semi-har-1

TECHNICAL SEMINAR

ON

VARIABLE FREQUENCY AC DRIVE

AND

HARMONICS :

CAUSE, EFFECTS AND CONTROL

AMTECHELECTRONICS (INDIA) LTD.E-6, GIDC Electronics Zone,Gandhinagar - 382 044. (Gujarat, India)Phone : 91 (079) 3225324, 3227294, 3227304Fax : 91 (079) 3224611Gram : AXPERTE-Mail : [email protected] : www.amtechelectronics.com

1

Edition - 1

BY

AMTECH GROUP2

CONTENTS

3

SECTION : 1 - AMTECH PAGE NO.- COMPANY PROFILE 5- PRODUCT RANGE 6- BUSINESS PARTNERS 7- AMTECH’S STRENGTHS 8- OUR CUSTOMERS 9

SECTION : 2 - VARIABLE FREQUENCY DRIVES- WHY AC DRIVES ? 11- EFFECTS OF INVERTER ON MOTORS 12- DERATING 13- HOW TO SELECT THE MOTOR FOR THE GIVEN SPEED & TORQUE? 14- MANUFACTURER’S CATALOGUES TO BE REFERED DURING MOTOR SELECTION 15- MOTORS : POINTS TO PONDER 16- NEW TRENDS IN AC DRIVES 17

AXPERT VT-230S AC VARIABLE FREQUENCY DRIVE- FEATURES 19,20- VT-230S CAN WORK IN FIVE DIFFRENT MODES 21- MULTI-PUMP CONTROL 22- PM MOTOR 23- INDUCTION MOTOR Vs PM MOTOR 24

SECTION : 3 - VFDs FOR ENERGY CONSERVATION- INTRODUCTION 26- ENERGY SAVING IN FAN 27 to 31- APPLICATION CASE STUDIES 32 to 42

SECTION : 4 - PLC- PROGRAMMABLE LOGIC CONTROLLER (PLC) 44- PROCESS PLC 45,46,47- PLC CONFIGURATIONS 48

SECTION : 5 - HARMONICS : CAUSE, EFFECTS & CONTROL- ABOUT HARMONICS 50- FUNDAMENTAL WAVE 51- FIFTH HARMONIC 52- WHAT IS NON-LINEAR LOAD? 53- GENERATION MECHANISM 54- EXAMPLES OF HARMONICS GENERATING EQUIPMENT 55- CALCULATION OF DISTORTIONS 56- INFLUENCE OF HARMONICS 57,58- COUNTER MEASURES 59- CURRENT HARMONICS IN 3PH, 6PULSE CONVERTER 60- STATIC HARMONIC CONVERTER (TYPE-A) 61- STATIC HARMONIC CONVERTER (TYPE-B) 62- USE OF HARMONIC TRAP FILTERS 63- PRINCIPLE OF ACTIVE HARMONIC FILTER 64- IMBALANCE COMPENSATION 65- UNIT COMPENSATION 66- GROUP COMPENSATION 67- IEEE STANDARDS 68,69- YOUR VALUABLE FEEDBACK 70

AMTECH GROUP

SECTION : 1

AMTECH

4AMTECH GROUP

COMPANY PROFILE

AMTECH IS A SYNONYM FOR AMERICAN TECHNOLOGY. THE COMPANY WASFORMED IN 1990 WITH A FACTORY LOCATED AT ELECTRONICS COMPLEXIN GANDHINAGAR. THE FOUNDER OF AMTECH ELECTRONICS (INDIA) LTD. ISMR. DHIREN L. PATEL, A HIGHLY QUALIFIED NRI TECHNOCRAT FROM USA.

AMTECH HAS A VISION - TOTAL SOLUTION TO AUTOMATION AND CONTROL.THE PROFESSIONAL MANAGEMENT HAS TRANSLATED THIS VISION INTO THEMANUFACTURE OF HIGH-TECH QUALITY PRODUCTS. AMTECH HAS WONMANY LAURELS IN THE AREA OF PROFESSIONAL MANAGEMENT AND PRODUCTEXCELLENCY.

SOON AFTER ITS FORMULATION, AMTECH HAD GONE FOR TECHNICALCOLLABORATIONS WITH MULTINATIONAL COMPANIES OF USA & UK. AMTECH’SSTRENGTH LIES IN PROVIDING SOLUTION FOR CUSTOMER REQUIREMENTSWITH RELEVANT TECHNOLOGY.

AMTECH HAS PROVED ITSELF ON ALL GROUNDS : TECHNOLOGY, PRODUCT,MANAGEMENT, SERVICE, CORPORATE IDEOLOGY AND OVERALL APPROACH.RECENTLY ANNOUNCED AWARDS SUCH AS UDYOG RATTNA , VIJAY RATTNA ,VIKAS RATTNA , NATIONAL UNITY AWARD , UDYOG GAURAV AND EXCELLENCEAWARDS HAVE PUT A SEAL OF APPROVAL ON IT. AMTECH HAS CREATEDA WELL-DESERVED IMPRESSION IN THE MARKET FOR HIGH-TECH PRODUCTS.

AMTECH STARTED WITH MOTOR CONTROL PRODUCT IN MIND. MOTORCONTROL IS FUNDAMENTAL TO ALMOST ALL MACHINERY’S USED INMANUFACTURING.HIS ESTABLISHMENTS IN USA ARE GOOD PROFIT MAKINGCENTERS.

IN 1997 AMTECH ELECTRONICS PVT.LTD. EXPANDED INTO AMTECH ELECTRONICS(INDIA) LTD. AND AMTECH POWER LTD.

IN 1998 AMTECH’S IN HOUSE R&D CENTER GOT APPROVAL FROM DSIR, GOVT. OFINDIA.

IN 1999 AMTECH ELECTRONICS ACHIEVED ISO-9001 CERTIFICATION FROM M/S DNV.

5 AMTECH GROUP

PRODUCT RANGE

F AMTECH ELECTRONICS (INDIA) LIMITED. (AEIL)

- AC DRIVES : 1HP TO 1000HP

- AC DRIVES (HIGH FREQUENCY) : UP TO 200HP

- ELECTRONICS SOFT STARTORS : UP TO 1000HP

- PROGRAMMABLE LOGIC CONTROLLERS

- STATIC HARMONIC CONVERTER

F AMTECH POWER LIMITED. (APL)

- ACTIVE HARMONIC FILTER

- STATIC EXCITATION UNITS (ANALOGUE / DIGITAL)

- AUTOMATIC VOLTAGE REGULATORS

- GENERATOR PROTECTION SYSTEMS

- ENGINE / GENERATOR CONTROLLERS

6AMTECH GROUP

BUSINESS PARTNERS

7AMTECH GROUP

SR NO BUSINESS PARTNERS PRODUCT COMPANY

1. GRASEBY CONTROL, USA AC DRIVES AEIL

2. M/S. RALSPEED, UK SOFT-STARTERS AEIL

3. M/S. JETTER GmbH, GERMANY PLC AEIL

4. MEIDENSHA CORPORATION AC DRIVES AEIL

5. BASLER ELECTRIC INTERNATIONAL, FRANCE

CAPTIVE POWER EQUIPMENT APL

6. MEIDENSHA CORPORATION ACTIVE FILTER APL

# AEIL : AMTECH ELECTRONICS (INDIA) LIMITED. # APL : AMTECH POWER LIMITED.

1. WE ARE THE MANUFACTURES & NOT MERELY SUPPLIERS.

2. WIDE INSTALLATION BASE OF OVER 1200 PRODUCTS ALLOVER INDIA & ABROAD

3. LONG ASSOCIATION WITH REKNOWNED CUSTOMERS.

4. DSIR APPROVED IN-HOUSE R&D.

5. BUSINESS PARTERNERS IN USA, GERMANY, FRANCE, U.K.& ITALY.

6. EMPHASIS ON CUSTORMER SUPPORT ACTIVITY.

7. CLOSE RELATIONSHIP WITH EDUCATIONAL INSTITUTIONS.

8. SOUND MANAGERIAL & TECHNICAL EXPERTISE.

9. CAPABILITY FOR CUSTOMISATION.

10. ISO-9001 CERTIFIED COMPANY.

8

AMTECH’S STRENGTHS

AMTECH GROUP

CHEMICAL· Gujarat Alkalies & Chemicals Ltd · Searle (India) Ltd· Apcotex Lattices Ltd · Asian Paints· Alembic Chemicals Ltd · Lupin Group· Kanoria Chemicals Ltd · ONGC· Ciba CKD Biochem Ltd

