how to improve industrial energy efficiency
TRANSCRIPT
Delta Power Solutions (I) Pvt. Ltd. Amol Bhendale
How to Improve Industrial Energy Efficiency
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Contents
• Electric System Efficiency Overview
• Save Energy by Improving Power Quality
• Power Quality Solution Evaluation
• Delta Power Quality Solution Portfolio
• Key Client
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Contents
• Electric System Efficiency Overview
• How Improving Power Quality Can Save Energy
• Power Quality Solution Evaluation
• Delta Power Quality Solution Portfolio
• Successful Stories
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Industrial Energy Efficiency
• Improvements in energy efficiency are generally achieved by adopting a more
efficient technology or production process or by application of commonly
accepted methods to reduce energy losses.
• There are many motivations to improve energy efficiency. Reducing energy use
reduces energy costs and may result in a financial cost saving to consumers if
the energy savings offset any additional costs of implementing an energy
efficient technology.
• Reducing energy use is also seen as a solution to the problem of reducing green
house gas emissions.
According to the International Energy Agency, improved energy efficiency
in buildings, industrial processes and transportation could reduce the world's
energy needs in 2050 by one third, and help control global emissions of
greenhouse gases.
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Electric System Efficiency Overview
Basic Structure of the Electric System
11kV/ 22kV
33kV & above
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Electric System Efficiency Overview
Electric System Efficiency
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Transmission & Distribution Losses
Cable & Wires
Copper Losses (I2R) (Load)
Dielectric Losses (No Load)
Corona Losses (No Load)
PILC Cable EPR Cable
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Transmission & Distribution Losses
Transformer
Copper Losses (I2R) (Load)
Core Losses (No Load)
Transformer Losses as Percent of Full Load
400kVA 11kV Transformer
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Contents
• Electric System Efficiency Overview
• How Improving Power Quality Can Save Energy
• Power Quality Solution Evaluation
• Delta Power Quality Solution Portfolio
• Successful Stories
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Power Quality Overview
Main Contributors to Poor Power Quality of Distribution
System
Reactive power
It loads up the power supply system unnecessarily.
Harmonic pollution
It causes extra stress on the electrical networks and reduces stability.
It makes installations run less efficiently.
Load imbalance
Unbalanced loads may result in excessive voltage imbalance causing
stress on other loads connected to the same network.
Increase neutral current and neutral to earth voltage.
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What’s Reactive Power?
It is the power that magnetic equipment (transformer, motor and
relay) needs to produce the magnetizing flux.
Fundamental Reactive Power
• Current waveform is leading 90 degree ahead of the voltage-----capacitive
• Current waveform is lagging 90 degree behind the voltage-----inductive
Leading
Capacitive Current
Lagging
Inductive Current
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What’s Reactive Power?
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What’s Harmonics?
Non-linear device or load cause the harmonic current and voltage
IEEE 519-1992 defines harmonic as a sinusoidal component of a periodic wave or
quantity (for example voltage or current) having a frequency that is an integral multiple
of the fundamental frequency.
50Hz (h=1)
150Hz (h=3)
250Hz (h=5)
350Hz (h=7)
450Hz (h=9)
550Hz (h=11)
650Hz (h=13)
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What’s Harmonics?
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Save Energy by Improving Power Quality
Reactive Losses
Power Factor Decreases
with Increased Reactive
Load
Low Power Factor
Increases Losses
Inductive Load
Resistive Load
Harmonic Losses
Electrical equipment efficiency decreases as
harmonic level increases.
Power Losses Caused by Imbalance
When loads are unbalanced, copper losses will
increase (@12.5%) as compared to the balanced
load case.
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222 PQS
SP /cos
cosI
IPF 1
Power Factor and CosΦ
Active Power
P (kW)
Reactive Power
Q (kvar)Apparent Power
S (kVA)
Harmonic Reactive Power
Q (kvar)
Active Power
P (kW)
Apparent Power
S (kVA)
Reactive Power
Q (kvar)
No harmonics condition Harmonics condition
I1 is the fundamental current
I is the total current
Reactive and Harmonics will increase the total current, so power losses
will be reduced by compensating Reactive and Harmonics.
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Power Quality Problems Bring Down Efficiency
Resonance
Over
Current
Service
Time
Reduction
Power
Loss
Capacity
Waste
Harmonic
Reactive
Imbalance
Voltage
Fluctuation
Switch
Gear
Fault
Voltage
Distortion
Disturbance
Service
Time
Reduction Switch
Gear
Fault
Device
Damaged
Operation
Abnormal
Service
Time
Reduction
Error
Metering
Device
Shutdown
Device
Damaged
Device
Shutdown
Device
Damaged Reactive
power
Penalty
Diesel
Generator
Failure
Power
Off
Neutral
Over Current
Device
Damaged Fire
Risk
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Boost Stability of Electric System
• Eliminate harmonics, so risk of resonance can be avoided.
