Hydraulic Variable Drive

Transcription

1 Hydraulic Variable Drive New Product, Proven Technology Innovative, Rugged, Efficient & Affordable Variable Speed Drive for Industrial & Commercial Applications E n g i n e e r i n g D r i v e n S o l u t i o n s, L L C w w w. E n g i n e e r i n g D r i v e n S o l u t i o n s. c o m i n f E n g i n e e r i n g D r i v e n S o l u t i o n s. c o m

2 GENERAL OVERVIEW Hydraulic Variable Drive (HVD) Energy authorities suggest that industrial electric motors account for over one billion kilowatt-hours per year of energy consumption, more than 50% of the world s usage. The correct application of an HVD can substantially drive down this consumption, saving you money. INDICATORS - NEED OF HVD Damper, control valve, or similar device is often times less than 80% open. HVD allows complete control of fan, pump output or other machinery for most efficient operation. Cost effective and efficient alternative to other variable speed drives (often the cost of HVD is approximately 50% the cost of VFD). Run multiple fans or pumps independently with one system and one electric motor. Reduced cost of redundant and backup systems. Rugged construction and high dependability. Cost effective maintenance and repair as well as reduced down time. Spill or bypass control is used. Flexible configurations. Systems that serve variable loads. Easily formatted for computer or electronic control, including feedback systems. Systems with common maintenance problems. Systems in which upgrades are Space Savings as HVD system is much smaller in size than VFD system of equal power. planned. Engineering Driven Solutions (EDS) is a HVDs offer benefits that other variable speed drives Systems that have large fans, company formed by experienced engineers with the sole cannot. Some of these include ability of pumps or other rotating machinery. purpose of reducing operating costs of large, industrial plants. EDS has developed a new product, based on independently operating and controlling multiple fans or pumps on a single HVD system with a single Use of device in which speed proven industrial technology. We are proud to introduce electric motor, constant and efficient operating speed may be altered for optimal operation. the Hydraulic Variable Drive (HVD) as the most innovative technology to control the speed and output of of electric motor while the fan or pump speed is being varied, as well as flexible configurations for effective Systems with Start/Stop operations. your fan, pump, or other rotating machinery at a fraction of the cost of other variable speed drives such as packing of components. Payback periods for HVD products are often months, if not less. EDS P E A CE O F M I ND P U R CH A S IN G FREE consultation. GUARANTEED payback periods. Variable Frequency Drives (VFDs). This new product allows optimal efficiency operation of common industrial machinery (e.g. fans, pumps, various rotational machinery, etc.) that in the end saves you money! also offers GUARANTEED payback periods and comprehensive warranties for peace-of-mind purchasing. Contact EDS today for a FREE consultation to see how a HVD can assist you. Comprehensive warranties. Available maintenance services. Available installation services. 1

3 TABLE OF CONTENTS Contents GENERAL OVERVIEW... 1 TABLE OF CONTENTS..2 PRODUCT DESCRIPTION.3 INDICATORS OF NEED FOR HVD.. 7 TECHNICAL DATA-EFFICIENCY AT NORMAL OPERATING CONDITIONS..8 TECHNICAL DATA-STARTING OPERATIONS...12 DEPENDABILITY & MAINTENANCE.13 SYSTEM FLEXIBILITY..14 MEETING YOUR NEEDS...15 OTHER SERVICES & CONTACT US

