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MAGNADRI.WMV
8/23/2013
Baldor Cooling
Tower Direct Drive
Motors
8/23/2013
MagnaDrive Benefits
About MagnaDrive
Founded in 1999
Technology of the Year by Industry Week
for 2001
20 Domestic Patents and More than 200
International Patents
Installed on Over 16,000 Systems
Recently Awarded $2.7 million Contract by
U.S. Navy
8/23/2013
8/23/2013
About MagnaDrive
About MagnaDrive
Inc. 500
Fastest Growing
Private Companies
Deloitte 500
Fastest Growing
Technology
Companies
8/23/2013
About MagnaDrive
8/23/2013
11
Principle of Operation
8/23/2013
12
MagnaDrive Benefits
Imagine
Operates While Misaligned
Cushions Shock Loads
Cushioned Start
Controls Load Speed
A Mechanical,
Easy to Install
Non-Electronic Device
Compact
Reduces Vibration
Easily Understood
13
Target Market
Application Types
Pumps
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14
Target Market
Application Types
Pumps
Fans
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15
Target Market
Application Types
Pumps
Fans
Blowers
8/23/2013
16
Target Market
Application Types
Pumps
Fans
Blowers
Centrifuges
8/23/2013
17
Target Market
Application Types
Pumps
Fans
Blowers
Centrifuges
Bulk Handling
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18
MagnaDrive is Solution
Energy
MagnaDrive
R
E
S
U
L
T
No Throttling
8/23/2013
No Motor Seizure
A
B
S
O
L
U
T
E
S
A
V
I
N
G
S 19
Product Lines
Couplings
Adjustable Speed Drives (ASDs)
8/23/2013
20
Magnetic Couplings
Constant and Variable Torque
1 to 5,000 HP Applications
Four Models:
First Generation Coupling (FGC)
Delay (MGD)
Torque Limiting (MGTL)
8/23/2013
21
Permanent Magnet
Couplings
FGC
Couplings:
MGD
Coupling
8/23/2013
MGTL
FGC Coupling
CONDUCTOR STEEL
CONDUCTOR STEEL
MAGNETS
COPPER CONDUCTOR
SHRINK DISC
MOTOR HUB
COPPER CONDUCTOR
SHRINK DISC
LOAD HUB
AIR CLEARANCE
(GAP)
ALUMINUM MAGNET ROTOR
8/23/2013
8/23/2013
MAGNETS
COPPER CONDUCTOR
SHRINK DISC
MOTOR HUB
AIR CLEARANCE
(GAP)
8/23/2013
COPPER CONDUCTOR
SHRINK DISC
LOAD HUB
Product Overview
Couplings
MAGNETS
COPPER CONDUCTOR
SHRINK DISC
MOTOR HUB
AIR CLEARANCE
(GAP)
8/23/2013
COPPER CONDUCTOR
SHRINK DISC
LOAD HUB
Coupling Benefits:
MGD
MGTL
Vibration
Periodic Load Seizure
Pulsating Loads
Thermal Expansion
8/23/2013
Higher Starting Inertia/Torque
Type of Loads
Centrifugal Loads
Centrifugal loads are rotating loads, such as centrifugal pumps, fans, and
mixers. They closely follow the affinity laws, which dictate how flow,
horsepower, and torque change as speed changes:
New Flow
New HP
8/23/2013
= Original HP Speed3
30
Technology
Technology
Torque Transmitted
& Flow Are Reduced
By Increasing the
ASD Air Gap
A 1% Reduction in
Speed and Flow
Yields a 3% Energy
Savings
Flow Reduction
(1-Flow1/Flow2)
Power Consumed
(HP1/HP2)
Power Saved
(1-HP1/HP2)
99%
1%
97%
3%
98%
2%
94%
6%
97%
3%
91%
9%
96%
4%
88%
12%
A 10% Reduction in
Speed and Flow Yields
a 27% Energy Savings
A 50% Reduction in
