Case Studies
Case Studies
- CASE STUDY - 1
- CASE STUDY - 2
- CASE STUDY - 3
- CASE STUDY - 4
- CASE STUDY - 5
- CASE STUDY - 6
- CASE STUDY - 7
Overview :
Lecon commissioned a FCMA plus soft starter with Dynamic Compensator inside an operator cabin of rope shovel rated 560kW at 6.6kV
- Industry: Open Cast Coal Mines
- Segment: Heavy Earth Moving Equipment
- Application: Rope Shovel
Solution :
Lecon Engineers took up the challenge and came up with a unique design of the FCMAplus Soft Starter Panel and Dynamic Compensator panel that enabled both the panels to be accommodated inside the Rope Shovel.
Achievement :
- Lecon successfully design, manufactured and commissioned FCMAplus Soft Starter Panel with Starting current of 1.5Ifl.
- Lecon matched the customer’s requirements and specifications and earned a strong stamp of approval from the customer for managing to provide a solution given the dimensional challenges.
Challenge :
- Lecon’s biggest technical challenge was to keep the FCMAplus Soft Starter and Dynamic Compensator panel inside the rope shovel as limited space was available.Customer
- Customer requested to limit the starting current to 1.5 times the full load current.
- Lecon had to rely on customer provided specifications as no motor data sheet was available.
Client Overview :
Lecon commissioned three FCMAplus soft starters with a common Dynamic Compensator (DYCO) panel for a leading textile company in Dadra and Nagar Haveli. The panels were rated at 1,940 kW and two at 1,270 kW). The common DYCO panel was used for the starting of all the three panels with a complex control logic.
Technical Challenge:
The challenge was to operate the DYCO for each soft starter’s motor starting and ensure sufficient delay between each start for capacitor discharge. The other soft starter panels would get a ‘start permission’ only when the DYCO panel was healthy. The logic called for DYCO operation to allow for two soft starter panels to not be operated at the same time.
Lecon Solution:
The DYCO panel was to support in the starting process of motor for compressor application. Capacitors were used in the soft starter panels to increase the power factor of the system. It needed a complex logic to not allow simultaneous starting of two motors. The DYCO panel operation was completely current based, and additional protection devices and in-panel protections were provided for the DYCO as well as soft starter panels to ensure the safety of the system.
Result or Outcome:
Lecon successfully designed, manufactured and commissioned FCMAPlus Soft Starter Panels with common DYCO panels with the committed starting currents. Our customer was very satisfied with the services provided by our site engineer Ananthraj C R and the Lecon team. The motor and starter continue to operate successfully at site.
Client Overview :
Lecon commissioned an FCMAplus soft starter with a motor feeder and Dynamic compensator (DYCO) panel for a leading tire and rubber manufacturer in Indore in association with a leading American multinational compressor manufacturer The panel was rated at 650KW,3.3KV, with 975 KVAR dynamic compensator.
Technical Challenge:
We needed to design the motor feeder, soft starter and the DYCO panel to be as compact as possible as per customer requirement while meeting customer and Lecon standards. Lecon had to invest significant company resources to come up with an optimal design. A strong requirement by the customer was to limit the starting current to 2 times the full load current to allow for motor starting without damaging internal circuitry.
Lecon Solution:
Unique design of panel included motor feeder, soft starter & Dynamic Compensator with a compact size, which is as per standard. Lecon provided DYCO which is completely current based operation & monitored delay for proper DYCO protection with PLC based control operations.
Result or Outcome:
Lecon successfully designed, manufactured and commissioned FCMAplus soft starter with motor feeder and Dynamic Compensator with the customer-committed starting current. The motor and soft starter continue to successfully operate at site.
Client Overview :
Lecon commissioned a FCMAplus soft starter for a irrigation project under Govt. of Karnataka at Anavatti in Shivamogga district, Karnataka. There were four motors rated at 850KW and 6.6 KV for a pump application.
