Project Description

Battery Charging Plant

TYPE OF INDUSTRY – Battery Charging Plant at Himachal Pradesh, India.

YEAR OF IMPLEMENTATION – 2014

PROBLEMS

  • Low Power factor
  • High KVAH consumption
  • High breakdown
  • Frequent failure of existing capacitor bank
  • Heating of transformer and cables.

OBSERVATIONS

After conducting Power Quality Audit in the plant, following observations are made:

  • Total Harmonic Distortion (THD) current is 64.60%

  • THD voltage is 23%

  • Power factor is 0.82

  • Due to resonance effect between conventional type APFC & system inductive impedance, the harmonic current amplify to dangerous level and badly affect Power Quality of whole electrical system.

SOLUTION

  • Detune Resonance condition by providing suitable Passive Harmonic Filter Banks.

  • Add Digitally controlled Active Harmonic Filter Bank to control THDI & THDV < 5% as per IEEE 519-1992

Project Implementation

Design, Manufacturing & Installation of Automatic Passive Harmonic filter bank 2000 kvar and Digitally controlled Active Harmonic filter banks of 450A, 3ph, 4 wire at main incomer.

System Improvement Post Implementation

Measurement at main incomer 4000A ACB, 433V Supply
Sr No. Parameters Before Installation of Harmonic Filter banks After Installation of Harmonic Filter bank
1. Fundamental current I1 Amp 1975 A 1974
2. 3rd Harmonic Current I3 — 27A
3. 5th Harmonic Current I5 1235 A 57A
4. 7th Harmonic Current I7 201 A 23
5. 11th Harmonic Current I11 62 A 54
6. 13th Harmonic Current I13 30 A 27
7. Total Harmonic Distortion Current % Rph-64.6%, Yph-60.4%, Bph-57.5% Rph-4.4%, Yph-4%, Bph-5.4%
8. Total Harmonic Distortion Voltage % 23 % 4 %
9. Cos Ø 0.99 1.0 lag
10. True Power Factor PF 0.82 0.996 lag
11. True RMS current Amp 2348 A 1999 A
12. True RMS Voltage V/ Phase 234 V 230 V
13. Total KW 1434 1425
14. Total Kvar 812 62
15. Total KVA 1648 1471

RESULT

  • THDI & THDV reduced to < 5% from initial value of 65%  & 23% respectively after Installation of Harmonic Filters.
  • PF improvement to unity (1.0) from 0.82 lag
  • Apprx 20% saving in KVA demand.
  • Apprx 7% saving in Monthly units consumption.