Energy saving using Mitsubishi Inverters for Fan and Pump Application

Automation Objective
The reasons and benefits of energy saving are numerous and pointless to repeat here. Simply, energy
is to be saved if it is just wasted because of inefficient process, methods of use or use of conventional
control mechanisms. When Induction Motor is run above the required speed, energy is wasted. If
speed is reduced to required operating condition, energy wastage is prevented.
The induction motor is used in industries mainly for following applications:
Centrifugal Fan (Blower)
Pump
Compressor
Plastic Injection Molding Machine
Mechanical Press






Figure 1 Total Cost of Running Motor
The total cost of running motor if considered (Figure 1), the more than 70 % is spend for energy bill
and rest is for investment and maintenance cost. The core objective is to reduce the running cost by
using Mitsubishi Inverters.

Basic Principle
The relationship between Power and speed of induction motor is the base of energy saving. This is
known as Cube Low. This is derived as below:

The 10% reduction in speed reduces 25 % power requirements which results in energy saving.

Centrifugal Fan Application
The centrifugal Fan is used as a blower and conventionally, flow is controlled by throttling device like
inlet vanes or damper while motor is running at maximum speed. The energy is wasted at flow
regulating devices.


Figure 2 Conventional Method






Figure 2 Air Flow Control using VFD

Using VFD from Mitsubishi, the induction motor speed is regulated as per the input received from flow
sensor. Figure 3 shows the mechanism.
Pump Application
Similar to blower applications, conventionally, pumps are run at constant speed and flow is regulated
by control valve as per the demand. The excess flow is bypassed to the reservoir or tank (Figure 4).
The energy used to generate this excess flow is totally lost. The inverter controlled system removes
the control valve and flow itself is controlled by manipulating speed of pump as per the input of flow
sensor and desired set point (Figure 5). Here, no need to bypass or divert excess flow and hence there
is an energy saving.

Figure 3 Conventional Flow Control
Figure 4 Flow Control using Inverter


Inverter Selection
Centrifugal Fan and Pump are used for variable torque loads and need low starting torque. Hence VFD
with 110% overload capacity is adequate. Further, while selecting the drive, motor Full Load Ampere
(FLA) should be considered rather than motor KW.

Application Area
The major potential areas of energy saving using Mitsubishi drives are:
HVAC systems AHUs, Pumps and Chillers, Cooling Towers (Pharmaceutical and Bio-Tech
Installations, IT Parks, Hospitals, Theaters, Commercial Malls, etc)
Paint Shops in Automotive Industries
All utility management centers across the Industry
Cold storage installations
Boilers (ID,FD Fans)

Advantages of Mitsubishi Inverters
The Mitsubishi VFDs are perfect selection for energy saving applications since it offers following
features:
Electronic protection of motor
High Starting Torque
Soft Starting & Stopping reduces mechanical
stresses
Optimum excitation control
Energy saving mode
PID control
Energy/Cost saving monitoring
Electronic bypass for changeover
Built-in PLC in A700 series
Multiple overload rating according to
application
Diagnostic Capabilities in VFD
Interface With Main SCADA System
Supports all major Field Buses
- Profibus- DP,
- DeviceNet,
- CC link,
- LonWorks
Modbus RTU as standard feature


Achievements
Over 4000 installations for energy saving for Fan and Pump applications are completed for Automotive
(Paint Shops of all major automotive manufacturers), Sugar, Pharmaceuticals and others.

Case study: Cooling Tower Pump
This is the case study of energy saving using Mitsubishi Drive for cooling tower pump for leading dairy
product manufacturer.

Inverter Model : FR-A540-11K
Power Rating : 11KW
Parameter Settings : LOAD PATTERN SELECTION Pr 14 = 1 (for Variable Torque Load)

Following readings are taken for actual operation at full load for calculation of power demand
reduction:

Frequency
(Hz)
I/P POWER
(kW)
O/P CURRENT (A) % Speed
Reduction
%Power
Reduction
50 8.32 18.9 0 0
47.5 7.15 18.3 5 14
45
42.5
6
5.05
16.6
15.7
10
15
27
39
40 4.16 14.4 20 50
37.5 3.42 13.7 25 59
35 2.73 12.5 30 67
32.5 2.19 11.5 35 73
30 1.68 10 40 79


The actual load is operated with 40 HZ frequency and hence there is a 20% reduction in speed
resulting in 50% reduction in power demand.

Calculation of saving and payback period:
Per Hour power saving for 20 hour per day run = (Full Load Actual Load)x20 KWH
= (8.32 4.16)x20 KWH
= 83.2 KWH
Power saving per year for 300 days operation = 83.2 x 300
= 24960 KWH
Using per unit charges for energy bill, per year saving can be calculated.

The investment cost is recovered within 9 moths for this application.