Electric power Quality Investigation
Power Good quality Analysis in the tyre conglomerate revealed the basis explanation for repetitive electronic card failures in SCADA, HMI, Difficult Disk and AC/DC Drives and Repeated unwelcome tripping in its method as a consequence of voltage fluctuation. The supervisory Handle and data acquisition program, that is a mix of program and PLC/Personal computer components, malfunctions in sending appropriate batch details from HMI to procedure Computer system lacking out several course of action information, every single day. The LED fitting driver fails due to triplen harmonics which in-addition lead to a neutral existing from the lights transformer feeder.
The Curing part is most delicate within the tyre production procedure which utilized to trip routinely on voltage fluctuation. Throughout monsoon, there was once persistent tripping with Serious grid voltage surges. The plant management planned to update the 33kV grid incomer to 132kV for resolving the tripping issue. It had been incredibly highly-priced, and that might not have solved the tripping dilemma in any case.
The introduction of steel radial tyres brought in sizeable non-linear loads (NLL) while in the varieties of variable speed generate (VSD), DC drives and sizeable SCADA and HMI controls during the tire manufacturing procedure. Premier tyre corporations complying with protection laws upgraded their method For top of the range and very long lifestyle radials, which further greater PLC and HMI control. It resulted in a heightened overall present-day harmonic distortion (THDi) which at the base degree, devoid of switching on capacitors, was between 20 to forty% at the principle incomer of varied procedure transformers with a corresponding whole voltage harmonic distortion (THDv) of involving five to 10%.
Manufacturing facility engineers have to have to maintain Energy Component (PF) for staying away from large need (kVAh) fees and low PF penalty through the utility organization. Nevertheless they faced a brand new issue in including capacitors both at load conclude throughout many higher ability motors or at PCC hundreds or centralized APFC panel throughout transformer LT busbar. It magnified harmonics within an unpredictable and non-linear manner. The magnification could possibly be as large as many moments The bottom harmonic stage or just some share issue higher, which depends upon the fault degree of the power technique. In the substantial fault stage ability procedure, THDi magnifies disproportionately higher than THDv. The reverse occurs having a reduced fault degree electrical power technique.
Then arrived the Detuned Harmonic Filter by using a six% reactor in collection Along with the capacitor. While it solved the harmonic magnification challenge and enhanced the PF, it couldn't address the repetitive equipment failure and nuisance tripping problem, and also the detuned filter itself failed frequently needing continuous component substitution. Other than, it cannot cut down harmonics. When the actual Option comes, the detuned filter ought to get replaced, paving the Place for that Tremendous tuned harmonic filter that solves every one of the failure and tripping troubles Apart from slashing down harmonics, the two THDi and THDv, inside of IEEE 519 limitations.
How did the higher harmonics bring in Energy High quality Issue and undesired products tripping inside the tire business? Well, that issue stated in facts in A different webpage "Electricity Good quality Remedy Delivered". What did it consider to take care of both equally The difficulty, tools failure and nuisance tripping? The approach to the solution, its methodology and efficacy explained exhaustively on A different webpage "Passive Harmonic Filter established useful When Gear Fails".
Power High-quality Investigation Report
The next Electrical power High quality Assessment Report was posted during the APQI EU-Asia electric power good quality initiative journal in 2009. Despite the fact that a summary report, it contained all significant developing blocks of an extensive electricity top quality analysis assistance. A synopsis knowledge table highlights the facility and harmonic stage in any respect feeders in the manufacturing unit, main gear groupings, energy quality measurement graphs and proposals for difficulty-solving. The specific report contained Electrical power Quality Signature Investigation for root lead to analysis for troubleshooting some elusive failures. This analyze design repeated in the succeeding a long time across all plant destinations on the PAN India basis, review suggestions implemented, projected success attained and regularly, Gains derived.
Summary: Big continual approach plants are significantly resorting to work with of non linear loads (NLL) for instance DC drives, variable speed AC drives, UPS, greater electronic controls and many others. to enhance general performance and productiveness in their vegetation. The plant engineers are significantly going through unfamiliar issues linked to electrical power good quality (PQ) mostly trouble of distortion of basic wave condition and related consequences.
