Ace enablers energy saving machine uptime-harmonic mitigation
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Transcript of Ace enablers energy saving machine uptime-harmonic mitigation
Energy Saving & Machine Uptime Through Harmonic Mitigation
CASE STUDY
ACE ENABLERS LLP
CHENNAI
Case - Overview
• The case is about PF and Harmonic mitigation solution done at a FMCG manufacturing company. Plant is situated in the State of Andhra Pradesh
• APGENCO, power utility, charges energy on KVAH billing at ₹.6.32 per unit
• There is no incentive for PF >0.95
• Plant consumed nearly 15000 units/month kVAh more than kWh value
• Client also had frequent failures of PCBs & other tripping
• Transformer and Busbar humming was evident
• Power-Harmonic audit, analysis and recommendation was carried out and Active Harmonic Filters (AHF) installation and commissioning was done
• This case study captures the effect of pre and post AHF installation while PF and DPF are close to unity
• A confirmatory audit done with direct measurement of distortion power, also establishes the new 3 dimensional power triangle discussed under IEEE: 1459/2010
Power & Harmonic Data at Transformer & DG Incomer
Transformer & Reactive Power Compensation in the Plant
IEEE 519/1992 Limits at the PCC
Current Distortion for <69 KV general system
Voltage Distortion for <69 KV general System
Full Day Recording of Harmonics & Energy Data Before AHF Solution
Average Current
Harmonic close to 20%
Full Day Recording of Harmonics & Energy Data Before AHF Solution
kVAh minus kWh = 610 Units/ day……. ……….15250 units/
month
The Solution Architecture
Plant Layout with AHF Solution
Power Triangle
• .
In the diagram, P is the active power, Q is the reactive power (in this case positive), S is the complex power and the length of S is the apparent power. Reactive power does
not do any work, so it is represented as the imaginary axis of the vector diagram.
Active power does do work, so it is the real axis
Power Triangle – Analogy To Beer
For easier understanding, the difference is shown with beer.
Reactive power is like the foam on top of a glass of beer, where the
liquid in the glass represents active power. The foam takes space in the
glass and, therefore, reduces the beer containing capacity. By
comparison, the reactive power reduces the electricity transport capacity of a power transmission
line
The New Power Triangle is 3 Dimensional
Nowadays the typical power triangle doesn’t fit any more because other parameters like the distortion or harmonic reactive power
have to be considered due to more and more non-linear loads (inverter, electronic
ballast unit, etc...)
IEEE Standard 1459-2010
• Definitions for the Measurement of Electric Power Quantities Under Sinusoidal, Non-sinusoidal, Balanced, or Unbalanced Conditions
Full Day Recording of Harmonics & Energy Data after AHF Solution
Average Current
Harmonic reduced to
<4%
Full Day Recording of Harmonics & Energy Data after AHF Solution
kVAh minus kWh = 150 Units/day……. ………3750 units/ month
Case Study – Summary
• This plant had installed detuned-APFC of 2 nos 1500 KVAR with 7% detuned reactors, as the first line of defense
• Harmonic analysis report showed 6.4% THD-U and 19.4% THD-I at the PCC level, exceeding the IEEE: 519/1992 limits.
• kVAh showed >600 units/day, against kWh due to distortion power
• Unit also reported frequent failure of PCBs and PLCs
• AHF for a total of 1440 A were installed at different DB and main panels. THD-I reduced to <5% and THD-U reduced to < 2% at the PCC level
• PCB failures and other interruptions reduced to less than 20% from previous level, as THD-I reduced to less than 8% at machines level
• KVAH reduced to around 485 units/ day or 145440 units /annum
• Direct saving in energy cost is ₹ 9.20 Lakhs per annum @ ₹6.32 tariff
• Indirect savings through reduction in PCB failures, machine tripping and reduction in I²R losses in the distribution system have also been observed
Confirmatory Recording Done on 29.09.2016 for 30 Minutes with all AHF Switched Off
kVAh minus kWh = 655.2 – 642.1 = 13.1 units. 13.1 *2*24*25*12
=188640 units/annum
Confirmatory Recoding Done on 29.09.2016 for 30 Minutes with all AHF Switched ON
kVAh minus kWh = 626.7 – 623.7 = 3.0 units.
3.0 *2*24*25 *12 =43200 units/annum. 77% reduction in energy
loss
Case Study- Summary - Conclusion
• Confirmatory survey at the plant was done on 29.09.2016.
• The Power-Harmonic Analyser was configured to record directly the Distortion reactive power D, apart from apparent (kVA), Active (kW) & Reactive (kVARh)
• Industries under kVAh billing must adopt techniques to improve PF and also mitigate Harmonics
Non-linear loads cause harmonics
and increase distortion power. Hence the kVAh
increases to cause revenue loss
#30/12, 4th Street, Dr. Subbarayan Nagar, Kodambakkam, Chennai-600 024
|[email protected]|+91-9962056416|
ACE ENABLERS LLP