Technical Challenge:
Motor during start-up needed an effective starting current less than 3.3Â IFLÂ for each motor to limit the Voltage drop to less than 10% across motor.
Lecon Solution:
Lecon came out with a robust design of soft starter to reduce the current to customer needs of 3.3 times of the full load current with a compact panel design to meet customer’s space requirements. A thorough starting protection, accounting for a FCMA high temp trip, Control supply failure, CPR trip, Bypass Device Failure and a Long start trip were programmed through the PLC.
Result or Outcome:
Lecon successfully designed, manufactured and commissioned FCMA Plus Soft Starter Panel with Starting current of 3.1Ifl which meets customer requirement. This was lower than the committed starting of 3.3 times the full load current, resulting in a satisfied customer.
Client Overview :
Lecon commissioned Neutral side FCMA+Â soft starters for compressors efficiently and time bounded at AGI Glaspac. There were 5 compressors rated at 650KW,11KV. These compressors are for the new plant in AGI Glaspac as part of expansion of AGI Glaspac.
Technical Challenge:
Starting current of the motor should be limited to 3-3.5 times full load current and power factor should be improved from 0.875 to 0.97 for better efficiency of the motors.
Lecon Solution:
Lecon came out with a very practical solution for AGI Glaspac’s specific requirements as customer need very reliable operation from soft starter side. Lecon came out with a eccentric design which reduced the starting current to less than 3.5 times of full load current during staring and the power factor was improved to 0.95 with the help of capacitors. For increased safety of capacitor bank vacuum contactor was given instead of LBS. The market leader in motor protection ABB’s REM601 was also included in the soft starter panel for motor protection. An extra digital ammeter was given to know the reactive current supplied by the capacitors specifically. The soft starter had all the standard protections such as CPR trip, control supply failure trip, long start trip FCMA high temperature trip programmed through PLC and the program was slightly customized for customer specific requirement.
Outcome:
Lecon successfully designed, manufactured, and commissioned FCMA+Â soft starter panel with starting current of 3.175 times of Full load current and power factor was improved to 0.95.The voltage drop was reduced to 2.76%. All the parameters came under the value committed to the customer resulting in a satisfied customer.
Client Overview :
Lecon commissioned Line side FCMA+Â soft starters for compressors efficiently for the prestigious and market leader in steel production in India, JSW Steel Limited at Thorankallu . There were 2 compressors rated at 900KW,6.6KV. These compressors are meant to replace the old compressors at the plant. One extra panel was also provided as spare as demanded by customer.
Technical Challenge:
The client was bothered more about the reliability of the soft starter more than the starting current measures. i.e, client was very much bothered about the smooth acceleration of motors every time since they can’t afford a failure in acceleration. This was the first time client using a soft starter for starting purposes.
Lecon Solution:
Lecon came out with a well founded product for JSW Bellary because of the distinct demands from the client. The motor accelerated with less than 3.5 times Full load current with 15% load during starting. The panel was designed with all the standard safety considerations and extra HT fuse protection was also given along with temperature and CPR protection through PLC separately.
Outcome:
Lecon successfully designed, manufactured, and commissioned FCMA+Â soft starter panel with starting current of 3.5 times of Full load current.The voltage drop was reduced to 2%. The customer was very happy with the service given by Lecon and especially the session Lecon Engineeers had with the Engineers in JSW explaining about the working and benefits of soft starters and how will it especially help their plant.
Client Overview :
Lecon commissioned four 634 KW line side soft starter for submersible pumps. These motors are for the Tidgundi lift irrigation project which has the longest and tallest canal structure in the country (14.73 km) as of April,2020. The Tidgundi lift irrigation project is part of the Mulawadi lift irrigation under Upper Krishna Phase III project.
Technical Challenge:
Since the motor was submersible, client needed a unique design and needed the panels in a cost-effective way.
Lecon Solution:
Lecon came with a line side soft starter for the customer in a very cost-effective way without compromising in quality and protection of our panels. The starting current was reduced to 3.6 times and the acceleration was done smoothly. All the standard protections are also given to this panels.
