Harmonic failure

IOCL Barauni Refienry thro' NTPC/Siemens


Crude Oil refinery plant.
Troubleshooting power quality and harmonics analysis for power plant's voltage fluctuations and electrical installation issues.

Central Power Research Institute Bangalore

2001 -2005


A R&D Research Institution - Third party testing and verification. Supplied 2sets Power quality analyzers
On behalf conducted troubleshooting, Power Quality and Harmonic Analysis studies for Ispat Industries Limited Dolvi and Tata Iron and Steel Company Limited TISCO at Jamshedpur.

Ispat Industries Ltd, Dolvi Maharashtra

2001 -2006, Repeat jobs.              



Electric Arc Furnace 2x 180 Ton, 150mva, 33kv/ 1120v transformer, 2x 2000A SF6 CB with Siemens, Germany make 2x 190mvar SVC with TCR, 50mvar 2HF, 30mvar 3HF, 30mvar 4HF, and 70mvar 5HF. Main I/C 4x155mva, 220/33kV, Ynynd1-tertiary for resistive earthing.
Root cause analysis for chronic SVC reactors and capacitor failures. Upstream 5000TPM Blast Furnace and SIP and Downstream Hot rolled mill and DRI sponge iron plant. 3rd party testing.

Shri Mahavir Ferro Alloys Ltd, Rourkela


DRI Sponge Iron Plant, 3nos each 4.5mw, 12Ton Induction Furnace, 5.5kva, 11kv/2x1kv, Dd0y11, transformer and Con Cast
Power Plant 12.5mw, 11kv Grid Synchronized with a 12.5MVA, 33/11kv grid transformer.

Mohan Steels, Kanpur

1997, UP

Induction furnace and TMT bar rolling mill
Harmonic study carried out and report submitted.

Eliminate Electrical Failure

Electrical Failure

Abstract: An Electrical Arc Furnace near a hyperactive railway traction line was facing electrical failure from an unusual power quality harmonic distortion problem. The Gigantic 22kA copper bus bar used to overheat visibly red-hot, vibrate audibly loud loosening nuts and bolts and wear out affected plates.

Solve VFD Drive Failure

VFD Drive Failure

Abstract:- An ACSR conductor manufacturing plant was facing high incidence of DC motor and AC VFD Drive Failure due to bad power quality and high harmonic distortion. The company is a world leader in non-ferrous metal industry. It manufactures ACSR conductors for HV and EHV power transmission and distribution lines. It had been facing a high incidence of operational problem across its plants A and B. It affected all electrical and electronic equipment with its conductor making process.

Increase Productivity through Harmonic Solution

Increase Productivity

Abstract- Harmonic solution is an engineer's approach to total productive maintenance (TPM) to Increase Productivity. No stoppage. No breakdown. No quality rejection. A 3500 TCD sugar milling unit was operating at 3000 TCD due to frequent drive stalling problem with dc mill motor. To increase productivity and sugar recovery, it installed a 2000A passive tuned harmonic filter in 2010, at a 3MW 415V Turbine Generator (TG).

Mitigate VFD Harmonic

VFD Harmonic

Abstract - VFD Harmonic forced a power plant to shutdown due to power quality failure. Starting with drive tripping it blasted switch gear, bus bar & electrical panel. This IPP with a 25mw, 11kV, 50Hz power plant and 5000TCD sugar milling unit had completed its first anniversary without harmonic problem. But during 2nd year's operation, it started-off with a massive blast of a 6300A Air Circuit Breaker (ACB). It was at the incomer of an electrical panel. The 415V PCC panel was supplying to sugar plant's process load.