Case study on Power Quality Solution at a textile industry with High Voltage Harmonics

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Introduction:

In textile mill, electricity consumption is in increasing trend, due to modernized machines and continuous usage of the equipment. After a lot of technological development globally, mills are now using power electronic driven equipment to run motors in processes like fibre production, dyeing, printing. These devises are efficient in operation as compared to old control mechanisms, but the only drawback is harmonics generated by these devices which effect the entire industry equipment if proper mitigation is not done.


For further knowledge on Voltage Harmonics & Current Harmonics, please refer Issue: 37

Background

Rameshwar Udyog is a textile industry located in Ahmedabad which manufactures a variety of fabrics and is one of the leading exporters in our country. This case study presents the impact of High Voltage Harmonics of Textile industry where major part of load is drives (6 pulse AC & DC drives).

Problem

Once the APFC panel is switched ON, harmonic levels recorded at main incomer level at LT side are rising as high as I-THD: 84.8% and V-THD: 13.5% resulting in failure of Drive’s PCB cards & Tripping of SCPDs.


Detuned reactors were not installed in APFC panel to avoid overheating & burning due to high V-THD%. Moreover, customer was facing penalties by Electricity Board for maintaining poor power factor.

Power quality study

A detailed power quality study has been conducted in the industry which revealed the following data:

Capacitor feeders were carrying almost 50% more than the rated current, due to low impedance & resonance, in the high VTHD system. High Voltage and Current harmonic levels are also reason for very low True PF. But these high harmonic levels can be brought down if harmonic amplification by capacitors is controlled effectively.

Level 1 solution – High V-THD reactors

Based on the readings obtained from the Power Quality study, customer installed capacitor duty contactor switched 350 kVAr APFC Panel with LK’s High V-THD reactors and 525 V LTXL Ultra Heavy Duty capacitors


The performance of high V-THD reactors can be understood by below mentioned observations:

After installing High V-THD reactors, they achieved a good PF with low heat generation and avoided PF penalty. Current and voltage harmonic levels came down effectively by restricting the harmonic amplification. The reactors are also working satisfactorily at normal temperature.

Level 2 solution - Active harmonic filter

To mitigate the existing harmonics below IEEE 519 limits and to fine tune PF close to unity, Active Harmonic Filter was to be installed. Accordingly, 300 amperes Active Harmonic Filter was installed. The performance with the combination of AHF and high-VTHD reactors are given below:

After installing Active Harmonic Filter, close to unity PF is achieved and current harmonic levels brought down to 5%. V-THD at the incomer came down to 7.2% and cannot be decreased further as there is grid distortion.


Also Read: Power Quality Solution at Printing press with HV Harmonics

Conclusion:

In the above case, after installing high VTHD reactors + capacitor combination we could achieve close to Unity PF in high Voltage Harmonics system. This also resulted in reducing the size and cost of Active Harmonic Filter, without these reactors, customer would have installed AHF with rating 2 times the existing rating (300 A).


Along with installing the electrical equipment (trending/old) in any industry, one should also understand its performance - impact on other equipment in industry and install suitable devices to monitor and control its ill effects for an efficient and cost-effective working of industry. Indian electrical industry has been compromising on solutions for good power quality in industries with high Voltage harmonics. Addressing the same with specially modified High V-THD reactors is one such step to gain significant benefits.

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