PLC PF Correctr
PLC PF Correctr
PLC PF Correctr
CHAPTER 1
INTRODUCTION
Page 1
The FACT Fertilizers and Chemicals Travancore Ltd was setup in 1943 for the
manufacture and marketing of fertilizers, chemicals and caprolactum. There are 2 manufacturing
divisions- The FACT Udyogamandal complex which began in 1947, and Cochin division. In
August 1960, FACT became a Kerala State Public Sector Enterprise and from 1962 onwards, a
Govt. of India enterprise. The consultancy unit known as FACT Engineering and Design
Organisation (PEDO) was setup in 1965 and has since diversified into chemicals,
petrochemicals, hydrometallurgy, pharmaceuticals and other areas. The project is done at the PD
of FACT. FACT has since then grown, expanded and branched out in a fantastic maenterprnner
so that today it is not merely one of the biggest fertiliser
legend of the modern times and a triumph of the public sector. FACTs annual sales turn over is
around Rs.2937 crores during 2011-12. FACT today has 3 manufacturing divisions, two at
udyogamandal, its birth place, which has by now become an industrial complex of several
industries, and other at ambalamukal close to the Kochi Refinerires Ltd. The overall production,
capacity of the company now is in the range of 3.2 Lakhs tons of nitrogen 1.27 tons of phosphate
and 50,000 tons of caprolactam.
FACT has the widest range of fertilisers which is made available to the farmers spread
over wide area covering the entire south, straight fertilisers like Ammonium Sulphate, Urea,
MOP and also complex fertilisers like Factamfos 20-20-0-13,FACT DAP and a host of NPK
mixtures to suite all crops and all soils. FACT also manufactures various grades of Biofertilisers. FACT has also successfully branched out in to the fields of chemicals and fertilizer
technology,
engineering
and
Design
capability,
Research
and
Development,
Fabrication/engineering services. Here the project concentrate on the power factor control
automatically using PLC.PLC (programmable logic control) also referred to as programmable
controller is to as the name given to a type digital computer commonly used in commercial and
industrial control applications. All PLC monitor input and other variable values make decisions
based on stored program, control output to automate a process or machine.
Dept. Of EEE, MLMCE
Page 2
CHAPTER 3
POWER SYSTEM IN PETROCHEMICHAL DIVISION (PD)
The power system in FACT-PD is divided into three sections - one fed from a turbo
generator and the other 2 fed from K.S.E.B. The TG of 16MW capacity & it supplies the major
portion of FACT-PD power requirements. The total load of FACT-PD is approximately 12.1 MW
& the whole of the power requirement of PD can be met by the 16MW TG. The TG can be used
for back feeding the other divisions in times of severe power crisis.
The 110 KV incoming lines from the K.S.E.B are terminated at the UDL ALIND Panel.
In UDL, the 110KV is stepped down into 11KV by 4 power transformers rated 15MVA and
12.5/20MVA power transformers. From there, it is taken to 11KV switch board through 2
incomers, incomer 1 & incomer 2. The TG and the incomer from UDL are connected to 4 bus
bars which are joined by bus couplers. BUS 1 & BUS 2 are connected to the 2 incomers from
UDL and BUS 3, BUS 4 are connected to the TG.
There are 4 capacitor banks named PQRS which is of two 500 and two 1000 KVAR for
power factor improvement. The 11 KV is stepped down to 3.45 KV using power transformers
rated 6.3 MVA 11/3.45 KV. The 3.3 KV switchboards are connected to 34 motors. The 11KV is
stepped down to 415 V by 1.6 MVA 11/0.433 KV transformers. Thus from the 11KV
switchboard, the supply is taken to two 415 V switchboards MPCC 1 and MPCC 2. Similarly the
11KV switchboard is connected to another 2 415V switchboards PPCCI 1 and PPCC 2. This is
done by 10 step down transformers of rating 11/0.415 KV 1.6 MVA. Most of the connected load
in FACT-PD is motors. There were a total of 786 motors and these motors are connected to 3.3
KV & 415V switchboard
Page 3
Power factor is a measure of how efficiently electrical power is consumed. In the ideal
world power factor is unity. Unfortunately in the real world power factor is reduced by highly
inductive loads to 0.7 or less. This induction is caused by equipment such as lightly loaded
electric motors, luminary transformers and florescent lighting ballasts and welding sets, etc.
Power factor is the ratio of true power or watts to apparent power or volt amps. They are
identical only when current and voltage are in-phase than the power factor 1.0.Power in the ac
circuit is very seldom equal to the direct product of the volts and amps.
In order to find the power of a single phase ac circuit the product of volts and amps must
be multiplied by the power factor. Ammeters and voltmeters indicate the effective value of volts
and amps. True power or watts can be measured with a wattmeter. If the true power is 1870 watts
and the volt amps reading is 2200. Then the power factor is expressed in decimal or percentage.
Thus power factors of 0.8 are the same as 80%. Low power factor unusually associated with
motors and transformers. An incandescent bulb would have a power factor of close to 1.0. A 1hp
motor about 0.80. With low power factor loads, the current flowing through the electrical system
components is higher than necessary to do the required work. This result in excess heating,
which can damage or shorten life of equipment. It does how ever become a problem in industry
where multiple large motors are used. Power Factor Correction Capacitors are normally used to
correct this problem.
