Cement, Energy and Environment

Applications in Adana Cimento Adana Cement within the project of "Improvement of energy quality and renewing compensation system" that it started in 2007 in our energy grid. Since starting the main project Enabling Parallel Active Harmonic Power Filters, Reactive Power Compensation System with Passive Harmonic Filters and Conversion of 6.3kV Fixed Capacitor Banks to the Automatic Compensation System project have been accomplished. The common aim of starting the projects is supplying distribution grid with "Quality Energy". It's very clear that solution will be done via a co– operation between manufacturers Distributor and consumer companies though Energy quality is a consumer-oriented problem. To improve energy quality, Adana Cement decided to apply a project in 2007. The project started by improving compensation systems and filtering dominant harmonics in the systems. In the project in question, capacitor banks are covered by explosion-proof metal clad panels and protected by current limiting reactors and internal fuses . Capacitor banks are connected to the system via vacuum contractors. By all those precautions, probable OSH risks such as explosion and fire risks are minimized. Additionally, at any possible faults on capacitor banks , only one cell will be affected and long-term problems will not be encountered in the system. Control of compensation systems are always done, harmonics are measured periodically and precautions needed in energy quality aspects are taken in our factory, in this phase where the electronic equipments must operate properly since the cement production sector follows and applies the technology. Project Step and Applied Applications 1. Applications of "Reactive Power Compensation System with Passive Harmonic Filter" to the TR 13-14-15-16 6,3/0.4kV, 2000kVA distribution transformers. 2. Application if "Reactive Power Compensation System with Passive Harmonic Filter" and "Parallel Active Harmonic Filter" to the ID Fan motor transformer of rotary kiln (6.3/0.69kV, 1636kVA). 3. Application if "Reactive Power Compensation System with Passive Harmonic Filter" and "Parallel Active Harmonic Filter" to the rotary kiln main drive motor transformer (6.3/0.69kV, 900kVA). 4. Removing fixed capacitor banks on 154/6.3kV 25MVA Transformer A Busbar and adding Automatic Reactive Power Compensation System on. • Enabling 3 steps of capacitor banks , total 2500kVAr • Adding 3 steps of capacitor banks more, while removing fixed capacitor banks directly connected to the motor circuit breakers. Total system became 5500kVAr with 6 steps. 5. Removing fixed capacitor banks on 154/6.3kV 25MVA Transformer B Busbar and adding Automatic Reactive Power Compensation System on. • Enabling 4 steps of capacitor banks , total 3500kVAR • Adding 5 steps of capacitor banks more, while removing fixed capacitor banks directly connected to the motor circuit breakers. Total system became 8500kVAR with 9 steps. 6. Removing fixed capacitor banks on 154/6.3kV 25MVA Transformer C Busbar and adding Automatic Reactive Power Compensation System on . Total system became 4750kVAr with 6 steps. 7. In order to prevent parallel resonance • Observing harmonic current flowing through the system by the control relays and setting them to alarm and disconnect capacitor banks from the system when the harmonic current limits are exceeded. • Observing the grid continuously by the analyzers connected to the system. • Observing all load changes on the grid, due to parallel response frequency and compensation systems response to this change. Results I. Application of "Reactive Power Compensation System with Passive Harmonic Filter'' to TR 13-14-15-1 6 6.3 /0.4kV, 2000kVA distribution transformers . 1.1 TR13-14 (Measurements are taken common because of parallel operation) 24