Electricity Quality Evaluation
Electrical power Top quality Analysis inside of a tyre conglomerate disclosed the foundation reason behind repetitive electronic card failures in SCADA, HMI, Difficult Disk and AC/DC Drives and Regular unwanted tripping in its method as a result of voltage fluctuation. The supervisory Management and facts acquisition system, which happens to be a mix of computer software and PLC/Pc components, malfunctions in sending accurate batch knowledge from HMI to method Computer system missing out several process details, day after day. The LED fitting driver fails due to triplen harmonics which in-addition induce a neutral recent while in the lighting transformer feeder.
The Curing section is most delicate during the tyre producing system which accustomed to trip usually on voltage fluctuation. Throughout monsoon, there was persistent tripping with Continual grid voltage surges. The plant administration prepared to update the 33kV grid incomer to 132kV for resolving the tripping dilemma. It had been very highly-priced, and that can not have solved the tripping dilemma in any case.
The introduction of metal radial tyres brought in appreciable non-linear hundreds (NLL) within the sorts of variable speed drive (VSD), DC drives and sizeable SCADA and HMI controls inside the tire manufacturing course of action. Leading tyre corporations complying with safety restrictions upgraded their procedure For prime quality and very long existence radials, which further amplified PLC and HMI Command. It resulted in an increased full existing harmonic distortion (THDi) which at The bottom stage, without having switching on capacitors, was among twenty to 40% at the principle incomer of assorted method transformers which has a corresponding total voltage harmonic distortion (THDv) of involving five to 10%.
Factory engineers have to have to take care of Energy Variable (PF) for steering clear of significant demand from customers (kVAh) costs and very low PF penalty in the utility corporation. Nonetheless they confronted a fresh challenge in introducing capacitors either at load close throughout a variety of substantial capability motors or at PCC loads or centralized APFC panel across transformer LT busbar. It magnified harmonics in an unpredictable and non-linear manner. The magnification can be as significant as various times The bottom harmonic amount or just a couple proportion level higher, which depends upon the fault volume of the facility process. In the higher fault level ability technique, THDi magnifies disproportionately increased than THDv. The reverse transpires by using a lower fault degree energy program.
Then arrived the Detuned Harmonic Filter having a 6% reactor in collection While using the capacitor. Though it solved the harmonic magnification trouble and enhanced the PF, it couldn't remedy the repetitive gear failure and nuisance tripping trouble, as well as the detuned filter alone unsuccessful regularly needing continual element substitution. Moreover, it can't minimize harmonics. When the real solution comes, the detuned filter ought to be replaced, paving the Area for the Tremendous tuned harmonic filter that solves every one of the failure and tripping concerns Other than slashing down harmonics, both equally THDi and THDv, within just IEEE 519 boundaries.
How did the higher harmonics bring in Electric power Good quality Dilemma and undesirable equipment tripping within the tire business? Well, that challenge defined in details in A further webpage "Electric power Good quality Answer Shipped". What did it just take to resolve both equally the trouble, equipment failure and nuisance tripping? The method of the solution, its methodology and efficacy explained exhaustively on Yet another webpage "Passive Harmonic Filter proven important When Products Fails".
Energy High-quality Investigation Report
The following Electric power Top quality Analysis Report was released inside the APQI EU-Asia ability excellent initiative journal in 2009. Despite the fact that a summary report, it contained all major developing blocks of an extensive electrical power high-quality Examination company. A synopsis facts table highlights the ability and harmonic amount in any way feeders within the manufacturing unit, main tools groupings, power good quality measurement graphs and recommendations for dilemma-solving. The thorough report contained Electricity Quality Signature Investigation for root trigger Investigation for troubleshooting some elusive failures. This research design recurring from the succeeding decades throughout all plant locations over a PAN India foundation, review recommendations executed, projected outcomes realized and regularly, Added benefits derived.
Abstract: Massive continuous method crops are increasingly resorting to implement of non linear loads (NLL) for example DC drives, variable velocity AC drives, UPS, elevated electronic controls etcetera. to enhance performance and productiveness in their crops. The plant engineers are more and more experiencing unfamiliar issues connected with ability high quality (PQ) largely challenge of distortion of essential wave shape and connected consequences.
