analysis of harmonic in cement plant in beawar & suggestion of filter at appropriate place in power system of plant

1. Analysis of harmonic at different level
on distribution system ,its effect and
reduction by using appropriate filters
ANUJ ARORA
IIT ROORKEE
MENTOR-MR. ARUN AGARWAL

2. 4:Current and voltage distortion factor and their limit
Content
3: Harmonic Hazards
1: Harmonic Definition
2: Generation of harmonics
5:Methods for Harmonic Mitigation
Study, analysis and reduction of harmonics in unit-3
to unit-8
6:

3. WHAT ARE HARMONICS –
Harmonics are integral multiples of some fundamental frequency that, when added
together, result in a distorted waveform.
• superimposed on fundamental
• produced by non-linear loads
• named by order number "n
Harmonic Definition
Example: In a 50 Hz electrical system, 150 Hz is the 3rd harmonic, 250 Hz is the 5th
harmonic, and so on.
harmonics
distorted wave
fundamental

4. In fact, any function may be constructed from a
sine wave and some number of its harmonics:

5. Where do they come from?
The power company typically supplies a reasonably
smooth sinusoidal waveform:

6. Where do they come from?
...but nonlinear devices will draw distorted waveforms,
which are comprised of harmonics of the source:

7. Common sources of Harmonics
Lighting ballasts
UPS systems
M
AC and DC drives
IN SHREE CEMENT plant DRIVES are main source of harmonic.

8. In recent years, as rectifier, variable frequency speed control devices,
electric arc, electrized railway and all kinds of power electric devices are
being widely used in power grid, the power quality is becoming more and
more poor than before because of non-linear, impact and unbalance caused by
these loads.Now the harmonic pollution is the main reason of poor power
quality.
The Generation of Harmonic
Ferromagnetic
Satuation
Type:
Transformer, Reactor, Mutual inductor
etc.
Solid State
Switch Type:
Rectifier, inverter etc. The harmonic is
mainly related to rectifier pulse. 6-pulse
generates 6K±1 harmonic, 12-pulse
generates 12K±1 harmonic.
Electric
Arc Type:
Electric arc furnace, metal melting device,
welding machine etc, harmonic change very
fast.

9. Harmonic Hazards
Power
Equipment
Products Money
expense
Safety
Harmonic
affects safety
operation of
production lines,
and then cause
product quality
problems, such
as Paper
production,
textile,
semiconductor
etc.
Capacitor
Aging, Reactor
burning, motor
damage,
transformer
overheating,
communication
device damage
and power
cable aging etc.
Harmonic
increases line
loss and
transformer
design
capacity, and
then cause
extra
electricity bill
and
equipment
cost.
Harmonic results
in misoperation
and failure
operation of
protection relays,
and then the
control cabinet
can’t work
normally; there
are potential
safety hazards of
harmonic
resonance and fire

10. The direct effects caused
by harmonics
● Reactive power
compensator (TSC) can’t
switch on or capacitor
burnt.
● Harmonics will cause
parallel resonance and series
resonance in power grid, it
will magnify harmonic, which
result in bad power accidents.

11. The direct effects caused
by harmonics
● Harmonic causes damage of control modules of numerical
control machine, PLC and home appliance and office
appliance.

12. The direct effects caused
by harmonics
● Harmonic causes transformer overheat, big noise and even
burning; power cable overheat and aging.

13. The direct effects caused
by harmonics
● Harmonics will cause interference to adjacent communication
systems, it will make communication devices generate noise,
reduce communication quality, and even result in data lost.

14. Harmonic-"Subtle Poison" in power
network
● Air pollution, water pollution etc, it can’t result in
dead immediately, but its threaten always exists, so,
the harmonic pollution to power grid is like
environment pollution to human, it is subtle poison.

15. Harmonic Distortion factors
• Harmonic Distortion is a mathematical way of describing how
non-sinusoidal a wave shape appears.
• THD v for voltage harmonics and THD i for current harmonic
measurement.

16. THD V
Individual distoration
limit
5
3
2.5
1.5
1.5
1
IEEE-519 voltage distortion limits
69 Kv and under 69000-161Kv 161 Kv and above
Current and voltage distortion limit

17. IEEE-519 current distortion limits
Concerning current harmonic distortion,IEEE-519 defines the limits as a function of the ratio
between the short-circuit current at the PCC ( Isc) and the average current corresponding to the
maximum demand during a period of 12months (IL).

18. Even harmonics are limited to 25% of the odd harmonic limits.
Current distortions that result in a DC offset (e.g., half-wave
converters) are not allowed.
IEEE-519 practically establishes a joint involvement of the
customer and the electric company to maintain harmonic
distortion levels within limits that will enable the power
distribution systems to operate within safe voltage distortion
limits.
The most widespread standards for harmonic control worldwide
are due to IEEE in the U.S. and IEC (International Electrotechnical
Commission) in the European Union.

