ISSN: 2319-8753

International Journal of Innovative Research in Science, Engineering and Technology

Vol. 2, Issue 2, February 2013

Reduction in Harmonics in Marble Industry

Prakash sundaram1, Shimi S.L.2, Dr.S.Chatterji3
Professor and Head, Department of Electrical Engineering, Vidya bhawan polytechnic college, Udaipur, Rajasthan, India1 Assistant Professor, Department of Electrical Engineering, NITTTR, Chandigarh, India2 Professor and Head, Department of Electrical Engineering, NITTTR, Chandigarh, India3

Abstract: Lower order harmonic are major problems in industries in India. This will get worse due to the increasing number of lagging power factor induction motors and harmonic generated non linear loads. During survey of Udaipur, Rajasthan (India) investigator found the poor condition of power quality in large number of marble, soft stone and minerals industries and took one marble industry for investigation of the power quality due to harmonic content in power supply. After measurement in Arihant Marble industry, Udaipur, Rajasthan (India), the investigator found that the 5th harmonic content was beyond the IEEE limits. Investigator then design the harmonic filter at Hercules Controls Panel Pvt. Ltd. Udaipur, Rajasthan (India), after installation of harmonic filter at Arihant Marble Industry and measurement were done again and found that 5th harmonic content was below IEEE limits. Investigator also calculate the kVA saving. Index TermsHarmonic Reduction, Passive Harmonic Filter, Marble / Soft stone Industry.

I. INTRODUCTION Highest power tariffs is paid by Indian industry in the world and the gap between supply and demand is expanding leading to poor quality and lower quantity of power resulting in loss of production and profits[2]. Unfortunately, in India, there is very less awareness of low power factor and harmonic pollution and the available solutions to curtail down it. Poor power factor was considered as the only parameter to measure the efficiency of electrical system in earlier days and hence, traditionally, more emphasis was given on the solutions to improve the power factor. The incentive schemes and imposition of penalty for maintaining the PF by Electricity Boards has drawn users attention toward the PF improvement. But only PF improvement does not compete the challenge posed by high percentage of harmonics getting injected into the supply. Thus there is large need of energy saving in electrical systems i.e. there is need to improve system power quality for several different benefits like reducing peak kW billing demand ,increased system capacity, reduced system losses in electrical system, increased voltage level in electrical system and cooler, more efficient motors. Harmonic: Power quality has caused a great concern to electrical system with the increasing use of sensitive and susceptive electronic and computing equipments and all nonlinear loads. The results are generation of harmonics. High level of harmonic distortion can create stress and resultant problems for the utility's distribution system, the plant's distribution system, as well as the plants equipments. .In electrical engineering harmonics are described as follows as per IEEE 11591995.[4] The Total Harmonic Distortion (THD) is a measure of the effective value of harmonic distortion .

THD%

2 2 2 I2 I 32 I 4 .......... .... I n

I1

100%

Where: THD is the total harmonic distortion of the waveform in %, I1 is the magnitude of the fundamental component and I2, I3, I4 is the magnitude of the 2nd, 3rd 4th harmonic components. Marble and soft stone industries are the largest consumers of electricity (approximately 60%) of the total industrial consumption of electricity of Udaipur, Rajasthan (India). Marble and soft stone industry has very poor power factor (0.4 to 0 .8) and they were penalized for that by Rajasthan State Electricity Board along with poor quality of power. Recently some industries used manually operated capacitor banks which are not effective and sufficient. Also a marble and soft stone industry uses non linear loads and various electronics loads which further degraded the quality of power supply by harmonic generation. That is why harmonic reduction is required.