Harmonics are as old a phenomenon since the introduction of AC Process. Mercury arc rectifiers (MAR) developed in 1920's and semiconductor controlled rectifiers (SCR) or thyristors designed in 1950's produced harmonics, due to their mother nature of non-linear hundreds. Nevertheless, utilization of non-linear load was fewer then (usually below five% in 1960), to obtain any significant influence. But it's now rising rapidly Therefore generating Power High quality a fantastic problem between plant engineers and involved equipment companies.
Magnified harmonics bring about intense stress around the plant & machineries. Electronics are the initial to fall short staying weakest among the all, followed by fuse, capacitors, thyristor, CT, Motor etc.
This energy top quality Examination report signifies summary of conclusions and proposals of comprehensive Examination & knowledge rising out from Electricity Excellent audit of the tyre production manufacturing unit.
The analyze uncovered that many of the feeders experienced incredibly significant volume of THD. Next are merely case in point for two feeders within the analyze-Transformers TR-fourteen & TR-fifteen with big NLL and Capacitors ON/OFF.
Capacitors ON/OFF: Desk 01 Illustration for prime harmonics degree at 2 feeders
Load with Significant NLL Without Capacitor With Capacitor REMARKS
THD-v THD-i THD-v THD-i
TR -14, two.5MVA, eleven/0.400kV six.8% 42% 9.1% 106% 450kVAr at Panel -OFF/ ON
TR -15, 2.5MVA, eleven/0.400kV eight.three% 77% 9.2% 126% 400kVAr at Panel -OFF/ ON
As THD-I and THD-v are much greater than IEEE norms, the review advisable putting in tuned harmonic filters at 400V secondary aspect for TR -14 and 15 (in Section -I) to Restrict harmonic distortion of the two THD-v & THD-i within regulatory norms, conserve Power significantly (generally 5%) and get rid of failure/nuisance tripping. It ought to help in improving solution top quality and All round profitability. Similarly, 2 sets of filters for 'Banbury' mixers and a person filter for 450 kW squirrel cage induction motor feeder ended up advisable to solve issues of high harmonics, irregular conduct for the duration of commencing of motors via soft starter which include setting up recent as large as 9 situations whole load existing, voltage dip of 23% and so on. The total expense of suggestion for phase I had been INR fifty nine,50,000 with an attractive uncomplicated shell out back duration of ten months.
In Stage -II, it absolutely was encouraged to put in tuned harmonic filters in seven additional transformers the place it was noticed that the extent of harmonics had been superior.
Sector Track record:
Processing & Production: The tyre building method starts by mixing unique kinds of rubber with process oils, carbon black, pigments, antioxidants, accelerators and various additives, Every single of which contributes particular Attributes on the compound. These ingredients are blended in big blenders (known as banbury mixers) less than remarkable heat and force. The components are blended alongside one another into a warm, black gummy compound that can be milled. The cooled rubber usually takes many forms. Most frequently it is processed into thoroughly identified slabs that could be transported to breakdown mills. These mills feed the rubber among significant pairs of rollers, frequently feeding, mixing and Mixing to organize different compounds to the feed mills, where They can be slit into strips and carried by conveyor belts to become sidewalls, treads or other areas of the tyre.
Indian Tyre Industry (Supply: Report on Indian Tyre Marketplace): The Indian Tyre Industry generated 736 lakh units of tyres (eleven lakh tonnes) garnering Rs. 19,000 crores in FY 07. MRF Ltd. was the market leader (22% sector share) followed carefully by Apollo Tyres Ltd. (21%). The other key gamers have been JK Tyre & Industries Ltd (eighteen%) and Ceat Ltd. (13%). The marketplace tonnage manufacturing registered a five year CAGR of nine.sixty nine% between FY 02-07.
Truck & Bus tyre group (accounting for fifty seven% of the tonnage creation) recorded a five yr CAGR of seven.eighty five% (a rate slower than that on the field) while Mild Business Vehicle (LCV), Motorbike and Motor vehicle tyre classes grew at fifteen%, 16% and 14% respectively (at fees faster than that of the market).From the road (OTR) tyres (tailored tyres which fetch a higher margin as compared to other tyres) class is expanding at a fast pace. The OTR tyre class registered a five year CAGR of above twenty% in the final five years.
The exports from your place clocked a CAGR of 13% in unit phrases and eighteen% in benefit terms within the period of time FY 0207. A large number of tyres which are exported are of cross ply layout.