Outcome:
Lecon successfully designed, manufactured, and commissioned FCMAplus soft starter panel with starting current of 3.6 times of full load current and resulted in another satisfied customer.
-
CASE STUDY - 1
-
Overview :
Lecon commissioned a FCMA plus soft starter with Dynamic Compensator inside an operator cabin of rope shovel rated 560kW at 6.6kV
- Industry: Open Cast Coal Mines
- Segment: Heavy Earth Moving Equipment
- Application: Rope Shovel
Solution :
Lecon Engineers took up the challenge and came up with a unique design of the FCMAplus Soft Starter Panel and Dynamic Compensator panel that enabled both the panels to be accommodated inside the Rope Shovel.
Achievement :
- Lecon successfully design, manufactured and commissioned FCMAplus Soft Starter Panel with Starting current of 1.5Ifl.
- Lecon matched the customer’s requirements and specifications and earned a strong stamp of approval from the customer for managing to provide a solution given the dimensional challenges.
Challenge :
- Lecon’s biggest technical challenge was to keep the FCMAplus Soft Starter and Dynamic Compensator panel inside the rope shovel as limited space was available.Customer
- Customer requested to limit the starting current to 1.5 times the full load current.
- Lecon had to rely on customer provided specifications as no motor data sheet was available.
-
CASE STUDY - 2
-
Client Overview :
Lecon commissioned three FCMAplus soft starters with a common Dynamic Compensator (DYCO) panel for a leading textile company in Dadra and Nagar Haveli. The panels were rated at 1,940 kW and two at 1,270 kW). The common DYCO panel was used for the starting of all the three panels with a complex control logic.
Technical Challenge:
The challenge was to operate the DYCO for each soft starter’s motor starting and ensure sufficient delay between each start for capacitor discharge. The other soft starter panels would get a ‘start permission’ only when the DYCO panel was healthy. The logic called for DYCO operation to allow for two soft starter panels to not be operated at the same time.
Lecon Solution:
The DYCO panel was to support in the starting process of motor for compressor application. Capacitors were used in the soft starter panels to increase the power factor of the system. It needed a complex logic to not allow simultaneous starting of two motors. The DYCO panel operation was completely current based, and additional protection devices and in-panel protections were provided for the DYCO as well as soft starter panels to ensure the safety of the system.
Result or Outcome:
Lecon successfully designed, manufactured and commissioned FCMAPlus Soft Starter Panels with common DYCO panels with the committed starting currents. Our customer was very satisfied with the services provided by our site engineer Ananthraj C R and the Lecon team. The motor and starter continue to operate successfully at site.
-
CASE STUDY - 3
-
Client Overview :
Lecon commissioned an FCMAplus soft starter with a motor feeder and Dynamic compensator (DYCO) panel for a leading tire and rubber manufacturer in Indore in association with a leading American multinational compressor manufacturer The panel was rated at 650KW,3.3KV, with 975 KVAR dynamic compensator.
Technical Challenge:
We needed to design the motor feeder, soft starter and the DYCO panel to be as compact as possible as per customer requirement while meeting customer and Lecon standards. Lecon had to invest significant company resources to come up with an optimal design. A strong requirement by the customer was to limit the starting current to 2 times the full load current to allow for motor starting without damaging internal circuitry.
Lecon Solution:
Unique design of panel included motor feeder, soft starter & Dynamic Compensator with a compact size, which is as per standard. Lecon provided DYCO which is completely current based operation & monitored delay for proper DYCO protection with PLC based control operations.
Result or Outcome:
Lecon successfully designed, manufactured and commissioned FCMAplus soft starter with motor feeder and Dynamic Compensator with the customer-committed starting current. The motor and soft starter continue to successfully operate at site.
-
CASE STUDY - 4
-
Client Overview :
Lecon commissioned a FCMAplus soft starter for a irrigation project under Govt. of Karnataka at Anavatti in Shivamogga district, Karnataka. There were four motors rated at 850KW and 6.6 KV for a pump application.
