C408 = ATT & iii A-“Auditing” Evaluate, Educate, Energise CUT) Dae eMart RLA - “Residual Life Assessment ” VOLT=CH EXCELLENCE IN ENGINEERING PRODUCTS & SERVICES 01 & Gas Industries ATT & RLA Steel Industries Cement industries ‘Sugar IndustriesVOLTECH GROUP, founded in 1995, headquartered in Chennal with global presence, is a professional services firm dedicated in the field of Products, Testing & Commissioning, Engineering, Erection, Operation & Maintenance, Energy Audit, Electrical Safely Audit, Technical Trainings and Third Party Inspection Services We have become the industry leader in our domain due to our unending quest for providing high quality services to our prestigious customers, Today, Voltech stands as a 500 Crore turn aver company with 3000+ employees. ~ Mr. M.Umapathi B.E., FLE., Managing Director Voltech Group of Companies Paice eel Electrical Safet AUDITING Energy Au Energy today has become a key factor in deciding the operating cost and in tum the Product cost at micro level and the debt burden at macro level. Energy cost has become a significant factor of economic activates. The energy shortage situation calls for energy conservation measures, which essentially means usage of optimum energy for the same level of activty/output. Energy Auditis carried out ) Level-1: Walk through audit Level-Il: Detailed Energy audit + To study, measure & evaluate the performance of nominated major equipment, plant & machinery and whole utilities to check operating capacity, efficiency & specific energy consumption, + Analyze energy data to identify potential areas for energy conservation. ‘The audit report shall tabulate the major/prospective areas of energy conservationjalong with saving proposals 4 Ingeneral, saving potentials are identified in three categories after detailed Energy Audit + Short term measures involving litle orno investment with immediate payback period, + Medium term measures involving marginal investment & with payback period less then one year + Long term measures involving capital expenditure with attractive payback returns, Undertake energy audit in packages as perclient's requirement: + Power Quality Audit * Sound Audit { ThomogaptAustby Cortethemogapher + AtCompretsor Aust eke cnn os me 2 were “AUDIT Implementation & follow up Audit tS We provide support service for implementation and follow up of the audit FONOWAP D I i“ comers svt recommendations with client's investment. ™ Provide service as an ESCO: Arranging finance for procurement, implementation and follow up of the audit recommendations to improve the energy efficiency and maintenance costs for facilities over mutually agreed time period sharing the benefits of energy savings.Electrical Safety Audit: Indian industries are growing at a faster pace and so the accidents. Industry managements invest & benchmark against global standards in areas like product development, energy conservation, Occupational Health, Environment etc., but is yet to adopt & achieve global bench marking in the area of Electrical Safety. Scope of Electrical Safety Audit: a y + Physical Inspection of the Plant with reference to applicable Indian standards, Indian Electricity Rules, and identity electrical hazards. + Reviewing Electrical Safety System with respectto total safety system of the Plant + Review of Protection Devices System ofthe electrical installation of Plant, ‘+ Examination of adequacy of Plant Lightning Protection System. + Examinations of adequacy of Plant through ARC Flash Studies. * Toreview the efficacy of Earthing System on the basis of IS: 3043 and to suggest recommendations for uv improving the earthing system. + Toreview the Electrical Preventive Maintenance schedule as per IE Rules at Plant. + Toidentify Training Needs of employees of the Plant keeping in view the electrical safely. + The recommendations modifications suggested will have Reference to the code of practices applicable standards statutory rules. Se Minin PO / Generally all topics pertaining to Electrical power systems are covered. Our faculties are well experienced & give confidence to the trainees by engaging them for 60% of the time on Hands-on training, Voltech Training Center offers following courses: 1. Testing of Electrics (Testing of Transformers, CT, PT, Circuit Breaker & Motors) 2.Power system Protection (All Types of Relays) 3. Design Engineering (Electrical Power systems) 4, Design Engineering (Civil & Structural) 5. In plant Training - Electrical (Manufacturing of Transformers, Circuit Breaker, Control & Relay Panel and Battery Chargers) 6. Project work supportin Electrical Power systems 7.Workshop on Electrical topics Any topic pertaining to Power System suitto client's requirement THIRD PARTY INSPECTION SERVICES Third party (or: We provide third Party Inspection for materials and mechanical, electrical and instrumentation equipment of relevance to Oil and Gas, Power and Industrial projects. VEPL provides independent, impartial and reliable third party (or second party) inspection services to ensure compliance to customer specification -ond party) inspection s 2s Vendor assessment services: (Supplier's capability assessment services) ves | RAN Vendor assessment services are generally second party assessments, based on \ pistons redler directsed¥or ied