Solution for Field Problem : A Case Study

Industry : -

Industry

Application : -

Brine Pump

Motor rating : -

AC Induction Motor, 3-Phase

kW : 90

Volt : 415

RPM : 1480

Hz : 50

Amp : 146

Motor was running on DOL

Previous system :

starter

Problem observed :

1) High maintenance cost

2) Energy losses due to flow control by valve.

Present system

Amtech 90 kW, Axpert-Eazy VFD used in place of DOL starter.

kW (Consumption)       Valve Position

Previous system (Without drive):

     40 kW                       65 % Open

Previous system (With drive):

     27 kW                       100 % Open

Merits of new system :

1. Easy & smooth operation.

2. Energy saving due to flow control by VFD.

Economical analysis

Energy consumption without VFD - P1 = 40 kW

Energy consumption with VFD - P2 = 27 kW

Energy saving per day ((P1 - P2) * 24) = 312 Units.

Saving per day @ Rs. 6/- Unit = Rs.1872 /-

Saving per year (Approx. 300 Days) = Rs.5,61,600 /-

Observation & Conclusion : -

The phase to phase insulation of cable near to motor terminal, was degrading due to heating, with passage of time and due to multiple removals/bendings of power cable connected to motor. When current flowing from cable generated, the heat caused expansion of aluminum resulting in phase to phase short leading to tripping of VFD . This was classic example of failure, not due to product VFD or Motor but due to problem beyond the product.

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