Extend Service time of electric equipment
• Reduce voltage distortion to extend service time of electric devices.
Investment Savings Transformer and Cable
• Suppressing harmonics and reactive power can reduce the total current, so more loads can be connected to the same transformer.
Reduce Electricity Bill and Harmonics Penalties
• Lower current could reduce thermal loss in power cables and transformer, also, improving power factor can avoid reactive power penalty bill.
Customer Value of Improving Power Quality
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Power Quality Regulation or Standard
Reactive power regulation
In India, electric power companies require power factor >0.9,
otherwise electric consumer will get penalty bill.
Harmonic standard
IEEE 519 standard for Voltage harmonics
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Harmonic standard
IEEE 519 standard for current harmonics
Power Quality Regulation or Standard
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Contents
• Electric System Efficiency Overview
• How Improving Power Quality Can Save Energy
• Power Quality Solution Evaluation
• Delta Power Quality Solution Portfolio
• Successful Stories
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Power Quality Problem in the Past
Transformer
Capacitive and Inductive Loads
Inductive Motor
Oil & Gas Industry Data Center Steel Industry Process Plants Automotive Industry
Incandescent Lamp
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Power Quality Solution in the Past
In the Past
Major Loads：
Inductive Motors
Incandescent Lamps
PQ Problems：
Inductive Reactive Power
PQ Solution:
Capacitor Banks
A、B、C 0.4 KV Bus
K1
Transformer
Capacitor Banks
10kV or 35kV provided by electric
power company
Inductive Motors Incandescentlamp
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Power Quality Problem in Modern Time
Nonlinear Loads
Grid Transformer Thyristor Rectifier VFD(Variable-Frequency Driver) UPS System
Oil & Gas Industry Data Center Steel Industry Process Plants Automotive Industry Modern Building
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In modern time
Major Loads：
VFD
Rectifier
UPS
LED
PQ Problems：
Harmonics
Reactive Power
Load Imbalance
PQ Solution:
Active Power Filter
A、B、C 0.4 KV Bus
K1
Transformer
10kV or 35kV provided by electric
power company
VFD LED Lights
APF
CT
MedicalInstruments
UPS/Server
Power Quality Problem in Modern Time
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Capacitor Banks
SVG (Static Var Generator)
APF (Active Power Filter)
Power Quality Solution Evolution
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Power Quality Solution Evolution
Comparison between Capacitor Bank, SVG and APF
Item Capacitor Bank SVG APF
Harmonic
Filtering Not available Not available
Eliminate 2nd~50th
harmonics (selectable)
Reactive
Power
Compensatio
n
Discretely compensate
inductive reactive power
only
Steplessly compensate
both inductive and
capacitive reactive power
Steplessly compensate
both inductive and
capacitive reactive power
Imbalance
Correction Not available Available Available
Response
Speed
slow, can't track dynamic
reactive power (20ms~5s)
fast, can track dynamic
reactive power (<0.1ms)
fast, can track dynamic
reactive power (<0.1ms)
Harmonic
Resonance
Problem
Potential resonance
between capacitor and
transformer sabotages
power system stability.
Active compensation
technology avoids
harmonic resonance from
the principle.
Active compensation
technology avoids
harmonic resonance from
the principle.
Output Ability Actual output capacity is
less than the rated capacity.
Actual output capacity is
the same as rated
capacity.
Actual output capacity is
the same as rated
capacity.
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CT1
Control
Algorithm
Harmonic & Reactive Detection
Power Circuit(Inverter)
10KV/0.4KV
PLL
Grid
APF
NonlinearLoad
i_LoadFunction & Mode
Setting
i_Reference
CT2
PWM
i_Apf
Phase
PT
u_Grid
L1 R C
L2
L3
Principle Diagram of APF
=
+
Principle of Active Power Filter (APF)
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Principle of Static VAR Generator (SVG)
0.4KV Bus
Reactive &
Unbalanced Load
Static Var Generator
(SVG)
CT
Us
Us
Active current
Igrid
UsILoad Us
Inductive &
Resistive Current
Us
Isvg Us
Capacitive
Reactive Current
Transformer
SVG is detecting the phase angle difference and generating the leading
current.
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Principle of Static VAR Generator (SVG)
SVG Operating
Mode Waveform and Vector Remark
No Load Mode
UI = Us，Isvg = 0，SVG
outputs no reactive
current.
Capacitive Mode
UI > Us，Isvg is leading
the voltage, and its
amplitude is continuously
adjustable.
Inductive Mode
UI < Us，Isvg is lagging the
voltage, and its amplitude
is continuously adjustable.
