From the Desk of Managing Director

Transcription

1 Official News Letter of Amtech Electronics (India) Ltd., Gandhinagar, Gujarat (India) QM 003 AN ISO 9001 : 2008 COMPANY FOR PRIVATE CIRCULATION ONLY JULY 2017 Inside Customer s Voice Techno-Talk Page 2 Some fundamental questions and answers Page 3 Appl. Case Study Energy saving in ID fan Page 4 Amtech Power Digital Excitation & Control System DEC-250 Page 5 From the Desk of Managing Director Someone wanted to test Mahatma Gandhi, knowing that he has two principles, non-violence and truth. He asked Mahatmaji, Suppose a cow is running away from a butcher. She comes across a junction of two roads, one going to the right and other going to left. She takes one of the roads. Chasing her, the butcher comes there. You happen to be at that point and you know which way the cow has gone. The butcher asks you, Did you see the cow here? Which way did it go? What will be your answer? If you say I don't know, you are a liar. If you tell him the truth, the cow will be killed and your non-violence principle will be defeated. But Gandhiji was very clear on his principles. He replied instantly, I will tell the butcher, I know by which road the cow went, but I will not tell you. Morale: A true follower of the principles does not waver in the odd situations. Piyush Patel CELEBRATIONS OF THE FOUNDATION DAY Product Overview Grabbing Crane Modernization Page 6 Product Overview Grabbing Crane Modernization Your Valuable Feedback Page 7 nd st On 2 July 2017 Amtech Electronics (India) Limited entered in to 31 year of its successful industrial career, as a leading manufacturer in Motion Control Systems. Since its nd inception on 2 July 1987 Amtech went from strength to strength, in terms of product range, customers served, manpower employed, manufacturing and R&D infrastructure developed---in all walks of its industrial life. I am thankful to my team members who were with us, who are with us and who will be with us, in our journey full of milestones of achievements said Mr. Piyush Patel, the Managing Director of Amtech Group of Companies, during celebrations of the Foundation Day. Presence Across the Nation Page 8 Editor: Atul Suthar Start everyday with a new hope. Leave bad memories behind and have faith for a better tomorrow Our honorable Prime Minister Shri Narendra Modi established 21st June as International Yoga Day. In tune with that Amtech celebrated Yoga Day in its own premises. Amtech team members participated with full enthusiasm in Surya-Namaskars organized during the event. A two days In-house Training Program, on Harmonics and their Mitigation through Active Harmonic Filter was conducted in Amtech Training Center on 22nd and 23rd June Engineers from Atandra Energy Pvt Ltd attended it.

2 CUSTOMER S VOICE Date 31/01/17 To Whom It May Concern This is to certify that we are using wide range of Amtech make AC VFD from 5.5 kw to 250 kw for various Application and Active Harmonic Filter supplied by M/s Amtech Electronics India Ltd Gandhinagar, Gujarat the details stated as under. kw & Model Quantity Application kw (AMT-250-4) - 2 Nos - FD fan (CPP) kw (AMT-132-4) - 4 Nos - ID fan & PAFan (CPP) & Bag Filter kw (AMT-110-4) - 1 No. - Bag Filter & Compressor kw (AMT-75-4) - 2 Nos. - Bag Filter kw (VT-240S 015H) - 1 No. - Biomass Belt Feeder (CPP) kw (VT-230S 7P5H) - 1 No. - Biomass Belt Feeder (CPP) kw (VT-240S 5P5H) - 2 Nos. - Drag Chain Feeder (CPP) 8. Active Harmonic Filter - 1 No. - CPP 200AMP AboveAC Variable Frequency Drive and Harmonic Filter are running successfully since 2012 and after sales service support also good. G. L. Suthar (HOD E&I) Ambuja Cements Ltd. (Unit Ropar) Panjab AMBUJA CEMENTS LIMITED (Unit Ropar) Village - Daburji, P.O. Lodhimajra Distt. Ropar (Panjab) Phone : , Fax : , (Regd. Off. : P.O. Ambuja Nagar, Taluka - Kodinar, Distt. Junagarth, Gujarat ) 2

