Power saving has become a critical issue today. This because an acute shortage of electric power has been felt worldwide and more importantly, it has been well accepted that the energy resources are limited. Therefore, energy conservation needs to be looked upon as one of the key initiatives to mitigate power-related problems in near future.
The normal practice of saving power is based on the parameter of the actual amount of money spent on usage of electrical energy. Direct expenditure incurred on power becomes the point of focus and efforts are centered on reducing the cost. Usually, efforts are oriented towers saving in terms of active energy, i.e. unless it is made mandatory by electricity boards to control the power factor.
In this process, the user is mostly unaware of power-related problems, which arise in the society. The adverse effects of the quality of power on energy conservation are generally unknown to the industrial user. In their pursuit to save energy, little attention is paid to power quality.
The indirect effects of power quality pose a problem not only to users, but also to those involved in generation and distribution of power. Power failure, load shedding, cascade failure of turbine in a a grid, blowing up of transformers, sustained low voltage etc are witnessed on a day-to-day basis. The root cause of these problems is increasing pollution of electrical power caused by the poor power factor, high harmonics content, high crest factor etc. Leads to tremendous strain on power resources. Power saving in real sense cannot be achieved, unless all these aspects are considered, studied and rectified. Moreover, optimum use of power must be exercised.
Consumers need to be cautious of all these factors, while using electricity in whichever form. The criterion should not be only from the perspective of direct saving, but should also include indirect and additional savings through power conservation.
Voltage and Current
Voltage and current are two most important parameters, which determines the
quality of power. While voltage is within the control of power generation and
distribution agency, current is under total control of the user. Maximum
synchronization o these two parameters would help achieve the goal of saving
energy in totality and would ensure the best quality of power. Voltage and
current must go hand in hand and any shift between them would lead to
ineffective use of power, thereby resulting in monetary losses.
For conserving power and improving the quality of power, power factor improvement is the most important area, which needs to be taken into consideration on a priority basis. Most of the electricity boards distribution companies have made it compulsory to improve the power factor to a level of 0.90 minimum. This level varies for different states.
Power capacitor plays a vital role not only in saving power, but also in improving the quality of power. The ordinary capacitor normally available in the Indian market is mainly in the range of 1 to 25 KV as single unit, which can be increased to any rating by way of parallel connecting these capacitors.
There are different technologies existing in the capacitor categories like MPP, APP, mixed dielectric etc. The latest state of the art technology is the metallised polypropylene capacitors, which has self healing property. It gets self healed even in case of any puncture in the dielectric due to over voltage or over current.
With advanced industrialization, MPP type capacitor is the best option for improving power quality. It also acts as a major component for optimum utilization of electrical energy. The entire range of MPP capacitor meticulously provides consumers the best and consistent performance.
Considering the current power scenario, it has become important to increase the use of MPP capacitors and perk up the power factor in all the area, which will save energy at local as well as national levels. This in turn will resulting less load shedding and improved level of power supply, without interruption at a low price.
Low Watt Loss Capacitors
Havells capacitors help perk up the power factor. These are low watt loss capacitors.
For manufacturing a consistent and reliable product, it is required to adopt the best practices, which necessitates having control on the following things:
Machinery Raw Material Control Environment Havells takes into account altheas parameters.
Winding Machine Presently, the world's latest generation of winding machines are available with Havells. These machines are imported from Switzerland and run at high speed. These are very useful from the customer point of view as these don't allow capacitor manufacturer to use low grade of poly propylene film in the capacitor, which was possible with the earlier machines of the same make.
The latest machines even do automatic staggering and provide consistent output quality. However, the earlier machines were also automatic in terms of winding, film feeding, core feeding etc. But the staggering had tobe done manually, thus increasing the chances of human error.
Raw Material: The base film, i.e. polypropylene, which is the main part of any capacitor should be of best quality. Havells produces high quality capacitors. For maintaining the quality standards, Havells uses films from Treofan, Germany and Oji, Japan that have good breakdown voltage.
Control Process: To have a control on output quality, process needs tobe controlled. At havells, even the small process of making the notch mechanism is fully automatic. Other processes that include testing, self clearing, spray painting are also automatic, where the function of the operator is only to load the job. For instance, the Zinc spray, which is an important process after winding.
Control Environment: Since moisture and dust is detrimental for capacitors, it is essential that winding should be done in a controlled environment. Winding room at Havells takes into account all important factors, which include:
Air in the work area is controlled on the basis of its flow, temperature, humidity and dust.
Winding room is equipped with air handle unit with filters, prefilters, fresh air source etc.
AHU is designed for 100 class accuracy (300 particles/ft 3 of 0.3 mm size and 100 particles/ft 3 of 0.5 mm size).
The winding room s provided with air showers (100 class) that blast dust from clothes and also act as airlocks to present contaminants.
Through implementation of all the control measures, havells could achieve the
lowest watt loss capacitor in the industry. Where industry norms are 0.5
watt/KVAr, even best of manufacturers were not be able to go beyond 0.35 w
Watt/KVAr. Watt loss per KVAr of Havells capacitor is to the tune of 0.06
watt/KVAr to 0.25 Watt/KVAr.