TEXTILE & RAYON· Morarji Goculdas Spinning Mills · JK Group of Companies· Vardhman Group of Companies · SIV Industries Ltd· Indian Rayon & Industries Ltd · Shree Synthetics· Precot Group of Companies · Birla Cellulosic· PT Indorama Synthetics Tbk · Himson Textiles· Ashima Group Companies · Arvind Mill Ltd· Grasim Industries Ltd · Century Rayon· Garden Engineering · Modern Group· Reliance Industries Ltd · Shriram Rayon

ENGINEERING· Bharat Heavy Electricals Ltd · Escort· Institute of Plasma Research · SPIC· Gujarat Machinery Mfgs. Ltd · LMW· Bharat Earth Movers Ltd · Sanghi Group· Modi Group of Companies · Birla VXL Ltd· Elecon Engineering Ltd · DGP Windsor· Anup Engineering Ltd · Thermax Ltd· Mahindra & Mahindra · TISCO Group· DLF Industries Ltd · Alfa Laval· Ingersoll-Rand (India) Ltd · E + L Ltd

ALUMINIUM & CEMENT· Manikgarh Cement Indian Cement · Indian Aluminium Co. Ltd

Nahar Group· Gujarat Sidhee Cement ACC Group · Vikram Cement Hindalo· Ambuja Group

MACHINE TOOLS & AUTOMOBILE· PMT Machine Tools Automatics Ltd · Bajaj Auto Ltd· NRB Bearing & Weaving Co. Ltd · Tata Bearing· FAG Precision Bearing · TVS Group· Kinetic Engineering Ltd · SKF

9

OUR CUSTOMERS

AMTECH GROUP

10

SECTION : 2

VARIABLE FREQUENCY DRIVE

AMTECH GROUP

11

WHY AC DRIVES ?

* PRECISE, ACCURATE & STABLE SPEED CONTROL

* FLEXIBILITY OF OPERATIONS

* REDUCED MACHINE SET UP TIME

* IMPROVED QUALITY

* IMPROVED PRODUCTIVITY

* IMPROVEMENT IN POWER FACTOR

* LESS ENERGY CONSUMPTION

* REDUCED HARDWARE

* EASE OF OPERATIONS

AMTECH GROUP

12

EFFECTS OF INVERTER ON MOTORS

EFFECTS OF INVERTERS ON MOTORS :

* REDUCED COOLING AT LOWER SPEEDS.

* HIGH VOLTAGE SPIKES ENDANGERING MOTOR WINDING INSULATION.

THIS IS DUE TO :

- HIGH RATE OF CHANGE OF VOLTAGE IN PWM WAVEFORM OF INVERTER

OUTPUT.

- CHARACTERISTIC IMPEDANCE OF LONG CABLES (> 50 METERS)

HOW TO PROTECT MOTORS FROM ADVERSE EFFECT OF VARIABLE SPEED DRIVES:

- SEPARATE COOLING OF MOTORS.

- DERATING OF MOTORS W.R.T. REDUCTION IN SPEED.

- USE OF INVERTER DUTY MOTORS WHICH ARE DESIGNED TO WORK ON

INVERTERS.

- USE OF OUTPUT CHOKES TO AVOID HIGH VOLTAGE SPIKES.

- USE OF SINE WAVE FILTERS.

AMTECH GROUP

13

DERATING

DRIVE :

1. SWITHING FREQUENCY : 4% / KHz

2. TEMPERATURE : 1% / degree C

3. AIR PRESSURE (ALTITUDE ) : 5% / 1000 METERS

MOTOR :

EVEN MOTORS ARE REQUIRED TO BE DERATED WHEN OPERATED AT LOW

SPEEDS ( SAY 20Hz , 15Hz, etc….. ) DUE TO FALL IN THEIR COOLING RATES.

THE FORMULA FOR THIS IS AS FOLLOWS :

FOR CLASS ‘F’ INSULA TION :

UPTO 50% SPEED NO DERATING REQUIRED ( i. e. UPTO 25 Hz ). BELOW 25Hz

OPERATION DERATING REQUIRED IS 1% / Hz.

FOR CLASS ‘ B’ INSULA TION :

1.25% / Hz BELOW 40 Hz INSTEAD OF 25 Hz. THIS IS ESPECIALLY A MUST

IN CONSTANT TORQUE APPLICATIONS.

FOR CENTRIFUGAL PUMP AND FAN APPLICATION NO SUCH DERATING IS

REQUIRED ( FOR ALL MOTORS ).

AMTECH GROUP

Let the required torque = 75 kgm, required speed = 2300 rpm Torque X SpeedCalculate the power capacity required as, KW = ————————- 974 75 X 2300 = ———————— 974 = 177 KW ____________________________ (1)

From the motor manufacturer’s data sheet select the motor with KW capacity more than 177 KW and rated torquemore than 75 kgm, from Siemens catalogue (Refer Internal News LetterDoc.no.04 01 00),the motor1LAO 317-4YACan be selected. The motor specifications are : 270 HP, 200KW,4 pole

Rated torque = 131 kgm _____________________________ (2)

Now we have to verify that this motor satisfies the requirements of 75 kgm torque at 2300 rpm.Mechanical speed limit of this motor is 2600 rpm,which is more than the required speed of operation, i.e. 2300 rpm,which is okay._________________________________________________________________(3)

Break-down (pull-out) torque at 1500 rpm ( base frequency) = 2.5 x 131= 327 kgm.

15002

Pull-out torque at 2300 rpm = 327x .................... 23002

= 139 kgm

Maximum permissible torque = 139/1.5 = 93 kgm.____________________________________________(4)

Torque at 2300 rpm, ( as 2300rpm is more than base speed of operation, as it is a constant power operation)

KW x 974 = ————- RPM 200 x 974 = ——— 2300 = 85 kgm ___________________________________ (5)

Minimum of the two torques given by (4) and (5) is 85 kgm, which is more than the required torque,Which is 75 kgm.Hence the selected motor can give the required torque at the required maximum speed._______ (6)

Select the class of insulation , which is generally ‘F’ or ‘B’Note that if the lower than base frequency operation is involved then :

Class-B motor requires derating of its power capacity 1% per Hz below 40 Hz;Class-F motor requires derating of its power capacity 1% per Hz below 25 Hz._______________________ (7)

HOW TO SELECT THE MOTOR FOR THE GIVENSPEED AND TORQUE?

14

1.Selection and Ordering Data:

1500 rev/min. 4Pole. 50Hz. Degree of Protection IP55. Class F Insulation

Operating characteristics at rated outputLockedrotor

current

Lockedrotor

torque

Break-downtorqueRated

Output RatedCurrentat 415V

Efficiency PowerFactor

RatedSpeed

RatedTorque

Rotorclass

GD2of

rotor

Weightapprox.

