Stabilizer

 

REASON FOR VOLTAGE VARIATION
Voltage fluctuation is a common phenomenon all over the country. Generally voltage is very low during day time and high during night hours. Industrial Units running round the clock, face the problem of both Low and High Input Voltage.
 
Also, voltage fluctuation is a seasonal phenomenon and increases in summer season. Moreover on holidays, peak hours, rainy days and when the agricultural load is switched off, the voltage rises sharply in the feeder lines. There are few consumers of electricity,in these days, there is comparatively lesser voltage drop in the feeder lines as a result consumers suffer from high voltage-which is more dangerous.
Inner view of stabilizer
Inner View of Stabilizer

EFFECT OF VOLTAGE VARIATION
Electrical equipments are designed for 230 volts(single phase) or 400 volts (3-phase) and operate with optimum efficiency at its rated voltage. 90% of industrial load consists of motors. Electric motor draws considerably high current at high voltage and increases energy consumption, increases MDI and reduces power factor etc. These excessive power losses of motors generated at higher voltage results in premature failure of electrical equipments.
 
Similar is the case with bulbs and tubes, when voltage increases above 230 volts. For example, at 270 volts, the power consumption of 60w bulb increase by almost 40% and the life of the bulb reduces from normal 1000 Hours to mere 100 Hours only(as per analysis report of ISI marked bulb manufacturers).
 
We have done many analysis on electrical equipments such as motors, bulbs, tubes etc. of variation of current drawn at different voltage.
 
You will find in the analysis that with the increase in the voltage above 390/400 volts, the current drawn by the electrical equipments increases thereby resulting in breakdown of electrical equipments, increases energy consumption, increases MDI and reduces power factor etc.
 
You can verify these facts in your premises by noting down hourly readings of voltage and current on particular motor having constant load on them for few days.
Inner view of regulator
Inner View of Regulator

 

HOW TO ASSESS POSSIBLE SAVINGS
You must be having Electronic Energy Meter installed in your works, you can easily varify and ascertain the ENERGY savings possible by recording the periodic(hourly)readings of KW and KVA corresponding to voltage.
 
From the recorded readings-different input voltages can be segregated in bands and the corresponding KW consumption. For example, 390-400, 400-410,410-420, 420-430.........450-460 volts(voltage readings in stemps of 10 volts bands) and the relevant KW consumption reading. The sum total of different KW consupmtion readings of particular voltage band can be divided with number of readings taken-to arrive at the average KW consumption at that voltage band.
 
From this data-sheet, you will find that overall KW consumption at 390-400 volts input voltage band will be minimum. Similarly, the overall KW consumption at other High/Low input voltage conditions can be saved by maintaining 390/400 volts by installing the Servo Voltage Stabilizer.
NOTE:
You may struck out the abnormally High/Low KW consumption readings from data-sheet, because these may be due to different load conditions than normal running load. This will give more precise and accurate analysis.
 
Also, you can workout the average monthly failure rate of electrical equipments e.g. electric motors, bulbs, tubes, mercury lights, contactor coils and electronic circuits etc. and the expenses incurred on repair/replacement of them.
 
We have installed number of Automatic Voltage Controllers to different type of industries throuhout India and our customers have confirmed the following advantages after installing the Automatic Voltage controllers :
 

1.REDUCTION IN BREAKDOWN OF ELECTRICAL EQUIPMENTS :
60-80% depending upon the input voltage variation and working hours of the plant.
 
2.ENERGY SAVING :
5-10% depending upon the Input voltage variation and working hours of the plant.
 
3.REDUCTION IN MDI :
There will be definite reduction in MDI by 10-15% after the insatllation of the equipment.
 
4.IMPROVEMENT IN POWER FACTOR :
There will be definite improvement in the power factor by 10-15% after the installation of the equipment.
 
5.Depreciation allowance @100% as per Income Tax Act.
 
6. Uniform Quality of End Products.

 

PAYBACK PERIOD OF 500 KVA CAPACITY SERVO VOLTAGE SATBILIZER :
Owing to its high efficiency and associated benefits, the payback period of POOJA's Servo Voltage Stabilizer is within 6-12 months and depends upon the input variation and the number of working hours.
 
The cost of our 500 KVA Stabilizer with input 340-460 Volts & output 400 Volts is Rs. 4,50,000/-.
 