3 TECHNO-TALK Title : Some fundamental questions and answers 1. Whether fuse should be connected at load -end or source-end? Fuse should be connected at source-end. At this location it will be able to protect from any short circuit in the cable at any point between source and load. 2. Whether Power Factor (PF) capacitor should be connected at load - end or source- end? PF capacitor should be connected at load end. At this location, it will be able to avoid power loss in cable, as cable will now carry less current due to reactive current compensation given by PF capacitor. 3. Why any equipment has to be derated at higher altitudes (typically at more than 1000 meters altitude)? At higher altitudes air density reduces. Hence air available for cooling reduces. This reduces cooling provided by the air to the equipment. Hence the equipment cannot work at its rated capacity. Therefore it has to be derated at higher altitudes. 4. Why high efficiency motors sometimes result in more power consumption than conventional motors? High efficiency motors have lower slip than conventional motors. This results in high efficiency motors running at slightly higher speed than conventional motors. Centrifugal loads like fans, blowers, pumps, compressors etc. typically have their power consumption proportional to the cube of the speed at which they work. Hence with high efficiency motors they consume more power. Consider the following example: Conventional 2 pole motor, having efficiency of 85%, rotating at 5% slip. connected to load consuming 100 kw power, Speed of motor = 1500 (1-0.05) = 1425 RPM Input power = 100 / 0.85 = kw (1) High efficiency 2 pole motor, having efficient of 90%, rotating at 2% slip, connected to same load. Speed of the motor = 1500 (1-0.02) = 1470 RPM. Now the power consumed by load, being proportional to cube of the speed, = 100 (1470 / 1425) 3 = kw Hence input power = / 0.90 = 122 kw (2) From (1) and (2) even if high efficiency motor is used its consumption will be 4.4 kw more then conventional motor, for centrifugal type of loads. 5. Why two capacitors connected in series to share the voltage, need to be connected with resistors across them? Consider the following example: Two capacitors 1000 uf/ 400 V are connected in series and put across 700 VDC voltage. Their leakage resistance is not identical, they are 1 Mohm and 1.3 Mohm respectively. Hence voltage across first capacitor will be = 700 x (1 / ( )) = 304 V The voltage across second capacitor will be 396 V The voltage difference between two capacitors will be 92 V (1) Hence they will share the voltage unequally and one capacitor may even exceed its rated voltage. Now suppose, the capacitors are shunted with 100 k resistance each, with 5% tolerance. Hence their values in the worst case can be 95 k and 105 k. These resistors will be in parallel with the leakage resistors of each capacitor. The equivalent resistor across first capacitor will be = 95 x 1000/ ( ) = 86.8 k The equivalent resistance across second capacitor will be = 105 x 1300/ ( ) = 97.1 k Hence now the voltage across first capacitor will be = 700 x (86.8/( )) = 330 V Voltage across second capacitor will be 370 V The voltage difference between two capacitors will be 40 V (2) From (1) and (2) the voltage difference between two capacitors will be drastically reduced, even if we have taken the worst possible combinations of capacitors and resistors across them. Hence now the capacitors will operate in safer operating conditions w. r. t. Voltages across them. Additional advantage of resistors across capacitors is, when the 700 V across them is switched OFF the capacitors can discharge to safe voltage value in about five minutes time, in this case. 3