Technical Challenge:
Motor during start-up needed an effective starting current less than 3.3Â IFLÂ for each motor to limit the Voltage drop to less than 10% across motor.
Lecon Solution:
Lecon came out with a robust design of soft starter to reduce the current to customer needs of 3.3 times of the full load current with a compact panel design to meet customer’s space requirements. A thorough starting protection, accounting for a FCMA high temp trip, Control supply failure, CPR trip, Bypass Device Failure and a Long start trip were programmed through the PLC.
Result or Outcome:
Lecon successfully designed, manufactured and commissioned FCMA Plus Soft Starter Panel with Starting current of 3.1Ifl which meets customer requirement. This was lower than the committed starting of 3.3 times the full load current, resulting in a satisfied customer.
-
CASE STUDY - 5
-
Client Overview :
Lecon commissioned Neutral side FCMA+Â soft starters for compressors efficiently and time bounded at AGI Glaspac. There were 5 compressors rated at 650KW,11KV. These compressors are for the new plant in AGI Glaspac as part of expansion of AGI Glaspac.
Technical Challenge:
Starting current of the motor should be limited to 3-3.5 times full load current and power factor should be improved from 0.875 to 0.97 for better efficiency of the motors.
Lecon Solution:
Lecon came out with a very practical solution for AGI Glaspac’s specific requirements as customer need very reliable operation from soft starter side. Lecon came out with a eccentric design which reduced the starting current to less than 3.5 times of full load current during staring and the power factor was improved to 0.95 with the help of capacitors. For increased safety of capacitor bank vacuum contactor was given instead of LBS. The market leader in motor protection ABB’s REM601 was also included in the soft starter panel for motor protection. An extra digital ammeter was given to know the reactive current supplied by the capacitors specifically. The soft starter had all the standard protections such as CPR trip, control supply failure trip, long start trip FCMA high temperature trip programmed through PLC and the program was slightly customized for customer specific requirement.
Outcome:
Lecon successfully designed, manufactured, and commissioned FCMA+Â soft starter panel with starting current of 3.175 times of Full load current and power factor was improved to 0.95.The voltage drop was reduced to 2.76%. All the parameters came under the value committed to the customer resulting in a satisfied customer.
-
CASE STUDY - 6
-
Client Overview :
Lecon commissioned Line side FCMA+Â soft starters for compressors efficiently for the prestigious and market leader in steel production in India, JSW Steel Limited at Thorankallu . There were 2 compressors rated at 900KW,6.6KV. These compressors are meant to replace the old compressors at the plant. One extra panel was also provided as spare as demanded by customer.
Technical Challenge:
The client was bothered more about the reliability of the soft starter more than the starting current measures. i.e, client was very much bothered about the smooth acceleration of motors every time since they can’t afford a failure in acceleration. This was the first time client using a soft starter for starting purposes.
Lecon Solution:
Lecon came out with a well founded product for JSW Bellary because of the distinct demands from the client. The motor accelerated with less than 3.5 times Full load current with 15% load during starting. The panel was designed with all the standard safety considerations and extra HT fuse protection was also given along with temperature and CPR protection through PLC separately.
Outcome:
Lecon successfully designed, manufactured, and commissioned FCMA+Â soft starter panel with starting current of 3.5 times of Full load current.The voltage drop was reduced to 2%. The customer was very happy with the service given by Lecon and especially the session Lecon Engineeers had with the Engineers in JSW explaining about the working and benefits of soft starters and how will it especially help their plant.
-
CASE STUDY - 7
-
Client Overview :
Lecon commissioned four 634 KW line side soft starter for submersible pumps. These motors are for the Tidgundi lift irrigation project which has the longest and tallest canal structure in the country (14.73 km) as of April,2020. The Tidgundi lift irrigation project is part of the Mulawadi lift irrigation under Upper Krishna Phase III project.
Technical Challenge:
Since the motor was submersible, client needed a unique design and needed the panels in a cost-effective way.
