Power Generation Corporation is a joint venture of Govt.of Orissa & AES Corp.

USA is having 2 x 210 MW Thermal Power Plant, namely Ib Thermal Power Plant. is situated at Banharpalli in the district of Jharsuguda,Orissa
It It

Orissa

VARIABLE FREQUENCY DRIVE AN ENERGY SAVING SOLUTION

Motor driven equipment accounts for 65 percent of the electricity consumed in industry. Industrial systems can account for a large part of the energy used in manufacturing processes and there is definitely an opportunity for increased efficiency and significant savings through system improvements. Based on analysis of the motor systems it is estimated that industrial motor energy use could be reduced by up to 18 percent.

Saving energy by using adjustable speed drives

An adjustable speed drive often uses less energy than an alternative fixed speed mode of operation. Fans and pumps are the most common energy saving applications. When a fan is driven by a fixed speed motor, the airflow may sometimes be higher/lower than it needs to be. Airflow can be regulated by using a damper which restricts the flow, but it is more efficient to regulate the airflow by regulating the speed of the motor.

 Saving energy with adjustable speed pump operation is similar to saving energy with adjustable speed fan operation. It is more efficient to regulate the flow of fluid by regulating the speed of the motor rather than by restricting the flow using a control valve. Process control and energy conservation are the two primary reasons for using an adjustable speed drive. Historically, adjustable speed drives were developed for process control, but energy conservation has emerged as an equally important objective.

 Now a days solid state AC & DC Drives maintain a good efficiency even at reduced speed. The development in electronics & simplicity of squirrel cage Motors are likely to ensure that the invertor & squirrel cage Motors combination is mostly preferable ones.

The following are process control benefits that might be provided by an adjustable speed drive: Smoother operation Acceleration control Different operating speed for each process recipe Compensate for changing process variables Allow slow operation for setup purposes Adjust the rate of production Allow accurate positioning

VARIABLE SPEED DRIVE Many electric motor-driven devices operate at full speed even when the loads they are serving are less than their capacity. To match the output of the device to the load, some sort of part load control is in use for the majority of their life. Examples include pumps, fans, conveyors, injection molding machines, air compressors .Many part load control strategies waste energy. The most efficient method of part load control, resulting in minimal wasted energy, is the variable speed drive (VSD).

What is a variable speed drive? The basic function of a variable speed drive (VSD) is to control the flow of energy from the mains to the process. Energy is supplied to the process through the motor shaft. Two physical quantities describe the state of the shaft: torque and speed. To control the flow of energy we must therefore,ultimately, control these quantities.

Initially, DC motors were used as VSDs because they could easily achieve the required speed and torque without the need for sophisticated electronics. However, the evolution of AC variable speed drive technology has been driven partly by the desire to emulate the excellent performance of the DC motor, such as fast torque response and speed accuracy, while using rugged, inexpensive and maintenance free AC motors.

The four milestones of variable speed drives: DC Motor Drives AC Drives, frequency control, PWM AC Drives, flux vector control, PWM AC Drives, Direct Torque Control

DC Motor Drives Field orientation via mechanical commutator Controlling variables are Armature Current and Field Current, measured directly from the motor Torque control is direct

In a DC motor, the magnetic field is created by the current through the field winding in the stator. This field is always at right angles to the field created by the armature winding. This condition, known as field orientation, is needed to generate maximum torque. The commutator-brush assembly ensures this condition is maintained regardless of the rotor position.Once field orientation is achieved, the DC motors torque is easily controlled by varying the armature current and by keeping the magnetising current constant.

