Tanzania Cigarette Company (TCC/JTI) implemented advanced electrical load separation to optimize energy distribution and ensure high availability. The project involved segregating essential and non-essential loads across multiple power sources. This strategic electrical load separation enhances energy efficiency, reduces downtime, and maximizes solar power utilization for sustainable operations.
Initial Energy Challenges
TCC initially connected all electrical loads to a single switchgear panel with all power sources. While simple, this setup caused significant operational problems. Specifically, faults in non-essential loads would trip breakers or shut down generators, causing production line stoppages. These interruptions resulted in substantial downtime and high operating costs for the cigarette manufacturing facility.
Power Allocation Difficulties
The previous system made proper power source allocation nearly impossible. TCC has four main power sources: two LV gas generators, one MV generator, 11kV utility supply, and a solar system. They needed to use solar and utility power for non-production areas while reserving gas generators for production machinery. However, generators typically powered the entire facility, preventing solar system utilization and its associated benefits.
Comprehensive Solution Implementation
System Evaluation and Design
First, we conducted a complete system evaluation to determine load requirements. We then designed detailed single-line engineering drawings for the new switchgear installation. This planning phase ensured optimal load separation and power source allocation.
Switchgear Fabrication and Installation
We fabricated, assembled, and installed a new switchgear system with four incomers. According to the engineering drawings, we carefully disconnected loads from the old switchgear and reconnected them to the new system. This meticulous process ensured proper load separation and system integration.
Control System Integration
The new system features advanced control components including Siemens LOGO controllers, phase monitoring devices, and ACB incomer breakers. These components enable automatic switchover functions and ensure maximum power availability.
System Configuration and Operation
Essential Loads Management
Production machinery and critical systems remain connected to generator power sources. This configuration ensures uninterrupted manufacturing operations during utility power interruptions.
Non-Essential Loads Optimization
Non-production areas now primarily use utility power and the tied solar system. This separation allows generators to serve as optional backup rather than primary power sources. The optimization significantly reduces generator runtime and fuel consumption.
Power Factor Correction
The new panel includes an integrated power factor controller that maintains optimal power factor levels. This feature improves energy efficiency and reduces electricity costs through better power quality management.
Significant Operational Benefits
Enhanced System Reliability
The load separation prevents non-essential load faults from affecting production operations. This isolation significantly reduces production downtime and associated financial losses.
Optimized Energy Utilization
Solar power now effectively serves non-essential loads, realizing the system’s intended benefits. This optimization reduces generator dependency and supports sustainability goals.
Improved Cost Efficiency
Reduced generator operation lowers fuel consumption and maintenance costs. Additionally, better power factor management decreases electricity bills and improves overall energy efficiency.
Increased Operational Flexibility
The system allows flexible power source allocation based on operational requirements. This flexibility enables TCC to adapt to changing energy availability and cost conditions.
Technical Implementation Details
Switchgear Design Features
The four-incomer switchgear design accommodates all power sources with proper isolation. Each incomer serves specific load categories with appropriate protection and control features.
Automation and Control
Automatic transfer switches and monitoring devices ensure seamless power source transitions. The control system prioritizes renewable energy usage while maintaining operational reliability.
Safety and Protection
Comprehensive protection systems prevent equipment damage and ensure personnel safety. All installations comply with industrial electrical standards and manufacturer specifications.
Conclusion: Sustainable Energy Management Achieved
This successful electrical load separation project establishes TCC/JTI as a leader in industrial energy management. The implemented solution demonstrates how strategic load separation can optimize energy utilization while ensuring operational reliability. Through this project, TCC now enjoys reduced operating costs, enhanced sustainability, and improved production efficiency. The achievement sets a benchmark for excellence in industrial energy management and reinforces IAES’s expertise in delivering innovative electrical solutions for manufacturing industries.
