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: • Comprehensive power system assessment including load flow, short circuit, and coordination studies • Power quality monitoring campaign (90 days) to characterize disturbance patterns • Reliability analysis identifying single points of failure • 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
