Topic : Variable Speed Drive Name : Salunke Yogesh Eknath Email : salunkeyogesh@hotmail.

com

VARIABLE SPEED DRIVE

Introduction Variable Speed Drives (VSD) are electronic motor speed controllers that allow the speed (RPM) of any three-phase electric motor to be varied from 0 to 120% of normal (rated RPM). VSD increase efficiency by allowing motors to be operated at the ideal speed for every load condition. In many applications VSD reduce motor electricity consumption by 30-60%. Considering that motor systems use more than 60% of the electrical power consumed by industry, the potential for savings is enormous. VSD were invented more than 25 years ago and are a mature and reliable technology. Over the last decade, however, VSD costs have dropped dramatically and improvements have vastly simplified their installation. Today they are enabling some of the best energy efficiency retrofit programs available to building and plant owners and operators. Application of VSD VSD can be installed on any electric motor, but achieve the largest energy savings when applied to fan and pumping system motors. The energy efficiency of almost any pump or fan system can be substantially increased by the addition of a VSD motor controller because these systems are either oversized or must respond to widely varying load conditions. In many systems excess capacity is still handled by mechanically throttling flow with dampers or valves. This is extremely inefficient because the motor continues to work hard to deliver at its full capacity. By changing the speed of the electric motors powering these fan and pump systems, VSD allow them to follow system loads while at the same time capturing the energy efficiency benefits offered by the so-called Fan Laws. The Fan Laws state that the power required by most fans or pumps varies with the cube of speed but that output varies directly with speed. For example, if a fan

load is 50% of its total capacity during some periods of its operation, the fans speed can be reduced to 50% to exactly meet that load, while the fan power is reduced by Power reduction = (1 (0.5) 3) 100 = 85 % VSD can be programmed to adjust motor speed based on a variety of load inputs including: temperature, pressure, flow rates, or time of day set points. VSD can be justified on motors as small as 5 hp. The larger the motor and the longer the number of operating hours per year the better the savings is likely to be. The installation of VSD motor controllers also often results in improved system operating performance and reduced wear and tear and maintenance. VSD used in conjunction with ac machines are typically more complex and requires high initial investment. High energy cost can cause a variable-speed electric drive to be extremely attractive alternative when the application requires operation over a range of speed. Variable-speed electric drive can provide significant energy saving if they eliminate devices that are inherently inefficient at reduced speed. Throttling valves and hydraulic coupling are example of devices that have relatively low efficiency at reduced flow rate or speed. Actual energy cost savings will vary based on mechanical characteristics and motor efficiencies. Using the following can derive a more conservative indication of actual savings Table 1: Efficiencies of fan and pump for variation of speed in percentage % Speed 90 80 70 60 50 Fan 0.78 0.70 0.59 0.46 0.32 Pump 0.80 0.64 0.49 0.38 0.28

40 30 20

0.22 0.13 0.10

0.20 -

Pump characteristic curves Figure 1: Performance characteristics of the pump Figure1 show the performance characteristics of the pump, i.e., the relations of the pump head (Hp), the efficiency (), and the brake horsepower to the flow rate (Q). A system curve (or system characteristic curve) shows the head required for various flow rates in the piping system. For most situations, the head requirement consists of the head required for the static lift, or the change in elevation (z) from the upstream end of the piping system to the downstream end, and for the head losses, which are a function of the velocity head (V2/2g). The operating point is the point at which the available pump head

(Hp) equals the head (Hs) required by the system, where .Hs = z + (KV2/2g) and K is a general representation for the loss coefficients, including (f L/D) for frictional losses Similarity or Affinity Laws If two pumps are geometrically and dynamically similar, their flow rates, pump heads, and horsepowers for homologous operation are related by

Q2 s 2 D2 = Q1 s1 D1 H 2 s2 = H 1 s1
2

where s = speed in rpm

2

D2 D 1
3

P2 2 s 2 = P1 1 s1

D2 D 1

P(shaft power) = QHp Where = g specific weight, g = acceleration of gravity, and = density. For the same pump and same fluid D and does not change, so
Q2 s 2 = Q1 s1

