harmonic distortions. The one or more capacitor banks may be comprised by the power factor correction system 202.

[0044] The control system 201 and the power factor correction system 202 operate together to both measure the power characteristics and apply a correction to the power supply to one or more loads in the processing plant. For example, the control system 201 and / or the power factor correction system 202 may comprise the central control unit 130 as disclosed in Figure 2 of PCT / GB2019 / 052374, or the central control unit 130 as disclosed in EP4258502 A2.

[0045] The control system 201 may be configured to communicate with the power factor correction system 202, the vibration sensor system 103, the flowrate sensor system 104 and / or the MID meter 203. The control system 201 may process received data from the power factor correction system 202, the vibration sensor system 103, the flowrate sensor system 104 and / or the MID meter 203 and communicate it an operator system and / or generate and send control instructions for processes performed in the processing plant. The control system 201 may comprise the earlier described communications system 101. The control system 201 may comprise a PLC Gateway that allows it to communicate directly with the power factor correction system 202, the vibration sensor system 103, the flowrate sensor system 104 and / or the MID meter 203.

[0046] The vibration sensor system 103 and flowrate sensor system 104 may be the same as the earlier described vibration sensor system 103 and flow'rate sensor system 104.

[0047] The MID meter 203 is an energy meter that is configured to generate energy data that is certified. The Mil) meter 203 may generate energy data in dependence on received current data 204 and voltage data 205, that may be respectively generated by split core CTs and a MID meter voltage connection. The MID meter may be configured automatically generate a certified monthly-report on energy suppl y / consumpti on.

[0048] The control system 201 may be configured to obtain and send, in substantial real time, power quality data, vibration data, flow rate data and / or energy data to an operator system.

[0049] The power control system may be configured to automatically control the switching of the one or more capacitors banks for improving power factor performance in dependence on the measured / determined power characterisation data and in addition vibration data and / or flowrate data. Advantageously, by determining switching data for controlling the capacitors banks in dependence on further data than the measured power factor data, the determined switching data is more appropriate given the actual circumstances in the processing plant. For example, a motor shaft loosening or breaking may cause a sudden change in power characterisation data and may also be detected in the vibration data. If the switching data is generated in dependence on the powder factor data alone, then an immediate correction may be applied that may destabilise, or damage, the capacitor banks or other components of the processing plant. However, when the switching data is generated in dependence on the power factor data and the vibration data, an immediate determination of the cause of the change in power characterisation data may be made and a different response to the situation made. For example, the faulty motor may be slowed down and / or stopped and the switching data slowly changed as appropriate during this process. Similarly, some fluids may comprise solids that break up and this cause changes in flowrates and motor loads that are measured in the flowrate data and the power characterisation data. By determining the switching data in dependence on both the flowrate data and the power characterisation data, the switching data may be quickly changed as appropriate given the changing condition of the fluids. If the switching data is determined based on the power characterisation data alone, it may only be slowly changed as appropriate for some causes of power characterisation data change, such as national grid power supply fluctuations.

[0050] Accordingly, embodiments provide a highly effective monitoring and control system for a processing plant. By incorporating the technologies as disclosed in PCT / GB2019 / 052374 and / or EP4258502 A2, the monitoring and control system comprises an effective and scalable system for correcting power factor that may operate with a plurality of separate inductive loads in a processing plant.

[0051] The above embodiments have been described with reference to operations in the food and beverage industry. Another preferred embodiment is battery storage industry.

[0052] Large battery storage systems are increasingly being used in industrial applications. A battery storage system may comprise inverters for converting its DC power output to an AC power supply. The battery storage system may also comprise a cooling system that cools the battery storage system using flows of liquid and / or air. Air cooling uses fans which are noisy. Liquid cooling does not require fans and so it is quieter. However, liquid cooling typically requires more maintenance than air cooling due to the need to monitor and occasionally replace the cooling liquid.

[0053] Embodiments include the power factor system 102, or control system 201, being configured to measure the power characteristics of such a battery storage system. In particular, the power factor system 102, or control system 201, may measure the power characteristics of the inverters such as their harmonic components, the state of the battery charge, and the state of the battery discharge. The flowrate sensor system 104 may be configured to measure the flowrate of the liquid and / or air in the cooling system of the battery storage system.

[0054] Accordingly, the power characterisation data that is determined by the power factor system 102, or control system 201, may include the power characteristics of the inverters, the state of the battery charge, and the state of the battery discharge. In addition, a flowrate sensor system 104 may measure flowrate data of the cooling system. The operator system may generate a display that includes both the power characteristics and flowrates. The operator system, and / or control system 201, may also automatically process the power characterisation data and flowrate data for automatic power factor correction, control, fault detection and performance improvement detection purposes.

