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Energy conservation using VFD

Conference Paper · October 2015

DOI: 10.1109/ICESA.2015.7503406

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2015 International Conference on Energy Systems and Applications (ICESA 2015)
Dr. D. Y. Patil Institute of Engineering and Technology, Pune, India 30 Oct - 01 Nov, 2015
Energy Conservation Using VFD
Prasad Bhase
Department of Instrumentation and Control
College of Engineering, Pune-411005
Email: prasad.bhase@gmail.com
Abstract—The AC induction motors converts the electrical
energy into mechanical and other usable forms. Therefore, for
this purpose about two third of the electrical energy is fed to
motors in world. So energy conservation for motors is the major
constraint. And this energy conservation is achieved by using
variable frequency drive at some extent. Generally, there are
three types of major load applications classified as
1. Variable torque type load
2. Constant torque type load
3. Constant Horsepower type load
This paper about variable frequency drive for 3 phase AC
Induction motor and energy conservation achieved using Variable
frequency drive for different types of loads.
Keywords: Variable frequency drive (VFD), Induction
motor, energy conservation, pulse width modulation (PWM)
I. I NTRODUCTION
Energy conservation is the important factor because of
increasing demand of electricity in day to day life can only
be meet by saving electrical power by installation of new
generating units. A major electrical power in industries is
consumed by electrical motors.Significant amount of energy
can be saved by use of the rigid and efficient type of drives.
Variable frequency drives (VFD) is one of the well-known
energy efficient drive.
To save electricity for our future generation we should be
aware of concept of energy conservation. From 1995, VFD
prices have dropped around 50 % that they have increasingly
cost effectiveness for most of the applications. Also, due
to emergence of power electronics Pulse width modulation
(PWM) technology, Variable frequency drive (VFD) enclosure
become more compact in size. Sound reduction during start
up and operation is also a benefit for our environment. In
addition to that Variable frequency drive (VFD) also provides
maintenance benefits over standard motor starters. Variable
frequency drives (VFDs) use power electronic devices to vary
the frequency of input power to the motor, thereby controlling
the speed.[1]
978-1-4673-6817-9/15/$31.00 ©2015 IEEE
Mahesh Lathkar
Department of Instrumentation and Control
College of Engineering, Pune-411005
Email: maheshh.lathkar@gmail.com
The primary purpose to use the VFD for 3 phase induction
motor is to save energy and operating cost. It is found that in
variable torque type of load, 20% reduction in speed of induc-
tion motor reduces about 45% energy consumption. Similarly
for constant torque type of load applications twenty percent
reduction in speed reduces about 20 % energy consumption.
Also for constant power type of load applications no energy
saving achieved.
[2][3] The traditional method used for flow control an induc-
tion motor at constant speed with 50/60 Hz power supply and
then controls the flow by throttle. Many motors running at fixed
speed can save energy when they are operated at variable speed
by variable frequency drive (VFD). Such energy cost saving
are generally used in centrifugal fan and pump applications.
In these type of applications load torque and power vary with
square and cube with respective to speed.
II. VARIABLE F REQUENCY D RIVE (VFD)
A variable frequency drive used for controlling the ro-
tational speed of an AC induction motors by controlling
the frequency of the electrical power supplied to the mo-
tor. Variable frequency drives are also known as AC drives
or inverter drives. Alternating current applied to the stator
winding produces a magnetic field that rotates the motor at
synchronous speed. This speed can be calculated by dividing
the line frequency by the number of magnetic poles in the
motor winding.
speed = (120 ∗ f requency)/p; (1)
where, p = number of poles per phase
For 60 Hz frequency and 4 pole the speed or magnetic field
will rotate with 1800 revolutions per second (rpm).
The rotor of an induction motor attempts to follow the
rotating magnetic field and in under load condition the rotor
speed slightly behind the rotating field called as slip. This small
slip generates an induced current, and the resulting magnetic
field in the rotor produces the torque. As an induction motor
531
rotates near synchronous speed, the most effective and energy
efficient way to change the motor speed is to change the
frequency of the applied voltage. Variable frequency drive
converts the fixed frequency supply to a variable frequency,
therefore allowing the adjustable motor speed. Variable fre-
quency drive consist of mainly three stages: Rectifier stage,
filter stage and the inverter stage.[4]
Fig. 1. Basic block diagram of VFD
Fig. 2. Actual Drive System
1) Rectifier Stage: A full wave rectifier section consist of
solid state rectifier converts three phase 50/60Hz power to
either fixed DC voltage or variable DC voltage.
532
2) Filter Stage: It consist of DC link choke or reactor
and capacitor filter. DC link chopper removes unwanted signal
harmonics and capacitor filter smoothen the rippled dc voltage.
3) Inverter Stage: The inverter section uses the power
electronic switches means power transistors or thyristors or
IGBTs which switches the rectified DC voltage on and off,
produces a current or voltage waveforms at the required
frequency. And the distortion occurred are depends on the
design of the inverter circuit and filter circuit.[5]
Variable frequency drives are classified in three types:
1. Variable voltage source Inverter
2. Current source inverter
3. PWM inverter
The current source type inverters also faces the same
problem like variable voltage type inverters.
Most currently available and due to emergence of advance
power electronics Pulse width modulation (PWM) technol-
ogy, Variable frequency drive (VFD) enclosure become more
compact in size. It uses the IGBTs as a switching devices
which have higher switching frequencies than that of bipolar
transistors also it has high input impedance, reduces base driver
power consumption.
III. S IMULATION FOR PWM I NVERTER
The simulation results of the variable frequency drive for
induction motor is done in Matlab/Simulink software and the
results are presented. The induction motor is fed by a current-
controlled PWM inverter.
Fig. 3. Simulation of SPWM with phase difference of 120 degree
Fig. 5. Voltage output waveform for each phase voltage v/s time