H 2 s2 = H 1 s1 P2 s 2 = P1 s1
3

D2 D 1

Evaluation of annual operating cost saving by reducing impeller diameter From figure 2 below and above equations it can be seen that pump volumetric flow rate is proportional to cube of impeller diameter, and head developed is proportional to square of impeller diameter. Based on above formulae for reduced flow rate new impeller diameter can be calculated and from new impeller diameter, new pump head can be calculated. If required head is greater that system head then changing to new diameter

is feasible solution. Pay back period of above changes are typically in range of 1 2 months. Limitation of changing impeller diameter is pump can be operated at reduced steady flow rate. For variable flow rate feasible solution would be using variable speed drive.

Figure 2: Manufacturers data for Type 1510 2-in. BB pump. (Adapted from 1967 Bell & Gossett data by J. W. Phillips, 1993.) [1] Evaluation of annual operating cost saving if throttling valve is replaced with variable speed drive. Two alternative are illustrated in accompanying block diagram
Pin Fixed-speed electric drive Centrifugal pump Throttling valve Variable flow

Pin

Variable-speed electric drive

Centrifugal pump

Variable flow

Figure 3: Block diagram of continuous speed and VSD Potential saving is illustrated in figure 4, which hypothetical pump curve for two situations.

Figure 4: Pump characteristics for fixed speed drive and VSD A curve representing the same system head is shown for each alternative. The system head curve might typically reflect the sum of a static head and head due to pipe friction. If a fixed speed drive and throttling valve head is added to the system head, yielding a total head curve as shown at the left in figure 4. Steady state solution point must lie on pump characteristics curve that applies at the fixed speed s1. If a variable speed drive is used, the pump characteristics changes for various steady states operating speed and solution point lie on the system head curve thus eliminating throttling head loss. In either case, the pump shaft power (typical in brake horse power BHP) that the drive motor must supply is proportional to product of head and flow rate divided with pump efficiency. Pump efficiency is function of flow rate and typically fall off if flow is reduced at constant shaft speed. If the pump is driven at constant speed, the shaft power 6

required at flow rates Q1 and Q2 is found out by determining appropriate value of head H1 and H2 from pump curve at speed s1. If the pump speed is reduced to effect flow reduction, the shaft power required at flow rates Q1 and Q2 is found out by determining appropriate value of H1 and H2 from the pump curve at speed s1. If the pump speed is reduced to effect flow reduction, the shaft power required at flow rate Q1 and Q2 is found by determining appropriate value of H1 and H2/<H2 from the system head curve. Throttling losses at reduced flow ratesQ2, which would be proportional to Q2(H2-H2/) with fixed speed drive, are eliminated with variable speed drive. Typical pump test data can be used to develop characteristics similar to those illustrated in figure 1. To determine saving the pump duty cycle must be considered. Table 2: Pump duty cycle Flow rate Q (Thousand gpm) 20 18 16 14 12 Time, t (% Of total time) 10 20 40 20 10

For fixed speed drive the following table can be established Table 3: Constant speed drive energy consumption Flow rate, Q (Thousand gpm) 20 10 733 Time, t (%) Pump BHP Ps (hp) Drive motor efficiency Line power Pin (kW) Energy, E (kWh/hr)

