2012 Nishat Mills LTD

Submitted by : Muhammad Gulraiz Ahmed NFC Institute Of Engineering & Fertilizer Research Faisalabad (affiliated with UET LHR)

[INTERNSHIP REPORT]
Electrical Engineering (power)

In the name of ALLAH The Gracious and The Benevolent

Acknowledgements First of all the whole praise to ALMIGHTY ALLAH, the creator of the universe and anything in this universe. He made us super creature, blessed us to accomplish this work. We are very thankful to Allah Almighty, Who has provided us such an opportunity to gain knowledge in Ibrahim Fibers Limited. It was a great experience to do internship over here. We learnt many things practically which we have learnt theoretically earlier. We also pay our gratitude to the Almighty for enabling us to complete this Internship Report within due course of time. Words are very few to express enormous humble obligations to our affectionate Parents for their prayers and strong determination to enabling me to achieve this job. We would like to thank all the administration engineers, operators and officials for helping us and for their kind behavior.

Introduction Nishat Group billion (US$ 5 billion), it ranks amongst the top five business houses of Pakistan. The group has strong presence in three most important business sectors of the region namely Textiles, Cement and Financial Services. In addition, the Group also has reasonable market share in Insurance (Adamjee and Security General), Power Generation, Paper products ( Nishat Shoaiba Paper Mills) and Aviation ( Phonix Aviation). It also has the distinction of being one of the largest players in each sector. The Group has a remarkable position in the market as good as any multinationals operating locally in terms of its quality of products, services and management skills.Nishat Group is one of the leading and most diversified business groups in South East Asia with fixed/ current assets of over Rs.300

Executive Summary Nishat has grown from a cotton export house into the premier business group of Pakistan with 5 listed companies, concentrating on 4 core businesses; Textiles, Cement, Banking and Power Generation. Today, Nishat is considered to be at par with multinationals operating locally in terms of its quality products and management skills. I recently have done my internship in Nishat Mills Limited, in which I got training from each of its department. The internship basically revolved around the product knowledge training. The system, the style of working & the commitment of the employees in NML is really exemplary. The difference between the success & failure is doing things right and doing things nearly right, & NML has always tried for success & that is why it is known to be one of the leading organizations in Pakistan. Irrespective of all these positive points of Nishat Mills Limited, I have
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noticed a few areas where the improvement can really increase the efficiency of NML. In this report I have given a very brief review of what I have seen during our internship I have mentioned all these as I have made an internship as according to the schedule. I also mentioned about the Textile industry in Pakistan and vision of its industry. Then I have done a detailed SWOT analysis as well as PEST Analysis. Then I have discussed about my learning in the whole internship that is all about the Textile Terminologies and process of the productions. I have made it possible to write each and every thing that I have learnt there. I have all my practical efforts in the form of this manuscript thats the asset for my future career.

Vision Statement To transform the Company into a modern and dynamic yarn, cloth and processed cloth and finished product manufacturing Company that is fully equipped to play a meaningful role on sustainable basis in the economy of Pakistan. To transform the Company into a modern and dynamic power generating Company that is fully equipped to play a meaningful role on sustainable basis in the economy of Pakistan.

Mission Statement To provide quality products to customers and explore new markets to promote/expand sales of the Company through good governance and foster a sound and dynamic team, so as to achieve optimum prices of products of the Company for sustainable and equitable growth and prosperity of the Company.

Company Profile Nishat Mills Limited is the flagship company of Nishat Group. It was established in 1951. It is one of the most modern, largest vertically integrated textile company in Pakistan. Nishat Mills Limited has 198,120 spindles, 655 Toyota air jet looms. The Company also has the most modern textile dyeing and processing units, 2 stitching units for home texitle, one stitching unit for garments and Power Generation facilities with a capacity of 89 MW. The Companys total export for the year 2011 was Rs. 36.015 billion (US$ 416 million). Due to the application of prudent management policies, consolidation of operations, a strong balance sheet and an effective marketing strategy, the growth trend is expected to continue in the years to come. The Company's production facilities comprise of spinning, weaving, processing, stitching and power generation.

