Chapter 1

PROJECT BACKGROUND
The Project
Unilever Philippines is located at UN Ave. Paco, Manila, a large company who manufacture the
laundry detergents and soaps, shampoos and hair conditioners, toothpastes, deodorants, skin care
products, household cleaners, and toilet that is being provided to the market and to the consumers, with its
huge amount of products that is being produced every day. This cause them to consume a lot of expenses
in their production, more specific in their electricity consumption. One major problems of Unilever is
presently facing is that they have a high electrical bill due to their continuous production in their plants. The
electric bill consumption of the whole factory is 25 million per month. The Electrical and Instrumentation
Department of Uniliver done a study in which load that the power consumed the most and they came up to
the conclusion that the Water Tank Farm of theirs caused this. Water Tank Farm is compose of different
motors who supply colorated water, chilled water and all water supply in the plant and facilities. This Tank
Farm consumed power with an amount of 5 million per month that is the 20% of the total bill of the
company consumed in a month. As a consumers of power we tend to pay a bill in a least amount of we
expect, so this problem is introduce to us for us to know what we will do to lessen it as them as our client.
The design project will focus to the various design in the motor pumps in the Tank farm to lessen
the amount of power it take. This motor pumps operates in nonstop operations within 6 days in a week, due
to the fact that the operator sometimes doesnt mind to stop this motor pumps if it not in used. This motor
pumps has a slow starting acceleration so it concerns the operator to stop it and turning it on when in the
operations, a little delay in production causes them a loss of products to be produced in that day. This
project aims to give a solution on how to lessen the consumption of power of the tank farm with various
designs and technology to be trade-off based in the constraints.
Project Objectives
This project aims to design a system that would be able to lessen the power bill of UNILEVER
Philippines specifically with their tank farm which handles all the water that is used for various uses of the
whole industrial plant.
Specifically:

Lessen the power consumed by the Tank Farm of the plant

Direct reduction of energy by improving the system efficiency

The Client
The client of this project is the UNILEVER Philippines located at UN Ave. Paco, Manila.

Project Scope and Limitation

The scope of the design will be concentrating on the energy saving method in the motor pumps
present in the tank farm of the Clients plant. The selection of methods to be used will be compared and
discussed in the tradeoffs in the remaining chapters below. However. The remaining equipment present in
the plant
Significance of the Project
The significance of the project is not only to help the company to attain its goal of having a
reduction on energy consumption and billing, but also to attain skills in designing a large system and to
apply industry based design wherein it can be apply on actual grounds and to present in the professionals.

Chapter 2
DESIGN INPUTS
Summary
Unilever Philippines is located at UN Ave. Paco, Manila, a large company who manufacture the laundry
detergents and soaps, shampoos and hair conditioners, toothpastes, deodorants, skin care products,
household cleaners, and toilet that is being provided to the market and to the consumers, with its huge
amount of products that is being produced every day. The design project will focus to the various designs in
the motor pumps in the Tank farm to lessen the amount of power it takes. This motor pumps operates in
nonstop operations within 6 days in a week, due to the fact that the operator sometimes doesnt mind to
stop this motor pumps if it not in used. This motor pumps has a slow starting acceleration so it concerns the
operator to stop it and turning it on when in the operations, a little delay in production causes them a loss of
products to be produced in that day. This project aims to give a solution on how to lessen the consumption
of power of the tank farm with various designs and technology to be trade-off based in the constraints.

Figure 2.1 Unilever Philippines

Figure 2.2 Tank Farms

Figure 2.3 Unilever Industrial Plants

Chapter 3
DESIGN METHODOLOGY
Design 1: Regenerative Converter
First option of the designs of energy saving of motor is the regenerative converter which is a
solution to replace the dynamic making of transistor and resistor network. It absorbs the regenerative
energy that produce by the VFD or VSD or PWM Inverter and return it to the source. The process is from
the flow of the motor to the source using regenerative converter, it activates by the charges stored in dc link
capacitors of the VFD or VSD or PWM Inverter then convert to return to the source.
Components computation:
Inertia Calculations
Motor Inertia
Load Inertia
Gear ratio (Output RPM / Input RPM)
Total Inertia
Load Calculations
Total system inertia
Maximum shaft speed
Desired deceleration time

--------ft-lb^2
--------ft-lb^2
--:---------ft-lb^2

Minimum shaft speed to decelerate to

Motor/Drive efficiency

--------ft-lb^2
--------rpm
--------min
--------sec
--- rpm
--%

Torque required
Peak power required (kW)
Peak power required (HP)

---------ft-lbs
--------kW
-------HP

Regen Brake Calculations

AC current rating
AC Line voltage
Continuous regenerative capacity
Peak regenerative capacity
Energy Savings
Total cycle time

Average power per cycle

Energy costs

----Amps rms
----Volts rms
-----kW
-----Hp
-----kW
-----Hp
----hr
----min
----sec
-----kW
P---- P/kW-Hr

Run hours per day

Run days per week
Run weeks per year

----Hr/Day
-----Days/Wk
-----Wks/Yr

Energy savings per week

Energy savings per year

P-----P-----------

Option 1: Using VFD (Variable Frequency Drive)

