1. 2. 3. 4. 5. 6.

INTRODUCTION BASIC CONFIGURATION OF SPRS TECHNICAL DETAILS SELECTION OF SPRS SCHEME SPRS DIMENSIONING LATEST DEVELOPMENTS

1.INTRODUCTION :
What is SPRS :
It is a system used for Energy conservation. Large fans & pumps are required at different places in a process plant. The volume of the fluid flow needs to be regulated as per the process requirement. The common method to achieve this is to run the fan/pump at a fixed speed. The flow is then adjusted by artificially increasing the resistance in the system by using a valve or damper. This method though simple,gives rise to high power losses as throttling losses. Further it results in higher vibrations also. Another method for speed regulation is by rotor resistors LRS or GRC.Again with this system losses and vibrations are at higher side,whereas speed regulation is poor.

 If a variable speed motor with an AC/DC Drive is used in the fan/pump,there will be considerable saving in power results. It is because of higher efficiency of the Drives  Drive is a static device and its efficiency is between 75-85%.  In case of AC drive the efficiency is 85% but the accuracy level is 2-3%.  Efficiency of a DC drive is around 75% and the accuracy level is less than 1%.  SPRS is basically a DC drive.  SPRS recovers the slip power which is normally lost in the rotor resistors.It also reduces the vibrations in the motor and regulates the speed accurately.

ENERGY FLOW IN SPRS:

+

HT BREAKER

NET SLIP POWER RECOVERY

STATOR

MOTOR

ROTOR

SLIP POWER

SPRS

MECHANICAL O/P POWER

LOSSES

WHY SPRS ?
IT AVOIDS LOSSES IN DAMPER. IT RECOVERS THE SLIP POWER NORMALLY LOST IN THE ROTOR RESISTOR. REDUCE VIBRATIONS IN THE FAN MOTOR & OTHER MECHANICAL COMPONENTS. REGULATE THE SPEED FINELY AS PER PROCESS REQUIREMENT.

SPRS EVOLUTION:
6 Pulse scheme (Analog Controller) with Relay logic & Harmonic filters: 12 Pulse scheme (Analog) with Relay logic: 6/12 Pulse scheme (Analog) with PLC : 1984 1986 1991 & 1993

6/12 Pulse scheme SPRS with Digital Controller & PLC :

2001 & 2003

SPRS INSTALLATION: ( B C L )

APPLICATION RATING (Kw) TYPE SCHEME OP.RANGE SAVING/DAY (UNITS)

C.S. FAN 2600

K.S. FAN 1500

B/H FAN 1025

CV FAN 800

12 PULSE

6 PULSE

12 PULSE

6 PULSE

(SERIES)

(SERIES)

80-95% 3200

78-95 2298

66-95% 2878

55-95% 1200

BASIC PRINCIPAL OF SPRS:

In any induction motor,when a 3 phase stator is fed with 3 phase supply, a magnetic flux of constant magnitude rotating at synchronous speed is set up. It is given by the equation: Ns = (120 x f / p) f= Input freq., P= no. of poles Due to relative speed between the rotating flux & rotor conductors,voltage is induced in rotor and the rotor starts rotating.The rotor is rotating at a speed lower than the field speed.The difference between the Synchronous speed of rotating magnetic flux (Ns),& the actual rotor speed (Nr), is known as SLIP of the motor.The % slip is given by

% s = (Ns-Nr)x100/Ns

Energy saving concept & fan curves

Load curve Damper control
P2

Load curve Damper full open

P1

Nr-Rated speed N-Reduced speed

N Nr

Pressure N/m2
P3

Flow m3/sec

Q2

Q1

Case 1:At full speed & Damper fully open: Power delivery by fan = P1 * Q1 Power input to motor = P1*Q1/nm *nf Case 2 : At full speed & damper control Power input to Motor = P2 * Q2/nm * nf Case 3 : At reduced speed ,without damper Power input to motor = P3 * Q2/nf * nm So Energy saved = (P2-P3)*Q2/nf*nm Here nm = Motor efficiency, nf = fan efficiency

Variation of Flow,Pressure and Power:

120 100 80 60 40 20 20 40 60 80 100 120 Power P

Flow Q

Speed % : N

From the Curve it is clear that FLOW is directly proportional to the SPEED,whereas POWER is proportional to the cube root of the speed.

