Bosch Project
33
ANALYSIS AND IMPROVEMENT OF POWER FACTOR AT BOSCH SHOP FLOOR BY INSTALLING CAPACITOR BANK BY External Guide Lingaraju.Ky(Sptd.Eng) P.Sreelekha Internal Guide Akash Roy A.M.Leela(Asct.Professor) Sunith Kumar.A
Transcript of Bosch Project
ANALYSIS AND IMPROVEMENT OF POWER FACTOR AT BOSCH SHOP FLOOR BY
INSTALLING CAPACITOR BANK
BY External Guide
Lingaraju.Ky(Sptd.Eng)
P.Sreelekha Internal Guide
Akash Roy A.M.Leela(Asct.Professor)
Sunith Kumar.A
SCOPE
Introduction to Problem Definition.Possible Solutions & Remedy Chosen. Present Situation & Conclusion.
Terminologies Power Triangle
Terminologies
Power Factor:
Cosine of the angle between the voltage & the current.
Types of Power Factor:• Unity• Lagging• Leading
Causes for Low Power Factor
Most A.C motors are of induction type having low lagging power factor.
Magnetizing current drawn by transformers lead to lagging current at low loads(specially during morning & evening).
Typical characteristics of Arc lamp in Cinema Induction furnace ,Short transmission lines.
Current limiting reactors used to minimize fault currents work at low power factor.
Disadvantages of Low Power Factor
Large KVA rating of equipment .Greater conductor size .Large copper losses .Poor voltage regulation .Reduced handling capacity of system.Unnecessary penalty is imposed (during
billing).
Different PF Correction Methods Available
Reduce the amount of reactive energy.Compensate artificially for the consumption
of reactive energy. ROTARY EQUIPMENT STATIC CAPACITORS
Remedy Chosen
STATIC CAPACITORS
Specification of the Capacitors
Specification of the Capacitors
Capacitors
Advantages Of Capacitors Over Other Method(s)
Capacitor banks ensures very low initial cost.
The running costs are minimal and they can be used with the same high efficiency on all sizes of installation.
Compact, reliable, highly efficient & convenient to install .
Present Situation At BOSCH
Present Situation At BOSCH
Procedure Followed• Calculations
Procedure Followed
Procedure Followed
Procurement List
Procurement List
Brief Installation List
,
Brief Installation List
,
Savings in Power
• Resistance of the cable 0.15ohm / km load ; Length= 175mt.• Resistance of the cable = 0.15 *0.175km = 0.026 ohm.
• P= √3 *VL*IL* Cos Φ1
• Current drawn by the load at 0.763 P.F , IL1= P/ (√3 *VL*Cos Φ1 )
=171.83/( √3 *430.52*0.763)
=302.009A.
• PF after correction Cos Φ2 = 0.96
• Current drawn by the load at 0.96 P.F , IL2 = P/ ( √3 *VL*Cos Φ2 )
= 171.83/( √3*430.52*0.96)
= 240.03A.
Savings in Power
• Power loss P1= 3*I12R = 7.114KW
• Power loss P2= 3*I22R = 4.493KW
• Saving in power = 7.114KW – 4.493KW = 2.621KW.• Time= 18Hours * 25 Days = 450.• KWh loss in P1 = 3201.3KWh.• KWh loss in P2 = 2021.85KWh.• Reduction in KWh (units) = 1179.45• Cost saving = 1179.45 *12 months * Rs. 6/-unit =
RS.84920.4
Installation Work
Single Line Diagram
Installation Work
Monday
Tuesday
Wedesd
ay
Thursday
Friday
Satu
rday
Sunday
0
0.2
0.4
0.6
0.8
1
1.2
0.57 0.54 0.54 0.6 0.550.67
0.575
0.94 0.93 0.93 0.96 0.90.98 0.93
Feeder 307
BeforeAfter
Installation Work
Monday
Tuesday
Wednesd
ay
Thursday
Friday
Satu
rday
Sunday
00.10.20.30.40.50.60.70.80.9
1
0.6820.7070000000000
010.673000000000002
0.7070000000000010.698 0.6670000000000
020.6680000000000
02
0.90.9500000000000
010.90.9500000000000
010.92 0.92 0.92
Feeder 504
BeforeAfter
,
106 307 312 402 501 415 504 505 5110
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0.650.57
0.8090.73
0.82 0.86
0.70.78 0.736
0.320.37
0.120.22
0.1 0.050.23 0.1 0.174
Previous Improvement
ALGORITHM • Identify the feeder to be worked based on the
difference of power factor• p= Power in KW• a= Power factor(current) • b= Target power factor • Find out the Reactive power Compensation required
for achieving target power factor• Compare the current and targeted P.F• Improvement done is displayed
Simulation using MATLAB
FLOW CHART
FLOW CHART
CONCLUSION
• Improved the power factor from the range of 0.65-0.85 to an existing range of 0.95-0.99 effectively.
• Significant decline in the rating of current flow & reduced I2R losses also leading to reduced stress on the cable there by increased durability of the cable.
• Finally reduced on the KVA demand there by reducing the penalty imposed ,also the total KWh consumption as a whole has been reduced. Thus
creating savings of 27.5lakhs p.a
THANK YOU
