As global energy demands continue to rise, industrial systems are evolving to meet the need. Whether powered by petroleum, natural gas, or other energy sources, these systems are consuming more than ever before. For example, a facility that used 100,000 liters of natural gas annually a decade ago may now require 200,000 liters or more. With this surge, power controller technology must also scale to match higher demands in process heating.
Ten years ago, a leading industrial power controller could manage up to 500 amps. Today, the ASPYRE® DT SCR power controller handles up to 2,100 amps, demonstrating just how far these systems have advanced. However, with this growth comes a challenge: managing power source issues and avoiding load capacity issues that can disrupt operations.
The Challenge: Pulsed Power and Its Impact
Industrial systems that rely on rapid, repeated power cycling to maintain target temperatures can place serious strain on generators. High-amperage pulses stress the electrical system, especially when temperature controllers or process controllers demand frequent on/off cycling. These pulses can cause voltage sags or even lead to brownouts, resulting in lost production time and expensive repairs.
The Solution: Staging with Power Controllers
One proven way to reduce these risks is staging power controllers. Instead of powering a large heater all at once, staging involves using several smaller heaters or segmenting the load to distribute demand over time.
Imagine flipping on a massive light switch—the full voltage hits all at once, creating a surge. Over time, repeated surges can wear out the system. By contrast, staging gradually increases the load. For instance, SCRs (silicon-controlled rectifiers) can ramp up power in increments—starting at 25%, then handing off to contactors at 50%, and so on until full capacity is reached. This approach eases stress on both the power controller and the energy source.
Benefits of Staging:
-
Reduces electrical stress and thermal cycling
-
Prevents power source issues in sensitive environments
-
Enhances system reliability and longevity
-
Improves energy efficiency in process heating applications
-
Location-Based Power Constraints
In remote or off-grid locations—such as offshore oil rigs or isolated industrial sites—load capacity issues are even more critical. Space and infrastructure limitations often restrict generator size and capacity. Switching between generators (e.g., diesel to turbo) requires precise synchronization, which becomes nearly impossible if the system is constantly pulsing to maintain temperature.
In these environments, staging the heater becomes essential. By controlling the load more gradually and efficiently, operators can maintain stable performance and avoid generator mismatch problems.
Consequences of Not Staging
-
Failing to implement a staging strategy can lead to:
-
Electrical brownouts
-
Generator failure or damage
-
Unplanned downtime
-
Lost productivity and revenue
-
Increased repair and maintenance costs
Do You Need to Stage Your Heater?
There’s no one-size-fits-all formula to determine the need for staging power controllers. However, if your system is using more than 75% of its available power capacity, it may be time to assess whether staging is necessary. Systems operating near the threshold of their load capacity are particularly vulnerable to inefficiencies and power disruptions.
Work with Experts in Power and Process Control
At Watlow®, we specialize in designing industrial heating systems that maximize reliability and energy efficiency. Our team can evaluate your setup, including your use of temperature controllers, process controllers, and heating components, to determine the right power management strategy for your facility.
Whether you're operating in an energy-constrained remote location or scaling up your heating infrastructure, we’ll help you minimize risks and optimize performance.
Contact Watlow® today to find out how staging with power controllers can solve your power source and load capacity issues.