Harmonics are as previous a phenomenon given that the introduction of AC Program. Mercury arc rectifiers (MAR) made in 1920's and semiconductor controlled rectifiers (SCR) or thyristors made in 1950's developed harmonics, because of their character of non-linear hundreds. Nonetheless, usage of non-linear load was significantly less then (ordinarily lower than 5% in 1960), to acquire any significant effect. But it is currently growing promptly Therefore building Electrical power Good quality a great problem between plant engineers and related devices manufacturers.
Magnified harmonics result in critical tension to the plant & machineries. Electronics are the first to fall short remaining weakest among all, followed by fuse, capacitors, thyristor, CT, Motor and many others.
This power top quality Examination report signifies summary of findings and recommendations of complete Examination & details emerging out from Energy Top quality audit of the tyre manufacturing factory.
The review discovered that the majority of the feeders experienced pretty superior level of THD. Subsequent are merely case in point for 2 feeders through the analyze-Transformers TR-14 & TR-fifteen with important NLL and Capacitors ON/OFF.
Capacitors ON/OFF: Table 01 Instance for top harmonics level at 2 feeders
Load with Big NLL Without Capacitor With Capacitor REMARKS
THD-v THD-i THD-v THD-i
TR -14, two.5MVA, eleven/0.400kV 6.8% forty two% nine.1% 106% 450kVAr at Panel -OFF/ ON
TR -15, two.5MVA, eleven/0.400kV 8.3% 77% nine.two% 126% 400kVAr at Panel -OFF/ ON
As THD-I and THD-v are much increased than IEEE norms, the analyze suggested putting in tuned harmonic filters at 400V secondary facet for TR -14 and 15 (in Period -I) to Restrict harmonic distortion of both equally THD-v & THD-i in just regulatory norms, conserve Strength significantly (ordinarily five%) and eliminate failure/nuisance tripping. It must assist in improving item good quality and In general profitability. Similarly, two sets of filters for 'Banbury' mixers and one filter for 450 kW squirrel cage induction motor feeder had been advisable to take care of issues of significant harmonics, irregular conduct all through starting of motors via comfortable starter for instance setting up latest as superior as 9 occasions total load recent, voltage dip of 23% and the like. The full cost of advice for section I was INR fifty nine,50,000 with a gorgeous uncomplicated pay back again period of 10 months.
In Stage -II, it had been encouraged to setup tuned harmonic filters in seven more transformers wherever it had been observed that the level of harmonics had been superior.
Field Background:
Processing & Production: The tyre creating method begins by mixing diverse types of rubber with procedure oils, carbon black, pigments, antioxidants, accelerators and various additives, each of which contributes certain properties towards the compound. These components are combined in large blenders (named banbury mixers) underneath huge warmth and force. The substances are blended alongside one another into a warm, black gummy compound that should be milled. The cooled rubber usually takes quite a few sorts. Most often it really is processed into diligently recognized slabs that should be transported to breakdown mills. These mills feed the rubber among enormous pairs of rollers, frequently feeding, mixing and Mixing to prepare the different compounds for the feed mills, exactly where They're slit into strips and carried by conveyor belts to become sidewalls, treads or other areas of the tyre.
Indian Tyre Field (Resource: Report on Indian Tyre Business): The Indian Tyre Business created 736 lakh units of tyres (11 lakh tonnes) garnering Rs. 19,000 crores in FY 07. MRF Ltd. was the market chief (22% sector share) adopted intently by Apollo Tyres Ltd. (21%). The opposite key gamers have been JK Tyre & Industries Ltd (18%) and Ceat Ltd. (thirteen%). The sector tonnage creation registered a five 12 months CAGR of nine.sixty nine% between FY 02-07.
Truck & Bus tyre category (accounting for fifty seven% of your tonnage generation) recorded a five 12 months CAGR of 7.85% (a rate slower than that of the field) whilst Light Industrial Car (LCV), Motorcycle and Car tyre types grew at 15%, 16% and 14% respectively (at fees faster than that in the business).Off the highway (OTR) tyres (customized tyres which fetch a greater margin in comparison to other tyres) class is increasing at a quick speed. The OTR tyre group registered a five 12 months CAGR of above 20% in the last five years.
The exports in the state clocked a CAGR of thirteen% in unit terms and eighteen% in benefit conditions during the period FY 0207. Many of these tyres that are exported are of cross ply style.