Quality Policy We work together as a team for implementation and continual improvement of total quality system in order to achieve satisfaction of our internal and external customers.

Board of Directors As on April 05, 2012 1 2 3 4 5 6 7 Mian Umer Mansha Mian Hassan Mansha Mr. Khalid Qadeer Qureshi Mr. Muhammad Azam Syed Zahid Hussain Ms. Nabiha Shahnawaz Cheema Mr. Maqsood Ahmad Director/CEO/Chairman Director Director Director Director (Nominee NIT) Director Director

Power Generation (MESSAGE FROM CEO) Mobilizing and generating affordable and environment-friendly energy resources is one of the key challengers for any nation in today's world. Today the top priority for Pakistan is Energy and Power Generation. Presently, Out of around 162 million population only 65-70% has access to electricity. To Enter into power generation business is one of the diversified decision of Nishat Group with the vision to enhance its Investment into Energy Sector. Nishat Power Ltd. (NPL) a public limited company was incorporated in February 2007 under the Companies Ordinance for setting up power plant under the Power Policy 2002 on Build, Own and Operate ("BOO") basis. Its a 200 MW Combined Cycle Power Plant based on Reciprocating Engine Technology. The
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primary fuel of the Plant is Residual Furnace Oil ("RFO") and its uninterrupted supply is guaranteed by SHELL Pakistan. The Plant Configuration is eleven (11) proven Engine sets of type 18v46 manufactured by WARTSILA of Finland and eleven (11) generating sets, One (1) Heat Recovery Steam Turbine with generator.As per the Power Purchase Agreement, the NTDC has contracted to purchase the total net generation capacity of 195.26 MW produced by NPL for a period of 25 years at US cents 12.1253 per KWh. As the plant will operate on residual furnace oil, a Fuel Supply Agreement ("FSA") has been signed between the Company and Shell Pakistan Limited for a period of ten years after the commencement of commercial production.The entire plant, machinery and equipment required for the project has been procured from Wartsila Finland Oy. Whereas, Wartsila Pakistan (Private) limited has been appointed for the construction, erection, installation testing and commissioning of the entire project. We have also awarded Wartsila Pakistan an Operations & Maintenance Contract for our Plant.The total cost of the project including interest during the construction period is around PkR17.704 billion.

Major Consideration of the Project were: The Project would offer significant relief locally in the transmission system of Lahore, as it would bypass long transmission lines and potential stepdown transformer bottlenecks. There is currently no significant power generation inside this area The plant generation would be consumed very close to the generation site, thus also reducing substantial transmission losses The Project has been finalized and commissioned on a fast-track basis within 18 months as a power generation plant based on reciprocating engine single fuel RFO fired technology It is hoped that NPL's power project, the RFO based power plant under Power Policy 2002, shall serve as role model for others to follow.
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Safety Precautions In order to avoid the hazards on the plant, company train their employees for the Safe handling and operation of materials and units installed on plant. So for this company follow following steps:

Authorization Even a small mistake on the plant can cause a serious damage so MMM (man, machine, material) is very important.

nting out and also some

crossing the roads and also tanks with explosive materials are present at different places and anything hitting them may cause a serious danger. workers and as a result, their work may be ignored. for every unit some guider is provided for the specific period of time and we are not allowed to go in any area according to our desire. other to prevent injury of workers. computer control systems to prevent the tripping of systems as they are very sensitive.

water in that area is of very high conductivity. for the workers. material for the safe handling and storage of the materials. ded for the safe operations.

