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From: Selvakumar <selvakumar@powerprojectsindia.com>
Subject: Case Study #6: Power System Safety in Industrial Network with VFDs
 and Large Motors
Message-ID: <02af627f-357d-7146-1344-42ab3f5e540c@powerprojectsindia.com>
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                                                Visit Website
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</tr></table></td></tr></table><table cellpadding=3D"0" cellspacing=3D"0" b=
order=3D"0" width=3D"600" class=3D"main container" style=3D"width: 600px;">=
<tr><td align=3D"left" valign=3D"top" class=3D"mobile-padding-small" bgcolo=
r=3D"#ffffff" style=3D"vertical-align: top; line-height: 1; padding: 40px; =
background-color: #ffffff;"><table cellpadding=3D"0" cellspacing=3D"0" bord=
er=3D"0" width=3D"100%" class=3D"block" style=3D"width: 100%;"><tr><td alig=
n=3D"left" valign=3D"top" style=3D"vertical-align: top; line-height: 1;"><h=
3 class=3D"h3" style=3D"padding: 0px; margin: 0px 0px 10px; font-style: nor=
mal; font-family: 'IBM Plex Sans'; font-size: 20px; line-height: 28px; colo=
r: #111118; font-weight: bold;">How Do You Ensure Power System Safety in an=
 Industrial Network with VFDs and Large Motors?</h3><p style=3D"padding: 0p=
x; margin: 0px 0px 20px; font-family: 'IBM Plex Sans'; color: #222228; font=
-size: 16px; line-height: 24px;">Here=E2=80=99s how we helped a large indus=
trial facility safeguard its 6.6=E2=80=AFkV and 0.415=E2=80=AFkV power netw=
ork, ensuring safe motor starting, harmonic compliance, and reliable protec=
tion coordination in a system loaded with VFDs, transformers, and dynamic s=
witching conditions.&nbsp;<br></p><span style=3D"display: inline-block; fon=
t-size: 0px; line-height: 0; vertical-align: top;" class=3D""><img border=
=3D"0" width=3D"520" src=3D"https://s3.us-east-1.amazonaws.com/contents.new=
zenler.com/13107/library/PL-316812f6e33e4f2_lg.jpg" style=3D"margin: 0px; p=
adding: 0px; max-width: 100%; border: none; vertical-align: top; width: 520=
px;"></span><p style=3D"padding: 0px; margin: 20px 0px 0px; font-family: 'I=
BM Plex Sans'; color: #222228; font-size: 16px; line-height: 24px;">In mode=
rn plants, power networks are no longer static. Multiple configurations, VF=
D-driven loads, and large motors demand more than default safety margins. T=
his project was a classic example of how assumptions can miss critical gaps=
 in protection, performance, and compliance.&nbsp;<br></p><table cellpaddin=
g=3D"0" cellspacing=3D"0" border=3D"0" width=3D"100%" class=3D"spacer" styl=
e=3D"width: 100%;"><tr><td align=3D"left" valign=3D"top" style=3D"vertical-=
align: top; line-height: 15px; padding: 0px; font-size: 15px; height: 15px;=
">&nbsp;</td></tr></table><table cellpadding=3D"0" cellspacing=3D"0" border=
=3D"0" width=3D"100%" class=3D"divider" style=3D"width: 100%;"><tr><td alig=
n=3D"left" valign=3D"top" bgcolor=3D"#111118" style=3D"vertical-align: top;=
 line-height: 1px; padding: 0px; font-size: 1px; background-color: #111118;=
">&nbsp;</td></tr></table><table cellpadding=3D"0" cellspacing=3D"0" border=
=3D"0" width=3D"100%" class=3D"spacer" style=3D"width: 100%;"><tr><td align=
=3D"left" valign=3D"top" style=3D"vertical-align: top; line-height: 15px; p=
