Professional Documents
Culture Documents
ENGINEERING &
DESIGN
Presented by
Mr.Alok Bhargava
Electrical Expert, PMDSC
INTRODUCTION
Electrical network designers have an important role
to play for continuous quality and energy efficiency
of treatment plants.
Treatment plants require an electrical network that
fits in with their continuous quality treatment
processes while cutting operating costs and, in
particular energy costs. Therefore a plants electrical
network must be reliable, easy to operate and
maintain throughout the plants lifetime, and scalable
to facilitate future expansion and process overhauls. In
addition, energy, mainly electricity, accounts for up to
30% of a plants operating costs, and makes the
plants electrical network a crucial factor for cost
effective treatment.
INTRODUCTION
The Network describes preferred solution architectures
by plant type and size. Each solution architecture is
presented with a single- line diagram for medium
voltage and low-voltage configurations, key design
principles, and the recommended equipment and
technologies.
All of the architectures shall be designed to meet
Treatment Plant performance requirements in area like:
Safety of people and property
Scope
Treatment
Plants with
power
demand from
125 kVA to
1250 KVA
ARCHITECTURE FOR MEDIUM SIZED
TREATMENT PLANTS (T2)
Main design principles
At this treatment capacity or power demand, a
medium-voltage supply is part of the electrical
network. These plants have more no of motors
(With or without variable speed drives), resulting
in degrading the power factor. The separate low-
voltage switchboards improve availability.
ARCHITECTURE FOR MEDIUM SIZED
TREATMENT PLANTS (T2)
Recommended architecture includes:
A single-line power grid connection
A simple medium-voltage configuration (radial
double feeder)
Optionally, two redundant transformers in parallel
Scope
Treatment
Plants
with
power
demand
from 1250
kVA to
5000 KVA
ARCHITECTURE FOR LARGE
TREATMENT PLANTS (T3)
ARCHITECTURE FOR LARGE
TREATMENT PLANTS (T3)
Main design principles
Plants of this size typically have high operating costs
and a significant environmental impact due to the
large volume of water they treat and their installed
power. The medium-voltage (MV) electrical network
which extends down to the shop floorshould
incorporate more redundancy.
For optimal performance, power availability and
monitoring should be managed with specific systems.
Large plants like these contain many motors, which
often use variable speed drives.
It is recommend a ring-main service from the plants
electric utility to feed the MV system.
ARCHITECTURE FOR LARGE
TREATMENT PLANTS (T3)
The primary MV switchboard should be located in a
main electrical room to supply each load center.
Depending on the plants layout and local
regulations and habits, It is recommend an open
MV loop architecture and the open MV loop
architecture is more suitable for larger plants and
offers better availability.
ARCHITECTURE FOR LARGE
TREATMENT PLANTS (T3)
Since MV/LV transformer failure can cause
extended plant downtimeand in order to
facilitate maintenanceit is suggested either
partial redundancy (to allow for downgraded
operation in the event of a transformer failure) or
total redundancy (to allow for normal operation in
the event of a transformer failure). Installing
several MV/LV transformerspreferably of equal
power as close as possible to the distributed
loads can reduce the low-voltage (LV) connection
distances.
Process units should be supplied by several LV
switchboards.
ARCHITECTURE FOR LARGE
TREATMENT PLANTS (T3)
Recommended architecture includes:
Power factor correction can be managed by
stepped capacitor banks, which are suitable for
large motors with fluctuating loads. Another
option would be to provide power factor
correction through a MV capacitor bank.
Given the large number of motors, it is
recommended that motor control via Motor
Control Center (MCC) to improve availability,
facilitate maintenance, and limit operating
costs.
ARCHITECTURE FOR LARGE
TREATMENT PLANTS (T3)
Power monitoring is also crucial to maintaining a
plants overall energy efficiency. This can be
achieved through power meters linked to an
Energy Management Information System (EMIS),
which could be part of a Supervision Control
and Data Acquisition (SCADA) system.
Backup generators should be used for critical
process units. A mobile generator could be
added for emergency backup. Uninterruptible
Power Supply (UPS) is used to protect the
critical loads.
FEATURES FOR THE WATER & WASTE WATER
TREATMENT PLANT
POWER QUALITY
Introduction
Power quality refers to both voltage and current
quality determined according to criteria like
magnitude, frequency, waveform, and symmetry.
