Electric power Quality Assessment
Ability High-quality Investigation in the tyre conglomerate uncovered the foundation reason behind repetitive electronic card failures in SCADA, HMI, Hard Disk and AC/DC Drives and Recurrent undesirable tripping in its course of action on account of voltage fluctuation. The supervisory control and facts acquisition program, which happens to be a mix of software program and PLC/Computer components, malfunctions in sending correct batch facts from HMI to approach computer lacking out a few procedure facts, daily. The LED fitting driver fails due to triplen harmonics which in-addition lead to a neutral present-day while in the lights transformer feeder.
The Curing area is most delicate inside the tyre producing system which accustomed to vacation often on voltage fluctuation. Through monsoon, there was persistent tripping with Long-term grid voltage surges. The plant management prepared to update the 33kV grid incomer to 132kV for resolving the tripping problem. It absolutely was pretty pricey, and that might not have solved the tripping trouble in any case.
The introduction of steel radial tyres brought in substantial non-linear loads (NLL) from the kinds of variable speed push (VSD), DC drives and sizeable SCADA and HMI controls from the tire production approach. Leading tyre companies complying with basic safety laws upgraded their course of action For prime quality and lengthy lifestyle radials, which even more increased PLC and HMI control. It resulted in an increased overall present-day harmonic distortion (THDi) which at the base stage, without the need of switching on capacitors, was in between twenty to 40% at the most crucial incomer of assorted process transformers having a corresponding whole voltage harmonic distortion (THDv) of amongst five to ten%.
Factory engineers need to maintain Electrical power Element (PF) for steering clear of superior need (kVAh) charges and reduced PF penalty from your utility organization. But they confronted a completely new trouble in introducing capacitors possibly at load conclusion throughout different substantial capability motors or at PCC masses or centralized APFC panel across transformer LT busbar. It magnified harmonics in an unpredictable and non-linear fashion. The magnification can be as superior as various periods the base harmonic level or just a couple percentage level higher, which relies upon on the fault standard of the facility technique. In a very significant fault stage electricity program, THDi magnifies disproportionately higher than THDv. The reverse happens that has a low fault stage ability program.
Then arrived the Detuned Harmonic Filter which has a six% reactor in series While using the capacitor. Nevertheless it solved the harmonic magnification dilemma and improved the PF, it couldn't address the repetitive devices failure and nuisance tripping difficulty, and also the detuned filter alone unsuccessful usually needing steady ingredient substitution. Aside from, it can not cut down harmonics. When the actual solution comes, the detuned filter needs to get replaced, paving the Area with the super tuned harmonic filter that solves all the failure and tripping difficulties Aside from slashing down harmonics, both THDi and THDv, in IEEE 519 limitations.
How did the high harmonics herald Energy Excellent Difficulty and unwelcome tools tripping during the tire market? Well, that situation explained in information in An additional webpage "Electricity High-quality Answer Shipped". What did it consider to solve both of those the trouble, devices failure and nuisance tripping? The approach to the solution, its methodology and efficacy explained exhaustively on An additional webpage "Passive Harmonic Filter established valuable When Products Fails".
Ability Top quality Examination Report
The following Electricity High-quality Examination Report was published inside the APQI EU-Asia ability quality initiative journal in 2009. Though a summary report, it contained all important developing blocks of a comprehensive electrical power excellent Assessment services. A synopsis knowledge desk highlights the facility and harmonic amount in any respect feeders in the factory, key equipment groupings, power top quality measurement graphs and proposals for trouble-solving. The specific report contained Ability Quality Signature Analysis for root trigger analysis for troubleshooting some elusive failures. This research product recurring through the succeeding a long time across all plant areas with a PAN India foundation, analyze recommendations executed, projected benefits accomplished and continuously, Positive aspects derived.
Abstract: Massive continual procedure crops are more and more resorting to employ of non linear masses (NLL) such as DC drives, variable pace AC drives, UPS, elevated Digital controls and so on. to further improve functionality and productivity of their crops. The plant engineers are progressively dealing with unfamiliar challenges associated with ability good quality (PQ) mostly trouble of distortion of basic wave condition and linked effects.
