VFD & Energy Conservation

USAGE OF VFD FOR ENERGY CONSERVATION

Why energy efficient industry???

Industry is motivated to become more energy

efficient for variety of reasons, including but not limited to: Cost reduction. Improved operation reliability & control. Ability to increase production without requiring additional & possibly constrained energy supply. Recognition as a green company. Access to investor capital through demonstration of effective management practices.

Energy Production/Consumption at USA

Why Variable Frequency Drive

Energy Crisis:
Current scenario is that everywhere the energy has got a limited source at continuous increasing cost. Energy can only be earned by saving it. Improve the efficiency of the energy system -making more productive use of energy resources to enhance overall economic performance while protection the environment and advancing national security.

Profit increasing by eliminating waste:

As now a days and henceforth price control is not in hand of manufacturer, the only option to increase the profit margin is, eliminate the waste to the best possible.

Scope For Variable Frequency Drive

Conventional method for controlling process parameters, which results in under load utilization of motor.

Volume control by
Throttling output valves. Adjusting output dampers.

Intermittent loading and unloading at

driven system.

Drives (VFDs) & Energy Savings

Heating Ventilation & Air Conditioning (HVAC) Fans & Pumps are some of the largest electrical loads in commercial buildings. Pumps and Fans are also used in many industrial manufacturing processes.

How did we control FLOW before Variable Frequency Drives?

Dampers & Valves (very inefficient) Air Dampers & Valves limit flow by placing a restriction in the system. Most HVAC pumps and fans do not shut down when the system is satisfied. Imagine pressing the accelerator of your car to the floor and trying to slow the car down by pressing the brakes at the same timewasteful!

Pump discharge control

Following are few practical examples for above: Volume control by throttling valve,
Close loop water circulation and distribution system. Chilled water loop for centralized air-conditioning. Cooling water lines for various applications.

Blower Flow Control

Volume control by controlling damper opening
Air handling units meant for centralized airconditioning system. ID/FD Fan for boilers to control inlet air w.r.t. the load. Process blowers for manufacturing equipments.

Intermittent Loading of equipment

Intermittent loading and unloading at driven system.

Air compressor. Cooling fan of cooling tower. Feed pump of Reverse Osmosis plant.

Energy usage in Industry

More than half the energy consumed by AC motors powers in any industry.

Electrical energy costs are often

the largest expenditure for industry owners.

Reducing energy demand and

improving the working environment of a industry are main objectives of facility managers.

The principle reason for using

VFDs is to reduce energy costs.

What is a VFD?
A Variable Frequency Drive is like the throttle on a car
It adjusts the speed of an drive based on demand, to save

energy and prolong motor and mechanical component life.

Without a VFD, an HVAC fan, pump

motor or Blower motor is either 100% on or 100% off

A VFD eliminates the initial power surge

and mechanical shock of switching the motor from off to 100% on

VFD Applications
A VFD conserves energy :when an 1).HVAC control systems senses that a fan or pump motor can meet heating or cooling needs, with reduced operation of electrical drives. 2).Damper controlled Blower motor,Replacing the manual control by VFD driven motors. 3).Throttled Discharge Valve Pump Motor,replaced by VFD driven pump motors.. .. All the above conditions can be met by running the electrical motors main driving component of the industry at less than 100% power consumption.

Electric Motor Facts

Electric motors account for more than two-thirds of all energy used in industry. 63% of the energy consumed is linked to air & liquid flow. A typical 50HP industrial motor, with an efficiency of 90%, costs over $25,000 to operate continuously over a year.

How Does A VFD Work?

It changes the speed of an AC HVAC fan or pump motor by adjusting or

varying the frequency and voltage.

Typical frequency adjustment range in

HVAC applications is from 10 - 50Hz AC.

A VFD is wired in series between main

power and motor.

A Bypass is added to Bypass the VFD

and run on main line power so HVAC operation is not interrupted if the VFD needs servicing

How Does A VFD Vary the Frequency?

A VFD, AC inverter, or electronic speed controller for AC motors

converts the AC supply to DC using a rectifier (diode), then converts it back to a variable frequency by using a inverter bridge.