Disturbances to any of these factors are considered
power quality problems, which can be of several
types:
waveform
Voltage sags or voltage interruption (magnitude)
Voltage unbalance (symmetry)
Voltage frequency fluctuation.
POWER QUALITY
Impacts and applications
For treatment plants , the main power quality
issues are voltage interruptions and waveforms.
Voltage interruptions
For Treatment Plants , long voltage interruptions
may result in the discharge of untreated water into
public waterways, creating a public health hazard
and resulting in fines for the plant. Secure power
equipment like generators and uninterruptible
power supply systems can be used to ensure a
continuous power supply.
POWER QUALITY
Waveforms
Plants also frequently encounter harmonics issues
since variable speed drives account for a
significant proportion of their total power.
Harmonics can increase the RMS current in the
different circuits and deteriorate supply voltage
quality. Correcting harmonics can help:
Reduce overloading of the electrical system,
thereby releasing useable capacity
Lower system losses and demand power
Limit the risk of an outage and
Extend equipment lifetime.
POWER QUALITY
Recommended solutions
This section treats the solutions for harmonic
mitigation only. The solutions for voltage
interruptions are treated in the Secure Power Supply
section. Harmonics can be corrected in several ways
and in different levels of the Electrical installation.
MOTOR MANAGEMENT
Motor protection and control is a plant-wide issue.
It concerns not only a plants motors and
processes but also operator safety, electrical
technician (at the motor starter, electrical feed,
and load levels via isolation and lockout), and the
protection of the plants electrical network.
MOTOR MANAGEMENT
Recommended solutions
Conventional motor protection systems based on
the thermal overload protection cannot
communicate with higher-level process control
systems and consequently fail to meet the needs of
todays continuous process industries.
MOTOR MANAGEMENT
This is due to several factors.
Introduction
Three-phase
motor
operation.
AC INDUCTION MOTOR THEORY
How a motor shaft rotates
Torque is produced as the induction motor
generates flux in its rotating field.
This flux must remain constant to produce
full-load torque.
As shaft torque load increases, the slip
increases and more flux lines cut the
rotor windings, which in turn increases
rotor current, which increases the rotor
magnetic field and consequently the rotor
torque.
AC INDUCTION MOTOR THEORY
Typical
speed
versus
torque
curve for
a NEMA
design B
motor.
% Synchronous Speed
AC INDUCTION MOTOR ISSUES
Starting Induction Motors
The starting current is very high, between 3
to 8 times the full load current. Depending
on the size of the motor, this can result in
voltage sags in the power system.
The full torque is applied instantly at
starting and the mechanical shock can
eventually damage the drive system,
particularly with materials handling
equipment, such as conveyors.
In spite of the high starting current, for
some applications the starting torque may
be relatively low, only 1.0 to 2.5 times full
load torque.
AC INDUCTION MOTOR THEORY
The speed of the rotating electric field
within the induction motor.
Vacuum tubes
Thyristors (SCRs)
provided the standard method for
rectifying AC. Also referred to as a
diode.
COMPONENTS OF VFDS
Transistors provide fast switching
capability for a relatively low cost.
The general types of transistors are:
The bipolar transistor;
The gate turn off transistor (GTO)
The field-effect transistor (FET);
The insulated gate-field-effect
transistor (IGFET);
The insulated gate-bipolar
transistor (IGBT).
VFD BASICS
A VFD in
a block
diagram.
COMPONENTS OF VFDS
All VFDs need a power section that
converts AC power into DC power.
This is called the converter bridge.
Sometimes the front end of the
VFD, the converter is commonly a
three phase, full-wave-diode
bridge.
COMPONENTS OF VFDS
Simplified
Inverter
Section of
a VFD
VFD BASICS
The DC waveform looks more like
an AC waveform but the voltage
waveform is much different.
The power semi-conductors in the
inverter section act as switches,
switches of the DC bus, and
therefore, are pulsing the motor
with some voltage.
VFD BASICS
A typical square wave takes its shape
on the square-wave look due to this
switching function ( which explains
the sharp rise to peak) rather than a
rotational, changing state of
amplitude.
This frequency and amplitude pattern
is sometimes called the carrier
frequency of a PWM drive.
VFD BASICS
Volts-per-
Hertz
Control
The area within
each pulse is the
power delivered
to the motor in
volt-
microseconds.
VFD BASICS
How VFDs Operate
Set-up Parameters
The Control Method
Acceleration or Accel-Ramp Rate
Automatic Restart
Stopping Method
Automatic Signals
VFD BASICS
Functions & Features