Variation of Flow,Pressure and Power:

In Cement plant SPRS is used for fan type of loads.The fan in turn controls the flow by regulating the draught in the duct. So for such application Torque proportional to (speed)2 Power proportional (speed) * Torque Power proportional to (speed)3 So Flow proportional (speed)3  Table showing power at different speed of fan:  73% P = 0.389  80% P = 0.512  85% P = 0.614  90% P = 0.729  95% P= 0.857  This shows between 73 -95% speed power drawn from the motor is 38- 86%.

2.BASIC CONFIGURATION OF SPRS

R
H.T. BREAKER HT ISOLATOR (OFF LOAD)

Y B N
CAPACITOR BANK

R Y B

PNL. OFF LOAD ISOLATOR

MOTOR

FEED BACK TRANSFORMER

Q1

D.C. LINK CHOKE AIR CORE

A2TH M

TH1 THYRISTOR MODULE ASSEMBLY

K1 :GRC CONTACTOR

K2:SPRS CONTACTOR

DIODE MODULE

TH2

R Y B (G.R.C.)

TYPICAL SCHEMATIC DIAGRAM OF A 12 PULSE SPRS SYSTEM

3.TECHNICAL DETAILS OF SPRS COMPONENTS : 1. POWER ELECTRONICS

a) DIODE BRIDGE b) THYRISTOR MODULE(S) c) ELECTRONIC CONTROLLER d) PLC

2. DC REACTOR (LINE CHOKE) 3. FEED BACK TRANSFORMER 4. SWITCH GEAR 5.H.T. BREAKER 6. MOTOR 7. GRC

POWER ELECTRONICS:
It consists following components: a) Diode Bridge: It rectifies the Rotor voltage.It converts Rotor AC voltage in to fixed DC voltage and feeds it to the Thyristor module. The Rotor voltage is high at lower speed and low at higher speed.A Diode bridge has 6 Diodes.

PWM Power Circuit: AC to DC Converter Section

AC to DC Rectifier DC Filter

AC Input Input Reactor (option)

DC Bus Caps

+ -

DC Reactor

The AC input is rectified and filtered into fixed-voltage DC

Certain manufacturers units contain an integral DC reactor (choke)
as part of the DC filter. Adding an external AC input reactor will yield similar benefits.

POWER ELECTRONICS:

b) Thyristor inverter (SCR module)  The Rotor output is balanced by the Thyristor. bridge.  It operates in regenerative mode at fixed frequency of 50 Hz.  A Thyristor module has 6 thyristors. +
R B
4 6 2 1 3 5

Firing sequence 1,2 RB 3,2 YB 3,4 YR 5,4 BR 5,6 BY 1,6 RY 1,2 RB

Relation between Firing angle & Voltage O/P

V output

30 60 90

120 150 180

Firing angle

 For 90-150 degree Firing angle,Output is Negative.  Since the current is unidirectional the power flows in the bridge and it is called Regenerative mode.

3 PHASE WAVE FORMS:

PWM Power C r t DC to AC Inverter Sect on

DC Filter DC to AC Inverter AC Output + Thyristor U s V W

Thyristor Firing Signals

An IGBT (Insulated G ate Bipolar Trans istor) is a high-speed power semiconductor switch . IGBTs are pulse-widt h modulated w ith a specific f iring pattern, chopping the DC volta ge into 3pha se AC voltage of the proper frequency and voltage. The resulting motor current is near-sinusoidal, due to m otor inductance.

Requirement of Firing circuit:

To turn ON a thyristor positively in the shortest time,it is desirable to have a gate current with a fast rise time to the maximum permitted value.This rise time is best achieved by pulse techniques, where the firing circuit generates a fast rise pulse of sufficient length to allow the anode current enough time to reach its latching value.The advantage of pulse is that much less power is dissipated in the gate compared to a continuous current, and is instant of firing can be accurately timed.

Electronic Controller(PLC based):

Basic functions of a controller are as under: Sequencing & inter-locking Speed referencing Settings for changeover speed,Rotor voltage,Over current etc. Fault logging 12 pulse configuration Voltage feedback Speed jump

ELECTRONIC CONTROLLER UNIT:A1ER

Input, Feedback and Control Signals

Feed back Trans..