KW HP

FrameSize

Order No. (forOrder no.suffixes forvoltage andtype ofconstruction,see tablebelow) A % Rev/min. Kgfm Current Torque Torque KL Kgfm2 Kg

160 215 315L 1LAO 316-4YA.. 271 95.5 0.86 1485 104.9 6.0 2.5 2.5 16 12.8 1060

200 270 315L 1LAO 317-4YA.. 339 95.5 0.86 1485 131.2 6.0 2.5 2.5 16 16.8 1200

250 235 355L 1LAO 356-4YB.. 421 96 0.86 1488 163.6 6.5 2.1 2.5 13 24.0 1590

2.Derating w.r.t. Ambient Temperature:

Maximum Ambient Temperature °C Restriction on Temp. Rise(Resistance Method) °C

Permissible Output as % of Rated Value

<30 - 10730-40 - 100

45 75 9650 70 9255 65 87

3.Derating w.r.t Altitude:

Altitude above Mean Sea Level in Meters Permissible Output as % of Rated Value1000 1001500 972000 942500 903000 863500 824000 77

4.Derating w.r.t. Voltage and Frequency Variation:

Voltage Variation % Frequency Variation%

Combined Voltage &Frequency Variation %

Permissible Output as % ofRated Value

± 6 ± 3 ± 9 100± 10 ± 5 ± 10 95

± 12.5 ± 5 ± 12.5 90± 15 ± 5 ± 15 85

5.Mechanical Speed Limit:

Motor Type1LA0 2 Pole 4 Pole 6 Pole 8 Pole

316,317 3600 2600 2600 2600

6.Class of insulation: Class-B , Class-F etc

MANUFACTURER’S CATALOGUES TO BEREFERED DURING MOTOR SELECTION

15AMTECH GROUP

MOTORS : POINTS TO PONDER

1. TORQUE CHANGES IN PROPORTION TO SQUARE OF VOLTAGE

2. STARTING CURRENT REDUCES WITH VOLTAGE, WHEREAS FULL LOAD CURRENT

INCREASES WITH DECREASE IN VOLTAGE

3. REDUCED VOLTAGE STARTING REDUCES CURRENT TO 150% ,BUT GIVES

STARTING TORQUE ONLY 30%, WHEREAS A DRIVE CAN GIVE 150% STARTING

TORQUE AT 150% STARTING CURRENT

4. A 2 POLE MOTOR CAN RUN UPTO 75Hz , 4 POLE MOTOR CAN RUN UPTO 135 Hz

5. MEDIUM VOLTAGE MOTOR HAS LESSER EFFICIENCY THAN A LOW VOLTAGE

MOTOR

6. A 3 % UNBALANCE IN VOLTAGE CAN LEAD TO 18 % CURRENT UNBALANCE

7. TORQUE AT 120 Hz WILL BE 25 % OF THE TORQUE AT 60 Hz, IF VOLTAGE IS KEPT

CONSTANT AT 100%

8. MOTORS CAN BE WOUND FOR HIGHER BASE SPEEDS

9. MOTOR EFFICIENCY IS IMPROVED BY

-- INCREASING THE SIZE OF ROTOR CONDUCTORS

-- REDUCINGTHE MOTOR AIR GAP FLUX AND DENSITY

-- MAKING THE ROTOR AND STATOR LAMINATIONS THINNER

10. IN CASE OF CONSTANT HP LOAD TORQUE VARIES AS 1/N WHEREAS THE TORQUE

CAPABILITY VARIES AS 1/ N*N

16AMTECH GROUP

NEW TRENDS IN AC DRIVES

17

* VECTOR CONTROLLED

* DSP CONTROLLED ( SURFACE MOUNTED )

* SELF DIAGNOSTICS.

* NETWORK – COMPATIBILITY

* COMPUTER INTERFACE

* USER FRIENDLY PROGRAMING

* AUTO – TUNNING WITH MOTORS

* REMOTE OPERATION

* MULTI – LANGUAGE DISPLAY

* DRIVES WITH BATTERY BACK UP

* MULTI PULSE CONVRTERS

* WIRELESS REMOTE CONTROL

AMTECH GROUP

18

AXPERT VT230S AC VARIABLEFREQUENCY DRIVE

AMTECH GROUP

AXPERT-VT230S is the world ’s most technologically

advanced AC drive range.

The primary feature of the VT230S series is Multi-Mode

operation. The five operating modes deliver, effectively,

five technologies in a single drive.

1. V/F control for variable torque load

2. V/F control for constant torque load

3. Sensor less vector control

4. Very high performance vector control with

sensor.

5. PM drive

AXPERT - VT230SFEATURES

AMTECH GROUP19

AXPERT - VT230S

AMTECH GROUP20

OUTSTANDING FEATURES

1. Can oprate in five different modes.

2. Tripless Opration.

3. Built in PID Controller.

4. Multi Pump Opration.

5. Auxiliary Motor Drive.

6. Audible Noise Reductions.

7. Three Phase Current Senssing.

8. Compliance to International Standards.

9. Manufactured from dioxin-free plastic

(indicated for recycling).

10. High Efficiency Opration.

11. Parameter Copy Function.

12. Ratio Interlock feature.

AXPERT - VT230S

AMTECH GROUP21

VT-230S CAN WORK IN FIVE DIFFRENT

MODES :

1. V/F control for constant torque loads

2. V/F control for variable torque loads

3. Sensor less Vector control

4. Vector Control with sensor (Closed Loop Vector

control)

5. Permanent Magnet Motor Drive.

AXPERT - VT230S

AMTECH GROUP22

MULTI-PUMP CONTROL

Permanent Magnet Synchronous Motor (PMSM)

PM MOTOR

R otor

Stator

AMTECH GROUP23

AMTECH GROUP24

INDUCTION MOTOR Vs PM MOTOR

INDUCTION MOTOR PM MOTOR ONLY SPEED DETECTION REQUIRED

POSITION DETECTION REQUIRED

OPERATION WITH V/F CONTRL POSSIBLE

AS MOTOR PULLS OUT WITH LOAD DISTURBANCE V/F OPERATION IS NOT POSSIBLE

WIDE CONSTANT POWER RANGE

NARROW CONSTANT POWER RANGE

DRAWS EXCITATION CURRENT ON NO LOAD

NO LOAD CURRENT IS ZERO IF DEMAGNETIZING CURRENT IS ZERO.

TORQUE GENERATION AT START IS DELAYED

TORQUE GENERATION IS INSTANTANEOUS WITH EXCITATION CURRENT

TERMINAL VOLTAGE IS ZERO,WHEN POWER IS REMOVED,WHILE MOTOR IS RUNNING

INDUCED VOLTAGE IS GENERATED ,WHEN POWER IS REMOVED,WHILE MOTOR IS RUNNING

LESS POWER DENSITY MORE POWER DENSITY LESS EFFICIENCY MORE EFFICIENCY MORE TEMPERATURE RISE LESS TEMPERATURE RISE

LESS TORQUE AT ZERO SPEED

FULL TORQUE AT ZERO SPEED

25

SECTION : 3

VFDs FOR ENERGY CONSERVATION

AMTECH GROUP

INTRODUCTION

26

The AC induction motor is the mainstay for energy conversion in industry

sector. It has been esrtimated that about 70 % energy is consumed by industrial

sector in India. From this 70% energy is used for AC motors only. Much of the

power that is consumed by AC motors goes into the operation of fans, blowers and

pumps. It has been estimated that approximately 50% of the motors in use are for

these types of loads.

These particular loads -- fans, blowers and pumps, are particularly attractive

to look at for energy savings. Several alternate methods of control for fans and

pumps have been advanced recently that show energy savings over traditional meth-

ods.

Basically, fans, blowers and pumps are designed to be capable of meeting

the maximum demand of the system in which they are installed. However, quite

often the actual demand could vary and be much less than the designed capacity.

These conditions are accommodated by adding outlet dampers to fans & blowers

or throttling valves to pumps. These are effective and simple controls, but severely

affect the efficiency of the system.

Now there are other forms of control to adapt fans and pumps to varying

demands that do not decrease the efficiency of the system as much. These type of

methods include direct variable speed control of the fan, blower or pump. This

method produces a more efficient means of flow control than the existing methods.

