EXPERT SYSTEMS AND SOLUTIONS

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PAIYANOOR, OMR, CHENNAI
Call For Research Projects Final
year students of B.E in EEE, ECE,
EI, M.E (Power Systems), M.E
(Applied Electronics), M.E (Power
Electronics)
Ph.D Electrical and Electronics.
Students can assemble their hardware in our
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projects.
POWER ELECTRONICS BASED ELECTRICAL
ENERGY CONSERVATION IN INDUSTRIES BY
CONTROLLING VOLTAGE,FREQUENCY AND
POWER FACTOR

C.THANGA RAJ,
M.E. POWER ELECTRONICS AND DRIVES,
GOVERNMENT COLLEGE OF ENGINEERING,
TIRUNELVELI-7.

GUIDED BY
Dr. N.S. Mari Muthu,
Prof. & Head,
Department of EEE,
Govt. College of Engineering,
Tirunelveli.
 Energy Management
Organization
-obtain top management energy commitment
- obtain people commitment
- set up a communication channel
-energy auditing, monitoring and reporting

Economics
- break-even analysis
- life cycle costing

Technology
- calculate the cost of electricity
- evaluate losses
-demand side management
 Energy conservation

 General Principle
When we don’t need electrical energy, turn it off.

 Modified Principle
In addition to general principle, we have to minimize losses
or use energy efficiently
Energy Conservation in India

 Energy conservation Act 2001

 BEE

 The energy demand-supply gap

It is expected to reach 100000 MW by the year 2012.
Thus frequent power failure in the future.
 Indian Energy Scenario

 Installed capacity nearly 110000MW

 36% of installed capacity wasted now

 70% of the population lives in villages

 70% of power consumption are in cities

 70000 villages have no electric poles

Why energy conservation in Industries

 Complicated energy tariff

 Industries consumes 30% of total capacity

 Migration from the grid

 80000MW EC potential available

EC potential area in Industries

 Induction motor drives

- pump and fan drives
- partial loaded Induction motor

 Power factor improvement

- thyristor switched APFC

 Lighting load
- High frequency electronic ballast
Induction motor Drives:
● Variable speed drives for pumps and fans
● Voltage control for partial loaded Induction motor.

Variable speed drives:

● Pump drive have applications in several industries such
as chemical plants, photo-chemical plants, refineries,
boilers, etc,
Earlier:
● The fluid flow was obtained by adjustment of opening of
valves (by throttling) — Inefficient.

When openings of the valves are reduced

● Friction component increased (pressure increases)
● new operating point Q.
Earlier cont….

Power consumption by the pump:

● Product of the head and fluid flow
● In earlier case, the above parameters are cancelled to
each other.
● No energy conservation using throttling valve.

Using variable speed drives:

● Valve opening kept at maximum (P is same)

● Water flow is depends on pump speed
● Pressure is somewhat reduced when pump speed is reduced (new
operating point Q’)
● Head and fluid flow reduced
● Power consumption α head and fluid flow
● Energy conservation at low speed
● These drives have ratings in MW range. Large amount of energy
can be saved.
Energy Efficient operation of Induction motor drives at partial load

● In many applications, induction motor operates under no load (or) lightly

loaded for prolonged periods.

Example: pressing machine, conveyers, rock crushers, drill

presses, wood saw, mixer drive in biscuit industry.

Results: Low efficiency and low power factor.

 Table: Motor efficiency and power factor at
different loads in percent (4 pole m/c)

HP KW HP Power Factor

100% 75% 50%

100% 75% 50%

5.0 3.7 82 82 80 .88 .84 .75

10.0 7.5 85 84 81 .85 .77 .64

25.0 18.5 89 89 87 .89 .85 .75

50.0 37.0 91 91 89 .84 .81 .73

75.0 55.0 92 92 91 .85 .81 .69

100 75.0 92 92 91 .91 .89 .86

● Reduced voltage operation in such cases helps improvement in both efficiency

and power factor.
Partial Load cont……..

● Maximum efficiency of Induction motor only at core loss =

copper loss.

● At no load, core loss has large value, efficiency reduced.