Fr om Rotor

Motor

HT Bus Under Voltage feedback

DC Over current feedback

Thyristor firing Signals

A1ER
AC M TO R D RI VE O 0. 75 KW 200 V v 1. 3

Speed reference

HE ALT H S E EQ

LO CA RE F L PR O G L R

Electronic Controller

TG Feedback

JO G RU N

F W RE V D ST O P RE SET RE SET

Basic block diagram

CONTROL LOOP
ACC DEC
SPEED CONTROLLER

:
TRIGGER CIRCUIT THYRISTOR

415 VAC

INV CONV

0:+10V
SA

0:-10V
CA

0:+10V
CURRENT AMPLIFIER

PG

RAMP REF: PLC

SPEED ACTUAL FROM TACHO

CURRENT LIMIT

CURRENT ACTUAL FROM CT CURRENT LOOP

CURRENT FEED BACK FROM CT

SPEED LOOP

TG

REF. +ve

RAMPO/P +ve

SA O/P -ve

CA O/P +ve

Nfb -ve

Ifb +ve

CONTROLLER:
TYRISTOR FIRING ANGLE CONTROL. IT ALLOWS A SMOOTH VARIATION OF THE SPEED THROUGOUT THE CONTROL RANGE. THE CONTROL SECTION CONVERTS THE SPEED REFERENCE SIGNAL TO A LEVEL WHICH IS GIVEN TO DETERMINE THE INSTANT OF FIRING. THIS REFERENCE LEVEL SETTINGS CAN BE ACHIEVED BY RAMP GENERATOR , PLC, SPEED AMPLIFIER AND CURRENT AMPLIFIER CIRCUIT. THIS IS FOR

RAMP GENERATOR & PLC

IT IS USED TO GIVE A SET REFERENCE TO GET THE REQUIRED SPEED. THE REFERENCE IS GIVEN IN THE RANGE 0 TO + 10 VOLT,WHICH IS EQUIVALENT TO 0 TO 100 % SPEED OF THE MOTOR. FOR EXAMPLE IF GRC TO SPRS CHANGEOVER SPEED IS 70%. MINIMUM REFERENCE VOLTAGE SHOULD BE 7.0 VOLT.PRACTICALLY IT IS KEPT 7.2 VOLT. MAXIMUM SPEED IS 100 %, SO THE REFERENCE SHOULD BE 10.0 VOLT.THESE SETTINGS ARE DONE IN PLC. SPEED CONTROL IS ACHIEVED BY COMPARING THE SET REFERENCE WITH THE ACTUAL SPEED OBTAINED FROM TACHO GENERATOR.

SPEED AMPLIFIER
THIS FORMS THE ERROR AMPLIFIER OF THE SPEED LOOP. SPEED REFERENCE IS GIVEN THROUGH THE PLC. THIS REFERENECE IS COMPARED WITH THE ACTUAL SPEED FEED BACK COMING FROM THE TACHO GENERATOR. INCASE OF TACHO FAILURE THE ROTOR VOLTAGE FEEDBACK ACTS AC A SPEED FEEDBACK. THE OUTPUT OF THE SPEED AMPLIFIER IS 0 TO -10 VOLT. IT HAS P & I GAINS TO TUNE THE SPEED LOOP, THE EFFECT OF WHICH IS ON THE OUTPUT OF AMPLIFIER. THE OUTPUT OF SA GOES TO CA. IT IS ALWAYS NEGATIVE BECAUSE CURRENT FEEDBACK IS UNIDIRECTIONAL.SO POSITIVE LIMIT IS CLAMPED.