Harmonics are as outdated a phenomenon because the introduction of AC Procedure. Mercury arc rectifiers (MAR) produced in 1920's and semiconductor controlled rectifiers (SCR) or thyristors designed in 1950's created harmonics, due to their character of non-linear loads. Even so, utilization of non-linear load was significantly less then (generally fewer than 5% in 1960), to obtain any considerable impression. But it is currently growing swiftly Consequently earning Energy Top quality a terrific concern amongst plant engineers and affiliated equipment companies.
Magnified harmonics induce extreme worry within the plant & machineries. Electronics are the 1st to fail staying weakest among all, followed by fuse, capacitors, thyristor, CT, Motor etcetera.
This energy excellent analysis report represents summary of findings and suggestions of thorough Assessment & information emerging out from Electrical power Good quality audit of the tyre manufacturing manufacturing facility.
The analyze uncovered that almost all of the feeders had very substantial volume of THD. Next are only illustration for two feeders from the study-Transformers TR-fourteen & TR-15 with major NLL and Capacitors ON/OFF.
Capacitors ON/OFF: Table 01 Illustration for prime harmonics stage at 2 feeders
Load with Major NLL Devoid of Capacitor With Capacitor REMARKS
THD-v THD-i THD-v THD-i
TR -14, two.5MVA, eleven/0.400kV 6.8% forty two% 9.one% 106% 450kVAr at Panel -OFF/ ON
TR -15, two.5MVA, 11/0.400kV eight.3% seventy seven% nine.2% 126% 400kVAr at Panel -OFF/ ON
As THD-I and THD-v are much increased than IEEE norms, the analyze suggested setting up tuned harmonic filters at 400V secondary aspect for TR -14 and 15 (in Stage -I) to limit harmonic distortion of both of those THD-v & THD-i inside regulatory norms, preserve Vitality substantially (usually five%) and do away with failure/nuisance tripping. It need to help in enhancing product high quality and All round profitability. Equally, 2 sets of filters for 'Banbury' mixers and one particular filter for 450 kW squirrel cage induction motor feeder had been advised to solve issues of large harmonics, irregular conduct in the course of setting up of motors via comfortable starter such as commencing recent as significant as nine occasions total load latest, voltage dip of 23% and so forth. The whole expense of advice for phase I was INR fifty nine,50,000 with a beautiful easy pay out back again duration of 10 months.
In Period -II, it had been advised to set up tuned harmonic filters in seven more transformers exactly where it was observed that the extent of harmonics were higher.
Industry Background:
Processing & Manufacturing: The tyre producing approach commences by mixing diverse forms of rubber with system oils, carbon black, pigments, antioxidants, accelerators and other additives, Just about every of which contributes sure Attributes to the compound. These elements are combined in giant blenders (known as banbury mixers) below great heat and stress. The components are blended collectively right into a warm, black gummy compound that can be milled. The cooled rubber will take numerous kinds. Most often it truly is processed into meticulously determined slabs that may be transported to breakdown mills. These mills feed the rubber amongst massive pairs of rollers, repeatedly feeding, mixing and blending to organize the various compounds for that feed mills, exactly where They're slit into strips and carried by conveyor belts to be sidewalls, treads or other areas of the tyre.
Indian Tyre Field (Resource: Report on Indian Tyre Field): The Indian Tyre Marketplace created 736 lakh units of tyres (eleven lakh tonnes) garnering Rs. 19,000 crores in FY 07. MRF Ltd. was the industry chief (22% current market share) adopted carefully by Apollo Tyres Ltd. (21%). The opposite key players had been JK Tyre & Industries Ltd (18%) and Ceat Ltd. (13%). The industry tonnage production registered a five calendar year CAGR of nine.69% among FY 02-07.
Truck & Bus tyre class (accounting for fifty seven% of your tonnage output) recorded a five 12 months CAGR of seven.eighty five% (a level slower than that with the sector) although Mild Industrial Car (LCV), Motorcycle and Automobile tyre classes grew at 15%, sixteen% and fourteen% respectively (at costs more quickly than that in the sector).Off the road (OTR) tyres (custom made tyres which fetch an increased margin when compared to other tyres) group is developing at a fast pace. The OTR tyre category registered a five 12 months CAGR of about twenty% in the last 5 years.
