Comprehensive Power Quality & Harmonic Audit Study with solutions in a large tyre manufacturing plant

Abstract: Large continuous process plants are increasingly resorting to use of non linear loads (NLL) such as DC drives, variable speed AC drives, UPS, increased electronic controls etc. to improve performance and productivity of their plants. The plant engineers are increasingly facing unfamiliar problems related to power quality (PQ) mainly problem of distortion of fundamental wave shape and associated effects.  

EID Parry India Ltd, Corporate bldg

Chennai, A 1932, 6story, 250,000Sq.Ft. heritage building. 2012- 2016. Repeat jobs.

PROJECT DETAILS
Head Office of Murugappa conglomerate that accommodates 1300 employees. Local Utility mandated harmonic limits. In-addition was facing failures with air conditioning compressor motors, transformer, Lighting ballast failure, computer cards and SMPS.
RESULTS ACHIEVED
Installed 750A and 646A tuned harmonic filters and that resolved all harmonic failures and limited harmonic distortions within CEA 2007 and IEEE 519 norms of local the utility.

ACR Towers, Multi tenanted bldg

Bengaluru, 2004 - 2011, Electrical and HVAC consultancy and Design Audit. Repeat jobs.

PROJECT DETAILS
To enhance DG capacity limitation for catering to full building load. 24/7 Electro mechanical operations and maintenance, O&M services. To solve voltage fluctuation tripping with 2nos 250TR trane screw chiller. Electrical consultancy for optimum SLD.
RESULTS ACHIEVED
Installed Tuned Harmonic filter and that resolved all issues. It also resolved the chiller's frequent tripping issues. Undertook energy management study for matching energy sub metering error for appropriate billing to its tenant clients.

Ashok Leyland Limited, Plant-II

Hosur, Tamilnadu, 2002

PROJECT DETAILS
Automobiles, Bus, Truck & LCV manufacturing plant was facing Seam welding equipment malfunction of bad welding quality due to excess deposit along the line of the welding.
RESULTS ACHIEVED
Problem occurred after installation of variable frequency drives at various sections of the plant. Supplied one 1300A Tuned harmonic filter at the main transformer LT PCC supplying the welding machine section and solved the problem.

Solving power system harmonic resonance; improving power quality and eliminating electrical failures

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

Solving failures in VFD, DC drives and motors; Enhancing production by 25%, and Slashing energy bill by 9%

Abstract: In this case study, a world leader in non-ferrous metal industry engaged in the manufacturing ACSR conductors for HT and EHV electrical power transmissions and distributions, had been facing high incidence of operational problems across its plants A and B, due to bad Power Quality and high harmonic distortions with its electrical power systems. The problem arose because of two reasons. First, it was using over 60% Non-Linear-Loads in the forms of DC-drives in rolling mills, Variable-Frequency-Drives (VFD) in the conductor making process and PLC in control system.

Enhancing 3P, Power, Productivity, and Profitability; solving drive stalling and increasing sugar recovery

Abstract- A 3500TCD sugar factory installed across 3mw 415v TG four DC Mill drives each 450kw and highly fluctuating cane preparation section's slip ring induction motor loads namely 2nos 560kw Fiberizer, 225kw Leveler and 187kw Chopper. It wanted uninterrupted power export from its 6mw 11kv TG and connected across it stable linear loads of boiling and sugar houses through a set of 3.15mva and 1.5mva, 11kv/415v, Dyn11 transformers.