In today’s industrial landscape, maintaining optimal power quality is not just a technical requirement but a critical factor in ensuring operational efficiency and cost savings.
Poor power quality can lead to equipment failures, increased energy consumption, and higher operational costs. One of the most effective solutions to address these challenges is the implementation of Hybrid Filters.
In this case study, we explore how well know EOU unit, a company specializing in critical component machining, successfully improved its power quality and achieved significant cost savings by deploying Hybrid Filters.
The Challenge: Power Quality Issues in Critical Component Machining
EOU company, based in Pune, Maharashtra, operates in the critical component machining industry, producing high-precision components for sectors such as automotive, manufacturing, and health industries. The company faced several power quality challenges that were impacting its operations:
Low Power Factor: The power factor was below 0.93, leading to inefficient energy usage and higher electricity bills.
High Current Harmonics: Current Total Harmonic Distortion (I-THDI) exceeded 22%, causing resonance issues and frequent failures of machine power supply PCBs.
Energy Losses: The average difference between KWH (active energy) and KVAH (apparent energy) was over 7,000 units, indicating significant energy losses.
Fuse Failures: Resonance issues led to frequent DO fuse failures, resulting in increased diesel consumption for backup generators until repairs were completed.
These issues not only increased operational costs but also disrupted production, leading to potential delays in delivering critical components to clients.
The Solution: Implementing Hybrid Filters with Advanced SVG
To address these challenges, Q Sine Energy Solutions LLP proposed a tailored solution: a Hybrid Filter combined with an Advanced Static Var Generator (SVG). Here’s how the solution worked:
- Hybrid Filter (600 kVAr): This system was designed to mitigate harmonics up to the 25th order, reducing current harmonics and eliminating resonance issues.
- Advanced SVG (125 kVAr): The SVG provided dynamic reactive power compensation, ensuring a near-unity power factor and improving energy efficiency.
The Hybrid Filter offered several advantages over traditional solutions like APFC (Automatic Power Factor Correction) or RTPFC (Real-Time Power Factor Correction):
- Stepless Operation: Unlike APFC, which operates in steps, the Hybrid Filter provides continuous and smooth power factor correction.
- Harmonic Mitigation: The system effectively reduces harmonics, protecting sensitive equipment from damage.
- Fast Response Time: The SVG ensures rapid power factor correction, adapting to load changes in real-time.
The Results: Significant Improvements in Power Quality and Cost Savings
After implementing the Hybrid Filter solution, Company witnessed remarkable improvements in its power quality and operational efficiency:
- Power Factor Improvement: The power factor improved from 0.93 to unity (1.0), ensuring optimal energy usage.
- Reduced Harmonics: Current harmonics were reduced to less than 6%, eliminating resonance issues and protecting equipment.
- Energy Efficiency: The difference between KWH and KVAH was reduced from 7,000+ units to 0, indicating minimal energy losses.
- Cost Savings: Company achieved monthly electricity bill savings of over INR 67,000, with a return on investment (ROI) expected in less than 18 months.
- Operational Reliability: There were no fuse failures post-implementation, reducing downtime and diesel consumption for backup generators.
Conclusion: A Game-Changer for Power Quality Management
The success story of this EOU company highlights the transformative impact of Hybrid Filters in addressing power quality challenges.
By implementing this advanced solution, Company not only improved its operational efficiency but also achieved significant cost savings, ensuring a competitive edge in the critical component machining industry.
At Q Sine Energy Solutions LLP, we specialize in providing cutting-edge power quality solutions, including Active Harmonic Filters, Static VAR Generators, and Hybrid APFC Systems. Our tailored solutions are designed to meet the unique needs of industries, ensuring optimal power quality, reduced energy costs, and enhanced operational reliability.
If your business is facing similar power quality challenges, contact us (Email: info@qsine.co.in | Phone: +91 87660 43510) today to explore how our solutions can transform your operations.
This case study is part of our ongoing series on how innovative power quality solutions are transforming industries. Stay tuned for more success stories!