adding: 0px; font-size: 15px; height: 15px;">&nbsp;</td></tr></table><h3 cl=
ass=3D"h3" style=3D"padding: 0px; margin: 0px 0px 5px; font-style: normal; =
font-family: 'IBM Plex Sans'; font-size: 20px; line-height: 28px; color: #2=
080b1; font-weight: bold;">
    <b>Challenge=E2=80=99s they faced:</b>
</h3><p style=3D"padding: 0px; margin: 0px; font-family: 'IBM Plex Sans'; c=
olor: #222228; font-size: 16px; line-height: 24px;">The facility faced oper=
ational risks across three electrical configurations:&nbsp;<br>=F0=9F=94=B8=
6.6=E2=80=AFkV switchgear was underrated for actual fault levels&nbsp;<br>=
=F0=9F=94=B8Concerns over voltage dips during large motor starting&nbsp;<b>=
<br></b><span data-start=3D"1051" data-end=3D"1081">=F0=9F=94=B8Harmonic di=
stortion due to VFDs could impact compliance&nbsp;<br>=F0=9F=94=B8Protectio=
n coordination across MV and LV levels had not been validated&nbsp;</span><=
/p><table cellpadding=3D"0" cellspacing=3D"0" border=3D"0" width=3D"100%" c=
lass=3D"spacer" style=3D"width: 100%;"><tr><td align=3D"left" valign=3D"top=
" style=3D"vertical-align: top; line-height: 15px; padding: 0px; font-size:=
 15px; height: 15px;">&nbsp;</td></tr></table><table cellpadding=3D"0" cell=
spacing=3D"0" border=3D"0" width=3D"100%" class=3D"divider" style=3D"width:=
 100%;"><tr><td align=3D"left" valign=3D"top" bgcolor=3D"#111118" style=3D"=
vertical-align: top; line-height: 1px; padding: 0px; font-size: 1px; backgr=
ound-color: #111118;">&nbsp;</td></tr></table><table cellpadding=3D"0" cell=
spacing=3D"0" border=3D"0" width=3D"100%" class=3D"spacer" style=3D"width: =
100%;"><tr><td align=3D"left" valign=3D"top" style=3D"vertical-align: top; =
line-height: 15px; padding: 0px; font-size: 15px; height: 15px;">&nbsp;</td=
></tr></table><h3 class=3D"h3" style=3D"padding: 0px; margin: 0px 0px 5px; =
font-style: normal; font-family: 'IBM Plex Sans'; font-size: 20px; line-hei=
ght: 28px; color: #2080b1; font-weight: bold;">
    <b>Solution</b>
</h3><p style=3D"padding: 0px; margin: 0px; font-family: 'IBM Plex Sans'; c=
olor: #222228; font-size: 16px; line-height: 24px;">We conducted a detailed=
 power system study using ETAP 22.5, covering:&nbsp;<br><b>=E2=9C=85</b><b>=
Load Flow Analysis</b> =E2=80=93 Simulated three switching scenarios and ve=
rified performance across critical buses&nbsp;<br><b>=E2=9C=85Short Circuit=
 Study</b> =E2=80=93 Identified mismatch between fault current and 6.6=E2=
=80=AFkV breaker capacity&nbsp;<br>
    =E2=9C=85<b>Motor Starting Simulation</b> =E2=80=93 Confirmed that moto=
r starting voltages remained above 96%, ensuring no instability<br>=E2=9C=
=85<b>Protection Coordination</b> =E2=80=93 Developed and fine-tuned relay =
settings with TCC curves&nbsp;<br>=E2=9C=85<b>Harmonic Analysis</b> =E2=80=
=93 Verified that THD and individual harmonics were within IEEE 519-2022 li=
mits, even under VFD load&nbsp;<br></p><table cellpadding=3D"0" cellspacing=
=3D"0" border=3D"0" width=3D"100%" class=3D"spacer" style=3D"width: 100%;">=
<tr><td align=3D"left" valign=3D"top" style=3D"vertical-align: top; line-he=
ight: 15px; padding: 0px; font-size: 15px; height: 15px;">&nbsp;</td></tr><=
/table><table cellpadding=3D"0" cellspacing=3D"0" border=3D"0" width=3D"100=