ADVANTAGE

Accurate and fast torque control High dynamic speed response Simple to control DRAWBACK Reduced motor reliability Regular maintenance Motor costly to purchase Needs encoder for feedback

AC Drive with frequency control Controlling variables are Voltage and Frequency Simulation of variable AC sine wave using modulator Flux provided with constant V/f ratio Open-loop drive

Both voltage and frequency reference are fed into a modulator which simulates an AC sine wave and feeds this to the motors stator windings. This technique is called Pulse Width Modulation (PWM) and utilises the fact that there is a diode rectifier towards the mains and the intermediate DC voltage is kept constant. The inverter controls the motor in the form of a PWM pulse train dictating both the voltage and frequency. Significantly, this method does not use a feedback device which takes speed or position measurements from the motors shaft and feeds these back into the control loop.

Advantages Low cost No feedback device required simple Drawbacks Field orientation not used Motor status ignored Torque is not controlled Delaying modulator used Torque cannot be controlled with any degree of accuracy. Furthermore, the technique uses a modulator which basically slows down communication between the incoming voltage and frequency signals and the need for the motor to respond to this changing signal.

AC Drives -flux vector control using PWM Features Field-oriented control - simulates DC drive Motor electrical characteristics are simulated - Motor Model Closed-loop drive Torque controlled indirectly

With flux vector PWM drives, field orientation is achieved by electronic means rather than the mechanical commutator/ brush assembly of the DC motor. Firstly, information about the rotor status is obtained by feeding back rotor speed and angular position relative to the stator field by means of a pulse encoder. A drive that uses speed encoders is referred to as a closed-loop drive. The electronic controller of a flux-vector drive creates electrical quantities such as voltage, current and frequency, which are the controlling variables, and feeds these through a modulator to the AC induction motor. Torque, therefore, is controlled indirectly.

Advantages Good torque response Accurate speed control Full torque at zero speed Drawbacks Feedback is needed Costly Modulator needed

AC Drives -Direct Torque Control In DTC technology field orientation is achieved without feedback using advanced motor theory to calculate the motor torque directly and without using modulation. The controlling variables are motor magnetising flux and motor torque.

Advantage Torque & Flux are being directly controlled no need for a modulator. Improve speed accuracy & faster Torque control. .

Variable frequency drives are making their way into systems and equipment for energy savings and as a means of part load control. In the future, expect more centrifugal chillers to be installed with variable frequency drives as opposed to inlet vane control, as well as an increased use of variable frequency drives for screw air compressors.

As prices continue to fall, variable frequency drives will be used more frequently for soft start capabilities and even for balancing fluid systems as opposed to using balancing (throttling) valves. The convenience of adding a drive to precisely and easily control equipment speed rather than complex, expensive, and maintenance intensive mechanical drives, or using guesswork to control processes, will continue to increase demand for this technology.

Fluid flow control The majority of variable frequency drive applications are for centrifugal pumps and fans. The savings potential for these devices is the largest since the theoretical input power varies with the cube of fan/pump speed and volume. For example, a fan operating at half speed will require only about 13 percent of full speed power. Losses in the variable frequency drive will reduce savings somewhat, but the savings are still very impressive. Air and water flow control is accomplished by either of several methods, including recirculating a portion of the flow, throttling, variable inlet vanes, and variable frequency drives.

Recirculating part of the flow results in the fan or pump operating at full volume all the time. Only a portion of the flow is used for the system or process and the rest is recirculated back to the inlet of the fan or pump. This is the least efficient means of controlling flow. Throttling essentially chokes the outlet of the pump or fan to decrease flow much like holding your thumb over the end of a garden hose. The pressure increases and the flow decreases. This results in some energy savings over a constant volume recirculating system but is still wasteful. So VFD provides most efficient method to save energy.

WORKING PRINCIPLE OF VFD

In a Motor the stator and rotor contain pole pairs wound with copper wire. When a current is applied, a magnetic field is generated and the north/south field rotates through the stationary stator as the rotor spins to catch up to the rotating field. The spinning of the rotor provides the torque necessary to drive a load. An electric motor turns at a given speed depending on the number of poles in the motor and the frequency of the alternating current applied.

Motor speed can be changed by changing the alternating current frequency. Nearly all variable frequency drives manufactured today are referred to as pulse width modulation drives. These drives contain electronic circuitry that converts the 50 Hertz line power to direct current, then pulses the output voltage for varying lengths of time to mimic an alternating current at the frequency desired.