Speed and Flow Yields
a 88% Energy Savings
8/23/2013
95%
5%
86%
14%
90%
10%
73%
27%
85%
15%
61%
39%
Energy
May
Energy Savings
Savings
May51%be
be Greater
Greater
80%
20%
49%
Due
Vibration
and
70%
30%
34%
66%
Due to
to Reduced
Reduced
Vibration
and
60% Misalignment
40%
22%
Tolerance
of
Misalignment Tolerance of 78%
50%
50%
13%
88%
MagnaDrive
Air
Gap
MagnaDrive
Air
Gap
40%
60%
6%
94%
31
Non-Centrifugal Loads
8/23/2013
32
Rigid Couplings
Rigid
Chain
Gear
Disc
Flexible
Flexible // Elastomeric
Elastomeric Couplings
Couplings
Rubber (Tire)
Flexible Shaft
8/23/2013
Jaw
Pin
33
Misalignment
Parallel / Offset
Misalignment
Axial
8/23/2013
Misalignment
34
Fixed Speed
Mechanical Couplings
Motor Shaft
Permanent
Permanent Magnet
Magnet
Rotor
Rotor
Load Shaft
Air Gap
8/23/2013
35
Motor Shaft
Fixed Speed
Mechanical Couplings
Load Shaft
MagnaDrive
MagnaDrive
can
can operate
operatewith
with
Angular
AngularMisalignment
Misalignment
8/23/2013
36
Fixed Speed
Mechanical Couplings
Motor Shaft
Load Shaft
MagnaDrive
MagnaDrive
can
can operate
operate with
with
Angular
Angular Misalignment
Misalignment
Motor Shaft
Load Shaft
Motor Shaft
MagnaDrive
MagnaDrive
can
can operate
operate with
with
Parallel
Parallel Misalignment
Misalignment
Load Shaft
MagnaDrive
MagnaDrive
can
can operate
operate with
with
Axial
Axial Misalignment
Misalignment
8/23/2013
37
Coupling Technology
Cushioned Start
Lower
Inrush at
Startup
Lowers
Peak
Demand
Immediate
Restarts
8/23/2013
38
Couplings
Motor Characteristics
Up to 5000 HP Motors @ 1500 RPM
Up to 3000 HP Motors @ 3000 RPM
Vibration Isolation
Vibration.mpg.mpg
Alignment Problems
MagnaDrive Corp - Distributor Demos Misalignment.wmv
Need for Cushion Start
Thermal Expansion Issues
Shaft Seizure Issues
Mechanical Seals are Present
Need to Protect Critical Equipment
8/23/2013
39
Fixed Speed
Mechanical Couplings
MagnaDrive
MagnaDrive ((MGE/FGC/MGD/MGTL)
MGE/FGC/MGD/MGTL)
Misalignment
Vibration transfer
Premature equipment failure
No vibration transfer
Longer equipment life (bearings, seals, etc.)
Overload protection
MagnaDrive is a GREEN technology
8/23/2013
Increased cost
of ownership
Lower cost
of ownership
40
Fluid Couplings
Applications:
Bulk Material Systems Conveyors:
Coal Handling
Ash Handling
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8/23/2013
41
Fixed Speed
Fluid / Hydraulic Couplings
42
Fixed Speed
Fluid / Hydraulic Couplings
Fluid
Fluid Coupling
Coupling Issues
Issues -- Oil
Oil
8/23/2013
43
Fixed Speed
Fluid / Hydraulic
Couplings
Fluid
Fluid Coupling
Coupling Issues
Issues High
High Maintenance
Maintenance
"Replacement parts for fluid couplings are notoriously
expensive. However, we had no choice but to keep
paying out as the Dryer-Pulveriser Mill is such a key
element within the refinery process. Unfortunately we
were in a lose-lose situation, when the application
faltered it not only cost us money to fix it, it was also
costing us money for the duration it was off-line.
