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Benefits of Increased Power Quality in the Textile Industry

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Harmonics are created when machines draw non-sinusoidal (incorrect sin waves that reduce power quality) currents when a sinusoidal voltage is applied. These harmonics are multiple of the fundamental frequency of an electrical power system. Machineries used in textile industry plants that draw non-sinusoidal currents are also known as non-linear load.

Below are some of these devices:
1) Adjustable speed drives
2) DC Drives
3) Variable frequency drives
4) 6 pulse converters
5) Power rectifiers
6) Uninterrupted power supplies
7) Computers

If a facility has more than 15% non-linear load, it is vital to conduct a harmonic study before applying the Power Quality (PQ) solutions. There are multiple methods used in order to promote the savings by applying PQ solutions. The most important method followed in textile industry is to claim significant benefits associated with the cost of solution equipment related to payback. Many are so called tangible or hard savings but many are intangible or related to payback. Most are so called tangible or hard savings but many are intangible or soft savings that are associated with or a side benefit of the solution.

In textile industry, hard savings include:

Reduced energy (kWH) usage
Demand reduction (kVA)
Improved PF & voltage quality
Reduction in I2R losses in conductor
Reduction in equipment losses (motors, transformers, switchyard)
Operating cost reduction
Reduction in taxes

In textile industry, soft savings include:

Reactive power savings (kVAR
Apparent power savings (kVA)
Increased electrical equipment life
Improved performance of equipment
Protection of sensitive electronic equipment
Reduced maintenance, decrease consumption of spare parts
Space savings
Better capacity utilization of transformer & generator
Less Heating ventilation & Air conditioning (HVAC) system

The hard savings are the direct financial benefits to the purchasing company. Each electrical parameter that contributes to hard saving must be assessed, monitored & measured accurately to claim the appropriate payback period.

M.K.Pradhan, Kamlesh Keharia, Rajesh Darapu, B. Mariappan,
R & D Department, EMCO Limited, Thane, India

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