pplicreltechniceliexecu ion helt plcal 2 ; deliverable is a gap assessment report including recommendations to move ae % forward and follow-up suggestions. a Expediting services With numerous suppliers involved in your supply chain, keeping your projects on schedule is a challenge. Delayed delivery of materials, products or equipment prevents your project from being completed on time and on budget. Our expediting services, keep your project firmly on schedule by ensuring that your suppliers deliver as committed.RLASTUDIES & CONDITION ASSESSMENT ‘The performance of equipments analyzed through various test under condition assessment and review of maintenance (break down maintenance, scheduled maintenance & condition monitoring) to determine its condition and predict when it will need attention, OBJECTIVES: Toarrest the deterioration in performance. Toimprove the availabilty, reliability efficiency and safety of the equipment. Toregain lost capacity ‘Toextend the useful life beyond designed life of 25 years. Tosave investments on new equipment Tomeet environmental pollution norms and to have more effective pollution control. MAIN STEPS INVOLVED IN R&M AND LIFE EXTENSION OF EQUIPMEN’ ‘The main steps involved in R&M and Life Extension of equipment are as under + Study of past performance data and review of O&M records e.g. loading conditions, number of tripping, failures, repairs/replacements etc. Condition Assessment of the equipment to know the present health e.g. efficiency and other operating parameters. ‘Assessment of remaining life of various components of the plant by conducting Residual Life Assessment (RLA) studies. Identification of components requiting replacements, repairs, up gradations/retrofiting, Implementation of R&M and Life Extension Program on equipment to equipment basis Replacement of equipment with latest state of art’ making new provisions as amodemization process. DIAGNOSTIC TOOLS /TECHNIQUES. FOR DISTRIBUTION EQUIPMENT 1A & Surge Arrester Testing Of Motors + Gatecton of 3 homonie > ‘fet Oierge (Geelong) Siecet emails | ‘Inuorentesinetdrotanon eer + Delstneonrenet + Saenger 1 Sebitonn SavalasHARMONIC STUDY & MITIGATION HARMONICS: Any Device with Non-linear operating characteristics, draw current from the source which does not follow the voltage wave form and introduce wave form distortion in current. These waveform distortion in current are called current harmonics. The harmonic current produced by the nonlinear loads flow through the system impedances and generate voltage harmonics. SOURCES OF HARMONICS: + Variable speed AC/DC Drives, UPS systems, Rectifiers + SMPS, Static converters, Thyristorcontrolled systems Frequency controlled induction furnaces + Arcing equipment, Arc furnace, Welding, Lighting + When saturations reached in Transformers, motors, Generators PROBLEMS CREATED BY HARMONICS: + Reduced energy efficiency in the networks Excessive Heating and failure of capacitors, Fuses, Motors, Transformers, Cables, Switchgears and Lighting Ballast et. Nuisance tripping of circuit breaker or frequent blowing offuses. Erroneous operation of control system equipments. Damages to sensitive electronic equipment's and communi tion interferences. OBJECTIVES ‘Tomeasure the total harmonics distortions THDV and THDI order of individual harmonics, power Factor atthe incomer and as well as each outgoing feeders to give solutions for power factor Improvement and harmonics mitigations. METHODOLOGY OF THE STUDY Site study & data collections Field data monitoring &measurement Data analysis Report preparation with recommendation/ proposal for the harmonics filter implementation. MITIGATIONS ‘Supply, Installation, Testing & commissioning shall be carried out by use of, + Passive filter + Active filter BENEFITS + Reduction of Harmonic currents in the electrical network Eliminates resonance condition ,improvement of True power factor No Derating of the transformers and motors due to harmonic losses Better utilisation of the electrical system and system efficiency alts best, Support energy savings Good Life expectancy for all the electrical and electronic. components. Penalty by EB authorities for Poor PF is avoided and hence reduced electricity bills ‘Compliance with IEEE 519 & Other power Quality standard TEEE 519-1992 Current Distortion limits (%) Harmonic order(odd Harmonics) Terk TD at Tishsi7_ | 17shs23_ | _23shs35 35zh 20 50 40 20 15 06 03 20250 180 70 35 25 10 05 ‘50<100 12.0 100 a5 40 15 o7 700000 | _15.0 120 35 350 20 10 >1000 200 150 70 60 25 14 TWiximurn harmonic current Distortion in percent of, (Even Harmonics are limited to 25% af the od@ harmonic limits above) IEEE 519-1992 Voltage Distortion limits (%) ‘Special applications (Hospitals, alrports) 3 ‘General systems applications 5 Dedicated systems (100% non-linear loads) 10OUR CLIENTS ALSTOM | Indianoil Skytanking @sunkdisos’ ETQ | ® yy sit BEAR lemontree Stim Anjoni Portland Cement Limited sige cener aren G wasevaroum Its all about Imagineering ) SW Limited ms J sicuchives Gon Conpary «Making our planet more productive Energy Management Cycle CesT 7 eral om litt 9 Voltech Eco Tower, No. 2/429, Mount Poonamallee Road, Ayyappanthangal, Chennai - 600 056. Ph: +91-44- 43978000 Fox: +91- 44 - 42867746 Email : voltech@voltechgroup.com Website : www.voltechgroup.com