Fig. 6. current output waveform for each phase current v/s time

Fig. 4. Inverter circuit simulation by using Simscape

Fig. 7. PWM waveform

These output of each PWM waveforms 1,2,3,4,5 and 6 are
given to IGBT gates and then output is taken and connected to
IV. B ENEFITS OF VFD FOR INDUCTION MOTOR
load. Then the voltage and current waveforms for each phase
are observed. The simulation results are shown in fig.5,fig.6 1. Substantial energy costs (due to direct speed control)
and fig.7 respectively. 2. Improves Process by smooth speed control

533
3. Energy costs by reducing maximum utility demand charges 3. Constant power (CHP)
4. Increase Life of mechanical equipment (due to soft starting)
5. Reduce Motor stress (lower heat, vibration, and transient
torques) A. Variable torque type load
6. Lower chances of System disruptions (by lowering current
Applications like Fans for example ID/FD fans, primary
inrush from 600 percent to 100-150 %)
air fans, cooling tower fans, ventilation fans, dryer fans
7. Substantially brings down Down time and Maintenance
etc. Also pumps for example chilled water pumps, pressure
costs
boosting pumps, cooling tower pumps, waste water pumps,
8. Smooth start and perfect control
syrup pumps etc. are the variable type loads.
9. Complete motor protection against overvoltage, overload,
motor stalling, short circuit, transients, phase loss etc.

In addition to enabling precise speed control of applications

such as conveyors or winders, other parameters such as pres-
sure, flow and even temperature may be accurately controlled.
The efficiency of the electrical supply is increased and more
of the electrical current drawn is used to drive the load. Hence
the implementation of VFD improves the power factor of
the system. In addition to this VFD provides good dynamic
response. This can be achieved by rapid adjustment of speed,
torque and power and hence gives better control in high speed
applications. In some applications it is also possible to operate
motors at higher speeds than their nominal speeds.[6][1]

V. E NERGY C ONSERVATION U SING VFD Fig. 8. Torque V/s Speed Characteristics for Variable Torque type load

The variable frequency drive offers several advantages.

The most significant benefit is to reduce the electrical energy Affinity Laws:
consumption and demand from motor driven processes. Even a
small reduction in rotational speed can give significant saving
in the energy consumed by induction motor. In order to do power ∝ pressure ∗ f low (2)
so we take a closer look to the so called affinity laws which 2
P ressure ∝ speed (3)
are used in hydraulics to express relationships between the
variables involved in the operation and performance of rotary f low ∝ speed (4)
3
machines such as pumps and fans.[7] power ∝ speed (5)
3
P 2 = P 1 ∗ (N 2/N 1) (6)
Some important advantages of variable frequency drive is
3
1. Input current is less than output since source voltage is =100Hp ∗ (1200/1440)
constant =58Hp
2. Lower demand on distribution line P owersaved = P 1 − P 2 = 100 − 58 = 42Hp
3. Power consumption is proportional to the motor speed
4. VFD provides high efficiency (greater than 97 percent)
5. Improves power factor to 0.98
We can calculate the operating cost with following formula:
6. Payback within 12 to 24 months for reduced energy
consumption Cost = power(Kw) ∗ runningtime ∗ cost/kwh (7)