overcoming fire. Safety Measures: Safety measures are activities and precautions taken to improve safety, i.e. reduce risk related to human health. Common safety measures include: o Root cause analysis to identify causes of a system failure and correct deficiencies. o Visual examination for dangerous situations such as emergency exits blocked because they are being used as storage areas. o Visual examination for flaws such as cracks, peeling, loose connections. o Chemical analysis o X-ray analysis to see inside a sealed object such as a weld, a cement wall or an airplane outer skin. o Destructive testing of samples o Stress testing subjects a person or product to stresses in excess of those the person or product is designed to handle, to determining the "breaking point".
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o Safety margins/Safety factors. For instance, a product rated to never be required to handle more than 200 pounds might be designed to fail under at least 400 pounds, a safety factor of two. Higher numbers are used in more sensitive applications such as medical or transit safety. o Implementation of standard protocols and procedures so that activities are conducted in a known way. o Training of employees, vendors, product users o Instruction manuals explaining how to use a product or perform an activity o Instructional videos demonstrating proper use of products o Examination of activities by specialists to minimize physical stress or increase productivity o Government regulation so suppliers know what standards their product is expected to meet. o Industry regulation so suppliers know what level of quality is expected. Industry regulation is often imposed to avoid potential government regulation. o Self-imposed regulation of various types. o Statements of Ethics by industry organizations or an individual company so its employees know what is expected of them. o Drug testing of employees, etc. o Physical examinations to determine whether a person has a physical condition that would create a problem. o Periodic evaluations of employees, departments, etc. o Geological surveys to determine whether land or water sources are polluted, how firm the ground is at a potential building site, etc.

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Different Safety Signs Safety signs are used for indication of the hazard involved while carrying out the certain action. They are very helpful in for the subject as they give clear guideline about the hazard that one could face at the site where they are erected. Some different safety signs are:

In safety there is a rule of triple M. Man safety Machine safety Material safety Man safety In safety the first thing is man safety. Man safety is one of the important things between the rules of safety. Man safety means how to safe man in working area (plant).Mask, safeguard, gloves etc are provided for safety. Also no use of mobile

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Machine safety Machine safety is also important. The trouble shoot, maintenance of temperature is the important one. No use of mobile near to machine because safety of tripping and matching of frequency.

Material safety The safety of material is also important. The thing like sand is safe according to its way of safety. Other things like PTA, MEG are store according to its conditions.

Power Distribution The feeder lines are fed to the panels situated there which are connected to each other with bus couplers along with VCB breakers. From there, these lines are fed to Transformer Room where the voltage is stepped down from 11KVA to 415V. The lines from the transformers are fed to LVD Room in the form of bus wires. The bus wires are fed to the panels in LVD Room where the panels are connected in the form of Ring Main System along with Power Factor Control and ACCB Breakers for safety purpose. From there, the power is supplied further as per requirement.

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MCC Room The purpose of this room is to control the speed of the motors hence controlling the output of the SPG/DL-1 section. The speed is controlled through inverters which in turn are controlled through PLCs via Control Room. The explanation of different terms and the equipment mentioned above will be explained after giving the summary of each section. MCC is the motor control centre which is controlling the all the motors and pumps connected in the specific area. In MCC room the panels which are controlling the Motors parameters the technology which is using in MCC room is the one of the modern technology which the inverters based. The inverter work is converts the voltage waves into one form to the other. The main two inverters are using in the MCC room of polyester plant are the following: AC to AC inverters DC to AC inverters The main purpose of the invertors is that many motors which are using in the plant are proportional to the frequency and the power we having the frequency of 50 Hz so that by using invertors we can vary the frequency of the power given to the motor. We known t the speed is directly proportional to the frequency we apply.

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UTILITIES Soft Water Fresh raw water is pumped from ground and is transported to the water plant. In plant they are further pumped to gravel bed in a closed vessel. Small portions of Hydro-chloric acid (HCl) are added to the filtered water kill bacteria and to lower pH value. Then it passes through bag filter which consists of series of fibers to deposit gravel on them. The water that passes the laboratory test is termed as Soft water, and this is the major production of plant. The soft water produced is then decarbonised. Decarbonisation is a process in which air is pumped into water to remove carbon content. Daemon Water The soft water is passed through the bed of mixed cation and anion bed and it become demineralised. Daemon water is then stored in another vessel (4010-V05). Daemon water is used in chilled water circuit, boiler house etc. Drinking Water Soft water from the storage vessel and some small amount of raw water is passed through the bed of calcium hydrolit. Drinking water produced is then stored in drinking vessel.