For a DC circuit the power is P=VI, and the relationship also holds for the instantaneous power
in an AC circuit. However, the average power in an ac circuit expressed in terms of the rms
voltage and current is
Pavg = VIcos
Where is the phase angle between voltage and current. The additional term is called the power
factor.
Page 4
R
Z
From the phasor diagram for AC impedance, it can be seen that the power factor is R/Z. For a
purely resistive AC circuit, R=Z and the power factor is 1.
4.1 IMPORTANCE OF POWER FACTOR
A power factor of 1 or unity power factor is the goal of any electric utility company
since if the power factor is less than 1, they have to supply more current to the user for a given
amount of power use. In so during, they incur more losses. They also must have larger capacity
equipment in place than would be otherwise necessary. As a result, an industrial facility will be
charged a penalty if its power factor is much different from 1.
Industrial facility tends to have a leading power factor where the current lags
the voltage (like an inductor). This is primarily the result of having a lot of electric induction
motors. The windings of motors act as inductors as seen by the power supply. Capacitors have
the opposite effect and can compensate for the inductive motor windings. Some industrial sites
will have large banks of capacitors strictly for the purpose of correcting the power factor back
toward one to save on utility company charges. The power factor of an AC electrical power
system is defined as the ratio of the real power flowing to the load to the apparent power in the
circuit,[1][2] and is a dimensionless number between 0 and 1. Real power is the capacity of the
circuit for performing work in a particular time. Apparent power is the product of the current and
voltage of the circuit. Due to energy stored in the load and returned to the source, or due to a
non-linear load that distorts the wave shape of the current drawn from the source, the apparent
power will be greater than the real power.
Linear loads with low power factor (such as induction motors) can be corrected with a
passive network of capacitors or inductors. Non-linear loads, such as rectifiers, distort the current
drawn from the system. In such cases, active or passive power factor correction may be used to
counteract the distortion and raise the power factor. The devices for correction of the power
factor may be at a central substation, spread out over a distribution system, or built into powerconsuming equipment.
Dept. Of EEE, MLMCE
Page 5
4.2.
LINEAR CIRCUITS
In a purely resistive AC circuit, voltage and current waveforms are in step (or in phase),
changing polarity at the same instant in each cycle. All the power entering the load is consumed.
Where reactive loads are present, such as with capacitors or inductors, energy storage in the
loads results in a time difference between the current and voltage waveforms. During each cycle
of the AC voltage, load does not change the shape of the waveform of the current, but may
change the relative timing (phase) between voltage and current. Extra energy, in addition to any
energy consumed in the load, is temporarily stored in the load in electric or magnetic fields, and
then returned to the power grid a fraction of a second later in the cycle. The "ebb and flow" of
this nonproductive power increases the current in the line. Thus, a circuit with a low power factor
will use higher currents to transfer a given quantity of real power than a circuit with a high power
factor. A linear Circuit containing purely resistive heating elements (filament lamps, cooking
stoves, etc.) have a power factor of 1.0. Circuits containing inductive or capacitive elements
(electric motors, solenoid valves, lamp ballasts, and others) often have a power factor below 1.0.
4.3
AC power flow has the three components: real power (also known as active power) (P),
measured in watts (W); apparent power (S), measured in volt-amperes (VA); and reactive power
(Q), measured in reactive volt-amperes (var).
The power factor is defined as:
In the case of a perfectly sinusoidal waveform, P, Q and S can be expressed as vectors that form
a vector triangle such that:
If
is the phase angle between the current and voltage, then the power factor is equal to
, and:
Since the units are consistent, the power factor is by definition a dimensionless
number between 0 and 1. When power factor is equal to 0, the energy flow is entirely reactive,
and stored energy in the load returns to the source on each cycle. When the power factor is 1, all
the energy supplied by the source is consumed by the load. Power factors are usually stated as
"leading" or "lagging" to show the sign of the phase angle.
If a purely resistive load is connected to a power supply, current and voltage will change
polarity in step, the power factor will be unity (1), and the electrical energy flows in a single
direction across the network in each cycle. Inductive loads such as transformers and motors (any
Dept. Of EEE, MLMCE
Page 7
transmission losses and improve voltage regulation at the load. It is often desirable to adjust the
power factor of a system to near 1.0. When reactive elements supply or absorb reactive power
near the load, the apparent power is reduced. Power factor correction may be applied by an
electric power transmission utility to improve the stability and efficiency of the transmission
network
Power factor correction brings the power factor of an AC power circuit closer to 1 by
supplying reactive power of opposite sign, adding capacitors or inductors that act to cancel the
inductive or capacitive effects of the load, respectively. For example, the inductive effect of
motor loads may be offset by locally connected capacitors. If a load had a capacitive value,
inductors (also known as reactors in this context) are connected to correct the power factor
Page 8
NON-LINEAR LOADS
A non-linear load on a power system is typically a rectifier (such as used in a power supply), or
some kind of arc discharge device such as a fluorescent lamp, electric welding machine, or arc
furnace. Because current in these systems is interrupted by a switching action, the current
contains frequency components that are multiples of the power system frequency. Distortion
power factor is a measure of how much the harmonic distortion of a load current decreases the
average power transferred to the load.