With radialisation catching up in Some markets, the producers will require to graduate to radial tyres so as to guard their share while in the export market place. Radialisation of tyres continues to be small in India. Just the vehicle tyre industry has moved to radial tyres (ninety five%) but in all other types cross ply tyres remain most popular. Poor street conditions, overloading in trucks, increased Original expense of radial tyres and bad consciousness stages in tyre people are the main factors to the non changeover in the domestic market place to radial tyres.
On the other hand, likely forward, radialisation in truck & bus tyres might boost resulting from governing administration's focus on infrastructure improvement. Analysis expects the tyre sector to sign up a tonnage development of 910% in the next 5 years (FY 0712).
The truck & bus and What is Power Quality LCV tyre category are envisioned to sign-up a CAGR of eight% and 14% respectively (FY 0712). As per the yearly report for your calendar year 2007-2008 of a number one enterprise, the Electrical power Intake was 671.fifty seven KWH/MT in 2007-08.
Technique particulars
Energy Source
1. GEB TR I/C -1, 10MVA, 66/11kV
2. GEB TR I/C -1, 10MVA, 66/11kV
three. DG-one, four.0MW, 11kV
four. DG-two, four.0MW, 11kV
five. GT-one, 5.0MW, 11kV
Banbury Mixtures -Standard Information - Cycle time & Strength Depth: The plant have outdated DC Push process for BNB-one to four put in for the duration of ninety's and new ABB VFD technique for BNB-105 & 106 mounted during recent instances. Their ability use depends upon product blend and cycle time. BNB-one has shortest one.seven minute cycle time for remaining blend and possess optimum electricity intake. BNB-2 to 4 has longest 3.three moment cycle for master blend & consumes the very least electric power. BNB-a hundred and five (grasp combine) and BNB-106 (last mix) have two.three moment cycle time & have its possess pattern of electric power consumptions.
Intake Information - Vitality pie - Desk 02 Strength usage information
Plant Aspects kW-ave. System Banbury Utility Remarks
Banbury & Aux
BNB-one, BIAS 650 650
BNB-2, BIAS 150 one hundred fifty
BNB-3, BIAS a hundred and ten a hundred and ten
BNB-four, BIAS one hundred twenty 120
BNB-five, PCR 340 340
BNB-six, PCR 240 240
TR-3, BNB-1+two Aux 1104 1104
TR-eleven, BNB-3+4 Aux 603 603
TR-sixteen, BNB-five+6 Aux 590 413 177
Process
TR-four, BIAS 860 860
TR-five, BIAS 746 746
TR-6, BIAS 657 657
TR-7, BIAS 317 317
TR-thirteen, BIAS+30%PCR 710 710
TR-14, PCR 270 270
TR-fifteen, PCR 440 440
Utility
TR-eight, Utility 1114 1114
TR-9, Utility 673 673
TR-18, PCR+Challenge 330 198 132
TR-19, PCR+Utility 910 637 273
TR-20, PCR 250
Whole Power (Ave.) 10934 5085 3730 2369
%-Consumption 46.five% 34.1% 21.7%
Electrical power Pie Chart -Based upon 24hrs regular working, total plant load was 10934kW-typical, comprising of Banbury & it auxiliary, System and Utility part for the two BIAS and PCR tyres. This pie chart (as while in the caption photo over) is based over the jogging problem that prevailed throughout the audit.
Aim
" To discover energy quality & harmonics distortion existing in the power system and evaluate The explanations for Regular failure of electronic components, capacitors, overheating/spurious tripping of switchgear as a consequence of substantial utilization of non-linear hundreds (NLL) like DC drives, VFD, UPS and so forth.
" To suggest acceptable correction actions for the issues of PQ just after Examination.
Methodology: A detailed electric power top quality analysis companies consisting of varied power good quality measurement was planned. Analyze Investigation integrated having a variety of electrical associated measurements using innovative info logger According to the requirements of applicable nationwide & International expectations namely IEEE. Refer Annexure - one for harmonic distortion limits According to IEEE-519,1992. Measurements were taken of suitable parameters, that are mentioned in subsequent tables and diagrams/graphs.
Process: An in depth Power Good quality Audit involving measurements of various parameters at unique places with the plant was undertaken.