Project Description

Tyre Plant

TYPE OF INDUSTRY – Tyre Plant at Dhaka, Bangladesh

YEAR OF IMPLEMENTATION – 2015

PROBLEMS

  • Not possible to operate Plant at Full load on Captive Plant (Gas Generator)
  • Frequent Electrical breakdowns

OBSERVATIONS

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

  • Total Harmonic Distortion (THD) current is 41.20 %.

  • THD voltage is 24.70 %.

  • Power factor is 0.46

  • The high Harmonics current generated by DC drive motor 1500 KW at 660 V Bus, result to very high Voltage Harmonics Distortion due to high impedance of Generators. Due to this , the Generators were hunting during operation and not able to operate DC drive motor at full load.

SOLUTION

  • Detune Resonance condition by providing suitable Automatic 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 3000 kvar, 900 V  and Digitally controlled Active Harmonic filter banks of 1350 A, 690 V, 3ph, 4 wire at main incomer.

System Improvement Post Implementation

Measurement at main incomer ACB.
Sr No. Parameters Before Installation of Harmonic Filter banks After Installation of Harmonic Filter bank
1. Fundamental current I1 Amp 1426 A 1384
2. — — —
3. 3rd Harmonic Current I3 158 34A
4. 5th Harmonic Current I5 440 A 127A
5. 7th Harmonic Current I7 68 A 8 A
6. 11th Harmonic Current I11 118 A 76 A
7. 13th Harmonic Current I13 70 A 3 A
8. Total Harmonic Distortion Current % 41.20% 10%
9. Total Harmonic Distortion Voltage % 24.70 % 9 %
10. Cos Ø 0.72 0.80  lag
11. True Power Factor PF 0.46 0.79 lag
12. True RMS current Amp 1448 A 1391 A
13. True RMS Voltage V/ Phase 358 V 366 V

RESULT

  • THDI & THDV reduced to < 10% from initial value of 41% & 25% respectively after Installation of Harmonic Filters.
  • 100% loading on Captive Generation is possible after installation of Harmonic Filter Banks.
  • Huge Saving in Energy Charges due to fully operation of plant on Gas Generation.