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APRIL 2018
Automation
Training Calendar
Piyush Patel (Managing Director)
See beyond darkness:
A person with torch in his hand sees only up to twentyfeet in darkness. However he has ten miles to walkthrough the darkness.
If he thinks: I can go only up to twenty feet, I cannotsee beyond, then why I should walk?
But if he gives up this thought and starts walking, he finds that the light iswith him throughout and he reaches his destination, leaving the darknessbehind him.
If we think that we will start only after we get the best resource, we will bewhere we are.
Hence let us start with what we have got and we will reach our goal.
Field problemcase study
You question,we answer
Worrying doesn’ttake away
tomorrow’stroubles. It takes
away today’speace. -Amtech Family
-Amtech Family
Amtech participated in , held in Noida. Our stallElecrama 2018was well attended by the visitors, including many of our customers.It was a great pleasure to interact with them and to understand theirrequirements, face to face.
EXHIBITION AT
Sudannese sugar co. Ltd.
Energy savingin boiler ID fan
Integrates the operationof sugar mill drive
Amtech Power Ltd.
CUSTOMER’S VOICE
TRAINING CALENDAR
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FIELD PROBLEM CASE STUDY
Problem reported:
110 kW inverter installed on fusion reactor was tripping during some of the processes. This was a new systemselected by customer and it was suspected that the motor and drive selection is not proper or under rated.
Customer askedAmtech to depute the expert, visit the site, observe the process and suggest proper sizing of themotor and drive.
Observation:
The inverter rating is 110 kW constant torque and the motor was:
Make: Crompton Greaves
110 kW, 176A, 1483 RPM, Class- F insulation
Motor was directly coupled with the gearbox. The gearbox ratio was 1500:21RPM
The application was fusion reactor.
The process and VFD operation is as follows:
The raw material for the process is heated through the hot oil circulated around the reactor at approximately 250°C. The evaporation takes place and the liquid is converted into the solid powder. It takes almost 12 – 15 hours atfull speed. The normal running current during this process is observed 50~60A.
During stage-2 operation (the next stage of the process), the load increases after 2 hours. The invertersometimes trips in this stage. At this stage the speed is reduced. But our expert kept full speed during thisoperation.
A maximum of 137A current was observed during this stage. Then the current got reduced to 70A, when thisstage is over. The material is then to be transferred to the other place for the next process. As the insidetemperature is very high, the water is added to form the liquid. During the first 1000-liter water addition, the lumpsformation takes place and the load on the inverter increases. As per the information obtained, the maximumchances of tripping of the inverter are observed in this stage. Once the inverter trips, it is very difficult to start theinverter due to the lumps formed inside. It requires water addition and proper mixture of powder and water and ittakes almost four to five hours.
During the expert's visit, the speed was reduced to 750 RPM only (as compared to 350 RPM by customer). It wasobserved that the current hardly went up to 145A – 150A. The process was successful. The expert changedsome of the current limit parameters also. The only difference was the speed during the two critical stages.During stage-2, the speed was kept to 1500 RPM instead of reduced speed and during the water addition speedwas kept at 750 RPM instead of 350 RPM.
Conclusion:
It was found and conveyed to the customer that the inverter has less to contribute to resolve the problem, but itwas the process parameter that ensured smooth operation. The various process parameters were discussedwith the process people and consultant also. There were various suggestions made to improve the process andsolve the tripping problem or low speed problem without increasing the size of the motor or inverter.
In short, customer was mentally ready to increase the motor + VFD rating and wanted our confirmation. Insteadof that we solved it just by changing few parameters (speed).
DOC. NO. CS-264TITLE: ENERGY SAVING IN BOILER ID FAN
Payback Period Approximately One Crushing Season
Industry : Sugar
Application : Boiler FanID
Motor rating : AC Induction Motor, 3 Phase
kW : 150
VOLT : 415
RPM : 1482
Hz : 50
AMP : 250
Previous system : Motor was running on star delta starter.
Problem observed : 1) High maintenance cost.
2) Energy losses due to flow control by damper.
Present system : 200 kW A Expert- azy Variable Frequency Drive Used.kW (Consumption) Damper Position
Previous system
(Without drive) : 131 kW 80 % Open
Present system
(With drive ) : 112 kW 100 % Open
System block diagram :
Merits of new system : 1. Easy mooth peration.and s o
s2. Energy aving due to flow control by VFD.
Economical analysis :
�Energy consumption without VFD - P1 = 131 kW
�Energy consumption with VFD - P2 = 112 kW
�Energy aving er ay ((P1-P2)*24) = 456 Unitss p d
�Saving er ay @ Rs.6/-Unit = Rs.2736/-p d
�Saving er ear (Approx. 300 Days) = Rs.4,10,400/-p y
150 kW, 3-PHASEINDUCTION MOTOR
AXPERT-EAZY
3-PHASE,
415 V,
AC SUPPLY
200 kWBOILER ID FAN
AMTECH POWER VISION
5
CUSTOMER’S VOICE
6
PRODUCT OVERVIEW
No matter green field or brown field, large or small, Amtech has the perfect solution for your mill drives. Startingfrom retaining the open gear systems and replacing steam turbines or DC motors, we provide the completesolution.
The new generation of control and monitoring system, developed by ,Amtech Electronics (India) Ltdintegrates the operation of Sugar Mill Drive by using variable frequency drive and Automation system forcontrolling and monitoring.
Features:
� CompleteAutomation system with ACFC (Auto Cane Feeding
Control).
� High torque VFD which delivers more than 200% starting
torque in constant control mode.
� Smooth start/stop operation without any jerks.
� Very low speed operation is possible.
� Energy saving as the VFD consumes the power based on the
requirement and the steam saved can be utilize to generate thepower.
� Infra Red type donnelly chute level sensors.
� Hall’s effect type cane blanket level and top roller lift sensors.
� Precision motor load / pressure sensors.
� Customized software is user friendly and the field and data
Benefits:
� Assistance from concept to commissioning.
� Increased Milling with the same equipment.
� Constant load on all mills.
� Better extraction in mills increased the bagasse poll.
� Constant levels in .donnelly chutes
� Avoiding unwanted roller lift.
� Constant steam / power consumption.
� Mill roller not exposed to shock loads.
� Continuous and Un-interrupted feeding reduces
downtime and increase throughput.
� Elimination of choking at preparatory devices, mills,
chutes or carriers.
� Maintained juice to imbibition water ratio increases
evaporation efficiency.
� Optimum mill speed with respect to load and level ensure
good milling results at all times.
� Effective water saving and cutting off water flow when crushing is stopped.
� Constant juice flow for process ensures even loading in the boiling house and stabilizes and reduces the steamconsumption which means higher boiling house efficiency and bagasse saving.
� Minimized maintenance reduces the cost and provides more up time.
� Easy troubleshooting.
� Quick and safe commissioning.
� Qualified after-sales service.
YOU QUESTION, WE ANSWER
What is the advantage of “S-curve” feature in variable frequency drive?
Whenever an AC motor accelerates or decelerates it generates a jerk which gets applied to the load connectedto motor. In case of applications such as a conveyer belt carrying delicate glass bottles or a lift carrying humanbeings who are sensitive to jerks, S-curve type of acceleration or deceleration characteristic is used to reducethe jerk to an extent that the load does not feel it. The variable frequency drive is provided with this feature whichis preferred in lift and bottling plant applications.
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