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Boilers Boiler house have 3 boilers. All boilers are of fire tube types having three passes and a super heater. Water is accumulated in the shell and it surrounds the tubes. Fire is passed through first pass where combustion take place, from first pass end it enters the second pass from behind, leave the second pass from front and the fire rises to the super heater then it enters the third pass, exhaust gases leave the boiler at boiler rear face to the exhaust chimney erected outside the boiler house. There are basically two types of boilers: Fire tube boiler Water tube boiler Fire tube boiler The name fire tube is very descriptive. The fire, or hot flue gases from the burner, is channeled through tubes that are surrounded by the fluid to be heated. The body of the boiler is the pressure vessel and contains the fluid. In most cases this fluid is water that will be circulated for heating purposes or converted to steam for process use. Every set of tubes that the flue gas travels through, before it makes a turn, is considered a "pass". So a three-pass boiler will have three sets of tubes with the stack outlet located on the rear of the boiler. Fire tube Boilers are: Relatively inexpensive Easy to clean Compact in size Available in sizes from 600,000 btu/hr to 50,000,000 btu/hr Easy to replace tubes
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 Well suited for space heating and industrial process applications

Disadvantages of Fire tube Boilers include: Not suitable for high pressure applications 250 psig and above Limitation for high capacity steam generation Three pass Fire tube boilers are used in the IFL. There are 3 fire tube boilers are used in IFL. One is stand by while 2 are in operation.

Water Tube Boiler A Water tube design is the exact opposite of a fire tube. Here the water flows through the tubes and are incased in a furnace in which the burner fires into. These tubes are connected to a steam drum and a mud drum. The water is heated and steam is produced in the upper drum. Large steam users are better suited for the Water tube design. The industrial watertube boiler typically produces steam or hot water primarily for industrial process applications, and is used less frequently for heating applications.

Water tube Boilers are: Available in sizes that are far greater than the fire tube design. Up to several million pounds per hour of steam. Able to handle higher pressures up to 5,000 psig Recover faster than their fire tube cousin
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 Have the ability to reach very high temperatures

Disadvantages of the Water tube design include: High initial capital cost Cleaning is more difficult due to the design No commonality between tubes Physical size may be an issue

Fuel for boiler: Natural gas (mostly used) Furnace oil (stand by) The steam at 25 bar pressure is then divided in to 3 different pressures 25-bar , 10-bar , 6-bar

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Parts Of Boiler:

Evaporator A liquid vapor refrigerant mixture enters the evaporator at state point 1. Liquid refrigerant is vaporized to state point 2 as it absorbs heat from the system cooling load.The vaporized refrigerant flows into the compressor first stage.

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Compressor first stage Refrigerant vapor is drawn from the evaporator into the first stage compressor. The first stage impeller accelerates the vapor increasing its temperature and pressure to state point 3. Compressor second stage Refrigerant vapor leaving the first stage compressor is mixed with cooler refrigerant vapor from the economizer. This mixing lowers the enthalpy of the vapor entering the second stage. The second stage impeller accelerates the vapor, further increasing its temperature and pressure to state point 4. Condenser Refrigerant vapor enters the condenser where the system cooling load and heat of compression are rejected to the condenser water circuit. This heat rejection cools and condenses the refrigerant vapor to a liquid up to point 5. Economizer and refrigerant orifice system Liquid refrigerant leaving the condenser at state point 5 flows through the first orifice and enters the economizer to flash a small amount of refrigerant a an intermediate pressure labeled P1. Flashing some liquid refrigerant cools the remaining liquid to state point 8. Another benefit of flashing refrigerant is to increase the total evaporator Refrigeration Effect from RE to RE. The economizer provides around 4 percent energy savings compared to chillers with no economizer. To complete the operating cycle, liquid refrigerant leaving the economizer at state point 8 flows
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through a second orifice. Here refrigerant pressure and temperature are reduced to evaporator conditions at state point 1. An innovative design feature of the CVGF chiller is maximizing the evaporator heat transfer performance while minimizing refrigerant charge requirements. This is accomplished by the Trane-patented falling film evaporator design. The amount of refrigerant charge required in CVGF is less than that in comparably sized chillers of flooded evaporator design.

