Transcript

ANALYSIS AND IMPROVEMENT OF POWER FACTOR AT BOSCH SHOP FLOOR BY

INSTALLING CAPACITOR BANK

BY External Guide

Lingaraju.Ky(Sptd.Eng)

P.Sreelekha Internal Guide

Akash Roy A.M.Leela(Asct.Professor)

Sunith Kumar.A

SCOPE

Introduction to Problem Definition.Possible Solutions & Remedy Chosen. Present Situation & Conclusion.

Terminologies Power Triangle

Terminologies

Power Factor:

Cosine of the angle between the voltage & the current.

Types of Power Factor:• Unity• Lagging• Leading

Causes for Low Power Factor

Most A.C motors are of induction type having low lagging power factor.

Magnetizing current drawn by transformers lead to lagging current at low loads(specially during morning & evening).

Typical characteristics of Arc lamp in Cinema Induction furnace ,Short transmission lines.

Current limiting reactors used to minimize fault currents work at low power factor.

Disadvantages of Low Power Factor

Large KVA rating of equipment .Greater conductor size .Large copper losses .Poor voltage regulation .Reduced handling capacity of system.Unnecessary penalty is imposed (during

billing).

Different PF Correction Methods Available

Reduce the amount of reactive energy.Compensate artificially for the consumption

of reactive energy. ROTARY EQUIPMENT STATIC CAPACITORS

Remedy Chosen

STATIC CAPACITORS

Specification of the Capacitors

Specification of the Capacitors

Capacitors

Advantages Of Capacitors Over Other Method(s)

Capacitor banks ensures very low initial cost.

The running costs are minimal and they can be used with the same high efficiency on all sizes of installation.

Compact, reliable, highly efficient & convenient to install .

Present Situation At BOSCH

Present Situation At BOSCH

Procedure Followed• Calculations

Procedure Followed

Procedure Followed

Procurement List

Procurement List

Brief Installation List

,

Brief Installation List

,

Savings in Power

• Resistance of the cable 0.15ohm / km load ; Length= 175mt.• Resistance of the cable = 0.15 *0.175km = 0.026 ohm.

• P= √3 *VL*IL* Cos Φ1

• Current drawn by the load at 0.763 P.F , IL1= P/ (√3 *VL*Cos Φ1 )

=171.83/( √3 *430.52*0.763)

=302.009A.

• PF after correction Cos Φ2 = 0.96

• Current drawn by the load at 0.96 P.F , IL2 = P/ ( √3 *VL*Cos Φ2 )

= 171.83/( √3*430.52*0.96)

= 240.03A.

Savings in Power

• Power loss P1= 3*I12R = 7.114KW

• Power loss P2= 3*I22R = 4.493KW

• Saving in power = 7.114KW – 4.493KW = 2.621KW.• Time= 18Hours * 25 Days = 450.• KWh loss in P1 = 3201.3KWh.• KWh loss in P2 = 2021.85KWh.• Reduction in KWh (units) = 1179.45• Cost saving = 1179.45 *12 months * Rs. 6/-unit =

RS.84920.4

Installation Work

Single Line Diagram

Installation Work

Monday

Tuesday

Wedesd

ay

Thursday

Friday

Satu

rday

Sunday

0

0.2

0.4

0.6

0.8

1

1.2

0.57 0.54 0.54 0.6 0.550.67

0.575

0.94 0.93 0.93 0.96 0.90.98 0.93

Feeder 307

BeforeAfter

Installation Work

Monday

Tuesday

Wednesd

ay

Thursday

Friday

Satu

rday

Sunday

00.10.20.30.40.50.60.70.80.9

1

0.6820.7070000000000

010.673000000000002

0.7070000000000010.698 0.6670000000000

020.6680000000000

02

0.90.9500000000000

010.90.9500000000000

010.92 0.92 0.92

Feeder 504

BeforeAfter

,

106 307 312 402 501 415 504 505 5110

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

0.650.57

0.8090.73

0.82 0.86

0.70.78 0.736

0.320.37

0.120.22

0.1 0.050.23 0.1 0.174

Previous Improvement

ALGORITHM • Identify the feeder to be worked based on the

difference of power factor• p= Power in KW• a= Power factor(current) • b= Target power factor • Find out the Reactive power Compensation required

for achieving target power factor• Compare the current and targeted P.F• Improvement done is displayed

Simulation using MATLAB

FLOW CHART

FLOW CHART

CONCLUSION

• Improved the power factor from the range of 0.65-0.85 to an existing range of 0.95-0.99 effectively.

• Significant decline in the rating of current flow & reduced I2R losses also leading to reduced stress on the cable there by increased durability of the cable.

• Finally reduced on the KVA demand there by reducing the penalty imposed ,also the total KWh consumption as a whole has been reduced. Thus

creating savings of 27.5lakhs p.a

THANK YOU

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