● Reduction in voltage, increase the copper loss but reduces core

losses by a large amount.

● At some voltage, core loss = copper loss; maximum efficiency.

● For each loading, there is an optimum value of voltage for loss

minimization.

● From no load and blocked rotor test, we can find core loss and
copper loss.
 Zero crossing detector for voltage
controller
CONTROL VOLTAGE

+12V
1/2 IC5
LM747
X1 +12V R21
230V AC PRI D7 6.8K
15V-0-15V SEC R25
500mA TRANSFORMER R22 IC6 D9 X2 D11
1 IC3 3 68
7812 -12V R19 1K 555 G1
D2 +12V
R15 C1 +
2 1K 0.5W
10K D1 1000 R26
C3
R16 - 25V 10K
1 16V
230V 2.2K
AC R17 C4
2.2K C2 1 X3
+ 1000 16V
D3 D4 - 25V 1
R20 R28
IC3 3 1K R23 IC7 D13 10K
R18 2 +12V
7912
-12V 1K 555
10K D8
G2
R27 D12 D14
R24 68
1/2 IC5 6.8K 0.5W
LM747

+12V
Power module
Motor line current sensor
DAC interface for 8085
 EXPERIMENTAL RESULTS

 Rating of the motor : 1 Hp, 1470 rpm,1.9A, 3

phase, class E, 50 Hz, Delta connected
Induction Motor
 LOAD TEST
 V0 in Volts I0 in Amps W0 in Watts

385 1.0 192

 BLOCKED ROTOR TEST

Vsc in Volts Isc in Amps Wsc in Watts
145.2 1.9 312
 No load phase current Is = 0.58 A
 No load voltage = 385 V
 Total resistance / phase refers to stator
 R01 = Ps / 3 * Is2
 = 86 ohm
 Z01 = 132 ohm
 X01 = 100.1 ohm
 Rotor resistance refer to stator ( R2i ) = 38.9 ohm
 Stator resistance ( R ) = 47.1 ohm
 No load power factor = Pi / 3 * V * I0
 = 192 / 3 * 385 * 0.58
 = 0.29
 Energy component of no load line current Il e = 1.0 * 0.29 = 0.29 A
 Magnetic component of no load line current ( Il m ) = 0.96 A
 Energy component of no load phase current ( Ie ) = 0.58 * 0.29
 = 0.168 A
 R0 = V / Ie = 385 / 0.168 = 2, 292 ohm
 Magnetic component of no load phase current = 0.55 A
 X0 = 385 / 0.55 = 700 ohm

 No Load Loss Vs Voltage

Voltage( 380 375 370 365 360 355 350 345 340 335 330 325 320 315
(V)
No load 176 168 160 152 152 144 136 136 128 128 128 120 112 104
loss (W)

Copper loss Vs line current

Current 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9
(A)

Loss (W) 86. 104.5 124.4 146 169.3 194.4 211.18 249.6 280 312
4
 Proposed Load Current Vs Voltage

Load Current 1.1 1.2 1.3 1.4 1.5

(A)

Voltage (v) 315 335 355 375 385

 Power factor

Consider a stein of beer,

Power factor= beer/ mug capacity
Foam referred as Reactive power
 Benefit of power factor improvement

 Reduce energy losses in conductors

 Reduce KVA demand needed
 Reduction in size of the conductor,protecting devices.

For example: A 1000 KW load,480 V of industrial load,

Current in 80% power factor = 1505 A

Current in 95% power factor = 1267.6 A
Thyristor switched APFC

● By fixed compensation
- not able to achieve desired power factor.
-Leading power factor under certain load conditions.
( Un healthy for the installation)

● Some loads (welding equipment, injection molding equipment,

starting of large induction motor) require large amount of
reactive power for very short duration of time.(contactor
control not suited)

● Thyristor switched ADFC have a response time in

milliseconds.
 Circuit diagram for power factor
improvement
R25 D9 D11
68 X2
GATE
0.5W