In addition, adjustable frequency drives offer a distinct advantage of energy sav-

ing with speed control of fans, blowers & pumps.

AMTECH GROUP

ENERGY SAVING IN FAN

27AMTECH GROUP

System Curve

System Curve

SYSTEM CURVE & FAN CURVE

FLOW (Q)

PR

ES

SU

RE

(P)

FAN CURVE

PR

ES

SU

RE

(P)

FLOW (Q)

Fan Curve

28AMTECH GROUP

OUTLET DAMPERS

OUTLET DAMPER-SYSTEM CURVES

OUTLET DAMPER- HORSE-POWER REQUIREMENTS

29AMTECH GROUP

VARIABLE INLET V ANES

VARIABLE INLET V ANES SETTINGS

VARIABLE INLET V ANESHORSEPOWER REQUIREMENTS

30AMTECH GROUP

VARIABLE SPEED METHOD

VARIABLE SPEED - HORSEPOWER REQUIREMENTS

31

VARIABLE INLET V ANE

OUT LET DAMPER

VARIABLE INLET VANEHORSEPOWER REQUIREMENT

VARIABLE SPEED DRIVES

VARIABLE INLET VANE SETTINGS

HORSE POWER REQUIREMENTOUT LET DAMPER - SYSTEM CURVE

AMTECH GROUP

AMTECH

A P P L I C A T I O NC A S E S T U D Y

DOC.NO. : AMTCS-40 March-2000

TITLE : ENERGY SAVING IN FAN

HOST ORGANIZATION : M/s. ASSOCIATED CEMENT COMPANY LTD. , WADI

INDUSTRY : CEMENT

PERFORMED BY : AMTECH ELECTRONICS (I) LTD. ON 28TH DECEMBER 1998

APPLICATION : COOLER FAN OF BOILER

MOTOR RATING : 100HP, 75 KW, 415V AC, 3 PH.,1440 RPM, 50Hz.

POWER CONSUMPTION WITH DAMPER CONTROL METHOD AND DOL STARTING

FREQUENCY DAMPER AIRFLOW CONSUMPTION 50 HZ 50% OPEN 4.17m/s 58 KW

ACTUAL POWER CONSUMPTION WITH AC V ARIABLE SPEED DRIVE WITHTHE SAME AIR FLOW AND DAMPER FULL Y OPEN.

FREQUENCY DAMPER AIRFLOW CONSUMPTION 44 HZ 100% OPEN 4.17m/s 52 KW / HOUR

* NET POWER SAVING : 58 KW - 52 KW = 6 KW/HR.

* ENERGY SAVING PER DAY : 6KW X 24HR./DAY = 144 KWH

* ENERGY SAVING PER MONTH : 4320 KWH

* ENERGY SAVING IN Rs. PER MONTH : 4320KWH X 3.5 (At the rate of Rs. 3.5 per KWH)= 15,120 Rs.

* ENERGY SAVING PER YEAR IN Rs. : 1,81,440/-

* PAYBACK PERIOD : 18 MONTHAS (APPROX)

ELECTRONICS (I) LTD.

PAGE : 01 OF 01

32

Regd.Office & Factory: E-6, GIDC, Electronics Zone, Gandhinagar - 382 044, Gujarat (India)

Phone : +91 (079) 3225324, 3227294, 3227304 Fax : +91 (079) 3224611Gram : AXPERT E-Mail : [email protected]

AMTECH DOC.NO. : AMTCS- 64 FEBRUARY - 2000

TITLE : ENERGY SAVING IN GAS COOLING TOWER PUMP FOR WATER SPRAY Page : 01 of 01



HOST ORGANIZATION : M/S AMBUJA CEMENT EASTERN LIMITED, RAIPURPERFORMED BY : AMTECH ELECTRONICS (INDIA) LTD. IN SEPTEMBER-1999INDUSTRY : CEMENTAPPLICATION : GAS COOLING TOWER PUMP FOR WATER SPRAYMOTOR RATING : 3 PHASE AC INDUCTION MOTOR

RATING : 125HP VOLT : 415VCURRENT : 170A RPM : 2975

PREVIOUS SYSTEM : 1. Star-Delta starter for motor operation.2. Flow pressure control by return line valve throttling.

PROBLEM OBSERVED : 1. Because of high starting current, power demand peak is more.2. As no smooth start, the vibration in m/c is high, resulting in reduction of life

of the mechanical system.3. Energy loss beacause of valve control.

PRESENT SYSTEM : Water flow control by varing the speed of motor through AXPERT ACVariable frequency drive (Valve fully open)

FREQ. KW (Consumption) Return line valve positionPrevious System (Without Drive) : 50Hz. 53.5KW 20% OPENPresent System (With Drive) : 44Hz 40.0KW 0% OPEN

MERITS OF NEW SYSTEM :1. Energy saving due to flow control by AC VFD.2. Due to smooth starting less wear & tear for mechanical system and motor.3. Not required valve throttling which was tedious job.

ECONOMICAL ANAL YSIS :

* NET POWER SAVING : 53.5KWH - 40.0 KWH = 13.5 KWH* MOTOR OPERATION : 24 HRS / DAY* UNIT SAVING / DAY : 324.0 KWH* UNIT SAVING / MONTH : 9720 KWH* TARRIF RATE RUPEES : 4.00 RS. / UNIT* ENERGY SAVING / MONTH : 38880/- RS. (APPROX)* ENERGY SAVING / YEAR : 466560/- RS. (APPROX)* INVESTMENT : 500000/- RS.* PAY BACK PERIOD : 13 MONTHS.

SYSTEM BLOCK DIA. :

3-Phase415V,50HzAC Supply

AXPERT VFD

MOTORGAS COOLINGTOWER PUMP

33



CONDUCTED AT M/s. ALEMBIC CHEMICAL WORKS COMP ANY LTD., BARODA.

PERFORMED ON 22.01.1999 BY AMTECH ELECTRONICS (I) LTD.

APPLICATION : BULK DRUG FERMENTATION

INDUSTRY : PHARMACEUTICAL

MOTOR : 300KW, 433V AC, 3PH., 1487 RPM, 50Hz, IP55, CLASS F INSULATION, SLIPRING INDUCTION MOTOR.

OLD SYSTEM : SLIPRING INDUCTION MOTOR WITH ROTOR RESISTANCE CONTROL

NEW SYSTEM : SAME MOTOR CONVERTED INTO SQUIRREL CAGE INDUCTION MOTOR BY SHORTING ROTOR RESISTANCE & AXPERT VARIABLE SPEED DRIVE OF 400 HP

PROCESS DESCRIPTION :

THE 300KW MOTOR DRIVES THE IMPELLER OF A FERMENTOR. THE ENTIRE ROCESSOF FERMENTATION IS CARRIED OUT IN DIFFERENT STAGES EACH OF WHICH REQUIRES ADIFFERENT SPEED.

THE TOTAL PROCESS TIME IS TYPICALY 240 HOURS (10 DAYS).

r NET POWER SAVING : 40KW / Hr.

r MOTOR RUNNING TIME : 7920 Hrs / Year

r UNIT SAVING PER YEAR : 316800 Kwh

r ENERGY SAVING PER MONTH : Rs.1.18 Lacs (approx., at the rate of Rs.4.5 / kwh)

ADVANTAGES OF NEW SYSTEMS :

1. MAINTENANCE FREE OPERATIONS SINCE ROTOR RESISTANCE IS ELIMINATED.

2. SMOOTH, EASY & STEPLESS SPEED CONTROL.

3. REDUCED STARTING CURRENT.

4. FIBER OPTIC INTERFACE OF INVERTER CONTROL FOR NOISE REDUCTION.

5. ENERGY SAVINGS DUE TO ELIMINATION OF ROTOR LOSSES.

6. OPTIMAL UTILISATION OF MOTOR CAPACITY.

7. ELIMINATION OF ROTOR RESISTANCE ELIMINATES AMBIENT TEMPERATURE RISE OF MOTOR.

8. VARIOUS PARAMETER MONITORING.




AMTECH DOC.NO. : AMTCS-3 FEBUARY-1999.