Variable frequency drives can be installed with manual or automatic bypasses. In the early days of the variable frequency drives, bypasses were more common since variable frequency drives were not as reliable as they are at the present time. The bypasses were installed in the event of a drive failure to ensure the system or process would remain on line.

Bypasses are still available but not always installed. The criticality of the application must be considered in each case to determine whether the added cost and security of a bypass is warranted.Harmonic filtering may be necessary in some applications. Variable frequency drives can produce harmonics that can make their way back to the rest of the building and interfere with sensitive electronic equipment and machines. Line reactors can be used on smaller drives of 20 hp and less to dampen and mitigate harmonics.

For larger applications, an isolation transformer may be warranted. The isolation transformer can be installed either on the drive or on the piece of equipment to be protected from the harmonics. Because the equipment being protected may be much lower in power, it may be most economical to isolate the piece of equipment from the building supply.

Energy Saving

In Ib Thermal Power Station Ball Tube Mill is used for pulverization of the Coal .Primary air is used inside the Mill for the transportation of the Coal to the Furnace.So the Mill is pressurised to primary air pressure of 600mmwc.As the inside of the Mill is presssuried so there is chance of leakage of Coal dust from Mil trunnions.Seal Air Fan is used for the sealing of the trunnions so that the coal dust will not escape outside.

The Seal Air header is always maintained at pressure 1200mmWC.But Seal Air Fan is designed to develop a pressure of 1660mmWC & flow of 13344Mcube /hr.The Fan is inlet damper control with damper is on suction side of the Fan.The Fan sucks clean air from atomsphere through auto viscous filter.The Fan is driven by 120KW,2990RPM,415V ,205 amp induction motor.

Single stage,Centrifugal type Orientation: Horizontal suction Top Horizontal delivery. Medium: Air. Capacity: 3.9 m3 /sec SP wet of medium: 1.0535 kg / m3 Total Head leveloped: 1662 mmwc Speeed: 2880 RPM Drive Motor Rating: 120 kw Speed: 2990 RPM

The required flow & pressure was achieved by throttling of Suction damper with a 30 % opening. Since the Motor was running at full speed so there is a loss of energy & also during starting the motor was taking 5 to 6 times full load current stressing the insulation consequently failure of motor.

It was decided to run the Motor at variable speed with 100% damper opening thus eliminating throttling losses in dampers. The variation of flow torque & power with speed is shown by relationship. As flow N Torque N2 Power N3

A considerable energy saving is achieved by running the motor at lower speed with 100% damper opening. Conventional damper control & inverter control with 100% damper opening, at different air flow quantities is shown in the graph. At 100% air flow quantity the amount of power consumption is same for both damper control & frequency control. The amount of power consumption is quite considerable when the air flow quantity requirement is less.

ENERGY METERS READING BEFORE COMMISSIONING OF VFD

Sl. No

Date/Ti me

Drive Freq.

SA F Dis . Pre .

V1

V2

V3

A1

A2

A3

Pow er fact or

Fre q.