X1
230V AC PRI
0 - 3 V SEC
500mA TRANSFORMER

R15
10K R25 D9 D11
68 X2
230V GATE
AC R17
2.2K
0.5W

R18
10K

R25 D9 D11
68 X2
R15 GATE
10K 0.5W
230V
AC R17
2.2K

R18
X1 10K
230V AC PRI
0 - 3 V SEC
500mA TRANSFORMER
CRO waveform
motor Speed(rpm)
HP 3000 1500 1000 750
Transformer Required
2.5 1.0 1.0 1.5 2.0 KVA Capacitor
5.0 2.0 2.0 2.5 3.5 KVAR*

7.5 2.5 3.0 3.5 4.5 9 4

10.0 3.0 4.0 4.5 5.5 12 6

15.0 4.0 5.0 6.0 7.5 18 8

20.0 5.0 6.0 7.0 9.0 24 12

25.0 6.0 7.0 9.0 10.5 30 15

30.0 7.0 8.0 10.0 12.0 36 18

40.0 9.0 10.0 12.0 15.0 57 25

50.0 11.0 12.5 16.0 18.0 95 45

75.0 16.0 17.0 21.0 23.0 128 50

100.0 21.0 23.0 26.0 28.0 160 75

150.0 31.0 33.0 36.0 38.0

200.0 40.0 42.0 45.0 47.0
250.0 46.0 50.0 53.0 55.0
 0.85 0.90 0.95 0.96 0.97 0.98 0.99 1.0
Cosø2

Tanø2 0.62 0.48 0.33 0.29 0.25 0.20 0.14 0.0

Cosø1 Tanø1

0.50 1.73 1.112 1.248 1.403 1.441 1.481 1.529 1.590 1.732
0.55 1.52 0.898 1.034 1.190 1.227 1.268 1.315 1.376 1.518
0.60 1.33 0.713 0.849 1.005 1.042 1.083 1.130 1.191 1.334

0.65 1.17 0.549 0.685 0.840 0.887 0.918 0.966 1.026 1.169
0.70 1.02 0.400 0.536 0.691 0.728 0.769 0.817 0.878 1.020
0.80 0.75 0.130 0.266 0.421 0.458 0.499 0.547 0.608 0.750
0.85 0.62 0.135 0.291 0.328 0.369 0.417 0.477 0.620

0.86 0.59 0.109 0.264 0.301 0.343 0.390 0.451 0.593

0.89 0.51 0.028 0.183 0.220 0.262 0.309 0.370 0.512

0.91 0.45 0.127 0.164 0.205 0.252 0.313 0.455

0.92 0.42 0.097 0.134 0.175 0.223 0.283 0.426

0.95 0.33 0.037 0.078 0.125 0.186 0.328

0.96 0.29 0.041 0.088 0.149 0.292

0.97 0.25 0.047 0.108 0.251

 Case study

 Name of the organization: M/s Haitima Textiles Limited,

Ciombatore

Energy saving from induction motor drives in loom shed: 85363KWh

Demand reduction from power factor improvement : 252 KVA

( 0.92 to 0.99)

Energy saving from lighting load : 27360 KWh

Conclusion

Adoption of Energy Conservation.,

1. Reduce effective demand
2. Help in abatement of green house
gases and other pollutants
3. Reduce global warming
4. Detuned filter must be used
 REFERENCES
[1] Mohan, Undeland, Robbins, “Power Electronics- Converters,
Applications, and design”, John Wiley and Sons Publications- Third
Edition.

[2] S.Y Ron Hui, Leung Ming Lee, Henry Shu-Hung Chung, Y.K Ho, “An
Electronic Ballast with Wide Dimming Range, High PF, and low EMI”,
IEEE transactions on power electronics, vol-16 No. 4, July 2001.

[3] G.K.Dubay, “Fundamentals of Electrical Drives”, Narosha Publications

New Delhi.

[4] C.Thangaraj, S.C.Ramesh, “Role of Power Electronics in Electrical

Energy Conservation”, IEE (UK) Calcutta branch, International
Conference Proceedings on Power, Energy and IT in Power Sector,
page 242-245.

[5] C.Thanga Raj, “ Energy Audit in Textile mill –A Case Study” National conference
on Emerging trends in Energy and environment, organized by Sri Sai Ram
Engineering college, Chennai, India