The exports with the region clocked a CAGR of 13% in unit conditions and eighteen% in worth terms during the interval FY 0207. The majority of these tyres which can be exported are of cross ply style.
With radialisation catching up in some of these marketplaces, the brands will require to graduate to radial tyres so as to protect their share from the export marketplace. Radialisation of tyres is still negligible in India. Just the motor vehicle tyre sector has moved to radial tyres (ninety five%) but in all other types cross ply tyres remain chosen. Weak street conditions, overloading in trucks, bigger First price of radial tyres and poor recognition degrees in tyre users are the main good reasons for the non changeover with the domestic current market to radial tyres.
On the other hand, heading forward, radialisation in truck & bus tyres could boost as a consequence of authorities's concentrate on infrastructure development. Investigation expects the tyre industry to sign up a tonnage advancement of 910% in another 5 years (FY 0712).
The truck & bus and LCV tyre category are anticipated to register a CAGR of 8% and fourteen% respectively (FY 0712). As per the once-a-year report to the year 2007-2008 of a number one organization, the Electrical power Use was 671.57 KWH/MT in 2007-08.
Process information
Electrical power Source
one. GEB TR I/C -1, 10MVA, 66/11kV
two. GEB TR I/C -1, 10MVA, sixty six/11kV
3. DG-one, 4.0MW, 11kV
4. DG-two, 4.0MW, 11kV
five. GT-1, five.0MW, 11kV
Banbury Mixtures -Common Aspects - Cycle time & Electricity Intensity: The plant have old DC Push method for BNB-one to 4 mounted in the course of ninety's and new ABB VFD technique for BNB-105 & 106 put in throughout the latest moments. Their power use is dependent on solution blend and cycle time. BNB-1 has shortest 1.seven minute cycle time for closing mix and possess greatest ability usage. BNB-2 to 4 has longest three.3 moment cycle for grasp mix & consumes minimum power. BNB-a hundred and five (master combine) and BNB-106 (final combine) have two.3 moment cycle time & have its have sample of power consumptions.
Intake Details - Strength pie - Table 02 Strength consumption facts
Plant Particulars kW-ave. Process Banbury Utility Remarks
Banbury & Aux
BNB-one, BIAS 650 650
BNB-two, BIAS one hundred fifty a hundred and fifty
BNB-3, BIAS one hundred ten 110
BNB-four, BIAS a hundred and twenty 120
BNB-five, PCR 340 340
BNB-6, PCR 240 240
TR-3, BNB-one+2 Aux 1104 1104
TR-eleven, BNB-three+4 Aux 603 603
TR-sixteen, BNB-5+6 Aux 590 413 177
Course of action
TR-four, BIAS 860 860
TR-5, BIAS 746 746
TR-six, BIAS 657 657
TR-7, BIAS 317 317
TR-13, BIAS+thirty%PCR 710 710
TR-14, PCR 270 270
TR-15, 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
Overall Energy (Ave.) 10934 5085 3730 2369
%-Intake forty six.5% 34.one% 21.seven%
Power Pie Chart -Based Study of Power Quality upon 24hrs regular running, complete plant load was 10934kW-normal, comprising of Banbury & it auxiliary, Process and Utility segment for both equally BIAS and PCR tyres. This pie chart (as within the caption photo above) relies to the running issue that prevailed in the audit.
Objective
" To discover ability high quality & harmonics distortion current in the facility system and assess The explanations for Recurrent failure of electronic parts, capacitors, overheating/spurious tripping of switchgear as a consequence of big utilization of non-linear hundreds (NLL) like DC drives, VFD, UPS etc.
" To suggest suited correction steps for the issues of PQ just after analysis.
Methodology: A detailed electric power top quality Investigation services consisting of various electrical power excellent measurement was prepared. Study Evaluation provided having various electrical associated measurements making use of complex details logger as per the requirements of appropriate countrywide & International specifications particularly IEEE. Refer Annexure - one for harmonic distortion restrictions as per IEEE-519,1992. Measurements were taken of related parameters, that happen to be listed in subsequent tables and diagrams/graphs.
Method: A detailed Electricity Excellent Audit involving measurements of varied parameters at diverse spots of your plant was undertaken.