TITLE : ENERGY SAVING IN FERMENTOR


Page : 01 of 01

34



Phone : +91 (079) 3225324, 3227294, 3227304 Fax : +91 (079) 3224611 Gram : AXPERT E-Mail : [email protected]

AMTECH DOC.NO. : AMTCS-35 DECEMBER-1999.

TITLE : I.D. FAN


Page : 01 of 01

HOST ORGANISATION : GRASIM INDUSTRIES, NAGDA, M.PPERFORMED ON : AMTECH ELECTRONICS ON OCTOMBER - 1999

INDUSTRY : GRASIM POWER-HOUSE

APPLICATION : I.D. FAN

MOTOR DATA : 3 PHASE AC INDUCTION MOTOR

RATING = 90KW / 125HP RPM = 742CURRENT = 192 Amp. VOLT = 415V, 3 PHASE.

PREVIOUS SYSTEM : In 40 Mw power plant for maintaing 103-105 T/hr. (Tonns / Hour) steam pressure, twoboilers are used. Each having two I.D. Fan with 90 kw motor along with damper valves& IGP operated from Remote station.

PROBLEM OBSERVED :

1. Very high starting current kick. ( About 5 to 6 times of full load current )2. Regular maintenance for damper valves & IGP valves.3. Steam loss due to damper & IGP valves leakages.

PRESENT SYSTEM : Right row same steam pressure is obtain with fully opened damper valve & IGP. Andworking with three I.D. Fan (Two in boiler-1 & only one in boiler-2) with speed controltechnique through ‘AXPERT’ AC Variable frequency drive control from remote station.

SYSTEM BLOCK DIAGRAM :

ADVANTAGES OF NEW SYSTEMS :(1) Energy saving (2) Soft-start action, limits starting current kick.(3) Free from mechanical maintaince of damper valves & IGP valves. (4) Inbuilt protection feature take care of motor.(5) Accurate steam pressure control, beacuse of fine speed control

through ‘AXPERT’ AC VFD.

ECONOMIC ANALYSIS :

Previous System = ID1 80 KW/h (DOL) ID1 80 KW/h (DOL)KW consumption ID2 80 KW/h (DOL) ID2 80 KW/h (DOL)

160 KW/H IN BOILER - 1 160 KW/H IN BOILER - 2Total KW consumption = 320 KW/h

With Axpert VFD = ID1 80 KW/h (DOL) ID1 50 KW/h ( Axpert)KW consumption ID2 50 KW/h (Axpert) ID2 OFF (DOL)

130 KW/h 50 KW/hTotal KW consumption = 180 KW/h

FD1

FD2

PA Fan-1

PA Fan-2

ID2 Fan-2

ID1 Fan-1

(DOL) 250KW

(DOL) 250KW

(DOL) 120KW

(DOL) 120KW

90KW

(DOL) 90KW

HT Motor

75KWAxpert VFD

BOILER - 1100 T/hr.

FD1

FD2

PA Fan-1

PA Fan-2

ID2 Fan-2

ID1 Fan-1

250KW (DOL)

250KW (DOL)

120KW (DOL)

120KW (DOL)

90KW

90KW (DOL) OFF

HT Motor

75KWAxpert VFD

BOILER - 2100 T/hr.

COMMONSTEAM HADDEN

40 MWTurbine set

105 Tonn/hour

(steam pressure)

NET POWER SAVING : 140KW / hr.MOTOR OPERATION : 7680 HRS / YEAR (Approx)ENERGY SAVING / YEAR : 10,75,200 KWH / YEARTARIFF RATE RUPEES : 1.55 / UNIT (Minimum)

ENERGY SAVING / MONTH : RS.1,38,880 / MONTH (Approx)ENERGY SAVING / YEAR : RS.16,66,560 / YEAR (Approx)PAYBACK PERIOD : 4 MONTHS

+

+

BOILER-1 BOILER-2

35

AMTECH DOC.NO. : AMTCS-52 JUNE- 2000

TITLE : HARMONICS REDUCTION WITH STATIC HARMONIC CONVERTER Page : 01 of 02





HOST ORGANIZATION : M/s ALEMBIC CHEMICAL, BARODA.PERFORMED BY : AMTECH ELECTRONICS (INDIA) LTD. ON 22ndJULY, 2000

INDUSTRY : CHEMICAL

APPLICATION : FERMENTER

MOTOR RATING : 3 PHASE INDUCTION MOTOR.

Rating : 650HP Volt : 415V.

Current: 802 A RPM : 1492

PREVIOUS SYSTEM : Std. AC Variable frequency drive..

PROBLEM OBSERVED : (A) Current Harmonic distortion was arround 78%

(B) Voltage Harmonic distortion was around 3.8%

PRESENT SYSTEM : AC Variable Frequency drive with ‘Static Harmonic Converter’


MERITS OF NEW SYSTEM :

When Harmonic measurements were carried out ( As per Annexure-I)

* Current Harmonic distortion is reduced to 6.7%

* Voltage Harmonic distortion is reduced to 2.2%

This leads to the following benefits :

1. The de-gradation of the components due to harmonics will be reduced to a great

extent,thusenhancing the life of the components ( Fuses, Transformers, Circuit

breakers etc. ) used in the plant.

2. The breakdowns in the plant due to component failures will be reduced, thus

reducing the plant downtime & improving the productivity.

3. The heating in the plant & the power losses in the cables, transformers, motor etc.

will be reduced, thus improving the electrical efficiency of utility.

4. The generators’ power capacity utilisation will be enhanced due to harmonic

reduction.

5. The power factor of the utility is improved from 0.94 to 0.97 without any adition of

power factor improvement capacitors.

3-PHASE415V,50Hz

AC SUPPLY

AXPERTAC VFD650HP

M3-PHASE

415V,50Hz AC SUPPLY

AXPERTAC VFD650HP

M

STATICHARMONIC

CONVERTER 650HPMOTOR

Fig. (1) Before Using Static Harmonic Converter Fig. (2) After Using Static Harmonic Converter

650HPMOTOR

36

AMTECH DOC.NO. : AMTCS-52 JUNE- 2000

TITLE : HARMONICS REDUCTION IN 650HP AC DRIVE Page : 02 of 02



ANNEXURE- IHARMONICS MEASUREMENTS

* Before Using Static Harmonic Converter :

Vdc % THD-R VHM VCF % THD-F

Voltage WaveformVoltage Text

Vrms Vpk

Adc % THD-R AHM ACF % THD-F

Current Text

Arms Apk AKF

PF

Wattage Text

KW KVA DPF KVAR

Current Waveform

* After Using Static Harmonic Converter :

Vdc % THD-R VHM VCF % THD-F

Voltage WaveformVoltage Text

Vrms Vpk

Adc % THD-R AHM ACF % THD-F

Current Text

Arms Apk AKF

PF

Wattage Text

KW KVA DPF KVAR

Current Waveform

0 3.7 16 1.37 418 573

3 61 170 2 258 520 78 14.9

3.8

150 190 0.79 0.99 2.1 lag

395 553 0 1.4 5 1.4 1.4

296 448 0.2 7.3 5.3 1.54 7.4 1.5

188 196 0.94 0.97 50 lag



37

DOC.NO. : AMTCS-57 JULY - 2000

TITLE : AUTOMATION & CONTROL OF OIL FIRED BOILER Page : 01 of 02



HOST ORGANIZATION : M/S CPRI, TRIVENDRUM.

PERFORMED BY : AMTECH ELECTRONICS (INDIA) LTD. IN AUGUST- 2000.

