Unalloyed power packed performance

December 12, 2013 7:15 am

Madhav Alloy is one of the leading manufacturers in secondary steel market in North India, with a turnover of  Rs 700 crore. The group’s name is synonymous with distinct quality and enhanced customer satisfaction. It has created a unique differentiation in the steel sector. Established in the year 2002, it has been progressing at a fast pace.
The group also manufactures and supplies various industrial products like mild steel angles and mild steel beams. Madhav Udyog Pvt. Ltd. and Madhav Alloy Pvt. Ltd. are companies within the Madhav Group.
ProductEaton Power Xpert 9395 UPS, 550 kVALocationsAkalgarh, Patiala, Punjab
Market servedManufacturing / steel
ApplicationSteel Industry(induction furnace – continuous casting machine)
ProductsTMT Bars/angles / beams / channels/ billetsChallengeUtility power supply challengesIn the city of Ludhiana, there are many unscheduled and untimely power failures and tripping for variable periods of time. These unannounced power failures negatively impact the engineering industry in the city. Many furnace units have been forced to close down their production activities which directly hit the price structure of the iron and steel products used as basic raw material in the engineering industry.
In such a dire power supply scenario, there are significant losses in the form of downtime, man-hours lost, productivity, process break ups and monetary losses in the manufacturing processes. Apart from power losses there are frequent power incidents.
A power incident can be a power failure, power tripping, power sag, power surge to under voltage, over voltage and onwards to switching transients, line noise, frequency variation and harmonic distortion. These power incidents can also lead to material wastage and productivity loss leading to a loss of business and loss of reputation.
Intrinsic challengesSteel manufacturing units like Madhav Alloy utilise a critical process called ‘continuous casting’ to manufacture TMT bars etc.
Continuous casting, also called strand casting, is the process whereby molten metal is given shape and solidified into a “semi finished” billet, bloom, or slab for subsequent rolling in the finishing mills. It allows lower-cost production of metal sections with better quality, due to the inherently lower costs of continuous, standardised production of a product, as well as providing increased control over the process through automation. The continuous casting machine (CCM) is installed in the induction furnace project.
It is extremely critical for the company to keep the CCM running during the tripping caused due to intermittent power failures. A continuous and conditioned power backup is required for CCM, so that there are no process breakages, which result in man-hours loss, productivity loss and material loss; whereby the entire process has to be restarted.
A ‘CCM machine’ needs a lot of motors to keep in a continuous running mode. During power tripping, if even one motor trips, the whole process breaks entailing huge losses for the company. Therefore, during steel manufacturing, steel units spend a lot of money to set up overhead water tanks. These are used in induction furnaces for a continuous supply of cooling water, to keep motors running smoothly, for at least 30 minutes despite power supply failures. Eaton is a diversified power management company providing energy-efficient solutions that help our customers effectively manage electrical, hydraulic and mechanical power. With 2012 sales of $16.3 billion, Eaton is a global technology leader in electrical products, systems and services for power quality, distribution and control, power transmission, lighting and wiring products; hydraulics components, systems and services for industrial and mobile equipment; aerospace fuel, hydraulics and pneumatic systems for commercial and military use; and truck and automotive drivetrain and powertrain systems for performance, fuel economy and safety. Eaton has approximately 103,000 employees and sells products to customers in more than 175 countries.
Munish Goyal, Managing Director, Madhav Alloy says, “Our plants run on full capacity approx. 500 TPD. We needed a power quality solution which could help us to cope with a hugely unpredictable power tripping situation. The downtime translates into enormous productivity and monetary losses due to process breakage in the CCM machine functioning. Continuous and quality power is really vital for Madhav Alloy.”
Eaton’s Power Xpert 9395 UPS offers the highest reliability and availability with Hot Sync paralleling, superior battery management, inherent redundancy and a scalable architecture that adapts to increasing power requirements.
SolutionMadhav Alloy decided to look for an efficient, cost effective UPS with over 90% availability which could prevent the massive production losses, due to daily power failures and tripping.
“A genset solution coupled with utility power is not viable for the highly frequent power tripping that we face in our city,” said Mr. Goyal. “We needed a unique solution which could tide over the time lag during the power tripping – from utility power supply to UPS; and from UPS to DG Set, without stopping any motor from tripping.”

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