4 APPLICATION CASE STUDY Title : Energy saving in ID fan DOC.NO. : CS-243 Industry : Cement Application : ID Fan Motor rating : AC Induction Motor, 3-Phase kw : 30 Volt : 415 RPM : 1480 Hz : 50 Amp : 52 Previous system : Motor was running on DOL starter. Problem observed : 1. High maintenance cost. 2. Energy losses due to flow control by damper Present system : Amtech 37 kw, VT240S VFD used in place of DOL starter. kw (Consumption) Damper Position Previous system (Without drive) : 29.5 kw 85% Open Present system (With drive) : 22 kw 100% Open System block diagram : 3-PHASE, 415 V, AC SUPPLY AXPERT-VT240S 37 kw 30 kw, 3-PHASE INDUCTION MOTOR ID FAN Merits of new system : 1. Easy & smooth operation. 2. Energy saving due to flow control by VFD. Economical analysis : Energy consumption without VFD- P1 = 29.5 kw Energy consumption with VFD - P2 = 24 kw Energy saving per day ((P1-P2)*24) = 132 Units. Saving per Rs.5/- Unit = Rs.660/- Saving per year (Approx. 320 Days) = Rs.2,11,200/- Payback period approximately 4-6 Months 4

5 AMTECH POWER VISION Title : Digital Excitation and Control System DECS-250 Continued from June 2017 newsletter Limiter functions: - V/Hz limiter - Over excitation limiter - Under excitation limiter - Stator current limiter - Var Limiter to limit the amount of reactive power exported from the machine Protection - Loss of sensing - Generator reverse power - Generator over voltage - Generator reverse var - Generator under voltage - Exciter eld overvoltage - Generator over frequency - Exciter eld overcurrent - Generator under frequency - Loss of PMG - Exciter diode open detection - Exciter diode short detection - User programmable protection All of the generator protective features will have two settings groups. Diagnostics and event recording Real time monitoring Oscillography Sequence of events Communications The digital excitation system will have the following communications available: USB communication for interface with a local PC CANBUS communication for interface with additional remote I/O Standard 100 base T Ethernet communication for Modbus TCP communications as well as interface with PC software. RS-485 communication for Modbus RTU communications Optional Pro bus communication Optional 100 base T Ethernet communication Physical requirements HMI The digital excitation system will have a 128 X 64 pixel LCD for viewing and changing settings, alarms, status and metering data. In addition, six LED indicators will be located on the front of the unit and will indicate the following conditions: Null Balance - PSS active - Internal tracking - Pre-position - Lower limit - Upper limit The digital excitation control system will have a six-pushbutton interface to scroll, select and edit parameters. 5

6 PRODUCT OVERVIEW Title: Grabbing Crane Modernization The new generation of control and monitoring system, developed by Amtech Electronics (India) Ltd, integrates the operation of EOT crane with four rope grabe by using variable frequency drive, Crane controller for controlling and monitoring. Grabing crane used to handle the powder material, having four rope which operates hoisting and grabing operation. Synchronization of this operation was carried out by differential gearbox. Being mechanical synchronization, it prones to backlash and takes lot of time to re-synchronize. Amtech has developed and successfully installed automation system for the grabbing crane. Automation system control the synchronization and whole crane operation like Cross Travel, Long Travel, Hoisting, Grabbing and safety interlocks. Automation system is using properly sized variable frequency drive for existing slip ring motor or new induction motor to control the operation. PLC system take care of Speed control, Thruster control, Synchronization and Various interlocks. Grab crane is a type of crane used in Cement, Metal industry, Ports etc. for handling of material in powder form. The grab mechanism is just like two jaws hinged at mid-point, used to grab the material. This mechanism can be operated by either hydraulic or electrical system. In Hydraulic system the grab jaws are operated by hydraulic cylinders. In case of electrical system, there are two rope & drum assemblies on the crab trolley. The grab operation gets carried out by one of the rope & drum assembly used to hoist the grab which in turn, gets driven by electrical motor. The motors get controlled by drive to allow multiple speed operations. Frequent Problems in grabbing cranes are: The original system in grab control uses a differential limit switch to get open/close positions & these positions cannot be changed. As this system is purely mechanical, setting the position is a tedious process. The position of the switch can get disturbed over multiple operations & to be re-set again Power & Rotor resistance contactors often required to change due to frequent operations Slip-ring, carbon brushes maintenance Arching, bigger size and bulkiness of motor puts extra load on trolley and bridge Frequent problems in slip ring motors due to single phasing Burning of resistor box Regular maintenance of current carrying contacts of contactor due to frequent braking and reversal involved Motor & Gear box coupling bolts damages & respectively motor & gearbox damage due to jerky operations Hoist & Grab wire rope broken out due to uneven load sharing Poor life of brake shoe as brakes used for braking the speed Continue to next page... 6