EFFECT OF P& I GAINS:(SPEED AMPLIFIER) V o/p I1 I2

P1

P2 t t1 t2

CURRENT AMPLIFIER
THIS FORMS THE ERROR AMPLIFIER FOR CURRENT LOOP. INPUT CURRENT REFERENCE REQUIRED IS 10 VOLT FOR RATED FULL LOAD CURRENT. THE CURRENT FEEDBACK IS TAKEN FROM CT FROM THE INPUT SIDE . TIME CONSTANT OF CA IS VERY SMALL (30ms) AS COMPARED TO SA (400 ms) HENCE ITS P & I GAINS ARE VERY SMALL . DUE TO THIS REASON THE CURRENT LOOP IS ALWAYS KEPT INSIDE. OUTPUT OF THE CA DECIDES THE FIRING ANGLE. CA OUTPUT GOES TO THE PULSE GENERATOR, WHICH ACCEPTS ONLY POSITIVE SIGNAL SO HERE THE NEGATIVE LIMIT IS CLAMPED.

PULSE GENERATOR
 INPUT SIGNALS TO THE PULSE GENERATOR ARE SYNCHRONIZING SIGNALS (WITH 3-PHASE) AND OUTPUT FROM CURRENT AMPLIFIER.  ACCORDING TO THE VARIATION IN THE CA OUTPUT,FIRING ANGLE VARIES BETWEEN 0-180 DEGREE.  PRACTICALLY IT IS ADJUSTED SUCH THAT IT REMAINS BETWEEN 30 - 150 DEGREE.  THE CONVERSION & INVERSION LIMIT WILL DECIDE THE CLAMP ON THE FIRING ANGLE, ALPHA.  IN SPRS MODE FIRING IS DONE IN INVERSION MODE ONLY,SO THE FIRING ANGLE IS BETWEEN 90-150 DEGREE ALWAYS.

UNDER VOLTAGE MODULE

 WHEN THE FAN IS RUNNING IN SPRS MODE, THE ROTOR VOLTAGE IS BALANCED BY THYRISTOR BRIDGE OUTPUT VOLTAGE.  SUDDEN UNDER VOLTAGE CAUSES THE THYRISTER BRIDGE INPUT VOLTAGE FROM FEED BACK TRANSFORMER TO CHANGE IMMEDIATELY.  ON THE OTHER HAND THE ROTOR VOLTAGE WILL NOT CHANGE IMMEDIATELY.  THE ROTOR VOLTAGE GETS MORE & MORE BALANCED,AS THE FIRING ANGLE ADVANCES TO THE INVERSION MODE.  A DIP BEYOND THIS IMBALANCE AND RESULTS IN OVER CURRENT .  THUS UNDERVOLTAGE SENSING APPLIES A SUCIDE TO CA AND THE SYSTEM MAY CHANGEOVER FROM SPRS TO LRS.

2) DC Reactor (Link Coke) :  The reactor (Inductor) acts as a de-coupling element,It has the property that the voltage across it is proportional to the rate of change of current through it hence it limits, sudden current change Di/Dt .  When the SCR is triggered by applying a pulse at the gate, it does not start conducting immediately.At the beginning the flow of current is limited to a small area near the gate and from there it spreads to other areas. Due to this local hot spots are created near the gate and if the rate of rise of current (Di/Dt) is too high,the SCR may be damaged.To limit the rate of rise of current a Choke is used in series with the SCR.

b) Circulating current: At firing angle between 90 - 120 degrees the Inverter voltage output is positive.During this time,the diodes become forward biased. Current thus flows from the Transformer to the DC link and back through Diodes without passing through the Rotor.This is called circulating current. At rated speed,the current can build up to 20% of the rated current.The diodes & thyristors needs to be overrated due to this. The Choke reduces the current to some extent. So the DC Reactor reduces stress on motor windings and also motor losses are less

3. FEED BACK TRANSFORMER: Primary winding is connected to HT BUS through HT Isolator. Secondary connected to Thyristor Inverter(s) and designed for blocked rotor voltage of motor and GRC to SPRS changeover speed. Tapping of Tertiary winding is used for synchronization of firing pulses and sensing supply dips.

4. SWITCH GEAR : Isolators : These are used to isolate the feedback transformer from the supply in case of a fault or if maintenance is required.Isolators also provide an earthing switch interlock.The opening of the isolators automatically closes the earthing switch.This is very important from the safety point of view. Contactors :For GRC K1 is used whereas for SPRS K2 contactor is used.Both are power contactors having higher current capacity.Auxillary contactors are low current contactors used for interlocking purpose. CTs & PTs (Instrument Transformer): These are used for stepping down high value quantities like current & voltage for protection and measurement. These should be very accurate.