Option 1: Gate Turn-Off Thyristor (GTO)
Option 2: Silicon Controlled Rectifier (SCR)
Option 3: Symmetric Gate-Commutated Thyristor (SGCT)
Option 2: Using VSD (Variable Speed Drive)
Option 4: Gate Turn-Off Thyristor (GTO)
Option 5: Silicon Controlled Rectifier (SCR)
Option 6: Symmetric Gate-Commutated Thyristor (SGCT)
Option 3: Using PWM Inverter
Option 7: Gate Turn-Off Thyristor (GTO)
Option 8: Silicon Controlled Rectifier (SCR)
Option 9: Symmetric Gate-Commutated Thyristor (SGCT)
Design 2: Sinusoidal PWM Converter
One of the designs option of energy saving of motor drive is the PWM (Pulse Width-Modulation)
converters that will perform both AC to DC and DC to AC conversions. In AC to DC conversion, the
converter draws currents from the main source, to supply the power to the motor. When the motor is
operating in a regenerative mode (i.e. DC to AC conversion), the converter injects the current into the main
source, such as like the renewable energy generator.
Option 1: Cycloconverter

Figure: Diagram of a six-pulse cycloconverter for a three-phase motor load

Option 10: IGBT
Option 11: SCR
Option 12: MOSFET
Option 2: Current source inverter PWM Converter (CSI)

Figure. Functional block diagram of the conventional CSI drive

Figure. Simulink model of the block diagram of CSI fed induction motor drive
Option 13: Gate Turn-Off Thyristor (GTO)

Modelling of induction motor

The stator equations are follows
dia 1
V a 1=R1 i a1 + La
[.]
dt+ ea 1
V b 1=R1 i b1 + Lb

dib 1
[.]
dt+ eb 1

V c 1=R1 i c 1+ Lc

di c1
[.]
dt+ ec 1

The rotor equations are as follows

0=R 2 i a 2 + La
0=R 2 i b 2 + Lb

di b 2
[.]
dt +e b 2

0=R 2 i c 2+ L c

dic 2
[ .]
dt+ ec 2

di a 2
[.]
dt +e a 2

Torque balance equation is as follows:

d
T d=T 1+ J w + B w [.]
dt
GTO Switching Loss
GTO switching power loss is also linearly interpolated. The

tr

(rise time) and

tf

are the major contributions to switching loss. The switching frequency is fixed at 240 Hz
Eon=1.35 x 103 x I onstate + 0.15
Eoff =7.67 x 103 x I onstate 0.2

Option 14: Silicon Controlled Rectifier (SCR)

Modelling of induction motor

The stator equations are follows
dia 1
V a 1=R1 i a1 + La
[.]
dt+ ea 1
V b 1=R1 i b1 + Lb

dib 1
[.]
dt+ eb 1

V c 1=R1 i c 1+ Lc

di c1
[.]
dt+ ec 1

The rotor equations are as follows

di a 2
0=R 2 i a 2 + La
[.]
dt +e a 2

(fall time) values

0=R 2 i b 2 + Lb

di b 2
[.]
dt +e b 2

0=R 2 i c 2+ L c

dic 2
[ .]
dt+ ec 2

Torque balance equation is as follows:

d
T d=T 1+ J w + B w [.]
dt
SCR Switching Loss
The SCR switching power loss is linearly interpolated because it is a function of current and
voltage. Switching frequency is fixed at 120 Hz. The turn-off switching energy includes the reverse recover
charge.
Ploss, sw =9.6 x 104 x P output

Option 15: Symmetric Gate-Commutated Thyristor (SGCT)

Modelling of induction motor

The stator equations are follows
dia 1
V a 1=R1 i a1 + La
[.]
dt+ ea 1
V b 1=R1 i b1 + Lb

dib 1
[.]
dt+ eb 1

V c 1=R1 i c 1+ Lc

di c1
[.]
dt+ ec 1

The rotor equations are as follows

di a 2
0=R 2 i a 2 + La
[.]
dt +e a 2

0=R 2 i b 2 + Lb

di b 2
[.]
dt +e b 2

0=R 2 i c 2+ L c

dic 2
[ .]
dt+ ec 2

Torque balance equation is as follows:

d
T d=T 1+ J w + B w [.]
dt
SGCT Switching Loss
Psw ,loss =f fund x N x E sw
Pcond , loss=V tm x I t
Ploss=P sw, loss+ P cond ,loss
Option 3: Voltage source inverter PWM Converter (VSI)
Option 16: IGBT
Option 17: SCR
Option 18: MOSFET
Design 3: Matrix Converter
Option 1: VFD (Variable Frequency Drive)
Option 19: IGBT
Option 20: SCR
Option 21: MOSFET
Option 2: VSD (Variable Speed Drive)
Option 22: IGBT
Option 23: SCR
Option 24: MOSFET
Option 3: PWM Inverter
Option 25: IGBT
Option 26: SCR
Option 27: MOSFET
Design 4: Pressure Transmitter
Option 1: VFD (Variable Frequency Drive)
Option 28: IGBT
Option 29: SCR
Option 30: MOSFET

Option 2: VSD (Variable Speed Drive)

Option 31: IGBT
Option 32: SCR
Option 33: MOSFET
Option 3: PWM Inverter
Option 34: IGBT
Option 35: SCR
Option 36: MOSFET
Option 1: VFD (Variable Frequency Drive)
VFD use is increasing because users say VFDs improve manufacturing processes and reduce
cost. Understanding how they do their job can help as you consider deployments. VFD controls the speed
of an AC motor, which provides flexibility to the process since speed can be changed easily for process
optimization. It takes the fixed power supplied to it and converts it into a variable frequency and variable
voltage source which then feeds a motor. This allows the drive to control the speed and torque the motor
produces.

Figure 2.2 Rectifier Circuit

Voltage Rating: VRMS*1.414
Current Rating: same as Diode current rating