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ISSN: 2319-8753
International Journal of Innovative Research in Science, Engineering and Technology
Vol. 2, Issue 2, February 2013

II. ENERGY SAVING TECHNIQUES In the areas for improvement in electrical systems resulting in energy conservation/saving are: (i) Power factor management (ii) Demand side management. (iii) Improvement in quality of power (Reduction in harmonics). III. METHODS FOR REDUCTION OF HARMONIC DISTORTION One of the ways to resolve the issue of harmonics would be using filters in the power system. Installing a filter for nonlinear loads connected in power system would help in reducing the harmonic effect. With the increase of nonlinear loads in the power system, more and more filters are required. There are two types of filters (i) Passive Filters (ii) Active Filters.[6] [12] Inductors and Capacitors are commonly used in the active and passive filters for harmonics reduction. The passive filters are used in order to protect the power system by restricting the harmonic current to enter the power system by providing a low impedance path. Passive filters consist of resistors, inductors and capacitors. The active filters are mostly used in distribution networks for elimination/reduction of problem like sagging in voltage and flickering, where there are harmonics in current and voltages, etc. There is also a third type of filter which is used i.e. the hybrid filter. Hybrid filters are composed of the passive and active filters both. [2] IV. DESIGN OF A PASSIVE HARMONIC FILTER (PHF) A harmonic filter essentially consists of a power capacitor, a tuning reactor and its control gear. It will act in parallel with an untuned basic power factor improvement capacitor bank. For the designing purpose investigator collected some datas such as load details, existing power factor, required new power factor, total harmonic distortion, individual harmonic details etc. This data can be obtained from a harmonic analyzer. Harmonic Filter Design Step-A: Investigator measured the electrical data of Arihant Marble with the help of energy meter and harmonic analyzer as follows: a) Energy meter data: Data was measured from the energy meter installed at Arihant Marble Pvt. LTD. Udaipur. From table 1 the maximum demand in HP = 57Hp, the maximum demand in kW = 53.15 kW, and Maximum load current =119.26 A.Design of harmonic filter is done at 30% of the load (kW) Load in kW = 30% of 53.15 kW =16 kW Lowest Power factor measured = 0.60 lag TABLE.I
Electrical Data of Marble Industry

S.No 1 2 3 4

Parameters Total load(HP) Total load(KW) Average monthly PF Maximum load current

Value 57 53.15 0.79 119.26 A

b) Data obtained from Harmonic Analyzer at 30% load:

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ISSN: 2319-8753
International Journal of Innovative Research in Science, Engineering and Technology
Vol. 2, Issue 2, February 2013

Total harmonic current in power supply system THD = 5.6 A 5th harmonic current = 8.0 A----------------------------- (3) During measurement investigators found that only 5th order harmonic was beyond the limit of harmonic and other orders were under limits. Step-B Assuming required power factor to be 0.99, calculate the total kVAR required to raise the power factor from 0.60 to 0.99. kVAR required = kW (tan 1-tan 2) ---------------------- (4) Lowest power factor Cos 1 = 0.60 tan 1 = 1.333 Required power factor Cos 2 = 0.99 tan 2 = 0.142 kVAR required = 16 (1.333 - 0.142) = 20 kVAR. Thus 20 kVAR capacitor required to raise the power factor to 0.99. It can be seen that, ITHD is 5.6 but maximum harmonic current distortion as recommended by IEEE specifications C-519-1992 is = 4.0. Out of 20 kVAR calculated from equation (4) to be installed we employ 30% kVAR towards filter duty and remaining kVAR for power factor correction. (Thumb rule). Filter kVAR= 30% of 20 kVAR = 6 kVAR. Step-C Design of filter: Investigators decided to design passive shunt harmonic filter. A 3-phase passive filter consists of 3 reactors and 3 capacitors in which capacitors are connected in star. Investigators have to calculate the reactor and capacitor value in mH/phase and F/phase and also in kVAR value. For designing of reactor, investigator calculates the condition of resonance. Since investigator found during measurement of harmonic content, 5th harmonic level beyond the IEEE standard. Thus calculation of capacitive reactance at 5th harmonic frequency (5x50=250Hz) at resonance was done. Inductive Reactance at 50Hz XC50 = 1/2fC = 1/2 x 50 x C Inductive Reactance at 250Hz XC250 = 1/2fC = 1/2 x 250 x C Using above two relation XC250 = XC50/ 5 ------------------------------------- (5) For XC250, first investigators calculated the capacitive reactance at 50Hz where XC50 =1/2fC ----------------------------------------- (6) Step-1 Capacitance per phase: For above relation capacitor value in F/phase is required thus investigators using the following relation kVAR per phase = (kV2 x 2fC x 10-3) C = kVAR per phase/ (kV2 x 2f x 10-3) ------------ (7) Where kVAR per phase = kVAR for 3-phase/ No. of phase = 6/3 = 2kVAR kVph = kVline/3= 0.415/1.732 = 0.230 kV Capacitor C becomes using equation (7) C = 2/ (0.2309)2 x 2 x 3.14 x 50 x 10-3 = 111.50 F /Ph. Step-2 capacitive reactance at 50Hz: capacitor value obtained in step-1, calculated the capacitive reactance at 50Hz frequency using equation (6) XC50 = 1/ (2x3.14x50 x 111.50 x 10-6) = 28.562/Ph. Step-3 capacitive reactance at 250Hz: Since only 5th order harmonic are beyond the limits of harmonic thus investigators calculated the capacitive reactance at 250Hz (5 X 50Hz) using equation (5) XC250 =XC50/ 5 = 28.562 /5= 5.712 /Ph. Step-4 Calculation of inductor: For resonance at 5th harmonic we should have, XL250 = XC250 --------------------------------------------- (8) XL250 = 5.712 /Ph. Investigators calculated the inductive reactance at 50Hz using following relation XL50 =XL250/5 = 5.712/5= 1.142 /Ph. ---------------- (9) From equation (9) inductive reactance at 50Hz, calculated the value of inductance from following relation by putting the value of inductance obtained in step- 4. XL50 = 2f L L = XL50/2=1.142/314 =3.6mH----------------------- (10) After calculated the values of inductor, Investigators calculated the values of inductor in terms of kVAR. Step-5 kVAR rating of Reactor: kVAR of inductor calculated by following relation
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ISSN: 2319-8753
International Journal of Innovative Research in Science, Engineering and Technology
Vol. 2, Issue 2, February 2013

