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January, 2009

ICPCI




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Case Study 04
Modernisation with New Non-Linear
Loads and TPP A Cement Industry
Case Study

Abstract
Whenever plant undergoes modernisation, basically several types of non-linear
loads are added newly in the process fresh PQ audit would help in identifying areas
of concern. The location of non-linear loads play a vital role, which may yield even
further engineering solutions in managing & mitigating the harmonics as explained in
this case study
Industry background
The Indian cement industry is the second largest producer in the world comprising of
130 large cement plants and 206 operating mini cement plants consisting 13 rotary
kiln plants and 193 VSK plants. With an annual production capacity of 180 M. tonnes
per annum is well established over the years. The industry employs most modern
technologies to be competitive with global companies.
Like any other growing industry sector, modernization and technology up-gradation
is a continuous process and is equally true for the cement industry. The Indian
cement industry today is by and large comparable to the best in the world in
respect of quality standards, fuel & power consumption, environmental norms, use of
latest technology and capacity. The specific energy consumption is 82 kWh energy
per tonne*. The major challenges confronting the industry today are raging
insecurity in indigenous fuel availability, perennial constraints like higher ash content,
erratic variations in quality of indigenous coal and inconsistent power supply with
unpredicted power cuts. Keeping these challenges in view, the efforts by the
industry towards energy conservation and finding alternate cheaper, renewable
and environmentally friendly sources of energy are given utmost importance.
The cement plant under study had a capacity 1500 tons per day under each of its
two units.




*(source: Status Report as on 31 December 2006 (SP-1516) Centre for Mining, Environment, Plant
Engineering & Operation through BEEs web site
http:/ / www.energymanagertraining.com/cement_code/ 2007/Chapter_2.pdf),




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Demonstration Site
Consequent to modernisation of the unit with additional non-linear loads and a new
Thermal power plant, a leading cement factory at southern India of 2 x 1500 TPD
capacity streams under took a Harmonic Audit, to identify the extent of harmonic
levels present in their plant distribution network and opportunity for improving power
quality at major load centre in its plant network.
Power System Details
The plant has just then added its own thermal power plant of 15.7 MW at 6.6 kV
which is further stepped down to other two levels of distribution voltages at 3.3 kV
and 433V.
Earlier the electrical supply was through the external grid only. Consequent to
establishment of new thermal power plant (TPP), the earlier system through 2 nos. of
8/10 MVA, 132/ 6.6 kV transformers takes care of emergencies. There are also 2 x
4000 kVA, diesel sets to cater the plant requirement during annual shutdown/
maintenance period of thermal power plant. The major loads at plants include kiln
areas, crusher, and indoor substation feeding several auxiliaries at 6.6 kV. The LT bus
supply to auxiliaries is through 6 x 1600 kVA transformers of 6.6 kV/ 433 indoor sub-
station. The plants peak operating power factor was at 0.97 at majority of time due
to several LT capacitor banks at distribution network.
Energy Details
The annual energy consumption was at 80 Million Units, with 98% generation from
house units (TPP) and plant specific energy consumption reaching a level of 90
kWhr/ MT.
Non-linear Loads
As part of modernisation several new non-linear loads were added in the plant load
system. These non-linear loads consisted of DC drives, Variable Voltage Variable
Frequency (VVVF) drives, ESP and lighting loads with electronic ballasts. The
cumulative loading due to non-linear load was estimated at 5 MW out of the total
load of 15.7 MW i.e. 32% distributed at various branch networks of plant process
area and auxiliaries.
The single line diagram of the major load centre consisting of 6 nos. of 1.6 kVA, 6.6 kV
/ 433 V feeding to majority of process / auxiliary loads is shown below. The harmonic
values shown within brackets were part of the measurements taken during the audit.












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LTElectrical Distribution network with % THD values (within brackets)


















The audit showed the share of non-linear loads at various plant network & power
plant area as follows:

Transformers Transformer
rating in
kVA
Normal
Transformer
Loading
Non-
linear
load in
kVA
(%) of total
load of
transformer
TR 1 1600 612 234 14
2 1600 684 231 14
3 1600 659 378 23
4 1600 1620 1326 82
5 Not in
service
Under
repair
Load was on
Tr-4
temporarily
6 1600 792 858 53
7 1600 720 593 37
TPP
auxiliaries
transformer
1&2
2000 1053 1222 61


(Bracketed figures represent:
[%THD (V), %THD (I)])




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PQ Study Observation & Suggestion
The plant network THD levels for both voltage and current in % have been shown
below.




