INDUSTRY : UTILITY

APPLICATION : AUTOMATION & CONTROL OF OIL FIRED BOILER

MOTOR RATING : There are mainly two motors in boiler system.Air Blower motor Fuel oil pump motor

Rating : 30HP 5HPVolt : 415V 415VAmp : 44A 7.5ARPM : 1440 1440

PREVIOUS SYSTEM : 1. Motor starting with Star-Delta & DOL Starter.2. Air flow control through conventional Damper Control method.3. Oil flow control through conventional Valve Control method.4. Openloop & Manual Control and operation of boiler functions.

PROBLEM OBSERVED :1. Electrical Energy Loss in both motors running at constant speed which

consumes almost constant power through out any steam flow requirementfrom processs. Also high starting current and jerk creates wear & tears.

2. Improper Fuel/Air ratio results in Poor effiency of Boiler. Due to higher Airflow unburnt carbon particals are thrown away as flue gas which resultsinto more Oil consumption.

3. Lower Air/Fuel ratio causes insufficient combustion of Oil due to lessOxygen available for combustion hence CO gas level in flue gas is higherwhich results in to pollution and poor efficiency.

4. Manual & Open Loop control and operation of system which is dependenton operator . In this case Steam temperature and pressure continuouslychanges according to process steam requirement which effects the qualityof final products.

PRESENT SYSTEM : AXPERT-JETTER boiler controller panel with FUZZY LOGIC and Vector ControlledAC drives commissioned for,

1. Automatic Air Flow control through speed control of Blower motor.2. Automatic Oil Flow control through speed control of Pump motor.3. FUZZY LOGIC control of boiler parameters with multi rules of following parameters.

SR.NO. INPUT TO PANEL RANGE DESIGNATION SENSOR TYPE

01 O2 (Oxygen) in flue gas 0 ->21% OG

4 -> 20mA02 Flue gas temperature 0 ->4500 C T

G‘K’ type thermo couple

03 Feed water temperature 0 ->2000 C TW

‘K’ type thermo couple04 Steam Pressure 0 ->280Psi P

T4 -> 20mA

AMTECH



38

DOC.NO. : AMTCS-57 JULY - 2000

TITLE : AUTOMATION & CONTROL OF OIL FIRED BOILER Page : 02 of 02


ELECTRONICS (I) LTD.AMTECH

SYSTEM BLOCK DIAG. :

MERITS OF NEW SYSTEM: 1. Smooth start of motors through Vector Controlled AC Drive results in less startingcurrent & mechanical wear & tears. Also all electronics motor protection throughAC Drive can be achieved.

2. Boilers are rated for 100% plant utilisation but in normal condition it runs at average80% capacity hence more than 45% energy saving in blower & pump is possibleby reducing the motor speed depending upon the process steam flow requirement.

3. AXPERT-JETTER FUZZY LOGIC of boiler parameters results in optimum controlof Fuel/Air ratio, hence maximum efficiency of boiler is achieved & approximately10 to 15% oil consumption can be reduced depending on the present operatingcondition of boiler.

4. Control of O2

in flue gas results is reduction of pollution by proper combustion of Oil5. Automatic control hence more reliability of the system. Also communication

between boiler and DCS is possible on any communication bus system.ECONOMICAL ANAL YSIS :

* Electrical energy saving : 6KW/Hrs ( compared to previous power consumption )* Electrical energy saving : Rs. 19500/- per month* Payback period : 13 Months (Considering only electrical energy saving.)* Oil consumption can reduced to 10 to 15% depending upon the present system.* Hence overall payback period is less than 1 Year

TGOG

PT

AXPERT-JETTERBoiler Controller panel

5HP MOTOR

30HP MOTOR

TW

BLOWER

PUMP

BOILER

STEAM

FEED WATER

FLUE GAS

Air

Oil



39

AMTECH DOC.NO. : AMTCS-66 MARCH -2001.

TITLE : AIR COMPRESSOR Page : 01 of 01



HOST ORGANISATION : M/S NOVA PETROCHEMICALS, AHMEDABAD.

PERFORMED ON : AMTECH ELECTRONICS (INDIA) LTD IN JULY 1998.

INDUSTRY : PETROCHEMICALS

APPLICATION : AIR COMPRESSOR

MOTOR RATING : 3 PHASE AC INDUCTION MOTOR

PREVIOUS SYSTEM : (1) Star-Delta starting of motor.(2) On-Off type control method for loading / unloading.

PROBLEMS OBSERVED : (1) High starting current & mechanical jerks.(2) Variation in pressure / flow due to change in frequency and voltage of mains.


PRESENT SYSTEM : (1) Axpert AC VFD in place of Star-Delta Starter.

MERITS OF NEW SYSTEM : (1) The output power frequency of AC VFD is stable (415V,50Hz) hence maximumpressure flow can be achieved even after lower frequency / voltage from utility.

(2) Smooth starting of motor hence less mechanical maintenance.(3) Closed loop opration, hence precise flow / pressure control is posrsible(4) Energy saving at lower flow demand.(5) Improved power factor at input side, more than 0.95(6) Easy to start with DG set due to lower starting current.

ECONOMIC ANALYSIS : (1) With Star-Delta starter the motor current was approx 290A, with Axpert AC VFD theInput Current is 218A.

(2) Quality improvement due to uniform air flow.

Hence payback period is 2 Years. (Approx).

RATING : 160KWVOLTAGE : 415V-440V CURRENT : 295ARPM : 1440 FREQ. : 50Hz.

AXPERT VFDDRIVE

3-PHASE415V,50Hz

AC SUPPLY160KWMOTOR

AirCompressor

4 to 20mASignal Output

ControllerCKTs & PID

Airtoward process

PressureTransducer



40

AMTECH DOC.NO. : AMTCS-79 September - 2001

TITLE : ENERGY SAVING IN SECONDARY AIR FAN OF BOILER Page : 01 of 01



HOST ORGANIZATION : M/S MODERN INSULATOR LTD, ABU ROAD.PERFORMED BY : AMTECH ELECTRONICS (INDIA) LTD. IN MAY, 2001.INDUSTRY : CERAMIC (INSULATOR)APPLICATION : SECONDARY AIR FAN OF BOILERMOTOR RATING : 3 PHASE AC INDUCTION MOTOR

RATING - 50HP VOLT- 415VCURRENT - 63A RPM - 2945

PREVIOUS SYSTEM : 1. Star-Delta starter for motor operation.2. Air flow control by damper through servo control motor.

PROBLEM OBSERVED : 1. Beacause of high starting current, power demand peak is more.2. During reduction period, start crrosion effect on burner due to non-available of

secondary air.(Fan totally off due to limitation of damper closing position)3. As no smooth start, the vibration in m/c is high, resulting in reduction of life

of the mechanical system.4. Energy loss beacause of damper control.

PRESENT SYSTEM : Air flow control by varing the speed of motors through AXPERT AC Variablefrequency drive.

FREQ. KW (Consumption) DAMPER POSITIONPrevious System (Without Drive) : 50Hz. 27.65KW 25 to 100% OPENPresent System (With Drive) : 5 to 50Hz 20.12KW 100% OPEN

MERITS OF NEW SYSTEM : 1. Silent operation & no vibration resulting in longer life of the machine.2. No crrosion effect on burner during reduction period as secondary air fan

available by redusing speed of motor up to 4 to 6Hz.3. Energy saving due to flow control by AC VFD.4. Easy operation and interfacing with other system.5. No variation in air flow due to frequency / voltage stability.

ECONOMICAL ANALYSIS :

1. Without drive energy consumption : 27.65KW2. With Axpert AC drive energy consumption : 20.12KW3. Energy saving per hours : 27.65 - 20.12 = 7.53KWH5. Tariff rate rupees : 4.0/-Rs. / Unit (Max.)6. Rs.saving per month (600 Hours operation) : Rs. 18,072/-7. Rs. saving per year : Rs. 2,16,864/-

8. Payback period : 07 Months (Approx)

SYSTEM BLOCK DIA. :

3-Phase415V,50Hz AC Supply

AXPERT VFDSteam Pressure Indi.

