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[Audio] DIN Micro Lesson Competition 2026 TEAM –Concept Crafters DELTA Rudrapur Feb, 21th 2026.

[Audio] Table of Content Team Introduction System Overview Purpose of PQR System Structure Power Stack Concept Why Power Stack in Series System Working Function & Uses Testing Challenges Solutions Implemented Benefits & Outcomes.

[Audio] Special gratitude:- Team Introduction Capacity Enhancement in Megawatt Solution While Ensuring Operator Safety. Mr. Manogya sir Plant Head Leader TEAM –Concept Crafters DELTA Rudrapur Mr. Prakash Pokhariya Member 2 Member 1 Mr. Ayush.K Mr. Anand Bhatt.

[Audio] General Overview In a perfect power system, the electricity flows smoothly in a regular wave pattern. But in real life, machines that don’t use power evenly cause irregular currents called reactive and harmonic currents, which can reduce the quality of power. Power companies set rules for maintaining good power quality, including a minimum power factor—a measure of how efficiently electricity is used. If this isn’t met, there can be extra charges. There are also standards (like IEEE 519-2014) that limit how much distortion or “noise” in voltage and current is allowed, based on the strength of the power system compared to the load it’s serving..

[Audio] Purpose of PQR The Power Quality Restorer (PQR) is an advanced medium-voltage solution developed by Delta for reactive power compensation in 3-phase 11/6.6 kV industrial systems. It ensures that current distortion remains within prescribed limits while enhancing the system’s power factor. With an exceptionally low loss of approximately 1.1%, the PQR delivers substantial energy savings compared to conventional LT solutions for similar applications..

[Audio] PQR Structure The PQR system is a large cabinet-based setup with forced air cooling. Fans are installed on top to keep the system cool. It includes power cabinet, filter cabinet, and control cabinet A 3/2 MVA system is used The system has: 12 stacks for 11 kV 9 stacks for 6.6 kV Each stack is part of a 3-phase system and helps in power control Each power stack has a local control board that sends its status to the main control unit using optical fiber cables. The system also has built-in protection like: Overvoltage Overcurrent Short circuit.

[Audio] PQR Structure Control Cabinet HMI (Simple) The control cabinet contains: Main control unit PLC HMI (Human Machine Interface) Front panel features: Local/Remote selector switch Start / Stop / Reset / Emergency buttons LED status indicators Internal light with door switch HMI Features: Easy to use Access control (permissions) 10.1-inch touch screen Resolution: 1024 × 600.

[Audio] Power Stack What a PS Unit Typically Contains. 1. Input Stage Takes high-voltage AC (25 kV indirectly via transformer/feeder) Includes: Circuit breaker / isolator Surge protection 2. Power Conversion Stage This is the core of the PS unit: Rectifier → Converts AC → DC DC Link → Smooths and stores energy (capacitors) Inverter / Chopper → Converts DC → controlled output (AC or DC) Depending on the system, this could be: Traction converter (railway) Industrial drive converter HV power supply module.

[Audio] Power Stack 3. Control & Monitoring Each PS has built-in electronics that: Measure voltage, current, temperature Detect faults (overcurrent, overvoltage, overheating) Communicate via fiber optics: Transmit (Trans) Receive (Rec) Fault signal 4. Protection System Fast shutdown during: Short circuit Overload Internal failure Sends fault status to Control Center (CC).

[Audio] Why Power Stack Why So Many PS Units in Series? Instead of one big unit, the system uses many smaller PS modules because: Advantages Modularity → easy maintenance (replace one unit) Scalability → add/remove units as needed Redundancy → system can sometimes run even if one fails Voltage sharing → each unit handles part of the total voltage Typical Real-World Use This kind of setup is commonly used in: Railway traction systems (25 kV AC lines) High-power industrial drives HV converter stations.