Process The evaporator is basically shell & tube heat exchanger in which the chilled water is in the tube side & the refrigerant (Freon) is on the shell side. The heat exchanger used here is a 1-2 pass heat exchanger. The wc (chilled water) stream from the process (11-12oC) enters the evaporator in the tubes & is discharged at a temperature of 6-7oC. It is present in the liquid form & when the WC stream passes through the evaporator tubes, the refrigerant gets heat from the water and evaporates.
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The vapors of the refrigerant are sent to the two-stage compressor. The compressor should be of such capacity that it should intake same amount of vapors from the evaporator as being produced in it if the capacity is low then the pressure in the evaporator will increase & thus the saturation temperature of refrigerant will increase. When the vapors are compressed their temperature & pressure increases. The compressed stream is sent to the condenser in the tubes, where cooling water is circulated for the cooling purpose in the shell side. Here the vapors are discharged at the same pressure but at lower temperature & sent to the economizer. A nozzle is fitted in the economizer, which acts as an expansion valve. Here the vapors are sprayed so their pressure decreases due to sudden expansion cooling occurs & most of the vapors go to liquid form. From the economizer these streams are discharged. To the evaporator (in liquid form) To the evaporator (in the vapor form) To the 2nd stage of compressor as an inter cooler (in vapor form) Cooling Tower Types of cooling towers Cooling towers are designed and manufactured in several types: 1. ATMOSPHERIC 2. MECHANICAL DRAFT FORCED DRAFT INDUCED DRAFT 1: Atmospheric The atmospheric cooling towers utilize no mechanical fan to create air flow through the tower; its air is derived from a natural induction flow provided by a pressure spray.
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2: Mechanical Draft Mechanical draft towers uses fans (one or more) to move large quantities of air through the tower. They are two different classes:

Forced draft cooling towers Induced draft cooling towers

The air flow in either class may be cross flow or counter flow with respect to the falling water. Cross flow indicates that the airflow is horizontal in the filled portion of the tower while counter flow means the air flow is in the opposite direction of the falling water. The counter flow tower occupies less floor space than a cross flow tower but is taller for a given capacity. The principle advantages of the cross flow tower are the low pressure drop in relation to its capacity and lower fan power requirement leading to lower energy costs. Forced Draft The forced draft tower, shown in the picture, has the fan, basin, and piping located within the tower structure. In this model, the fan is located at the base. There are no louvered exterior walls. Instead, the structural steel or wood framing is covered with paneling made of aluminum, galvanized steel or asbestos cement boards.

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During operation, the fan forces air at a low velocity horizontally through the packing and then vertically against the downward flow of the water that occurs on either side of the fan. The drift eliminators located at the top of the tower remove water entrained in the air. Vibration and noise are minimal since the rotating equipment is built on a solid foundation. The fans handle mostly dry air, greatly reducing erosion and water condensation problems

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MOTORS

Electromechanical device that converts electrical energy to mechanical energy Mechanical energy used to e.g. Rotate pump impeller, fan, blower Drive compressors Lift materials Motors in industry: 70% of electrical load

Three types of Motor Load Motor loads Constant loads Description Examples

torque Output power varies but Conveyors, rotary kilns, torque is constant constant-displacement pumps torque Torque varies with square Centrifugal pumps, fans of operation speed power Torque changes inversely Machine tools with speed