BoilerS.A.FanMotor

Damper

PressureFeedback

<- 4-20mA

Control ckt.



41

A P P L I C A T I O NC A S E S T U D Y AMTECH

DOC.NO. : AMTCS-50 JUNE-2000.

TITLE : HYDRO EXTRACTOR


Page : 01 of 01

HOST ORGANISATION : M/S PRAGATI DYEING & PRINTING , SURAT

PERFORMED ON : AMTECH ELECTRONICS (INDIA) LTD. IN FEBRUARY 2000

INDUSTRY : DYEING & PRINTING

APPLICATION : HYDRO EXTRACTOR

MOTOR DATA : 3 PHASE AC IND.MOTOR

FREQ : 50Hz. HP RATING : 7.5 HP

CURRENT : 9 AMPPREVIOUS SYSTEM : AC motor connected to washing drum with clutch & brake system with

DOL starter.

PROBLEM OBSERVED : Drum was connected to motor through operation of clutch which wasresulting into 38Amps current kick & heavy jerk to machine.motorwas connected to mains through dol stater,which results heavy inrushcurrent from mains. Stop operation also carried out through immediateapplication of brake , which was creating wibration to drum & equipmentdamage.overall frequent start-stop leads to wear & tear to machine andrequired maintanence,wasting considerablemanpower.

PRESENT SYSTEM : Ac variable frequency drive for 7.5HP AC Induction motor coupled withdrum.

BLOCK DIAGRAM :

MERRITS OF NEW SYSTEM :

DRUM WITHBOTTOMDISCHARGE

3-PHASE415V,50Hz AC SUPPLY

7.5 HP MOTOR

AC VFD 7.5 HP

1. Washing cycle is fully programmable through customised software

which results into direct saving of energy due auto shut-off of

machine after complication of cloth washing.

2. Ac drive reduces current kick from 47 amps to 15 amps which results into

reducing kva demand.

3. Electronics brake provides smooth stop as well as reduce jerk and

mechanical maintanence to machine.

4. Due to variable speed operation system is flexible for diff.cloth washing.

Overall system saves considerable energy, reduce maintanence, wastage of manpower and increase life of machine.



42

SECTION : 4

PROGRAMMABLE LOGIC CONTROLLER

43AMTECH GROUP

PROGRAMMABLE LOGIC CONTROLLER (PLC)

44

WHY PLC IS NEEDED ?

- TO MEET THE NEEDS OF INCREASING COMPLEXITY IN AUTOMATION.

PROBLEMS WITH HARD WIRED LOGIC (USING RELA YS AND CONTACTORS)

- REDUCED RELIABILITY DUE TO LOOSE/OPEN CONNECTION.

- UNEVEN TIMINGS OF TWO LOGIC OPERATIONS LEAD TO FAILURE OF LOGIC

- HIGH POWER CONSUMPTION.

- LACK OF FLEXIBILITY.

- MORE SPACE REQUIREMENT DUE TO BULKY COMPONENTS.

ADVANTAGES OF PLC

- LOGIC IS IN THE FROM OF WRITTEN PROGRAM WHICH ADAPTS TO THE

CHANGING INPUT CONDITIONS.

- MORE FLEXIBILITY TO CHANGE THE LOGIC.

- OPERATOR ORIENTED PROGRAMMABILITY.

- PROGRAMME EXACTLY FOLLOWS THE ELECTRICAL CIRCUIT.

AMTECH GROUP

PROCESS PLC

45

DEFINITION : It combines the demands on axis control,data processing, handling in a pro-gramming written in plain text language.

FUNCTION : The Process PLC includes :

(1) Interface free programming (Refer fig . 1)

Aim of the Process PLC technology is to combine all functions to be found in automa-tion technique.

- Inputs and outputs (Analoge and Digital)- Servo motor axes- Stepper motor axes- PID controllers- Timers

(2) Plain text language

- Electric wiring being defined by description- No basic knowledge of informatics is required.- Simple command and as few language conventions as possible : precautions against typing and syntax errors.- Closeness to public language,- Plain text language commands used for,

* Text edition* Data input* Data managements* Arithmatics.

(3) Multitasking- In traditional PLC entire program is run constantly.- In Process PLC automation task is spilt up into 32 independent programs. (so-called “tasks”)- In multitasking no special knowledge of informatics required- Programmer must have experience in handling real time automation system.- Multitasking allows splitting up whole program logically.- Fulfils task like,

* Delay with emergency stop recognition* Manual operation* Automatic operation* Display management

- Counters- Operator guidance- Data managements- Serial ports

AMTECH GROUP

PROCESS PLC

46

Fig- 1AMTECH GROUP

PROCESS PLC

47

PROGRMMING :

CONVENTIONAL PLC Vs PROCESS PLC

COST Vs COMPLEXITY OF OPERATIONS :

AMTECH GROUP

PROCESS PLC

48AMTECH GROUP

Delta-1 Delta-4 Delta-8 PASE-E

BasicExpansion Basic

Expansion Basic Expansion

1 Digital Inputs. 8 54 8 144 16 80 480 224 480 5122 Digital Outputs 6 54 8 144 16 80 480 224 480 5123 Analogue Inputs 8 4 41 4 35 184 88 184 5124 Analogue Outputs. 8 1 41 3 35 184 88 184 512

5 Counters1,10 KHz

2,10 KHz

4 dual ch.

1, 10 KHz

1, (optional)

6

Freely Proggrammable Registers 200 2000 1000 20000 20000 20000 20000 28000

7 Flags 255 255

8 Field Bus InterfaceRS 485 RS 485

RS 485, RS 232

RS 232, RS 485, RS 422

RS 232, RS 485, RS 422

RS 232, RS 485, RS 422

RS 232, RS 485, RS 422

9(Jetway)JETTER Field Bus Yes Yes

10Programming Interface

RS 232 RS 232

RS 485, RS 232 RS 232 RS 232 RS 232 RS 232

11 Program Memory 6 Kb 16 Kb 16 Kb 128 Kb 128 Kb 128 Kb 128 Kb12 Real Time Clock No Yes Yes Yes Yes Yes Yes13 Stepper Motor Axes No No No 4 Yes Nil 9 21 6414 Servo Motor Axes No No No 3 Nil 6 14 6415 PID Controllers No No No 12 Nil 12 28 12816 Arithmatic Yes Yes Yes Yes Yes Yes Yes17 Data Management Yes Yes Yes Yes Yes Yes Yes18 Operator Guidance Yes Yes Yes Yes Yes Yes Yes19 Monitoring Yes Yes Yes Yes Yes Yes Yes20 Complex arithmatic Yes Yes Yes Yes21 CPU Slot 1 1 1

22 Slots for Submodules 2 11 23

23

Freely Programmable Interface No RS 232

RS 232, RS 485, RS 422

RS 232, RS 485, RS 422

RS 232, RS 485, RS 422

PLC-CONFIGURATIONS

Nano-A Nano-B Micro-D

SECTION : 5

HARMONICS :CAUSE, EFFECTS AND CONTROL

49AMTECH GROUP

50

ABOUT HARMONICS

What is harmonics?