kVAR =VL x IRMS--------------------------------------- (11) Where VL = Voltage across reactor and given by relation VL=VL50 + VL250-------------------------------------------- (12) and IRMS= Resultant rms current due to fundamental and 5th order harmonics and given by following relation IRMS = [I50) + (I250) ] ------------------------------------ (13) (a) VL50 = Voltage drop across reactor due to fundamental Current and is given by following relations VL50 = IC50 x XL50---------------------------------- (14) Where IC50 = Capacitor current at 50 Hz and is calculated by following expression IC50 = kVAR/ (1.732 x line voltage) ----------------------- (15) = 20/ (1.732 x 0.415) = 27.82 Amp Putting the value of IC50 from equation (15) and value of XL50 from equation (9) in equation (14) VL50 = I50 x XL50 = 27.82 x 1.142 = 31.77 V. -------------------------- (16) (b) VL250 = Voltage drop across reactor due to 5th harmonic current and is obtained by relation VL250 = I250 x XL250 ----------------------------------------- (17) Where I250 = current at 250Hz and XL250 is Inductive reactance at 250Hz. Putting the value of I250 from equation (3) and value of XL 250 from equation (8) in equation (17) VL250 = 8.0 x 5.712 = 45.696V. ------------------------- (18) Putting the value of VL50 from equation (16) and value of VL250 from equation (18) in equation (12) VL= VL50 + VL250 = 31.77+45.69 = 77.466 Say 78 V. ------------- (19) (c) RMS current:- For calculating the resultant rms current due to fundamental and 5th order harmonic, putting the value of current at 50Hz from equation (15) and value of current at 250Hz = 8 Amp from equation (3) in equation (13) IRMS= [(27.82) + (8) ]