Variable loads Constant loads

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Classification of Motors

Electric Motors
Alternating Current (AC) Motors
Synchron ous Inductio n

Direct Current (DC) Motors

Separate ly Excited Self Excited

SinglePhase

ThreePhase

Serie s

Compou nd

Shunt

DC motors Speed control without impact power supply quality Changing armature voltage Changing field current Restricted use Few low/medium speed applications Clean, non-hazardous areas Expensive compared to AC motors

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Relationship between speed, field flux and armature voltage Back electromagnetic force: E = KN Torque: T = KIa

E = electromagnetic force developed at armature terminal (volt) = field flux which is directly proportional to field current N = speed in RPM (revolutions per minute) T = electromagnetic torque Ia = armature current K = an equation constant

Separately excited DC motor: field current supplied from a separate force Self-excited DC motor: shunt motor DC compound motor

AC Motors Synchronous motor Constant speed fixed by system frequency DC for excitation and low starting torque: suited for low load applications Can improve power factor: suited for high electricity use systems Synchronous speed (Ns):
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Ns = 120 f / P
F = supply frequency P = number of poles Most common motors in industry Advantages: Simple design Inexpensive High power to weight ratio Easy to maintain Direct connection to AC power source

Components

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 Rotor Squirrel conducting in parallel slots cage: bars

Wound rotor: 3-phase, double-layer, distributed winding Stator Stampings with slots to carry 3-phase windings Wound for number of poles definite
Electromagnetics

Rotor

How induction motors work Electricity supplied to stator

Stator

Magnetic field generated that moves around rotor Current induced in rotor Rotor produces second magnetic field that opposes stator magnetic field Rotor begins to rotate
(Reliance)

Single-phase induction motor One stator winding Single-phase power supply Squirrel cage rotor
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 Require device to start motor 3 to 4 HP applications Household appliances: fans, washing machines, dryers

Three-phase induction motor Three-phase supply produces magnetic field Squirrel cage or wound rotor Self-starting High power capabilities 1/3 to hundreds HP applications: pumps, compressors, conveyor belts, grinders 70% of motors in industry!

Speed and slip Motor never runs at synchronous speed but lower base speed Difference is slip Install slip ring to avoid this Calculate % slip:

% Slip = Ns Nb x 100 Ns
Ns = synchronous speed in RPM Nb = base speed in RPM
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Efficiency of Electric Motors Motors loose energy when serving a load Fixed loss Rotor loss Stator loss Friction and rewinding Stray load loss

(US DOE)

Factors that influence efficiency Age Capacity Speed Type Temperature Rewinding
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 Load Motor part load efficiency Designed for 50-100% load Most efficient at 75% load Rapid drop below 50% load

(US DOE) Motor Load Motor load is indicator of efficiency Equation to determine load:

Load =

Pi x HP x 0.7457

= Motor operating efficiency in %

HP = Nameplate rated horse power

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Load = Output power as a % of rated power Pi = Three phase power in kW

Three methods for individual motors Input power measurement Ratio input power and rate power at 100% loading Line current measurement Compare measured amperage with rated amperage Slip method Compare slip at operation with slip at full load

Input power measurement Three steps for three-phase motors

Step 1. Determine the input power:

V x I x PF x 3 Pi 1000
Pi V = Three Phase power in kW = RMS Voltage, mean line to line of 3 Phases
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I PF

= RMS Current, mean of 3 phases = Power factor as Decimal

Step 2. Determine the rated power:

Pr hp x

0.7457

Pr hp r

= Input Power at Full Rated load in kW = Name plate Rated Horse Power = Efficiency at Full Rated Load

Step 3. Determine the percentage load:

Pi Load x 100% Pr

Load Pi Pr

= Output Power as a % of Rated Power = Measured Three Phase power in kW = Input Power at Full Rated load in kW

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Action
R eplace with more efficient, properly sized models R eplace with more efficient, properly sized models when they fail R eplace most of these with energy-efficient models when they fail Result 1. Significantly oversized and underloaded 2. Moderately oversized and underloaded 3. Properly sized but standard efficiency