With radialisation catching up in A few of these markets, the manufacturers will require to graduate to radial tyres In order to safeguard their share while in the export current market. Radialisation of tyres continues to be minimum in India. Just the motor vehicle tyre market has moved to radial tyres (95%) but in all other groups cross ply tyres are still favored. Weak highway disorders, overloading in vehicles, increased Preliminary cost of radial tyres and lousy recognition degrees in tyre consumers are the principle factors for that non changeover on the domestic marketplace to radial tyres.
Having said that, likely ahead, radialisation in truck & bus tyres may well raise due to governing administration's target infrastructure growth. Exploration expects the tyre market to register a tonnage growth of 910% in another 5 years (FY 0712).
The truck & bus and LCV tyre classification are expected to sign up a CAGR of eight% and fourteen% respectively (FY 0712). As per the yearly report to the 12 months 2007-2008 of a leading corporation, the Vitality Consumption was 671.fifty seven KWH/MT in 2007-08.
Method aspects
Electricity Source
one. GEB TR I/C -1, 10MVA, sixty six/11kV
2. GEB TR I/C -one, 10MVA, 66/11kV
3. DG-one, 4.0MW, 11kV
four. DG-2, four.0MW, 11kV
5. GT-one, 5.0MW, 11kV
Banbury Mixtures -Normal Specifics - Cycle time & Electrical power Depth: The plant have old DC Push method for BNB-one to 4 mounted in the course of ninety's and new ABB VFD program for BNB-105 & 106 put in throughout recent periods. Their energy use is dependent on solution mix and cycle time. BNB-one has shortest 1.seven minute cycle time for ultimate mix and also have highest electric power use. BNB-two to four has longest 3.three minute cycle for learn mix & consumes the very least energy. BNB-a hundred and five (master combine) and BNB-106 (final combine) have two.3 moment cycle time & have its very own sample of electricity consumptions. Power Quality Study
Use Specifics - Electrical power pie - Table 02 Electrical power usage aspects
Plant Particulars kW-ave. Course of action Banbury Utility Remarks
Banbury & Aux
BNB-1, BIAS 650 650
BNB-two, BIAS 150 one hundred fifty
BNB-three, BIAS one hundred ten a hundred and ten
BNB-4, BIAS one hundred twenty a hundred and twenty
BNB-5, PCR 340 340
BNB-six, PCR 240 240
TR-3, BNB-one+two Aux 1104 1104
TR-11, BNB-three+four Aux 603 603
TR-16, BNB-five+6 Aux 590 413 177
Method
TR-four, BIAS 860 860
TR-5, BIAS 746 746
TR-six, BIAS 657 657
TR-seven, BIAS 317 317
TR-13, BIAS+thirty%PCR 710 710
TR-fourteen, PCR 270 270
TR-15, PCR 440 440
Utility
TR-eight, Utility 1114 1114
TR-9, Utility 673 673
TR-18, PCR+Job 330 198 132
TR-19, PCR+Utility 910 637 273
TR-20, PCR 250
Whole Electrical power (Ave.) 10934 5085 3730 2369
%-Usage forty six.5% 34.1% 21.seven%
Energy Pie Chart -Depending on 24hrs ordinary operating, overall plant load was 10934kW-average, comprising of Banbury & it auxiliary, Method and Utility part for both BIAS and PCR tyres. This pie chart (as while in the caption photograph over) relies to the running problem that prevailed over the audit.
Objective
" To recognize electric power quality & harmonics distortion current in the facility system and assess the reasons for Recurrent failure of electronic elements, capacitors, overheating/spurious tripping of switchgear on account of significant usage of non-linear masses (NLL) like DC drives, VFD, UPS and many others.
" To recommend appropriate correction actions for the problems of PQ after Evaluation.
Methodology: An in depth electric power high-quality Evaluation companies consisting of assorted ability high quality measurement was planned. Review Assessment integrated using a variety of electrical linked measurements using advanced info logger According to the necessities of applicable national & International specifications particularly IEEE. Refer Annexure - one for harmonic distortion restrictions According to IEEE-519,1992. Measurements were taken of related parameters, which can be stated in next tables and diagrams/graphs.
Process: A detailed Energy Top quality Audit involving measurements of varied parameters at diverse destinations of your plant was undertaken.