KW

KW H

Adv KW H

10/01/0 6 10.00H rs

12 00

24 8.8

243 .6

244 .8

145 .9

138

14 3.1

0.94 6

49. 9

105. 6

2099 60

11/01/0 6 10.00H rs

12 00

24 7.3

242 .5

244 .6

141 .4

134 .4

13 9.2

0.94 4

49. 51

102. 1

2124 50

2490

12/01/0 6 10.00H rs

12 00

24 5.7

240 .2

242

146 .6

140 .2

14 4.2

0.94 6

49. 69

105. 6

2149 40

2490

13/01/0 6 10.00H rs

12 00

25 0.3

245 .4

247 1

142 .4

135 .5

13 9.2

0.94 4

49. 53

103. 8

2174 40

2500

14/01/0 6 10.00H rs

12 00

25 1.9

240

249

142 .8

132 .8

13 8.8

0.94 4

49. 59

103. 7

2198 90

2450

15/01/0 6 10.00H rs

12 00

24 9.2

243 .7

245 .5

141 .5

132 .9

13 7.9

0.94 6

49. 88

102. 1

2223 88

2498

16/01/0 6 10.00H rs

12 00

24 5.9

240

243

147

140 .9

14 5

0.94 8

49. 7

105. 3

2248 89

2501

ENERGY CALCULATION BEFORE COMMISSINING OF VFD

Average Energy advance for 1 day = 2489 KWH Average KW during operation = 104 KW Average Power Factor during operation = .945 Average Current during operation = 144 Amps.

ENERGY METERS READING AFTER COMMISSIONING OF VFD

Sl. No

Date/Time

Driv e Fre q.

SA F Dis c. Pre

V1

V2

V3

A1

A2

A3

Pow er fact or

Fre q.

K W

KW H

Adv KWH

3/3/06 00.00 hrs

40

116 0

25 0.4

242. 3

245 .7

98. 21

84. 09

95. 25

0.99

49.8 7

73. 5

2343 20

4/3/06 00.00 Hrs

40

120 0

24 9.8

241. 18

245 .9

98. 7

85. 6

93. 12

0.99

49.1

73. 8

2361 20

1800

5/3/06 00.00 Hrs

40

118 0

25 0.8

240

244 .9

98. 21

82. 37

92. 19

0.99 1

49.7 2

74. 8

2379 40

1820

6/3/06 00.00 Hrs

40

120 0

24 8.9

245. 9

249 .1

98. 6

85. 09

97. 6

0.99

49.4 4

75. 3

2397 40

1800

7/3/06 00.00 Hrs

40

118 0

24 9.3

248. 5

246 .7

94. 01

82. 45

92. 61

0.99

49.5 1

74. 8

2415 50

1810

8/3/06 00.00 Hrs

40

116 0

25 1.2

243. 2

244 .8

96. 94

81. 36

90. 69

0.99

49.5 9

73. 2

2433 60

1810

9/3/06 00.00 Hrs

40

118 0

25 0.6

243. 5

244 .7

95. 71

80. 52

90. 68

0.99 1

50.0 3

72. 6

2451 60

1800

ENERGY CALCULATION AFTER COMMISSINING OF VFD

Average Energy advance for 1 day = 1806 KWH Average KW during operation = 74 KW Average Power Factor during operation = .990 Average Current during operation = 97.2 Amps.

CALCULATION OF SAVINGS
Avg. Energy Adv. before comm. of VFD for 1 day = 2489 KWH Avg. Energy Adv. after comm. of VFD for 1 day = 1806 KWH Energy saving for 1 day = 2489 1806 = 683 KWH % Energy Saved = 27.5 % 1. Energy saving of 27.5% achieved after commissioning of VFD in 1 Sear Air Fan. 2. Energy saved for 1 day = 683 KWH. 3. Payback period for 1 drive is 1.4 years. 4. Improvement of power factor from .945 to .990 is achieved due to commissioning of VFD. 5. Reduction of average KW from 104 to 74 is achieved due to commissioning of VFD. 6. Reduction of Motor current from 144 Amps to 97.2 Amps is achieved due to commissioning of VFD.

Conclusion: 1.Variable speed drive saves energy by reducing throttle loss & improving fan/pump efficiency at low flow. 2.Variable speed drive provide elegant options to vary flow so that advantage can be taken of production variation ambient temp. variation. 3.Variable speed drive can be provided by belt, pulley, gear hydraulic & compressor to save energy. 4.Increased life of rotating components due to lower operating speed.

5. Reduced noise & vibration level. 6. Smooth starting without any jerk & without any transient overloading of supply. 7. System harmonies with use of electronics variable speed drives can be mitigated by the use of filter. 8. Improve system power factor.

PLEASE.

THANKS