"The coupling requires inspection every 12 weeks with
frequent oil top ups, the oil used within a fluid coupling
is highly volatile. The coupling incorporates a fusible
drain plug which is designed to discharge oil if the
operating temperature is too high. This feature was
causing a considerable health and safety risk to
operators, we had experienced several fires in the past
caused by hot oil blowing the fusible plug and
consequently igniting.
Source: http://www.hub-4.com/news/696/wbb-minerals-grind-down-maintenance-costs-using-siemens-soft-starters
8/23/2013
44
Fixed Speed
Fluid / Hydraulic Couplings
Fluid
Fluid Coupling
Coupling Issues
Issues -- Hazardous
Hazardous
8/23/2013
45
Fixed Speed
Fluid / Hydraulic Couplings
Fluid
Fluid Coupling
Coupling Issues
Issues -- Hazardous
Hazardous
8/23/2013
46
Fixed Speed
Fluid / Hydraulic Couplings
Fluid
Fluid Coupling
Coupling Issues
Issues -- Hazardous
Hazardous
47
Fixed Speed
Fluid / Hydraulic Couplings
Fluid
Fluid Coupling
Coupling Issues
Issues -- Hazardous
Hazardous
Curbing the killer Conveyors
Recently a steel worker was injured when an inclined conveyor ran
backwards, out of control, and the fluid coupling in the drive train
exploded like a bomb, spreading shrapnel and hot hydraulic oil
everywhere. It should never have happened.
The fluid coupling is sized to soft-start the conveyor and protect the
motor/drive package from overloads. It is made from aluminum and is
intended to run, in this case, at 1,500 to 1,800rpm. If it is run at speeds
of up to 6,000rpm then the aluminum casing will be put under massive
centrifugal loads sufficient to make the whole thing explode like a
bomb.
Then, when the drive train fails and the conveyor back-drives, the
fluid coupling becomes a bomb just waiting to explode.
Source: http://www.renold.com/Company/News/Curbing_the_killer_conveyors.asp
8/23/2013
48
Fixed Speed
Fluid / Hydraulic Couplings
Fluid
Fluid Coupling
Coupling Issues
Issues -- Hazardous
Hazardous
8/23/2013
49
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50
1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61
60 Minute Interval
20
10
0
1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61
60 Minute Interval
8/23/2013
Increased cost
of ownership
Fixed Speed
Fluid / Hydraulic Couplings
MagnaDrive
MagnaDrive ((FGC/MGD/MGTL)
FGC/MGD/MGTL)
Lower cost
of ownership
54
8/23/2013
8/23/2013
55
Variable Speed
Valve / Damper Systems
56
Variable Speed
VFDs (Variable
(Variable Frequency
Frequency Drives)
Drives)
8/23/2013
57
Variable Speed
VFDs (Variable
(Variable Frequency
Frequency Drives)
Drives)
Principle
Principle of
of Operation
Operation
8/23/2013
58
VFD
VFD Issues
Issues Installation
Installation Complexity
Complexity and
and Space
Space Requirement
Requirement
Building
Buildingto
tohouse
houseVFDs
VFDs
MagnaDrive
MagnaDriveminimal
minimal
space
spacerequirement
requirement and
and
simple
simpleinstallation
installation
8/23/2013
59
Product Lines
8/23/2013
60
ASD Benefits
8/23/2013
61
8/23/2013
62
8/23/2013
63
8/23/2013
Increased cost
of ownership
Variable Speed
VFDs (Variable
(Variable Frequency
Frequency Drives)
Drives)
MagnaDrive
MagnaDrive ASDs
ASDs
MagnaDrive ASDs:
of ownership
64
Location
Delhi
Coke Oven
WMD
Power House
Pune
Qty. in
Nos.