Based on the harmonic levels measured, some of the areas were identified having
higher level of % THD of voltage & current, requiring further analysis from harmonic
point of view. These details are:
% THD Areas Loading
(in kW) V I
(i) Transformer 4
LT incomer
620 9.6
(5.8)*
29
(14)*
(ii) Transformer 7
LT incomer
896 5.1
(3.6)*
12.4
(8.8)*
(iii) Power plant area individual
feeders
806 7.2 17.6
a) Auxiliary main incomer 225 7.1 38.7
b) Cooler tower MCC 40 7.2 50.2
c) LDB MCC 199 7.2 34.1
d) ID fan 47 7.1 72
e) Turbine MCC 37 7.1 22.6
f) ESP MCC 17 6.8 14.2
*When capacitors are switched -off




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For Transformer # 4 and # 7 433V side bus were connected with LT capacitors of 300
kVAr and 250 kVAr respectively. During PQ study with switching off of capacitors,
there was significant reduction of %THD distortion levels both for voltage and current
indicating that magnification of harmonics were happening at these load centres.
Possibility of shifting these capacitors to other major load centres where linear loads
(like motor loads) with low P.F. exist were examined in detail and recommended
after due discussions with plant authorities. Reduction in %THD levels at Transformer #
4 and # 7 helped further in reduction in LT cable losses in the feeders. The overall
benefit due to this measure was estimated at 21,346 units on annual basis with
annual cost saving of Rs.39, 000/-. But these are without any additional investment,
as it involved only a small cost of shifting of LT capacitors to other identified
locations.
The other area of concern was high level of %THD levels (both voltage & current) at
power plant auxiliary circuit of station transformers. There were two auxiliary
transformers of each 2000 kVA with 6.6kV/415V voltage ratings. They fed station LT
auxiliary loads with bus-coupler in between for sectionalisation and flexibility. On
detailed examination of auxiliaries load, it was found that these are motor control
circuits with VVF drives, the capacity varying from 360 kW to 12.2 kW. The sample
analysis of waves indicated presence of 5th & 7th order harmonics due to VVF
drives, which were with six pulse investor. The 3rd harmonic components were also
present due to imbalances created by two phase load like ESP and lighting circuit.
This 3rd harmonic current in the neutral circuit had created operation of NGR relay
(Neutral to ground relay protection) resulting in tripping of TPP leading to black out of
power supply. For managing predominantly 5th order harmonics present in their
circuit, the plant was suggested to opt for new fixed harmonic filter tuned to 4.7th
harmonic value at LT bus of auxiliary transformer. Further for dealing with high 3rd
harmonic current at the LT auxiliary neutral, it was suggested to duplicate the cables
of phase and neutral to ESP & lighting loads and also to re-distribute the loads to
rectify major imbalance of loads at auxiliary transformer. This helped in reducing
%THD(V) and %THD(I) to a permissible level. The investment on this account was
only INR.100,000, avoiding production loss for at least two hours against each
tripping due to false alarm of generator (TPP) protection. It was gathered that at least
four such instances of down time in years period had happened earlier and would be
avoided now onwards.
Conclusion
In order to correct harmonic problems within an industrial facility:
1. An evaluation of system harmonics need to be performed especially in the
areas where the application of capacitor banks at identified areas of load
centres in the system, especially where more than 20% load of the transformer
capacity are non-linear loads
2. If the source transformer is large, relative to the non-linear load connected to
it, this would result in lowering of voltage and current distortions
3. Increasing the capacity (decrease in impedance) of the connecting cables
from source to the PCC would help in a reduction in voltage harmonics
4. Adequate sizing of neutral conductor is important while dealing single-
phase power harmonics and phase-to-neutral loads




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About the Author and Company

Author : Mr M K HALPETH, Senior Fellow & Co-ordinator
Company : TERI, Bangalore Centre, INDIA
(www.teriin.org)

Mr. Halpeth has a Masters degree from University of Roorkee, India and over 39 years
experience in Energy, Energy Generation, Distribution Management. He is presently working
on energy efficiency issues since more than 13 years. He has led several projects for energy
efficiency and conservation projects for various types of industries and industrial applications,
including power quality studies.

Established in 1974, TERI has grown substantially over the years, and has created an
environment that is enabling, dynamic and inspiring for the development of solutions to
global problems in the fields of energy, environment and current patterns of development,
which are largely unsustainable.
The TERIs SRC (Southern Regional Centre) was set up at Bangalore in 1990 with its main
objective to promote concepts and practices for improving industrial energy efficiency. Over
the years, the Centre has grown as a specialist organization on energy efficiency and
successfully executed innumerable efficiency projects for various eminent Indian and
multinational organizations, corporates, state and government departments, public and
private sector enterprises, and international financial and aid agencies.






















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The sole responsibility for the content of this document lies with the authors. It does not represent the
opinion of the European Communities. The European Commission is not responsible for any use that
may be made of the information contained therein.


















APQI is supported by Asia Invest Europe Aid Co-operation Office and Leonardo Energy.

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