Approximate Power Bill of the 500 KVA stabilizer. considering 50% running load and assuming that the plant is running 20 hours daily for 25 days in a month and the tariff is charge @Rs. 3.50 per Unit will be Rs. 4,00,000/-.
 
i) 5% Saving in Power Bill on account of voltage fluctuation. The power saving can be 10%, if you are getting higher voltage most of the time.
20,000/-
ii) As per the customer feed back the failure rate of their Electrical equipments reduced upto 80% after installing the stabilizer. Thereby Saving in the cost of repairs/replacement of burntout equipment amounting to
10,000/-
iii) Better production in plant due to lesser breakdown in production will generate additional earning of Rs. 20,000/- p.m. Approx
10,000/-
ii)
 
TOTAL SAVING: RS.
40,000/-p.m.
In addition to the above there are certain over heads such as staff to purchase above material, maintain and install the above material.
 
From the above it is clear that the cost of equipment will be recovered with in a period of 10-12 months and in subsequent years it will give you additional earning of approx Rs. 40,000/- per month.
Carbon Roller Assembly
Carbon Roller Assembly

 

REASON FOR HIGH PRICES OF POOJA's MAKE AUTOMATIC VOLTAGE CONTOLLER
 
A. We are manufacturing Industrial type Rectifiers for Electroplating and Hydrogenation purpose since 1969 and Industrial type stabilizers (specially bigger capacity stabilizers above 100 KVA) since 1989 and have supplied our equipments all over India. As stabilizers being a capital equipment, its Life should be 15-20 years. Considering this we design our equipment as per feedback received from the customer.
B.We are manufacturing LINEAR TYPE (+-) heavy Duty Regulators with rollers Rolling on both the sides of the coil. The size of conductor used is more than THREE TIMES than used in conventional wire wound type regulators. Being +- type, the same winding is used for boosting the voltage on one side and bucking the voltage onn the other side of the regulator. So,the rating of the regulator required is half of the conventional type regulator. The losses of our regulator should be 1/18th of the conventional type regulator but due to heavy section of copper used in our regulator, overall size is more and practically losses of our regulator are 1/5th of the conventional type regulator.
The cost of the regulator is THREE TIMES the cost of conventional type Regulator offered by other manufacturers.
 
C. As per our regulator design, the regulator is OUT OF CIRCUIT, when the input voltage is LOWEST/HIGHEST as per the voltage range of the stabilizer. While in stabilizer with conventional brush type regulators, the regulator is maximum in the circuit and losses are maximum at LOWEST/HIGHEST as per the range of the stabilizer.
 
D. The Actual Efficiency of our stabilizer in running conditions at 100% Load will be more than 99-99.5% in comparison to less than 95-97% of conventional type stabilizer.
The stabilizer with Brush type Regulator of 100 KVA will consume additional Power as compared to our stabilizer with Roller type Regulator even when running at 60% load and 20 hours a day, 25 days a month, considering 0.9 Power Factor as explained under :
MODEL
ADD. POWER CONSUMTION
UNITS PER ANNUM
AMOUNT @RS 3.5/- Per unit
360-460 V
2%
6,480
22,680/-
340-460 V
3%
9,720
34,020/-
320-460 V
4%
12,960
45,360/-
300-460 V
5%
16,200
56,700/-
 
E. CONTINUOUS DUTY CYCLE : The stabilizers with Roller type Regulators are wound with heavy section of copper strip for continuous duty on 100% load. You may plan and consider to install stabilizer as per your running load. Also, our stabilizers can with stand 10-15% overload for shorter duration without any harm.
 
F. LIFE : Life of our stabilizer is more than 15-20 years as compared to 2-3 years of conventional type stabilizers at FULL LOAD. In the conventional type stabilizers, you have to bear the cost of repair and replacement, which will ultimately cost much higher than our stabilizers.
 
G. SERVICING : We have all India based servicing network to provide prompt/immediate after sales service to our customers. Also our service engineers will visit inspection of the equipment once in two months for routine checkup.
 
H. GUARANTEE : Our equipments are guaranteed unconditionally for FIVE YEARS against any defects. During this period, we donot charge anything for spares, services and routine checkups provided to the installation.
 
I. Some manufacturers have started manufacturing stabilizers with Roller type regulators and quote lower prices. Practically, they just copied the technology and there are lot of technical drawbacks and life of the stabilizer will be much lesser.
 
J. We have supplied more than 1000 stabilizers above 100 KVA to reputed firms all over India. As you are planning to purchase capital equipment, you can verify from any of our customer and the customer of the other manufacturer offering lesser prices regarding quality, performance of the stabilizer in running condition and the services provided. This method will hardly cost you maximum Rs. 2000/-.
Close View of Regulator Coil
Close View of Regulator Coil