4. SELECTION OF SPRS
 SELECTION OF DRIVE MAINLY DEPEND UPON THE  

POWER RATING OF THE MOTOR. IF THE POWER REQUIRED IS BELOW 1 MW, A VARIABLE FREQUENCY DRIVE CAN BE USED. FOR HIGH POWER OUTPUT AND SPEED REDUCTION UPTO 50% OF THE BASE SPEED,SPRS MAY BE SELECTED. A COMPARISION OF THE COSTS AND BENEFITS OF THE SPRS AGAINST SIMPLE DAMPER CONTROL AND GRC/LRS SHOULD ALWAYS BE MADE. SINCE GRC/LRS IS COMPULSORY,SPRS IS AN EXTRA COST BURDEN.SO PAY BACK CALCULATION MUST.

SCHEME OF SPRS
ONCE DECIDED FOR SPRS,THE NEXT STEP IS,

WHICH TYPE OF SPRS TO BE USED. BASED ON THE OPEN CIRCUIT ROTOR VOLTAGE Rv & ROTOR CURRENT RA SPRS SCHEME IS SELECTED. GENERALLY FOR POWER RATING BELOW 1000 kW, 6 PULSE SPRS SCHEME IS USED. FOR POWER RATING ABOVE 1000 Kw 12 PULSE SPRS SCHEME IS USED. 12 PULSE SCHEMES ARE FURTHER CLASSIFIED INTO 3 MORE CATAGORIES.

6 PULSE SPRS SCHEME:

 USED WHEN Rv & RA,BOTH ARE SMALL.  IN THIS SCHEME ONE DIODE BRIDGE HAVING 6

DIODES & ONE THYRISTOR MODULE HAVING 6 THYRISTORS, IS USED.  FOR EXAMPLE, KILN STRING FAN SPRS IS 6 PULSE SPRS SYSTEM.
HT Bus HT Breaker HT Isolator

K2 Motor K1 Diode L Thyristor Feed back Tr.

12 PULSE SERIES SPRS :

 IT IS USED FOR POWER RATING ABOVE 1000 KW.  Rv IS HIGH BUT RA IS LESS .  ONE DIODE BRIDGE WITH TWO THYRISTOR MODULES IN SERIES IS

USED.  EACH THYRISTOR MODU HAS 6 THYRISTORS IN SERIES.  THE HIGH VOLTAGE IS BEING SHARED BY BOTH THE THYRISTOR MODULE WHEREAS THE ROTOR CURRENT REMAINS THE SAME.  EXAMPLE: BAG HOUSE & CALCINER FAN SPRS
HT Bus HT Breaker HT Isolator

K2 Motor K1 Diode L 2 Thyristor module in series Feed back Tr.

12 PULSE PARALLEL SPRS :

 IT IS USED FOR POWER RATING ABOVE 1000 KW.  Rv IS LOW BUT RA IS HIGH .  ONE DIODE BRIDGE WITH TWO THYRISTOR MODULES IN PARALLEL IS

USED.  THE HIGH ROTOR CURRENT IS BEING SHARED BY BOTH THE THYRISTOR MODULE WHEREAS THE ROTOR VOLTAGE REMAINS THE SAME.
HT Bus HT Breaker HT Isolator

K2 Motor K1 Diode L 2 Thyristor module in series Feed back Tr.

12 PULSE SERIES-PARALLEL SPRS :

THIS SPRS SCHEME IS USED WHEN BOTH Rv AND RA ARE HIGH . TWO DIODE BRIDGES AND TWO THYRISTOR MODULES ARE USED. TWO CONTACTORS K2 & K3 ARE USED, INSTEAD OF ONE. FOR A CERTAIN SPEED RANGE,SAY 60-80 %,WHERE Rv IS HIGH & RA IS

LOW,SPRS RUNS IN SERIES MODE AND HIGH ROTOR VOLTAGE IS BEING SHARED BY BOTH THE THYRISTOR MODULES.
HT Bus

HT Breaker HT Isolator

K2

Motor K1 K3

Diode 1

Thy 1

L Diode 2 Thy 2

Feed back Tr.