%" class=3D"divider" style=3D"width: 100%;"><tr><td align=3D"left" valign=
=3D"top" bgcolor=3D"#111118" style=3D"vertical-align: top; line-height: 1px=
; padding: 0px; font-size: 1px; background-color: #111118;">&nbsp;</td></tr=
></table><table cellpadding=3D"0" cellspacing=3D"0" border=3D"0" width=3D"1=
00%" class=3D"spacer" style=3D"width: 100%;"><tr><td align=3D"left" valign=
=3D"top" style=3D"vertical-align: top; line-height: 15px; padding: 0px; fon=
t-size: 15px; height: 15px;">&nbsp;</td></tr></table><h3 class=3D"h3" style=
=3D"padding: 0px; margin: 0px; font-style: normal; font-family: 'IBM Plex S=
ans'; font-size: 20px; line-height: 28px; color: #2080b1; font-weight: bold=
;">
    As a Result
</h3><table cellpadding=3D"0" cellspacing=3D"0" border=3D"0" width=3D"100%"=
 class=3D"spacer" style=3D"width: 100%;"><tr><td align=3D"left" valign=3D"t=
op" style=3D"vertical-align: top; line-height: 10px; padding: 0px; font-siz=
e: 10px; height: 10px;">&nbsp;</td></tr></table><p style=3D"padding: 0px; m=
argin: 0px; font-family: 'IBM Plex Sans'; color: #222228; font-size: 16px; =
line-height: 24px;">=E2=9C=85Switchgear      upgrade recommendations based =
on verified fault levels<br>=E2=9C=85No      motor starting concerns, valid=
ated through dynamic voltage studies<br>=E2=9C=85Protection      schemes co=
nfirmed for fast, selective fault isolation<br>=E2=9C=85Harmonic      perfo=
rmance well within limits=E2=80=94no filter installation required<br></p><t=
able cellpadding=3D"0" cellspacing=3D"0" border=3D"0" width=3D"100%" class=
=3D"spacer" style=3D"width: 100%;"><tr><td align=3D"left" valign=3D"top" st=
yle=3D"vertical-align: top; line-height: 10px; padding: 0px; font-size: 10p=
x; height: 10px;">&nbsp;</td></tr></table><p style=3D"padding: 0px; margin:=
 0px; font-family: 'IBM Plex Sans'; color: #222228; font-size: 16px; line-h=
eight: 24px;">
    This project is a reminder that safety doesn=E2=80=99t lie in installed=
 hardware=E2=80=94but in what that hardware has been designed and tested to=
 handle. That=E2=80=99s what makes system studies not just necessary, but b=
usiness-critical.
</p><table cellpadding=3D"0" cellspacing=3D"0" border=3D"0" width=3D"100%" =
class=3D"spacer" style=3D"width: 100%;"><tr><td align=3D"left" valign=3D"to=
p" style=3D"vertical-align: top; line-height: 15px; padding: 0px; font-size=
: 15px; height: 15px;">&nbsp;</td></tr></table><table cellpadding=3D"0" cel=
lspacing=3D"0" border=3D"0" width=3D"100%" class=3D"divider" style=3D"width=
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"vertical-align: top; line-height: 1px; padding: 0px; font-size: 1px; backg=
round-color: #111118;">&nbsp;</td></tr></table><table cellpadding=3D"0" cel=
lspacing=3D"0" border=3D"0" width=3D"100%" class=3D"spacer" style=3D"width:=
 100%;"><tr><td align=3D"left" valign=3D"top" style=3D"vertical-align: top;=
 line-height: 15px; padding: 0px; font-size: 15px; height: 15px;">&nbsp;</t=
d></tr></table><p style=3D"padding: 0px; margin: 0px; font-family: 'IBM Ple=
x Sans'; color: #222228; font-size: 16px; line-height: 24px;">If you need s=
upport on Power System Studies Consulting using Softwares like ETAP, DIgSIL=
ENT PowerFactory, PSSE, CDEGS and PSCAD.&nbsp;<br></p></td></tr></table><ta=
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