= 28.94Amp. ------------------- (20)

kVAR rating of Reactor: For kVAR rating of reactor, putting the values of VL from equation (19) and values of IRMS from equation (20) in equation (11) kVAR = VL x IRMS = 78 x 28.96 = 2243.41 VAR/Ph. = 2.243kVAR/Ph ------------------ (21) kVAR rating of capacitor. As per maximum demand of plant, investigator found the total value of capacitor was 20 kVAR. Out of 20 kVAR, 6 kVAR were used in filter and remaining was used in P.F correction. Thus 6kVAR was used for 3 phase i.e 2 kVAR/phase was used in harmonic filter. The voltage rating of capacitor was calculated as follows. VC = VC50 + VC250 ----------------------------------------- (22) Where VC50 (Phase) = Line voltage/3
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ISSN: 2319-8753
International Journal of Innovative Research in Science, Engineering and Technology
Vol. 2, Issue 2, February 2013

= 415/1.732= 239.6 V. ------------ (23) VC250 = I250 x XC250 = 8 X 5.712. (From equation (3) and step 3) = 45.696V. ------------------------------------------- (24) Total voltage across capacitor VC = VC50+ VC250 = 239.6+45.696 (From equation (23) and (24) = 285.296 V (ph voltage) = 494.13 V (line voltage) = 500 V After designing the harmonic filter, the fabrication of the harmonic filter has been done at Hercules panel Pvt. Ltd. Udaipur (India). V. INSTALLATION OF HARMONIC FILTER AND MEASUREMENT During the measurement of harmonic content in supply system using harmonic analyzer, investigator found that only 5th order of harmonic is beyond the limit of harmonic as per IEEE specifications C-519-1992 and limit is 4%. To reduce the 5th harmonic content, above 5th order harmonic filter was installed and again measurement was done by harmonic analyzer. Investigator tabulated all lower order harmonic values with and without filter shown in Table 4 and graphically in fig.I VI. RESULTS OF HARMONIC MEASUREMENT The following observations were made: (1) Input current reduced from 52 to 44 A / Ph (2) kVA demand reduced from 50.51 to 43.18 (3) Input PF is improved from 0.79 to 0.85 (4) 5th harmonic level is reduced from 7.1% THD to 3.5% THD . VII. CONCLUSION From installation of harmonic filter at Arihant Marble Industry following conclusions were made: (1) The 5th harmonic component was found 3.5%. (2) The line current and the line losses were reduced and heating of cables were avoided. (3) Harmonic filter improved the supply voltage waveform (4) The overall efficiency of the plant increases and overall maintenance cost of plant reduces. (5) Noise, EMI and RFI in the plant are eliminated. (6) Generator and transformer heating issues were resolve. TABLE II
Measured Harmonics by Harmonic Analyzer

S.No. 1 2 3 4

Order of Harmonics 5th 7th 9th 11th

Harmonics in % without filter 7.1 2.5 3.5 2.5

Harmonic in % with filter 3.5 2.5 3.5 2.5

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ISSN: 2319-8753
International Journal of Innovative Research in Science, Engineering and Technology
Vol. 2, Issue 2, February 2013