8
4
6
1
1
Tata Steel
Tata Steel
Reliance Energy
Bhilai Steel Plant
Bhushan Steel Ltd
Infosys Ltd
NALCO
Power House 4
Coal Plant
CHP
Sinter Plant
Dewatering
ETP
CHP
Tata Steel
Jindal Power
Coke Plant
Power House
Drive
Power in KW
Status
Pump
Pump
Pump
ID Fan
Pump
Coupling
Coupling
Coupling
ASD
Coupling
290
45
110
190
15
Installed
Installed
Installed
Installed
Installed
1
1
1
1
1
1
1
Pump
Conveyor
Conveyor
Conveyor
Pump
Pump
Conveyor
Coupling
Coupling
Coupling
Coupling
Coupling
Coupling
Coupling
75
75
110
55
18.5
7.5
37.5
Installed
Installed
Installed
Supplied
Installed
Installed
Installed
1
1
Crusher
Pump
Coupling
Coupling
550
11
Under Installation
Installed
CHP
Conveyor
Coupling
45
Installed
Compressor House
Compressor
Coupling
90
Installed
CHP
Coupling
18.5
Shipped
Coupling
230
Installed
DM Plant
DM Transfer Pump
Coupling
18.5
Installed
CHP
Crusher
Coupling
450
Under Shipment
CHP
Conveyor
Coupling
110
Shipped
Infosys Bangalore
HVAC
Chiller Pump
Coupling
18.5
Under Shipment
66
93732.00
Other Benefits
Reduction in Vibration Level
Zero Maintenance
Increased MTBF
Performance report of FGC 18.5S on 110 KW
Conveyor at Dahanu Thermal Power.pdf 67
Client:
Delhi Jal Board
Project:
Rithal ETP
Application:
Pump
Liquid:
Water
Motor Power:
280 KW
Voltage:
3.3 KV
Speed of Pump:
1466 RPM
Quantities:
8 Nos.
Performance Parameters:
Full Load Current:
63 Amps
Magnadrive Coupling: FGC 21.0S
Current Drawn with
Magnadrive Coupling: 46 Amps
Energy Savings:
78 KWH
Energy Saving in Rs.
40.80L / Yr.
Magnadrive Magnetic Coupling
Model FGC 21.0S
8/23/2013
68
Client:
SAIL
Project:
BSP
Application:
Pump
Liquid:
Hot Benzyl
Flow:
40m3/Hr
Motor Power:
45 KW
Voltage:
415 Volts
Speed of Pump:
2980 RPM
Quantities:
4 Nos.
Performance Parameters:
Current before
Magnadrive:
53 Amps
Magnadrive Coupling: MGE - 11
Current Drawn with
Magnadrive Coupling: 43 Amps
Energy Saving in Rs.
201480 / Yr.
Reduction in CO2
1 Ton / Day from 4
Emission:
Couplings.
8/23/2013
69
Client:
SAIL
Project:
BSP WMD
Application:
Pump
Liquid:
Water
Motor Power:
110 KW
Voltage:
415 Volts
Speed of Pump:
1480 RPM
Quantities:
6 Nos.
Performance Parameters:
Current before
Magnadrive:
163 Amps
Magnadrive Coupling: FGC 16.5
Current Drawn with
Magnadrive Coupling: 134 Amps
Energy Savings:
17 KWH
Energy Saving in Rs.
438000 / Yr.
Performance_certificate_from_WMD.pdf
8/23/2013
70
Client:
Tata Motors Pune
Project:
ETP
Application:
Pump
Liquid:
Effluent
Motor Power:
15 KW
Voltage:
415 Volts
Speed of Pump:
1480 RPM
Quantities:
1 Nos.
Performance Parameters:
Power before
Magnadrive:
9.77 KW
Magnadrive Coupling: MGE-11
Power Consumed with
Magnadrive Coupling: 6.91 KWH
Energy Savings:
2.9 KWH
Energy Saving in %.