– Components of electrical waveformother than fundamental sinusoidalwave

– The total harmonic componentsare resolved into sinusoidal wavesof multiple of fundamentalfrequency (Fourier transform)

AMTECH GROUP

51

FUNDAMENTAL WAVE

n Fundamental sinusoidal wave

ππ 22ππ

00

Freq. = 50Hz

AMTECH GROUP

52

FIFTH HARMONIC

2ppppp

n Fundamental and 5th harmonicwaves

Freq. = 50Hz

Freq. = 250Hz, Amplitude = 20%

ppppp

0

AMTECH GROUP

53

WHAT IS NON-LINEAR LOAD ?

n A load that draws a non-sinusoidalcurrent wave when supplied by asinusoidal voltage source.

n PRIMARY LINEAR DEVICES

- Incandescent lamp- Heating loads- Some motors

n MAJOR NON-LINEAR LOADS

- DC drives- AC drives- Solid state UPS- Induction furnace / Arc furnace- Switch mode power supply

AMTECH GROUP

54

GENERATION MECHANISM

R

T H 1 T H 3

T H 4T H 2

i

e e0

n Single phase bridge rectificationcircuit

n Current waveforme

e0

id=e0/R

i

TH1,4 TH3,2 TH1,4 TH3,2

AMTECH GROUP

TYPICAL EXAMPLES OF HARMONICS GENERATING EQUIPMENT

Source circuit typesExample input

current waveformson AC side

Example harmonic componentsof input current (100% for

fundamental-wave component)Typical example applications

Control delay angle 0BCommutation lap angle 20BC

· Electrolysis rectifiers· Electric railroads· Chargers· General DC source

· AC speed control driving· CVCF unit· High-frequency heating unit

3 P

hase

rec

tifie

rci

rcui

ts

1

2

3 · Dimmers· Temperature regulators for thermal equipment

· AC speed control driving (primary voltage conlrol)· Heating controls for electric furnaces

· TV receivers· Audio equipment· Personal computers· Electromagnetic cookers· Room air-conditioners

To A

C s

yste

ms

PWM type

Same as for 3-phaserectifier circuitPulse freq-uency /fundamental fre-quency = 15%

· AC interlinkages for solar power generation, fuel-cell power generation, etc.

Externallyexcited type

Pow

er re

gula

tion

circ

uits

Sin

gle-

phas

ere

ctifi

erca

paci

tors

smoo

thin

gci

rcui

t

Inve

rter

circ

uits

4

5

6

55

EXAMPLES OF HARMONICS GENERA TINGEQUIPMENT

AMTECH GROUP

56AMTECH GROUP

CALCULA TION OF DISTORTIONS

57

INFLUENCE OF HARMONICS

Equipment Influence

Capacitors andreactors

Overheating, burnout, or generation of vibrationand beat noise due to inflow of excessive currentor reduction of circuit impedance againstharmonic currents resulting from resonancephenomena

Neutral cablesOverheating of neutral lines in 3-phase-4-wiresystem due to flow of harmonic current

Rectifiercontroller

Faulty control due to phase shifting of controlsignals

Relays Faulty operations due to excess of setting level orphase variation caused by harmonic current orvoltage

MCCBsFaulty operations due to excessive harmoniccurrent

Overheating in coils and coresGenerators

Communicationline

Generation of noise voltage due toelectromagnetic induction

AMTECH GROUP

58

INFLUENCE OF HARMONICS

Equipment Influence

Audio equipmentand homeappliances

Defects, influence on life and influence onperformance of components such as diodes,transistors and capacitors, caused by harmoniccurrent and voltageNoise and flickering of video image

Computer Adverse influence on performance

Watt-hour meter

Measuring error due to non-linear characteristicsof effective voltage and current fluxBurnout of current coils due to inflow of excessiveharmonic current

Power fuses Blowing out due to excessive harmonic current

Transformer Generation of beat noise due tocore’s magnetostriction phenomena caused byharmonic currentReduction of capacity due to increase of core andcopper loss caused by harmonic voltage and cur-rent

AMTECH GROUP

59

COUNTERMEASURES

n BEFORE GENERATION OFHARMONICS

-AC REACTOR-MULTI-PULSES CONVERTER-PWM CONVERTER

n AFTER GENERATION OFHARMONICS

-PASSIVE FILTER (LC FILTER)-ACTIVE FILTER

AMTECH GROUP

60

MEASURED HARMONIC CURRENT AT FULL LOAD FOR ONE PAR-TICULAR INSTALLATION ARE GIVEN IN TABLE:

CURREENT HARMONIC IN 3 PHASE, 6 PULSE CONVERTER

AMTECH GROUP

61

PRACTICAL RESULTS OF STATIC HARMONIC CONVERTER TYPE-A

STATIC HARMONIC CONVERTER TYPE-A

AMTECH GROUP

62

STATIC HARMONIC CONVERTER TYPE-B(CLEAN POWER CONVERTER)

PRACTICAL RESULTS OF STATIC HARMONIC CONVERTER TYPE - B

AMTECH GROUP

63

USE OF HARMONIC TRAP FILTERS

AMTECH GROUP

64

IL = IF + IH

IC = -IH

IS = IL + IC = (IF + IH) + (-IH) = IF

IL

IF

IH

IC

IS

L oa d

A ctiveF ilter

IS = IF IL

ICIH

DETECTION

PRINCIPLE OF ACTIVE HARMONICFILTER

AMTECH GROUP

65

IMBALANCE COMPENSA TION

n Phase imbalance by single phaseload is compensated (option)

S ingle p h ase lo a dA F

IR

IY

IB

V

R

YB

AMTECH GROUP

66

UNIT COMPENSATION

n IDEAL METHOD

- REDUCTION OF HARMONICS INJECTION

A F A F A F

AMTECH GROUP

67

GROUP COMPENSATION

n ALTERNATIVE METHOD

- PREVENTION OF HARMONIC OUTFLOW TOUTILITY SIDE

A F

A F

AMTECH GROUP

68

IEEE STANDARDS

Current Distortion Limits for General Distribution Systems End-User limits (120 Volts Thru 69,000 Yolts)

Maximum Harmonic Current Distortion in % of IL

Isc/IL <11 11 < h<17 17<h<23 23<h<35 TDD<2020<5050<100100<1000>1000

4.07.010.012.015.0

2.03.54.05.57.0

1.52.54.05.06.0

0.61.01.52.02.5

5.08.012.015.020.0

Even harmonics are limited to 25% of the odd current harmonic limitsabove.Current distortions that result in a direct current offset, e.g. half waveconverters are not allowed.All power generation equipment is limited to these values of currentdistortion, regardless of actual Isc/IL.WhereIsc = Maximum short circuit current at PCC.And IL = Maximum Demand Load Current (fundamental frequencycomponent) at PCC.

AMTECH GROUP

69

IEEE STANDARDS

Bus Voltage at PCC Individual VoltageDistortion (%)

Total VoltageDistortion THD (%)

69 kV and below69.001 kV Thru 161 kV161 kV and above

3.01.51.0

5.02.51.5

Note :

High voltage systems can have upto 2.0% THD where the cause isan HVDC terminal that will attenuate by the time it is tapped for auser.

Two very important points must be made in reference to the above.

1. The customer is responsible for maintaining current distortion to withinacceptable levels, while the utility is responsible for limiting voltagedistortion.

2. The limits are only applicable at the point of common coupling (PCC)between the utility and the customer. The PCC, while not explicitlydefined, is usually regarded as the point at which the utilityequipment ownership meets the customer’s or the metering point.Therefore, the above limits cannot be meaningfully applied to,say, distribution panels or individual equipment within a plant- theentire plant must be considered whwn complying with these limits.

AMTECH GROUP

ELECTRONICS (INDIA) LTD.AMTECH

E-6, GIDC Electronics Zone,Gandhinagar - 382 044. Gujarat (India)PhoneFaxE-mailWeb

::::

079 - 3225324, 3227294, 3227304.079 - [email protected]

MOTION CONTROL SYSTEMS

Date :

Please attach your

business card here

Name :

Designation :Name of

organisation :

Address :

Telephone No :

Fax. No :

Title of seminar :

n You find such seminar useful for your organisation ? : Yes / No

n The seminar presentation is (Tick as per your opinion) :

(1) Excellent (2) Good (3) Satisfactory (4) Poor

n Your Suggestions / Comments on seminar :

Doc.No : AMT/CSD/103-A

Place :

Date : Sign :

AMTECH

ELECTRONICS

YOUR VALUABLE FEEDBACK

70

semi-har-1

Documents