UI
Us
UI
Us
(a) UI = Us
SVG Outputs no Current
UI
Us
IsvgUI
Us jxIsvgIsvg
(b) UI > Us
Leading Current
UI
UsIsvg
UI
Us
jxIsvgIsvg
Lagging Current
(c) UI < Us
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Contents
• Electric System Efficiency Overview
• How Improving Power Quality Can Save Energy
• Power Quality Solution Evaluation
• Delta Power Quality Solution Portfolio
• Successful Stories
Delta Confidential
Modular APF
Type
Draw Type (Hot-swappable)
Fixed Type (Non-swappable)
Feature
Each module can work independently, and modules
can be paralleled to increase the capacity.
Draw type module needs the designated frame
when wiring.
Fixed type module needs to screw when wiring,
while frame of module is not necessary, which will
help reduce cost.
Delta PQC Series APF Portfolio
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Delta PQC Series APF Portfolio
Modular APF—Draw type
Delta PQC Series APF –Cabinet System
Voltage Rated Current Dimension (mm)
415V 50A~525A 600x800x2000
Delta PQC Series APF –Draw type Module
Voltage Rated Current
Dimension (mm)
415V 50A 513x603x180
415V 75A 513x603x180
Cabinet system is a combination of Draw modules
The dimension above includes the frame of module
Rear View
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Delta PQC Series APF Portfolio
Delta PQC Series APF –Cabinet System
Voltage Rated Current Dimension (mm)
415V 50A~525A 600x800x2000
690V 100A~500A 800x1000x2200
Delta PQC Series APF –Fixed type Module
Voltage Rated Current
Dimension (mm)
415V 50A 440x522x174
415V 75A 440x522x174
415V 100A 600x728x220
690V 100A 600x728x270
Cabinet System is a combination of fixed modules
Each module is an independent filter system
Modular APF—Fixed type
Rear View
Front View
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Wall-mounted APF
Feature
Wall-mounted
Other features are the same as fixed type
modular APF
LCM kit is optional
Model
Delta PQC Series APF Portfolio
Delta PQC Series APF –Wall-mounted
Voltage Rated Current Dimension (mm)
415V 50A 440x175x610
75A 440x175x610
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Delta PQC Series SVG Portfolio
Modular SVG—Fixed type
Delta PQC Series SVG –Cabinet System
Voltage Rated Current Dimension (mm)
415V 50kvar~350kvar 600x800x2000
Delta PQC Series SVG –Fixed type Module
Voltage Rated Capacity
Dimension (mm)
415V 50 kvar
440x522x174
Cabinet system is a combination of Fixed type modules
The dimension is the same as 75A Fixed type APF
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CT
PM2
PM7
PM1
10KV/ 0.4KV
Q1
Q2
Q7
HMI
Grid
System(7 PMs)
Nonlinear Load
Max capacity per Cabinet : 525A or 350kvar with 7 PMs
APF/SVG Modules in Parallel
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Cabinets in Parallel
CT
PM2
PM7
PM1
10KV/ 0.4KV
Q1
Q2
Q7
HMI
Grid
System N
Nonlinear LoadPM2
PM7
PM1Q1
Q2
Q7
HMI
System 1
Max number of cabinets in paralle: up to 10 racks
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Size and Cable Entry
Cable Entry
- Bottom
2000mm
Cable Entry
- Top
180mm
Cable Entry - Rear
Cable Entry: (Cabinet)
1. Top
2. Bottom
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Airflow and Cooling
System
Power Module
IN
OUT
OUT
IN
OUT OUT
OUT
PM ≥ 480m3/Hour
System ≥ N x 480m3/Hour
Cooling fans
Cooling fans
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Contents
• Electric System Efficiency Overview
• How Improving Power Quality Can Save Energy
• Power Quality Solution Evaluation
• Delta Power Quality Solution Portfolio
• Key Client
Confidential
Potential Industry Harmonic Source
Rubber & Tire industry DC Internal Mixer(SCR Rectifier),
Metro Power Supply System VFD, LED Lighting
Petrochemical & Coal chemical Industry VFD, Rectifier
E-Vehicle Charge Station SCR Rectifier
Metallurgy Electric Arc Furnace
Automobile manufacturing/Shipyard Arc Welder、SCR Rectifier
Harbor VFD
Hospital Medical Instrument
Telecom、IT Datacenter UPS、SMPS
Airport、Stadium LED Lighting
Fairground VFD
Building(Hotel、Skyscraper) LED Lighting、Air conditioner、
Elevator， etc.
Chemical Fiber/Papermaking VFD
Potential Industry
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Some of Our Customers
Smarter. Greener. Together.
Thank you!
Amol Bhendale
+91 9920216606