25%
71
Client:
Tata Steel Tata Nagar
Location:
Power House - 4
Application:
Pump
Liquid:
Effluent
Motor Power:
75 KW
Voltage:
415 Volts
Speed of Pump:
1480 RPM
Quantities:
1 Nos.
Performance Parameters:
Power before
Magnadrive:
50.6 KW
Magnadrive Coupling: FGC 16.5S
Power Consumed with
Magnadrive Coupling: 44.27 KWH
Energy Savings:
6.3 KWH
Energy Saving in %.
12.45%
Magnadrive Magnetic Coupling Model
FGC 16.5S at Tata Steel
8/23/2013
72
Client:
Tata Steel Tata Nagar
Location:
Coal Plant
Application:
Conveyor No. 4A
Motor Power:
75 KW
Voltage:
415 Volts
Speed of Pump:
1480 RPM
Quantities:
1 Nos.
Performance Parameters:
Power Consumption Before
Magnadrive:
54.1 KW
Magnadrive Coupling: FGC 16.5S
Power Consumed with
Magnadrive Coupling: 50.1 KW
Energy Savings:
4.0 KWH
Energy Saving in %.
8%
FGC 16.5S on Conveyor No. 4A
At Tata Steel Ltd.
8/23/2013
Continue
73
8/23/2013
74
Magnadrive Magnetic Adjustable Speed Drive Model ASD 26.5 for 190 KW ID
Fan at Jindal Steel & Power Ltd. Raigarh
8/23/2013
75
Performance parameters for ASD 26.5 from JSPL.pdf
Magnadrive Magnetic Adjustable Speed Drive Model ASD 26.5 for 190 KW 6.6
KV ID Fan at Jindal Steel & Power Ltd. Raigarh Energy Savings around 73 KWH
8/23/2013
76
27%
2.25 KW
26%
2.25
18
6570
6
2.25X6570X6 = Rs. 88695
88695 / 12 = Rs. 7392
Rs. 70478.00
9.5 Months.
8/23/2013
77
Cost Benefits
Ease of Installation
Troubleshooting Ease
Lower Maintenace Costs
Maintained In-house
Longer Service Life
Reliability/Reduce Downtime
Lower Total Cost (1-50HP)
Lower Total Cost (50HP+)
8/23/2013
X
X
X
X
X
X
X
X
X
X
X
X
s
s
X
X
s
s
s
s
X
s
X
X
s
s
s
Mechanical Benefits
Non-contact Power Transfer
Reduce Vibration
Reduce Wear
Misalignment Tolerance
Reduce Power In-Rush
Soft Start/Stop
Increase Bearing, Seal, Eqpt Life
Electrical/Electronics Issues
Complex to Install/Support
Extensive Infrastructure
Sensitive to Power Quality
Harmonic Distortion
Frequent Parts Replacement
Parts Obsolescence
nica l D
evices
Flu id an
d Belt
Drives
Eddy C
urrent
X
X
X
X
X
X
X
M echa
X
X
X
X
X
X
X
VFD
Driv e A
SD
Drive C
oup lin
g
Eddy C
urrent
M echa
nical D
evices
Flu id a
n d Bel
t Driv es
X
X
M agna
X
X
X
X
X
X
s
s
VFD
Driv e C
oup ling
X
X
X
Competitive Analysis
M agna
Operation
Variable Speed
Process Control
Energy Efficiency
Overload/Failure Protection
Constant Load
Hi/Medium Voltage (High HP)
M agna
M agna
Driv e A
SD
s
s
X
X
X
X
s
s
X
X
X
X
X
X
X
X
X = Very Characteristic
s = Somewhat Characteristic
78
8/23/2013
79
About MagnaDrive
US Navy
Over 1,000 Couplings Delivered
Applications from 40 to 500 hp
No Electromagnetic Interference (EMI)
Issues
Fire Suppression System Pumps
Seawater Pumps
Aircraft Carrier JP-5 Fuel Pumps
Testing Adjustable Speed Drive Applications
8/23/2013
About MagnaDrive
8/23/2013
8/23/2013
MagnaDrive Update
8/23/2013
8/23/2013
MagnaDrive Update