Lecon Solution:
Lecon came with a line side soft starter for the customer in a very cost-effective way without compromising in quality and protection of our panels. The starting current was reduced to 3.6 times and the acceleration was done smoothly. All the standard protections are also given to this panels.
Outcome:
Lecon successfully designed, manufactured, and commissioned FCMAplus soft starter panel with starting current of 3.6 times of full load current and resulted in another satisfied customer.
FCMA Soft Starter in Rope Shovel
FCMA Soft Starter in Rope Shovel
Overview : Lecon commissioned a FCMA plus soft starter with Dynamic Compensator inside an operator cabin of rope shovel rated 560kW at 6.6kV
- Industry: Open Cast Coal Mines
- Segment: Heavy Earth Moving Equipment
- Application: Rope Shovel
Textile Plant Commissioning
Client Overview : Lecon commissioned three FCMAplus soft starters with a common Dynamic Compensator (DYCO) panel for a leading textile company in Dadra and Nagar Haveli. The panels were rated at 1,940 kW and two at 1,270 kW). The common DYCO panel was used for the starting of all the three panels with a complex control logic.
Textile Plant Commissioning
Client Overview : Lecon commissioned three FCMAplus soft starters with a common Dynamic Compensator (DYCO) panel for a leading textile company in Dadra and Nagar Haveli. The panels were rated at 1,940 kW and two at 1,270 kW). The common DYCO panel was used for the starting of all the three panels with a complex control logic.
Starter Installation in Tyre Factory
Starter Installation in Tyre Factory
Client Overview : Lecon commissioned an FCMAplus soft starter with a motor feeder and Dynamic compensator (DYCO) panel for a leading tire and rubber manufacturer in Indore in association with a leading American multinational compressor manufacturer The panel was rated at 650KW,3.3KV, with 975 KVAR dynamic compensator.
CNNL Water Supply Scheme - Shivmogga, Karnataka
Client Overview : Lecon commissioned a FCMAplus soft starter for a irrigation project under Govt. of Karnataka at Anavatti in Shivamogga district, Karnataka. There were four motors rated at 850KW and 6.6 KV for a pump application.
CNNL Water Supply Scheme - Shivmogga, Karnataka
Client Overview : Lecon commissioned a FCMAplus soft starter for a irrigation project under Govt. of Karnataka at Anavatti in Shivamogga district, Karnataka. There were four motors rated at 850KW and 6.6 KV for a pump application.
PF Capacitor and FCMA Soft Starter - Glass Factory
PF Capacitor and FCMA Soft Starter - Glass Factory
Client Overview : Lecon commissioned Neutral side FCMA+ soft starters for compressors efficiently and time bounded at AGI Glaspac. There were 5 compressors rated at 650KW,11KV. These compressors are for the new plant in AGI Glaspac as part of expansion of AGI Glaspac.
FCMA Soft Starter in Steel Plant
Client Overview : Lecon commissioned Line side FCMA+ soft starters for compressors efficiently for the prestigious and market leader in steel production in India, JSW Steel Limited at Thorankallu . There were 2 compressors rated at 900KW,6.6KV. These compressors are meant to replace the old compressors at the plant. One extra panel was also provided as spare as demanded by customer.
FCMA Soft Starter in Steel Plant
Client Overview : Lecon commissioned Line side FCMA+ soft starters for compressors efficiently for the prestigious and market leader in steel production in India, JSW Steel Limited at Thorankallu . There were 2 compressors rated at 900KW,6.6KV. These compressors are meant to replace the old compressors at the plant. One extra panel was also provided as spare as demanded by customer.
FCMA Starter - KBJNL Water Supply Scheme
FCMA Starter - KBJNL Water Supply Scheme
Client Overview : Lecon commissioned four 634 KW line side soft starter for submersible pumps. These motors are for the Tidgundi lift irrigation project which has the longest and tallest canal structure in the country (14.73 km) as of April,2020. The Tidgundi lift irrigation project is part of the Mulawadi lift irrigation under Upper Krishna Phase III project.
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