(%)
94.0 582 58.2

18 16 14 12

20 40 20 10

721 708 692 665

94.0 93.5 93.0 93.0

572 565 555 533

114.4 226.0 111.0 53.3 562.9

The values shown in table are typical values, which are obtained as follows. The brake horsepower is read directly from pump characteristics. Drive motor efficiency is line-to-line shaft efficiency for the electric drives, such as might be determined from characteristics similar to illustrated in figure 1. (Alternatively, it could be estimated by knowing motor efficiency at full, three quarter, and half load.) For example, an 800hp motor would operate at (665/800)100 = 83.1% load at the minimum flow rate anticipated in this case, and this might correspond to a typical efficiency of 93%. Note that induction machine speed changes very little from no load to full load and may be regarded as essentially constant. Line power Pin is obtained by dividing brake horsepower Ps by drive motor efficiency and converting to kilowatts. Energy E at particular flow rate required per hour of operation is obtained by multiplying Pin by the time t. Thus, the total of 562.9 kWh per hour can be used to determine energy cost for operation with fixed speed and throttling valve system. A similar table can be developed for variable speed drive system Table 4: Variable speed drive energy consumption Flow rate, Q (Thousa nd gpm) Time, t (%) Pump BHP Ps (hp) Motor shaft speed, s (rpm) Torque T (ft-lb) VS drive motor efficien cy (%) 20 10 733 900 4,278 85 643 64.3 Line power Pin (kW) Energy, E (kWh/hr )

18 16 14 12

20 40 20 10

632 522 428 348

857 804 752 702

3,873 3,410 2,988 2,604

82 80 78 75

575 487 409 346

115.0 194.8 81.8 34.6 490.5

The values shown in table are typical values, which are obtained as follows. The brake horsepower is determined by reading values of head from the system head curve corresponding to the various flow rates, taking the product of head and flow rate, dividing by pump efficiency, and converting to horse power. For small speed change pump efficiency remains relatively constant, and in this case a value corresponding to maximum efficiency for typical pump characteristics at nominal speed is assumed to be 83%. The value of shaft speed s and torque T are required as input data for determination of the overall variable speed drive line to shaft efficiency. Typically, these data would be furnished to supplier of variable speed drive system so that supplier can furnish the required drive system line to shaft efficiency. The determination of speed s is not easy. If a family of pump H versus Q characteristic with speed s as parameter is available, it is possible to estimate speed from the curves at each of desired flow rate, working with points along the system head curve. Given a pump characteristics (H vs. Q) at nominal pump speed, a family of curves can be developed using approximations. In order to predict the curve for a new speed s, any point on the new curve has to it head adjusted according to H/ = H(s//srated)2 and Q adjusted according to Q/ = Q(s//srated), where Q and H are determined from points on the rated speed curve H/ and Q/ locates points along the curve at speed s/. A simpler approach is to assume that brake horsepower Ps is proportional to speed to the third power (Ps s3), which is not unreasonable for a centrifugal pump. Speed s in the table above was determined by using latter approximation. Torque T can be easily determined from T = (33,000BHP)/2s or equivalently in this case, by assuming T proportional to speed square (T s2). Efficiency

are conservative (line to shaft value) values for a variable speed drive of this size. It is

not difficult to find instance of efficiency in manufacturers data sheet. To determine VSD line to shaft efficiency at various speeds, the load torque verses speed characteristics are essential. Line power is obtained by dividing brake horsepower Ps by efficiency and converting to kilowatts. Energy E is again obtained by multiplying Pin by t. The total 490.5 kWh per hour of operation can be used to determine energy cost for operation with variable speed alternative. Assuming 4,160 hr/yr operation and an energy cost of RS. 4/kWh, annual operating cost saving would be Savings = (562.9-490.5) kWh/hr 4160 hr/yr 4/kWh = 12,04,736 RS. /yr Features of VSD

Payback period will depend on numbers of hours of operation and duty cycle variability.

Payback period for VSD is typically 10 month to 2 years Systems friction head is proportional to flow rate; hence at low flow rate total head requirement also decreases resulting in reduced brake horsepower requirement. If static head requirement of the system is large in proportionate to total head, still brake horsepower requirement of pump may not reduce and use of VSD may not be remain economically viable. In such case parallel pump option should be considered.

Reference 1. L. C. White, P. S. Schmidt and D. R. Brown Industrial Energy Management and Utilization, First edition Hemisphere Publishing Company. 2. www.tam.uiuc.edu/courses/TAM235/Lab_manual/T.pdf

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