Fig. I Variation of Different Harmonic Order

REFERENCES
Walter T.J. Hulshorst, Keet L. and John Enslin E.R., Harmonic Analysis and Mitigation in Large Industrial Steel Plants Electrical Power Quality and Utilization Magazine, Vol. 11, pp 57-63, 2006. [2] Khatavkar V.V., Chapbekar S.N., Study of Harmonics in Industries - Power Quality Aspect, Electrical India Magzines, Vol. 46, pp 188 -192, 2006. [3] Aware M.V., Kothari A.G. and Bhatt S.S., Power Factor Improvement Using Active Filter for Unbalanced Three -Phase Non-Linear Loads International Journal on Energy Technology and Policy, Vol. 4, pp 103-117, 2006. [4] Ashish Pandey, Kothari D.P. and Bhatt S.S., Power Quality Issues and Power Electronics International Journal Energy Technol ogy and Policy, Vol. 4, pp 4-18, 2006. [5] Escobar, G., Stankovic, Cardenas A.M., Mattavelli V.P., An Adaptive Controller for a Series Active Filter to Compensate Voltage Sags, Unbalance and Harmonic Distortion, Proceedings of VIII IEEE Technical Proceedings, pp. 275 - 280, 20-24, 2002. [6] Antnio P. Martins, The Use of an Active Power Filter for Ha rmonic Elimination and Power Quality Improvement in A Nonlinear Electrical Installation. IEEE Transactions on Industrial Electronics, pp 1 -5, 2000. [7] Sharmeela C., Mohan M.R., Uma.G and Baskaran J., Fuzzy Logic Controller Based Three -phase Shunt Active Filter for Line Harmonics Reduction Journal of Computer Science Publications, pp 76 -80, 2007. [8] Elham B. Makram, Kasikci, Harmonics and Quality of Power Proceedings of Ninth International Conference, IEEE, Vol.3, pp 810 - 815, 2000. [9] Akagi H., Modern Active Filters and Traditional Passive Filters Bulletin of the Polish Academy of Sciences, Technical Sciences, Vol. 54, pp 255269, 2006. [10] Jonathan K. Piel, Daniel J. Carnovale, Economic and Electrical BenefitsOf Harmonic Reduction Methods in Commercial Facilities Proceedings of 13-International Conference, IEEE, pp 81- 89, July 2004. [11] Moinuddin K Syed, Sanker Ram B.V., A Fuzzy Logic Model for Harmonic Reduction in Three Phase Shunt Active Filter Proceeding s of International Journal of Electronic Engineering Research, Vol. 2, pp 357 364, 2010. [12] Bhonsle D.C., Kelkar R.B., Zaveri N.K., Power Quality Improvement: Harmonic Measurement and Simulation, 23rd National Conve ntion of Electrical Engineers, Pune, pp 108-111, 2007. [1]

Biography
Mr. Prakash Sundaram is presently working as Assistant Professor and Head, Electrical Engineering Department, Vidya Bhawan Polytechnic College, Udaipur (Rajasthan). He has 20 years of experience out of which 17 years are of teaching and 2 year is of Industrial. Mr. Prakash Sundaram earned his AMIE Degree in Electrical Engineering from The Institution of Engineers (India), Kolkata. And pursing his Master of Instrumentation and Control from Electrical Engineering Department, NITTTR Chandigarh. Up till now he has guided more than 50 students for Polytechnic. He has 3 Research Articles to her credit. His areas of specialization are Energy Management, Non conventional Energy sources and Electrical Machines etc.

Mrs Shimi S.L is presently working as Assistant Professor, Electrical Engineering Department, and NITTTR Chandigarh. She has 10 years of experience out of which 9 years are of teaching and 1 year is of Industrial. Mrs. Shimi S.L earned her Bachelor of Electrical and Electronics Engineering from J.J College of Engineering and Technology, Trichy, Tamil Nadu and Master of Power Electronics and Drives from Saranathan College of Engineering,
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ISSN: 2319-8753
International Journal of Innovative Research in Science, Engineering and Technology
Vol. 2, Issue 2, February 2013

Trichy, Tamil Nadu and pursing her Ph.D from PEC University of Technology, Chandigarh. Up till now she has guided more than 20 students for BE and 10 students for Masters Degree. She has more than 25 Research Articles to her credit. Her areas of specialization are Power Electronics, Digital Electronics, ANN, Fuzzy, ANFIS etc. Mrs. Shimi S.L is a Member of IEEE (USA).

Dr. S. Chatterji is presently working as a Professor and Head, Electrical Engineering Department, NITTTR Chandigarh. He has 37 years of experience out of which 35 years are of teaching and 2 years are of Industrial. Dr.S.Chatterji earned his Bachelor of Electrical Engineering from Bhopal University, Master of Electrical Engineering from Allahabad University and Ph.D from Panjab University, Chandigarh. Up till now he has guided more than 100 students for Masters Degree and 10 students for Ph.D. He has more than 150 Research Articles to his credit. He has also authored 3 books in the field of Electronics, 4 Lab Manuals in Electrical and has produced a series of 21 Video films in Power Electronics. His areas of specialization are Power Electronics, Digital Electronics, Electrical Power, ANN, Fuzzy logic applications, Soft Computing Techniques etc. Dr.S.Chatterji is a Fellow member of Institution of Engineers (India), Member of IEEE (USA) and Life member of ISTE. He is also a adjunct professor of Instrumentation and Control, Manipal University. He is also a member of BOS for large number of Universities.

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