Page 9
Sinusoidal voltage and non-sinusoidal current give a distortion power factor of 0.75 for this
computer power supply load.
4.6.
NON-SINUSOIDAL COMPONENTS
Non-linear loads change the shape of the current waveform from a sine wave to some other form.
Non-linear loads create harmonic currents in addition to the original (fundamental frequency) AC
current. Filters consisting of linear capacitors and inductors can prevent harmonic currents from
entering the supplying system.
In linear circuits having only sinusoidal currents and voltages of one frequency, the
power factor arises only from the difference in phase between the current and voltage. This is
"displacement power factor". The concept can be generalized to a total, distortion, or true power
factor where the apparent power includes all harmonic components. This is of importance in
practical power systems that contain non-linear loads such as rectifiers, some forms of electric
lighting, electric arc furnaces, welding equipment, switched-mode power supplies and other
devices.
4.7.
In a 3 phase supply, kW consumed is (VOLTS x AMPS x 1.73 x Power Factor) / 1000. The
Electricity Company supply you VOLTS x AMPS and they have to supply extra to make up for
the loss caused by poor Power Factor. When the power factor falls below a set figure, the
electricity supply companies charge a premium on the kW being consumed, or, charge for the
whole supply as kVA.
4.8.
Inductive loads cause the AMPS to lag behind the VOLTS. The wave forms of VOLTS and
AMPS are then "out of phase" with each other. The more out of phase they become then the
Dept. Of EEE, MLMCE
Page 10
minimising the inductive component of the current and thereby reducing the losses in the supply.
The introduction of Power Factor Correction capacitors is a widely recognised method of
reducing an electrical load, thus minimising wasted energy and hence improving the efficiency
of a plant and reducing the electricity bill. It is not usually necessary to reach unity, ie Power
Factor 1, since most supply companies are happy with a PF of 0.95 to 0.98
The low power factor is mainly due to the fact that most of the power loads are inductive
and, there-fore, take lagging currents. In order to improve the power factor, some device taking
leading power factor should be connected in parallel with the load. One of such devices can be a
capacitor. The capacitor draws a leading current and partly or completely neutralizes the lagging
reactive component of load current. This raises the power of the load.
Page 11
4.10
STATIC CAPACITOR
Power factor can be improved by connecting capacitor in parallel with the equipment
operating at lagging power factor. The capacitor (generally known as static capacitor) draws a
leading current and partly or completely neutralizes the lagging reactive component of load
current. This raises the power factor of the load. For three-phase loads, the capacitors can be
connected in delta or star as shown in Fig. 6.4. Static capacitors are invariably used for power
factor improvement in factories.
Page 12
Page 13
5.1
Page 14
CHAPTER 6
DETAILS ABOUT PLC
Page 15
LADDER DIAGRAM
The system is user programmable. It uses a language called "Relay Ladder" or RLL
(Relay Ladder Logic). The name of this language implies that the control logic of the earlier
days, which was built from relays, is being simulated.
Ladder diagrams are specialized schematics commonly used to document industrial
control logic systems. They are called "ladder" diagrams because they resemble a ladder, with
two vertical rails (supply power) and as many "rungs" (horizontal lines) as there are control
circuits to represent.
A program consists of instructions that accomplish specific Tasks. The degree of
complexity of a PLC program depends upon the complexity of the application, the number and
type of input and output devices, and the types of instructions used. Ladder logic (LAD) is one
programming language used with PLCs. Ladder logic incorporates programming functions that
are graphically displayed to resemble symbols used in hard-wired control diagrams. The left
vertical line of a ladder logic diagram represents the power or energized conductor. The output
coil instruction represents the neutral or return path of the circuit. The right vertical line, which
represents the return path on a hard-wired control line diagram, is omitted. Ladder logic
diagrams are read from left-to-right and top-to-bottom. Rungs are sometimes referred to as
networks. A network may have several control elements, but only one output coil.
Page 16
6.3
turns on and off outputs based on input conditions and the internal program. In this aspect, a PLC
is similar to a computer. However, a PLC is designed to be programmed once, and run repeatedly
as needed. In fact, a crafty programmer could use a PLC to control not only simple devices such
as a garage door opener, but their whole house, including switching lights on and off at certain
times, monitoring a custom built security system, etc.
Most commonly, a PLC is found inside of a machine in an industrial environment. A PLC
can run an automatic machine for years with little human intervention. They are designed to
withstand most harsh environments.
6.4
HISTORY OF PLCS
Page 17
CHAPTER 7
PROJECT DESCRIPTION
As the part of project we visited the Petrochemical Division of FACT whose electrical
load connected in KSEB is 4.5MW.The load is supplied from KSEB and TG set of
16MW of which 7.5MW is utilized.
Page 18
Page 19
Page 20
Page 21
Page 22