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Energy Efficiency Opportunities

1. Use energy efficient motors. 2. Reduce under-loading (and avoid oversized motors) 3. Size to variable load 4. Improve power quality 5. Rewinding 6. Power factor correction by capacitors 7. Improve maintenance 8. Speed control of induction motor

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Use Energy Efficient Motors

Reduce intrinsic motor losses Efficiency 3-7% higher Wide range of ratings More expensive but rapid payback Best to replace when existing motors fail

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Use Energy Efficient Motors

Power Loss Area 1. Fixed loss (iron) Efficiency Improvement Use of thinner gauge, lower loss core steel reduces eddy current losses. Longer core adds more steel to the design, which reduces losses due to lower operating flux densities. Use of more copper & larger conductors increases cross sectional area of stator windings. This lower resistance (R) of the windings & reduces losses due to current flow (I) Use of larger rotor conductor bars increases size of cross section, lowering conductor resistance (R) & losses due to current flow (I) & Use of low loss fan design reduces losses due to air movement Use of optimized design & strict quality control procedures minimizes stray load losses

2. Stator I2R

3 Rotor I2R

4 Friction Winding

5. Stray Load Loss

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2. Reduce Under-loading

Reasons for under-loading Large safety factor when selecting motor Under-utilization of equipment Maintain outputs at desired level even at low input voltages High starting torque is required Consequences of under-loading Increased motor losses Reduced motor efficiency Reduced power factor Replace with smaller motor If motor operates at <50% Not if motor operates at 60-70% Operate in star mode If motors consistently operate at <40% Inexpensive and effective Motor electrically downsized by wire reconfiguration Motor speed and voltage reduction but unchanged performance

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3. Sizing to Variable Load Motor selection based on Highest anticipated load: expensive and risk of under-loading Slightly lower than highest load: occasional overloading for short periods But avoid risk of overheating due to Extreme load changes Frequent / long periods of overloading Inability of motor to cool down

4. Improve Power Quality

Motor performance affected by Poor power quality: too high fluctuations in voltage and frequency Voltage unbalance: unequal voltages to three phases of motor

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Example 1 Voltage (%) unbalance 0.30

Example 2 2.30

Example 3 5.40

Unbalance in current 0.4 (%) Temperature increase 0 (oC)

17.7

40.0

30

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Keep voltage unbalance within 1% Balance single phase loads equally among three phases Segregate single phase loads and feed them into separate line/transformer

5. Rewinding
Rewinding: sometimes 50% of motors Can reduce motor efficiency Maintain efficiency after rewinding by Using qualified/certified firm Maintain original motor design Replace 40HP, >15 year old motors instead of rewinding Buy new motor if costs are less than 5065% of rewinding costs

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6. Improve Power Factor (PF)

Use capacitors for induction motors Benefits of improved PF Reduced kVA Reduced losses Improved voltage regulation Increased efficiency of plant electrical system Capacitor size not >90% of no-load kVAR of motor

7. Maintenance

Checklist to maintain motor efficiency Inspect motors regularly for wear, dirt/dust Checking motor loads for over/under loading Lubricate appropriately Check alignment of motor and equipment Ensure supply wiring and terminal box and properly sized and installed Provide adequate ventilation

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8. Speed Control of Induction Motor

Multi-speed motors Limited speed control: 2 4 fixed speeds Wound rotor motor drives Specifically constructed motor Variable resistors to control torque performance >300 HP most common Variable speed drives (VSDs) Also called inverters Several kW to 750 kW Change speed of induction motors Can be installed in existing system Reduce electricity by >50% in fans and pumps Convert 50Hz incoming power to variable frequency and voltage: change speed Three types

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Direct Current Drives Oldest form of electrical speed control Consists of DC motor: field windings and armature Controller: regulates DC voltage to armature that controls motor speed Tacho-generator: gives feedback signal to controlled

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