THIS IS ACHIEVED BY MAKING K2 ON AND K3 OFF. ABOVE CERTAIN SPEED, SAY 80% AND ABOVE WHERE ROTOR

CURRENT RA STARTS INCREASING AND ROTOR VOLTAGE Rv STARTS DECREASING,K3 CONTACTOR BECOMES ON. NOW SPRS STARTS RUNNING IN PARALLEL MODE AND THE HIGH ROTOR CURRENT RA IS BEING SHARED BY BOTH THE MODULES. IN THIS MANNER WE CAN CONTROL BOTH Rv & RA
HT Bus

HT Breaker HT Isolator

K2

Diode 1 Motor K1 K3 L Diode 2

Thy 1

Feed back Tr. Thy 2

5.SPRS DIMENSIONING
THE OBJECTIVE OF THIS EXERCISE IS TO RATE THE POWER CIRCUIT COMPONENTS AND THE VOLTAGE & CURRENT LEVEL IN THE CIRCUIT. THIS IS MAINLY REQUIRED AT THE TIME OF DESIGNING AN SPRS SYSTEM / UPGRADATION OF EXISTING SPRS. FOLOWING ARE THE MAIN COMPONENTS OF AN SPRS SYSTEM:  FEED BACK TRANSFORMER  DIODE & THYRISTORS  DC REACTOR  GRC / SPRS CONTACTOR

EXAMPLE: FOR A MOTOR OF GIVEN DATA,WE CAN CALCULATE THE RATING OF DIFFERENT COMPONENTS. MOTOR DATA:

STATOR VOLTAGE STATOR CURRENT ROTOR VOLTAGE ROTOR CURRENT OPERATING SPEED RATED RPM SLIP

Sv = 6.6 KV +/- 110% SL = 87 A Rv = 1175 V RA = 380 A = 60-100 % Ns = 1000 RPM Sm = 100-60/100 = 0.4

FEED BACK TRANSFORMER: Sm * Rv * 1.1 Vrms = COS 1500

COS 150 = 0.866 10% MARGIN

BY PUTTING ALL THE VALUES

Vrms = 597 VOLT

I dc(PEAK) = SQ.ROOT 2 * RA I dc(PEAK) = 537 A

KVA = SQ RT3 * Vrms * IAC KVA = SQ RT3 * Vrms * IAC = 453KVA F/B TRANS. = 6600 /597V,453 KVA

IAC= IDC * 0.816

# DIODE RATING:

PIV = SQRT2 * Rv * Sm * 2.2 * 1.1

SUPPLY VOLTAGE VARIATION

SAFETY FACTOR

BY PUTTING ALL THE VALUES

PIV = 1608 V CURRENT RATING = Idc = 537 A

# THYRISTOR RATING:
SUPPLY VOLTAGE VARIATION

PIV = SQRT2 * Vrms * 2.5 * 1.1

SAFETY FACTOR

BY PUTTING ALL THE VALUES

PIV = 2322 V CURRENT RATING = Idc = 537 A

# DC REACTOR: L = 2.43 * Vrms Idc mH

BY PUTTING ALL THE VALUES

L = 2.7 mH

By using these equations we can upgrade the existing SPRS systems.

6.LATEST DEVELOPMENTS
 TILL 2001, ANALOG CONTROLLERS WERE USED FOR SPRS SYSTEMS.  DIGITAL SPRS CONTROLLER HAVE BEEN INTRODUCED BY L&T IN THE YEAR 2001 WITH THE NAME ACEREG SPRS.IN THE YEAR 2003 SOME MORE MODIFICATION DONE IN THIS ACEREG SPRS CONTROLLER.  ACEREG SPRS IS A MICRO PROCESSOR BASED DIGITAL CONTROLLER FOR SPRS APPLICATION.  IT HAS FREELY PROGRAMMABLE INPUTS & OUTPUTUS.  IT HAS 16 INPUTS & 8 OUTPUTS.  ALL THE PARAMETERS CAN BE VIEWED ON 7 SEGAMENT DISPLAY.  PARAMETERS CAN BE ALTERED THROUGH KEY- PAD EASILY.  DETECTION OF FAULT IS EASY.  DIGITAL TACHO CAN BE CONNECTED DIRECTLY

Thanks