Industrial Systems Upgrade with Advanced VFD Technology

The project, completed at Pan Africa CNG in Ubungo, involved upgrading a failed 250HP motor caused by insulation breakdown. The upgrade included replacing the motor and transitioning from a traditional soft starter to a 250kW SINAMICS VFD. This comprehensive solution was designed, installed, and commissioned to ensure a reliable and efficient system tailored to operational needs.

During installation, the VFD was integrated with the motor while minimizing interference and ensuring compatibility with transformers and generators. The project, handled by Industrial Automation & Electrical Systems, included rigorous testing to calibrate the VFD for smooth motor starts and stops. This reduced inrush current, alleviated transformer stress, and addressed generator startup issues, significantly improving system efficiency and stability.

Benefits of the Upgrade

This comprehensive upgrade brought several key benefits:

1. Smooth Starting and Stopping: The SINAMICS VFD eliminated the abrupt start and stop issues of the previous system. By controlling the motor’s acceleration and deceleration, it significantly reduced starting current surges, thereby alleviating electrical stresses on the transformer and ensuring compatibility with generator-based power sources.
2. Enhanced Energy Efficiency: With precise speed control, the system achieved substantial reductions in energy consumption compared to the legacy soft starter.
3. Reduced Maintenance: Smooth motor operations minimized mechanical wear and tear, extending the lifespan of equipment and reducing maintenance costs.
4. Improved Reliability: Advanced VFD features, such as overload protection and fault diagnostics, ensured consistent and uninterrupted operations.
5. Sustainability and Cost Savings: The energy-efficient design not only reduced operating costs but also aligned with environmental goals by lowering power consumption and emissions.

Conclusion

This project demonstrates the value of replacing legacy systems with advanced technologies to improve industrial performance. By addressing the motor failure and transitioning to a 250kW SINAMICS VFD, the facility overcame previous limitations such as high starting currents and generator incompatibility. The upgrade resulted in a reliable, energy-efficient, and sustainable solution, showcasing the importance of adopting modern drive systems for long-term operational success.