[0055] The present embodiment may differ from the embodiments shown in Figures 1 and 3 by not comprising the vibration sensor system 103. The present embodiment may still comprise the other components shown in Figures 1 and as described above.

[0056] Embodiments include a number of modification and variations to the above described techniques.

[0057] The monitoring system and method of embodiments may be applied in any industry. In particular, embodiments may be applied in manufacturing plants of pharmaceuticals. Pharmaceutical manufacturing plants typically include systems with a large electrical power consumption as well as flows of liquids and air that need to be monitored.

[0058] The processing plant may comprise a plurality of separate control systems for controlling different equipment. The operator system may determine control data in dependence on the received data from the communications system 101 and communicate the control data to one or more of the separate control systems. The control data may be communicated via the communications system 101 or via a different communications path.

[0059] Embodiments are not restricted to comprising all of the systems described throughout the present document. In particular, embodiments include the monitoring system as shown in Figure 1 including the power factor system and flowrate sensor system but not the vibration sensor system.

[0060] The embodiment shown in Figure 1 may also comprise a MID meter 203 arranged to measure and send energy data to the communication system 101.

[0061] Embodiments include the below numbered clauses: 1. A monitoring system of a processing plant, the monitoring system comprising: a communications system; a power factor system configured to generate and transmit to the communications system power characterisation data of the power supply to one or more loads in the processing plant; a vibration sensor system configured to generate and transmit to the communications system vibration data of one or more locations in the processing plant; a flowrate sensor system configured to generate and transmit to the communications system flowrate data of fluid in one or more conduits in the processing plant; and an operator system; wherein the communications system is configured to transmit the received power characterisation data, vibration data and flowrate data to the operator system; and wherein the operator system is configured to generate and display performance data of the processing plant in dependence on the power characterisation data, vibration data and flowrate data. 2. The monitoring system according to clause 1, wherein the displayed performance data is a substantial real time indication of the performance of processes in the processing plant. 3. The monitoring system according to clause 1 or 2, wherein the communications system is configured to transmit the received power characterisation data, vibration data and flowrate data to the operator system via the Internet. 4. The monitoring system according to any preceding clause, wherein the communications system is configured to transmit the received power characterisation data, vibration data and flowrate data to the operator system via a mobile communication network that is preferably a 4G network. 5. The monitoring system according to any preceding clause, wherein: the monitoring system further comprises a temperature measurement system configured to generate and transmit to the communications system temperature data of the processing plant; the communications system is configured to transmit the received temperature data to the operator system; and the operator system is configured to generate and display performance data of the processing plant in dependence on the temperature data. 6. The monitoring system according to any preceding clause, wherein the power factor system is a power factor correction system configured to apply a power factor correction to the power supply of one or more loads in the processing plant. 7. The monitoring system according to clause 6, wherein the power factor correction system configured to automatically apply a power factor correction to the power supply of one or more loads in the processing plant in dependence on the power characterisation data. 8. The monitoring system according to any preceding clause, wherein the operator system is configured to generate control data for controlling one or more processes in the processing plant. 9. The monitoring system according to clause 8, wherein the operator system is configured to automatically generate control data for controlling one or more processes in the processing plant in dependence on the received power characterisation data, vibration data and flowrate data. 10. The monitoring system according to any preceding clause, wherein the operator system is configured to automatically determine a problem / fault in the processing plant, or an action that may be taken to achieve a performance gain in the processing plant, in dependence on at least two of the received power characterisation data, vibration data and flowrate data. 11. The monitoring system according to clause 10, wherein the operator system is configured to automatically display the determined problem / fault or the determined action. 12. The monitoring system according to clause 10 or 11, wherein the operator system is configured to automatically generate control data for correcting the determined problem / fault or performing the determined action. 13. A method of monitoring a processing plant, the method comprising: generating and transmitting to a communications system, power characterisation data of the power supply to one or more loads in the processing plant; generating and transmitting to the communications system vibration data of one or more locations in the processing plant; and generating and transmitting to the communications system flowrate data of fluid in one or more conduits in the processing plant; transmitting, by the communications system, the power characterisation data, vibration data and flowrate data to an operator system; and generating and displaying, by the operator system, performance data of the processing plant in dependence on the power characterisation data, vibration data and flowrate data. 14. The method according to clause 13, wherein the displayed performance data is a substantial real time indication of the performance of processes in the processing plant. 15. The method according to clause 13 or 14, wherein the communications system transmits the received power characterisation data, vibration data and flowrate data to the operator system via the Internet. 16. The method according to any of clauses 13 to 15, wherein the communications system transmits the received power characterisation data, vibration data and flowrate data to the operator system via a mobile communication network that is preferably a 4G network. 17. The method according to any of clauses 13 to 16, further comprising: generating and transmitting to the communications system temperature data of the processing plant; transmitting the received temperature data to the operator system; and generating and displaying, by the operator system, performance data of the processing plant in dependence on the temperature data. 18. The method according to any of clauses 13 to 17, further comprising applying a power factor correction to the power supply of one or more loads in the processing plant. 19. The method according to clause 18, wherein the power factor correction is automatically applied to one or more loads in the processing plant in dependence on the power characterisation data. 20. The method according to any of clauses 13 to 19, further comprising the operator system generating control data for controlling one or more processes in the processing plant. 21. The method according to any of clauses 13 to 20, further comprising: the operator system automatically generating control data for controlling one or more processes in the processing plant in dependence on the received power characterisation data, vibration data and flowrate data; and / or the operator system automatically determining a problem / fault in the processing plant, or an action that may be taken to achieve a performance gain in the processing plant, in dependence on at least two of the received power characterisation data, vibration data and flowrate data, and the operator system automatically generating control data for correcting the determined problem / fault or performing the determined action. 22. The monitoring system according to any of clauses 1 to 12, wherein the monitoring system is configured to monitor and / or control processes performed in a food and beverage manufacturing plant, a pharmaceutical manufacturing plant or a battery storage system. 23. An arrangement comprising a battery storage system and monitoring system of the battery storage system, wherein: the battery storage system comprises one or more batteries, a cooling system of the one or more batteries, and one or more inverters for generating an AC power output from the battery storage system; and the monitoring system comprises: a communications system; a power measurement system configured to generate and transmit to the communications system power characterisation data of the battery system; a flowrate sensor system configured to generate and transmit to the communications system flowrate data of fluid through the cooling system; and an operator system; wherein the communications system is configured to transmit the received power characterisation data and flowrate data to the operator system; and wherein the operator system is configured to generate and display performance data of the battery storage system in dependence on the power characterisation data and flowrate data. 24. The arrangement according to clause 23, wherein the power characterisation data includes the power characteristics of the inverters, the state of the battery charge, and / or the state of the battery discharge. 25. The arrangement according to clause 23 or 24, wherein the cooling system is arranged to cool the battery storage system with flows of liquid and / or air.

