A mid-size manufacturing facility was experiencing recurring power quality issues and unplanned outages that were costing an estimated $2.3M annually in lost production, equipment damage, and emergency repairs.
Challenge: • 3-5 unplanned outages per quarter • Voltage sag events causing PLC resets and production line shutdowns • Aging switchgear with unknown reliability characteristics • No comprehensive power system study had been performed in 15+ years
Eradeh's Approach: 1. Comprehensive power system assessment including load flow, short circuit, and coordination studies 2. Power quality monitoring campaign (90 days) to characterize disturbance patterns 3. Reliability analysis identifying single points of failure 4. Prioritized mitigation roadmap balancing cost vs. risk reduction
Results: • Identified 12 critical vulnerabilities, 4 requiring immediate action • Recommended UPS protection for critical control systems ($180K investment) • Redesigned protection coordination to eliminate nuisance tripping • Projected 85% reduction in unplanned outages • ROI achieved within 8 months of implementation
