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Case story: GHCL Mills

India

In Madurai textiles manufacturer GHCL Ltd was facing penalties due to excessive harmonics in the Sree Meenakshi Mills spinning plant

LOCAL PARTNER: Texservices
INDUSTRY: Textiles
LOCATION: India
TIMELINE: From 2016

Background

In Madurai, an ancient city in the south of India, textiles manufacturer GHCL Ltd was facing penalties due to excessive harmonics in the Sree Meenakshi Mills spinning plant. GHCL is one of India’s leading manufacturers and exporters of Home Textiles and their operations in Madurai is an integrated setup beginning with the spinning of yarn and continuing on to weaving, dyeing, printing and processing.

The harmonics in their spinning plant were not only in violation of IEEE 519, but were also having a negative effect on productivity. After trying locally made solutions, which led to even more problems in the plant, GHCL turned to Texservices (founded by a technokrat Mr N Kanakarajan in 1995), our partner in Tamil Nadu, for a proposal on how to meet regulatory requirements and improve system efficiency.

GHCL’s main challenge was the penalties being imposed by the Tamil Nadu Electricity Board due to the IEEE 519 violation

Challenge

GHCL’s main challenge was the penalties being imposed by the Tamil Nadu Electricity Board due to the IEEE 519 violation. Many non-linear loads were contributing to the harmonics in the plant, and the poor power quality was also causing failures in electronic components, reducing overall efficiency. GHCL needed a solution that would ensure compliance with local regulations and boost reliability and productivity.

Solution

Texservices proposed and began installing several Comsys ADF P100 units at various Points of Common Coupling (PCCs) within the facility. Thanks to the Active Dynamic Filter technology, which reduces the need for derating, Texservices could propose a solution involving lesser rated ADFs than the competition.

Texservices installed several Comsys ADF P100 units at various Points of Common Coupling (PCCs) within the facility

Spectrum view – before compensation

Spectrum view – before compensation

Spectrum view – after compensation

Spectrum view – after compensation

 

Result

With 16 ADF P100s dynamically compensating the harmonics, the spinning plant has been running fine since 2016 and the harmonic levels have been kept within the allowed limits, increasing plant productivity and avoiding penalties for GHCL. According to Nithya Kanakarajan at Texservices, GHCL is very happy with the successful outcome and new installations are planned, including remote monitoring of filters over IOT. “In fact,” says Nithya, “the customer is so happy with the results that they are recommending us to all the other textile industries and also choosing us for all of their expansion projects.”

THDI Without ADF

Harmonic compensation without ADF

THDI With ADF

Harmonic compensation with ADF

 

Dynamic compensation

Dynamic compensation

Nithya Kanakarajan, Jr Managing Director – Texservices

The customer is so happy with the results that they are recommending us to all the other textile industries and also choosing us for all of their expansion projects.”
– Nithya Kanakarajan, Jr Managing Director, Texservices

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