[0062] The foregoing description of the preferred embodiments has been provided for the purposes of illustration and description. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but where applicable may be interchangeably used in combination with other features to define another embodiment, even if not specifically shown or described. The description is therefore not intended to limit the scope of the present invention, which is defined in the claims.

[0063] Although the present invention has been described in connection with specific exemplary embodiments, it should be understood that various changes, substitutions, and alterations apparent to those skilled in the art can be made to the disclosed embodiments without departing from the spirit and scope of the invention as set forth in the appended claims.

[0064] Methods and processes described herein can be embodied as code (e.g., software code) and / or data. Such code and data can be stored on one or more computer-readable media, which may include any device or medium that can store code and / or data for use by a computer system. When a computer system reads and executes the code and / or data stored on a computer-readable medium, the computer system performs the methods and processes embodied as data structures and code stored within the computer-readable storage medium. In certain embodiments, one or more of the steps of the methods and processes described herein can be performed by a processor (e.g., a processor of a computer system or data storage system). It should be appreciated by those skilled in the art that computer-readable media include removable and non-removable structures / devices that can be used for storage of information, such as computer-readable instructions, data structures, program modules, and other data used by a computing system / environment. A computer-readable medium includes, but is not limited to, volatile memory such as random access memories (RAM, DRAM, SRAM); and non-volatile memory such as flash memory, various read-only-memories (ROM, PROM, EPROM, EEPROM), magnetic and ferromagnetic / ferroelectric memories (MRAM, FeRAM), phase-change memory and magnetic and optical storage devices (hard drives, magnetic tape, CDs, DVDs); network devices; or other media now known or later developed that is capable of storing computer-readable information / data. Computer-readable media should not be construed or interpreted to include any propagating signals.

Claims

1. A power control system of a processing plant, the power control system comprising: a control system configured to determine power characterisation data of the power supply to one or more loads in the processing plant;a power factor correction system configured to apply a power factor correction to the power supply;a vibration sensor system configured to generate vibration data of one or more locations in the processing plant and to transmit the vibration data to the control system; anda flowrate sensor system configured to generate flowrate data of fluid in one or more conduits in the processing plant and transmit the flowrate data to the control system;wherein the power factor correction applied to the power supply by the power factor correction system is generated in dependence on the determined power characterisation data and at least one of the vibration data and flowrate data.

