Case Study: Resolving Frequent Breakdown of Extruder Drive System
Client: Leading Wind Mill Material Manufacturing Unit
Problem Statement:
The client, a major supplier of wind mill materials, faced frequent breakdowns of their extruder drive system. These breakdowns were caused by peak voltage issues, leading to the failure of the Variable Frequency Drive (VFD). Each breakdown resulted in a 12-hour downtime to restart the system. The existing extruder drive was imported, with no service support available, and the cost of a new drive was three times higher compared to a Danfoss drive, with a long lead time for delivery if we import from other countries.
Solution Overview:
Our team designed and supplied a 315KW FC302 VFD with a control panel, which was integrated into the existing system. Additionally, an isolation transformer was installed to rectify the peak voltage problem. The new setup ensures that in the event of a VFD issue, the system can switch to a bypass mode within 3 minutes, preventing production losses.
Application:
- Extruder
- Rating: 315KW
Implementation Details:
- Root Cause Analysis:
- Identified peak voltage as the cause of frequent VFD failures.
- Determined the need for a reliable VFD replacement with quick bypass capabilities.
- Solution Design:
- Designed a 315KW FC302 VFD control panel.
- Integrated the new VFD with the existing control panel to ensure seamless operation.
- Installation:
- Installed an isolation transformer to mitigate peak voltage issues.
- Ensured the system could switch to bypass mode within 3 minutes in case of VFD failure, thus avoiding production downtime.
- Testing and Commissioning:
- Conducted thorough testing of the new VFD system and bypass mechanism.
- Validated the effectiveness of the isolation transformer in stabilizing voltage levels.
Team Members and Responsibilities:
- Coordination: Mr. Abdul Rahman
- Managed project coordination and client communication.
- Design and Logic Creation: Manikandan Sekar
- Designed the VFD system and created the necessary control logic.
- VFD Programming Support: Mr. Nihal Bash
- Provided expertise in VFD programming and configuration.
- Panel Wiring/Assembly/Site Work: Panel Team
- Conducted wiring, assembly, and on-site installation of the control panel.
Results:
- Reduced Downtime: The new system reduced downtime from 12 hours to 3 minutes during VFD issues, significantly improving operational efficiency.
- Cost Savings: Implemented a cost-effective solution by using a Danfoss VFD, which is three times cheaper than the previous drive.
- Enhanced Reliability: The isolation transformer effectively mitigated peak voltage issues, preventing future VFD failures.
Conclusion:
The successful implementation of the 315KW FC302 VFD with an isolation transformer and bypass capability resolved the client’s frequent breakdown issues, ensuring reliable and efficient operation of their extruder drive system. The project showcased our ability to deliver innovative and cost-effective solutions, enhancing client satisfaction and operational productivity.