For constantly running motor at 100 percent speed, the

Classification according to type of load and their
annual operating cost of 20hp motor (assuming 5 Rs/kwh) is:
corresponding energy saving:
1. Variable torque (VT) So, for variable torque type load, twenty percent reduction
2. Constant torque (CT) in speed reduces the fourty five percent energy consumption.

534
B. Constant torque type load

Constant torque type load applications are like food pro-

cessing equipment, machine tools, conveyor equipment, pack-
aging machinery, wagon tippler, screw feeder, crane/hoist,
compressor, lifts, winder etc. Characteristic curve for these
type of load given in the figure.

Fig. 10. Torque V/s Speed Characteristics for Constant Power type load

Affinity law:
P = 2 ∗ pi ∗ N ∗ T (12)

As in Constant power type of load applications power is

Fig. 9. Torque V/s Speed Characteristics for Constant Torque type load constant So, no energy saving is possible.

For constant type of load by affinity law, VI. C ONCLUSION

It is found that the speed control of induction motor using

variable frequency drive can save energy according to affinity
P =2 ∗ pi ∗ N ∗ T (8) laws and equations. As from these results a small reduction in
power ∝speed (9) speed can save a large amount of energy.
P 2 =P 1 ∗ (N 2/N 1) (10) Apart from speed control and energy savings, the uses
=100hp ∗ (1200/1440) of Variable Frequency Drives soft start, reduction in starting
=84hp current, and also reduce tear and wear. Also a VFD fed
P owersaved =p1 − p2 induction motor is modeled using open loop and closed loop
and simulated using Matlab.
=100 − 84
=16hp
R EFERENCES
(11)
[1] V. F. D. VFD, “Variable frequency drive,” Same as VFC, 2005.
[2] P. N. Enjeti and A. Rahman, “A new single-phase to three-phase
We can calculate the operating cost with following formula:
converter with active input current shaping for low cost ac motor drives,”
Industry Applications, IEEE Transactions on, vol. 29, no. 4, pp. 806–
Cost = power (Kw)*running time*cost/kwh
813, 1993.
So, for constant torque type load, Twenty percent reduction [3] D. S. Kirschen, D. W. Novotny, and T. A. Lipo, “On-line efficiency
in speed reduces the twenty percent energy consumption. optimization of a variable frequency induction motor drive,” Industry
Applications, IEEE Transactions on, no. 3, pp. 610–616, 1985.
[4] L. Brittian, “Variable frequency drives,” Audel Electrical Trades Pocket
C. Constant power type load Manual, pp. 79–87, 2012.
[5] B. J. Baliga, “Power semiconductor devices for variable-frequency
Constant power type of load applications are blower motor, drives,” Proceedings of the IEEE, vol. 82, no. 8, pp. 1112–1122, 1994.
spindle motor, mixer etc. the characteristic curve for these type [6] G. R. Slemon, “Electrical machines for variable-frequency drives,”
of load is given in figure. [8], [9], [10] Proceedings of the IEEE, vol. 82, no. 8, pp. 1123–1139, 1994.

535
 [7] A. Birdar and R. G. Patil, “Energy conservation using variable fre-
quency drive,” International Journal of Emerging Trends in Electrical
and Electronics (IJETEE–ISSN: 2320-9569), vol. 2, no. 1, pp. 85–91,
2013.
[8] A. Hughes and B. Drury, Electric motors and drives: fundamentals,
types and applications. Newnes, 2013.
[9] A. T. de Almeida, P. Bertoldi, and W. Leonhard, Energy efficiency
improvements in electric motors and drives. Springer Berlin, 1997.
[10] V. I. Utkin, “Sliding mode control design principles and applications to
electric drives,” Industrial Electronics, IEEE Transactions on, vol. 40,
no. 1, pp. 23–36, 1993.

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