VFD Block Diagram

Motor

Main Power

Rectifier

Capacitor

Switches (IGBTs)

Motor

Estimating Energy Savings

Motor Nameplate Data Motor Hp Motor Efficiency Operating Hours of the Fan or Pump / Year Load profile (% amount loaded and for how long) For industrial processes, this needs to be monitored to develop accurate savings numbers. Cost per kWh Drive and Installation cost

Payback Calculation

Pumps/Fan flow control

Affinity laws for Centrifugal Equipment

Case Study-1

Power Saving

Case Study-2
Volume control by controlling damper opening. EQUIPMENT : BOILER CAPACITY: 6000 KG/HR ID/FD FAN:It is meant for supplying the air for combustion of fuel for utilization

of thermal energy for production of steam. There will be a change in required amount of volume of air for combustion as per change in steam demand from processing area.

Existing system for air volume control

An electro-mechanical operated setup is provided for controlling the openings of damper at the inlet of fan. Damper will be operated as per the change in steam demand keeping the electrical motor of fan, running at constant speed. Details of Utilization of system : (8.0 running hours) Fan motor capacity: 25 HP (18.5 KW)

Damper opening 100% 75% Below 25%

Stage /Duration for damper position Initial firing for 1Hour Normal running 6 Hours 1 Hour Stopping of fire

Capacity utilization of motor 75 - 80% 55 - 60% 35 - 40%

Loss of design capacity 20 - 25% 40 - 45 % 60 - 65%

Energy Savings Damper controlled blower

Potential energy savings using a VFD vs. modulating flow with a

damper.
140 130 120 110

Damper

Input Power (%)

100 90 80 70 60 50

VFD
Ideal Fan Control

Energy Saving Potential

40
30 20 10

Flow Rate (%)

10 20 30 40 50 60 70 80 90 100

 Proposed system for air volume control

To remove electro-mechanical operated setup provided for controlling the openings of damper and the damper at the inlet of fan and to install variable frequency drive (VFD) for fan motor. By this we can achieve the variable speed of motor resulting required volume of air as per combustion requirement w.r.t. Steam demand.
CONCLUSION: This method of volume control is energy

efficient and we can eliminate energy wastage by more than 35 - 40%

Case Study-3
FOR INTERMITTENT LOADING/UNLOADING EQUIPMENT:AIR COMPRESSOR CAPACITY:300 CFM MOTOR: 75 HP (55 KW)
EXISTING OPERATION:

Air compressor normally runs at discharge pressure ranging between 7.0 to 8.0 kg/cm2. Compressor is made 'LOAD' at 7.0kg/cm2 and 'UNLOAD' at 8.0 kg/cm2 pressure, keeping the motor running at constant speed at both 'LOAD' and 'UNLOAD' running mode. Details of Utilization of system : (8.0 running hours) Running mode %Duration Capacity utilization of motor 75 - 80% 40 - 45% Loss of deigned capacity 20 - 25% 55 - 60 %

Load Unload

84 - 85 % 15 - 16%

 PROPOSED OPERATION

A required output of compressed air (cfm) can be made variable w.r.t. demand from process area, by putting a speed variation option. Speed variation of air compressor can be achieved by installing variable frequency drive (VFD). This system can be installed as per CLOSE LOOP INSTALLATION for effective benefits.
CONCLUSION: This method of cfm control is energy

efficient and we can eliminate energy wastage by more than 25 - 30%

Conclusions on Energy Conservation

Energy conservation has saved the need for many

power plants and fuel imports. It has also avoided CO2 and environmental pollution. Much has been done, but much more can be done In this new era of global warming and high energy costs and energy shortages, the public must be informed and politicians sought who are sensitive to these issues. Using VFDs greatly reduces energy consumption, hence it is called environmentally GREEN technologyI like to say it puts $GREEN$ in your pockets

SUMMARY
From above case studies ,we can say that wherever

there is a 40 - 70% effective utilization of the available capacity we should go for VARIABLE FREQUENCY DRIVE with CLOSE LOOP INSTALLATION. In short we can say as below For contribution towards for ENERGY CONSERVATION-VARIABLE FREQUENCY DRIVE IS ONLY THE RELIABLE "FREQUENCYDRIVE

Questions Sessions & Thanks note