[Audio] System Working Working & Control (Simple) Voltage is measured using a transformer Current is measured using sensors (Hall sensors) If high current is detected: Protection system trips the circuit breaker (VCB) The main control unit: Controls switching operations Communicates with all power stacks Processes data using DSP boards Each stack: Sends voltage and status data Receives control signals Protection & Cooling (Simple) System monitors current rise (di/dt) Trips breaker if limit exceeds Uses temperature and humidity sensors Cooling is done using fans based on system condition.

[Audio] Function &Uses A Power Quality Restorer (PQR) is used to improve electrical power quality in systems. Its main functions are: 1. Reactive Power Compensation It provides dynamic reactive power compensation. This helps improve the power factor, making the system more efficient and reducing losses. 2. Harmonic Current Filtering It filters out harmonic currents generated by loads. Ensures that harmonic distortion stays within acceptable limits at the Point of Common Coupling (PCC). 3. Harmonic Distortion Control Maintains: Voltage THD (THDᵥ) < 5% Current TDD (TDDᵢ) < 8% These limits comply with the IEEE 519-2014 standard. PQR monitors the system and injects the right current to clean the power and improve efficiency..

[Audio] Application Where it’s used PQR systems are commonly installed in: Industrial plants (steel, cement, textiles) Data centres Hospitals Large commercial buildings Why it’s important Poor power quality can: Damage sensitive equipment Cause production losses Increase energy costs One solution multiple benefit: Dynamic reactive power Current harmonic suppression: Configurable priority for Harmonic/Reactive Power Load balancing Allow to parallel for higher rating MD reduction Voltage regulation Low losses.

[Audio] Problem Description Productivity of 6MVA/3MV/11KVA stack was not as per requirement 1 Excess time in system Stack Testing 2 Capacitor discharging was done manually/ Ideally 3 Initial system design 4.

[Audio] Brainstorming & Kaizen Idea BRAIN STORMING Idea’s Trial Feasibility Remark Deploy additional resource for capacitor discharge 2 × no No change in discharge mechanism (still passive). Cycle time governed by RC time constant → no productivity gain Manual discharge using manpower 5 × no Forced discharge reduces time, but operator-dependent. No control over discharge current/voltage → safety risk, inconsistency Implement automatic capacitor discharge system 4 √ yes Provides controlled discharge path (bleeder resistor / switched circuit). Optimized RC → reduced discharge time, ensures voltage threshold compliance & interlock safety IDEA Need to convert Capacitor discharging activity from Manual to auto ..

[Audio] Before Condition-1 Pic 3- Capacitor discharge activity Ideal Condition Pic 1- Stack Assy stage 1 Pic 2- Stack slab Assy stage 2 During calibration testing, the capacitor bank gets charged to operating voltage. Post-test, no active discharge path is available; hence, stored energy dissipates only through internal leakage. The system is kept in idle condition for approximately 30 minutes to reach a safe voltage level before the next test. Total Discharge time : 30 Min ..

[Audio] Before Condition-2 Pic 3- Capacitor discharge activity Manually Capacitor discharge is currently performed via manual intervention, reducing discharge time from ~30 min (natural decay) to ~2 min. However, the process is operator-dependent and lacks control. Total Discharge time : 2 Min ..

[Audio] After Condition Pic 3- Capacitor discharge activity done through auto Circuit Combination of Relay Power resistor & Driver board ( Built inhouse ) To overcome from Operator Safely issue and reduce discharging time . In house developed an auto Circuit board combining Relay power resistor and driver board as shown above . After this improvement the discharging time reduced from 30 Min to 4 Sec with safety . Total Discharge time : 4 sec ..

[Audio] Benefits PQCDSM P Productivity Out put /day increased Q Quality Improved C Cost Conversion cost saved D Delivery Smooth delivery S Safety Improved M Moral Moral improved Before After 2 3.5 Before After 0.59 0.9 FY'24 45901 45931 45962 45992 20 22 3 0.

[Audio] Intangible Benefits Analytical ability improved Technical & System Knowledge Improved Customer satisfaction . Communication & team sprit enhanced . 01 02 03 04.

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