Case Study
Industry Type: Automobile Industry
Problems:
Duroshox which is situated in Pune was facing frequent failures of motors, drives & critical Measuring / QC equipments. Heating of power cables, transformers & heavy neutral currents were recorded by the installed Electrical Monitoring Systems. The utility company had issued notice to provide compliance to Harmonic level at PCC as per IEEE 519-2014 standard.
Study Recommended:
A detailed Power Quality Analysis was recommended to the client to identify the problem area & for implementing solution. We carried out a detailed 24Hr data collection at Transformer level & a detailed downstream audit of the connected loads at various load conditions.
Observations:
The data collection activity was conducted & analysis of collected data provided the following inputs:
- Harmonics audit conducted at the client site at Incomer Supply, Client site power was polluted & observed heavy Harmonics (THD- Current) as well as flickers in the power.( 5.6% ITHD)
- System was highly polluted with ITHD & Major components are 5th and 7th Harmonics (5.7%)
- The System Power factor is controlled with the Plane capacitor banks. This is also amplify the VTHD & I THD
- Higher current was drawn from the transformer for fixed kW resulting in kVA losses
Solutions Provided:
- 1. Installed 200 KVAR APFC with 7% detuning filters.
- 2. After installing the detuned harmonics filter the Current Harmonics Reduced from 5.7% to 1%
- 3. This will help to reduce demand as well as transformer and system losses. ( The effective energy bill will be reduced to 1.5 to 2.0 % )
Results Achieved:
We successfully reduced the V (THD) and I (THD) level for the transformer no. 1, 2 and 3 using the detuned passive filters. Voltage regulation and power factor also improved. This has also reduced Transformer losses & additional load can be now connected on the same transformer. Currently the installation is successfully functional & can be visited with prior intimation.
Industry Type: Automobile Industry (Forging Industry)
Problems:
Wheels India Limited which is situated in Ranjangaon MIDC (Pune) was facing frequent failures of motors, drives & critical Measuring / QC equipments. Heating of power cables, transformers & heavy neutral currents were recorded by the installed Electrical Monitoring Systems. The utility company had issued notice to provide compliance to Harmonic level at PCC as per IEEE 519-2014 standard.
Study Recommended:
A detailed Power Quality Analysis was recommended to the client to identify the problem area & for implementing solution. We carried out a detailed 24Hr data collection at Transformer level & a detailed downstream audit of the connected loads at various load conditions.
Observations:
The data collection activity was conducted for 3 days & analysis of collected data provided the following inputs:
- There were three transformers of 2000 KVA capacity with 22KV/433V voltage ratings. Across each transformer approximately 700-900 KVAR fixed plane capacitor banks were installed.
- Another 4th transformer of 750KVA capacity was there. The fixed plane capacitor bank of approx. 500 KVAR was connected across this transformer. This transformer is having Butt welding machine as well as Induction Hardening equipments
- Current harmonic distortion range was recorded from 8% to 58.8% which was not within TDD limits as per IEEE 519 norms. Major harmonic components were 5th and 7th. Harmonic distortion was load generated & was getting amplified by the fixed reactive compensation from the Capacitors installed.
- Due to plain capacitors, The Harmonics get amplified and distortion level increased.
Parameters To Be Achieved:
In order to Implement the proper solution we need to achieve the following parameters.
- Reducing current harmonic distortion and enhancing power quality.
- Achieving unity power factor for all load conditions.
- Achieving compliance to IEEE 519-2014 norms as demanded by the utility company.
Solutions Provided:
For Transformer No.1:
- We added the 7% detuned reactor in the capacitor bank which is installed at LT ROOM and Shop Floor.
- In LT ROOM we installed 700 KVAR capacitor bank with 7% detuned reactors.
- In Shop Floor we Installed 400 kVAR capacitor bank with 7% detuned reactors.
For Transformer No.2:
- We added the 7% detuned reactor in the capacitor bank which is installed at LT ROOM and SHOP FLOOR.
- In LT ROOM we installed 600 KVAR capacitor bank with 7% detuned reactors.
- In SHOP Floor we Installed 400 KVAR capacitor bank with 7% detuned reactors.
For Transformer No.3:
- We Installed 450 KVAR RTPFC Panel with 7% detuned reactors.
- We also added the 200 KVAR for transformer no. 3 at LT ROOM.
Results Achieved:
We successfully reduced the V (THD) and I (THD) level for the transformer no. 1, 2 and 3 using the detuned passive filters. Voltage regulation and power factor also improved. This has also reduced Transformer losses & additional load can be now connected on the same transformer. Currently the installation is successfully functional & can be visited with prior intimation.
Before Installing Detuned Passive Filter
After Installing Detuned Passive Filter