2. The power control system according to claim 1, wherein:the power factor correction system comprises one or more switchable capacitor banks that are configured to apply a capacitive load to the power supply; andthe power factor correction system is configured to apply the power factor correction to the power supply by controlling the switching of the one or more capacitor banks.

3. The power control system according to claim 2, wherein the control system is configured to:automatically generate instructions for controlling the switching of the one or more capacitor banks so as to apply the power factor correction to the power supply; andsend the instructions to the power factor correction system.

4. The power control system according to claim 2, wherein the power factor correction system is configured to:automatically generate instructions for controlling the switching of the one or more capacitor banks so as to apply the power factor correction to the power supply.

5. The power control system according to any preceding claim further comprising an energy meter;wherein energy meter is configured to:generate certified energy data; andsend the certified energy data to the control system.

6. The power control system according to claim 5, wherein the power factor correction applied to the power supply applied by the power factor correction system is generated in dependence on the certified energy data.

7. The power control system according to any preceding claim further comprising an operator system;wherein:the control system is configured to transmit the power characterisation data, vibration data and flowrate data to the operator system; andthe operator system is configured to generate and display performance data of the processing plant in dependence on the power characterisation data, vibration data and flowrate data.

8. The power control system according to claim 7, wherein the displayed performance data is a substantial real time indication of the performance of processes in the processing plant.

9. The power control system according to claim 7 or 8, wherein the control system is configured to transmit the power characterisation data, vibration data and flowrate data to the operator system via the Internet and / or via a mobile communication network that is preferably a 4G or 5G network.

10. The power control system according to any of claims 7 to 9, wherein:the power control system further comprises a temperature measurement system configured to generate and transmit to the control system temperature data of the processing plant;the control system is configured to transmit the received temperature data to the operator system; andthe operator system is configured to generate and display performance data of the processing plant in dependence on the temperature data.

11. The power control system according to any of claims 7 to 10, wherein the operator system is configured to generate control data for controlling one or more processes in the processing plant.

12. The power control system according to claim 11, wherein the operator system is configured to automatically generate control data for controlling one or more processes in the processing plant in dependence on at least two of the received power characterisation data, vibration data and flowrate data.

13. The power control system according to any of claims 7 to 12, wherein the operator system is configured to automatically determine a problem / fault in the processing plant, or an action that may be taken to achieve a performance gain in the processing plant, in dependence on at least two of the received power characterisation data, vibration data and flowrate data.

14. The power control system according to claim 13, wherein the operator system is configured to automatically display the determined problem / fault or the determined action.

15. The power control system according to claim 13 or 14, wherein the operator system is configured to automatically generate control data for correcting the determined problem / fault or performing the determined action.

16. The power control system according to any preceding claim, wherein the power control system is configured to monitor and / or control processes performed in a food and beverage manufacturing plant, a pharmaceutical manufacturing plant or a battery storage system.

17. A method of controlling a processing plant, the method comprising:determining power characterisation data of the power supply to one or more loads in the processing plant;generating vibration data of one or more locations in the processing plant;generating flowrate data of fluid in one or more conduits in the processing plant;determining power factor correction in dependence on the power characterisation data and at least one of the vibration data and flowrate data; andapplying the power factor correction to the power supply.

18. The method according to claim 17, further comprising:automatically generating instructions for controlling the switching of one or more capacitor banks; andapplying the power factor correction to the power supply by controlling the switching of the one or more capacitor banks.

19. The method according to any of claims 17 or 18, further comprising: transmitting the power characterisation data, vibration data and flowrate data to an operator system; andgenerating performance data of the processing plant in dependence on the power characterisation data, vibration data and flowrate data;displaying the performance data at the operator system.

20. The method according to any of claims 17 to 19, wherein the displayed performance data is a substantial real time indication of the performance of processes in the processing plant.

21. The method according to any of claims 17 to 20, further comprising: automatically generating control data for controlling one or more processes in the processing plant.

22. The method according to claim 21, further comprising automatically generating control data for controlling one or more processes in the processing plant in dependence on at least two of the received power characterisation data, vibration data and flowrate data.

23. The method according to any of claims 17 to 22, further comprising automatically determining a problem / fault in the processing plant, or an action that may be taken to achieve a performance gain in the processing plant, in dependence on at least two of the received power characterisation data, vibration data and flowrate data.

24. The method according to claim 23, further comprising:automatically displaying the determined problem / fault or the determined action; and / or automatically generating control data for correcting the determined problem / fault or performing the determined action.

25. The method according to any of claims 17 to 24, wherein the processing plant is a food and beverage manufacturing plant, a pharmaceutical manufacturing plant or a battery storage system.

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