7 PRODUCT OVERVIEW Continue from previous page... Features Retrofitting the crane using existing slipring motor/new induction motor and removed the mechanical differential gearbox limit switch operation. Close loop control with encoder feedback from rope drum, to synchronize the Hoisting and Grabbing operations with proper load sharing For the crane operator, the crane works as if there were only a single hoisting device with the additional functions of open and close. Setting the nominal grab positions only has to be performed once after a change of a rope or grab unit. Latest series Variable frequency drive with state-of-the-art engineered panel with protection of crane vibration and dusty environment, ensures trouble free operation of the crane. Operator cabin is equipped with monitoring system, which gives status of whole crane operation to make the ease of operation for operator. User friendly HMI provides powerful diagnostic in case of any problem to reduce the downtime. Variable frequency drive control eliminates the problems of slip-ring motor contactor, resister and thruster brake. Benefits Assistance from concept to commissioning New system with existing components Minimized maintenance reduces the cost and provides more up time Ease of setting Open/Close limits through HMI instead of adjustment of mechanical limit switch. Optimized four-rope grab control minimizes cycle time and reduces stress on ropes Higher reliability - Less Mechanical wear / tear more uptime Full motor protection Smooth crane operation Electronic braking hence reduced maintenance of brake Energy saving Easy troubleshooting Quick and safe commissioning Qualified after-sales service OPEN/CLOSE ROPE DRUM GRAB CLOSED HOIST PULLEY HOLD DRUM OPEN/CLOSE PU GRAB OPENED Your Valuable Feedback How do you find our newsletter? Excellent Good Not worth reading Any other comments How do you rate our product quality? Excellent Good Not good Cannot give feedback Will refer the product to others companies Any other comments Name & Signature: Designation: Date: Contact Number: Kindly your feedback to info@amtechelectronics.com 7

8 PRESENCE ACROSS THE GLOBE H.O. Gandhinagar Amtech Service Center Gandhinagar Mumbai Bangalore Chennai Delhi Indore / Raipur Hyderabad Kolkatta H.O. and Service Center Contact Person Phone No. (O) Mobile No. Bhavana Thakkar sales@amtechelectronics.com Rajesh Moradiya csd@amtechelectronics.com Regional Offices Contact Person Phone No. (O) Mobile No. Vrajesh Yadav mumbai@amtechelectronics.com M. D. Kamath T. S. Sridhar bangalore@amtechelectronics.com. chennai@amtechelectronics.com S. Senthil Kumar chennai@amtechelectronics.com delhi@amtechelectronics.com Umesh Bhatia mp@amtechelectronics.com G. Sateesh Kumar hyderabad@amtechelectronics.com Kaushik C kolkatta@amtechelectronics.com From Atlanta Chandigarh Muzaffarnagar Delhi (Gurgaon) Jaipur Lucknow Udaipur Gandhinagar Jamshedpur Jamnagar Ahmedabad Bhopal Vadodara Kolkata Veraval Surat Indore Vapi Nagpur Nasik Raipur Aurangabad Mumbai Pune Vizag BelgaumHyderabad Head Office Branch Office Bangalore Dealer Chennai System Integrator Pondicherry Resident Engineer Trichy Global Distribution To Book - Post Gandhinagar Works & Regd. Office : Amtech Electronics (India) Ltd. E-6, GIDC Electronics Zone, Gandhinagar , Gujarat (India) Phone : Fax : Web : , , info@amtechelectronics.com