19. Methods for Harmonic Mitigation
● large power electrical nonlinear equipments often requires
mitigation equipment in order to attenuate the harmonic currents
and associated voltage distortion to within necessary limits.
● There are two types of filters:
Passive filters
Active filters

20. ● An LC circuit, tuned to each harmonic order to be filtered, is
installed in parallel with the non-linear load . This bypass circuit
absorbs the harmonics, thus avoiding their flow in the distribution
network.
● The passive filter is tuned to a
harmonic order close to the order
to be eliminated
● Passive filter easily effected by load
impedance and can be damage if its
overload and its require floor area
that is 3 time large than Active filters
so people prefer active filter over
passive filter.
Passive filters

21. Active Power filter(APF)
● Active Power Filter Capabilities-
Eliminating Voltage and Current Harmonics
Reactive Power Compensation ( power factor improvement)
Regulating Terminal Voltage
Compensating the Voltage flickering
● Active filter uses harmonic reduction techniques to improve the
quality of power, by injecting equal current or voltage distortion
into the network but in opposite magnitude, which automatically
cancels the actual distortion presented in the circuit and it utilize
fast-switching insulated gate bipolar transistors (IGBTs) bridge

22. Active Power filter

23. Study, analysis and reduction
of harmonics in unit-3 to unit-8
● We measured THD of values only on the cooler bas bar
(415 Volt) of all unit because mainly all the VFD or drives are
present at the cooler pcc.
●All THD are in %(percentage) , current in ampere and losses in
Watt.
● In many of A.C. drive and all d.c. drive because of their low
frequency ALM-35(harmonic measurement meter) can’t
measure THD V and THD i . it only work in range of 40 to 50
HZ.(It represent by - in table)

24. Study, analysis and reduction
of harmonics in unit-7

25. Study, analysis and reduction
of harmonics in unit-7
THDv
(%)
THDi
(%)
Cur-
rent
(A)
Wire
CU
losses
(W)
THDv
(%)
THDi
(%)
Curr
ent
(A)
CU
Wire
losses
(W)
Motor
Losses
(W)
Motor
+wire
CU
Looses
(W)
FN-8A 5.76 38.1 225 312.8 12 28.2 245 585.2 2481.3 3379.5
FN-9A 5.56 36.3 270 328 14.43 6.16 273 1062 2110.6 3500.6
FN-10 5.53 40.8 180 300.3 13.8 15.9 160 777.2 1305.6 2383.1
FN-11 5.46 58.5 65 39 - - 105 306.6 992.25 1337.8
FN-12 5.26 39.7 190 334.5 12.16 4.86 270 2027 3013.6 5375.5
BOOSTER
FAN
7.33 39.03 200 360 7.9 1.86 250 1875 2583.7 4818.7
Kiln M.D. 6.2 62.4 580 2523 - - 500 1125 25000 28648
GRATE-1 4.8 60 50 72 - - 55 183.9 248.05 503.95
GRATE-2 4.9 70 45 46 - - 50 139.1 187.5 372.65
Before DRIVE After DRIVE

26. Study, analysis and reduction
of harmonics in unit-7
THDv (%) THDi (%) Current(A) CU losses(W)
Lighting D.B. 5 6.533 60 81.9
Welding D.B. 5.4 13.733 15 1
Cooler APFC 7.733 44.766 580 1009.2
Cooler transformer with
APFC OFF
4.333 13.66 1500 5015.25
Cooler transformer with
APFC ON
7.133 28.1 1420 4494.56
NOTE-1. We found out that after use of APFC electricity bill is decreased but
harmonic contents is increase its means APFC is actually enhancing harmonics
by decrease impedance for harmonics voltage.
2. If we use filters as place of APFC than along with power factor improvement
it’s also decrease harmonic contents.

27. THD v R
THD v B
THD I Y
THD I AVG
0
10
20
30
40
50
60
70
LC-20

28. • Total CU losses=60921.8 W
• Total Cu losses per day=60921.8*24=1462.123
KWH per day
• 1KWH=3.5 RS
• Money loss due to Cu losses =5117 RS per day
• If we use filter at the cooler bus pcc than we can
save 15% losses due to harmonics
• Saves money per day if we use
filters=5117*0.15=767.61 Rs per day
• Saves money per month if we use filters=23030
RS

29. • Cost of filter to be- 15, 00,000 RS for rating of
400A
• Payback time=15, 00,000/23,030=57 month=
5 year 5 month
• Actually after use of harmonic filter power
factor also increase upto 0.98 so if we use
harmonic filter then there will be no need of
APFC .so we can implement this APFC to
another place.
• APFC cost=5, 70,000 RS
• PAYBACK TIME=(15,00,000 - 5,70,000)/23,030
=3 YEAR 4 month

30. 1. There will be no false tripping of circuit breaker, relay and fuses
due to harmonics.
2. Due to harmonics current wire is overloaded and their
temperature increase upto 10 degree C above their normal
temperature due to this insulation life decrease upto 50% in motor
actually after use of active we increase insulation life of motor and
decrease the current in wires so losses also decrease.
3. Power factor improve upto 0.98.
Remark- For remove harmonics and decrease losses in wire, motor
and transformer harmonics Filter of 400 A suggested at the
cooler bus bar.
And along with this there are other benefits of
use the active filters –

31. UNIT-3 to UNIT-8 Cooler bus (415 V)
Cooler pcc
Bus bar
UNIT-3 UNIT-4 UNIT-5 UNIT-6 UNIT-7 UNIT-8
THD v (%) 10.833 3.4 5.966 6.7 7.133 6.4
THD i (%) 48.866 7.533 16.1 21.166 28.1 18.466
● UNIT-3 and UNIT-7 have THDv and THDi very high.
● So firstly we will have to implement Active filter at Cooler
pcc bus bar of unit-3 and unit-7.