4 PRODUCT DESCRIPTION ENGINEERING Information Technology DRIVEN Solutions SOLUTIONS SCHEMATIC OF SYSTEM O P E R A T I O N C H A R A C T E R I S T I C S VERSUS VFD Constant prime mover operating speed for all operating conditions. No customer supplied belt or gear drive reduction required for torque multiplications in most cases. Start-up conditions performed with no external load applied on prime mover. Torque multiplied during start-up conditions as equipment is brought up to speed. VERSUS FLUID COUPLING Much higher efficiency, particularly in start/stop applications as well as widely varying operating conditions. Smoother or softer starts. Smooth or soft start-ups accomplished without vast waste of energy. A Hydraulic Variable Drive (HVD) is a system that allows variable speed control of a fan, pump or other piece of rotating machinery. This system is a variable drive that operates between the prime mover (e.g. electric motor, internal combustion engine, etc.) and the equipment (e.g. fan, pump, rotating machinery, etc.) as compared to a Variable Frequency Drive (VFD) that varies electrical frequency to the electric motor. Therefore, the prime mover operates at a constant, optimalefficiency speed regardless of equipment operating condition. This is different than the operation of a VFD, where the electric motor speed changes according to equipment operating conditions. If there is a need, the HVD can easily be designed with torque multiplication capabilities, eliminating the need for customer supplied gear or belt drive reduction in most cases. The HVD system is much different than a fluid coupling. A fluid coupling is a device in which energy is transferred through a fluid, similar to a torque converter in an automatic transmission vehicle. To allow a difference in input and output torque or speed, the fluid coupling slips. HYDRAULIC RESERVOIR HYDRAULIC FILTER This slip essentially wastes output energy produced by the prime mover, converting the energy to destructive heat, heating up the fluid inside the fluid coupling. This is why automobiles now use lock-up converters for efficiency. A fluid coupling cannot develop output torque without slip. Therefore, a fluid coupling always wastes input energy. The percentage of wasted input energy is substantial during start up and varying speed applications. This wasted energy is a tradeoff to produce a smooth or soft start. The HVD accomplishes a soft start without the substantial amounts of wasted energy and heat generation with a fluid coupling. VARIABLE HYDRAULIC PUMP HYDRAULIC MOTOR HYDRAULIC COOLER EXISTING MOTOR EXISTING MACHINERY NOTE: Not all components are illustrated. Additional configurations are utilized in some applications. 3

5 PRODUCT ADVANTAGES OVERVIEW Variable speed control allows complete control of fan, pump, or other equipment output. B E N E F I T S VERSUS VFD Fraction of the cost. Comparable total efficiency in converting electrical power to shaft work. No effect on power factor. Longer prime mover life as it maintains constant, most efficient operating speed regardless of equipment operating condition. Rugged industrial components which are not susceptible to harsh environments or electricity failure or surge. No gear or belt drive required. VERSUS FLUID COUPLING Much higher efficiency, particularly in start/stop applications as well as widely varying operating conditions. Allows infinite and independent control of equipment speed, regardless of prime mover speed. Longer prime mover life as it maintains constant, most efficient operating speed regardless of equipment operating condition. No gear or belt drive required. With the HVD system, output of fan or pump can easily be altered without changing speed of the motor thus eliminating the need to change fan or pump output conditions by opening or closing a damper. Virtually eliminates the need for inlet and outlet dampers or valves used to control fan or pump output. Cost effective and efficient alternative to other variable speed drives. HVD systems are a fraction of the cost of VFD systems of equal size improved efficiency over wide range of operation. Total efficiency in converting electrical power to shaft power is greater with a HVD than with a fluid coupling and comparable efficiency to a VFD. Power factor not adversely affected. Cost savings are multiplied when multiple fans or pumps are implemented on same system. HVD is inherently able to be a torque & speed multiplier or reducer, eliminating the need for belt or gear drives in most cases. This reduces the number of parts to be purchased and maintained, further reducing cost. The elimination of need for a belt or gear drive also eliminates the inefficiency that comes with these products. This can generate 5% and greater improvements in efficiency. Rugged construction and high dependability. The HVD system consists of industrial hydraulic components designed for years of trouble-free continuous use. No fragile electronics or computer hardware. Unlike many other variable speed drive systems, in the rare occurrence of a failure, HVD system components rarely fail spontaneously. Any problems that may arise typically provide advance symptoms, thus allowing the plant to be prepared and in turn reducing down time if a failure does occur. Impervious to power surge. Tolerant to harsh operating conditions as compared to specific environment requirements of VFD (i.e. temperature, humidity, particulate, etc.). Electric motor maintains virtually constant speed regardless of operating condition of fan or pump system. This allows motor to operate at most efficient operating speed regardless of operating condition of fan or pump system. Energy is not consumed to accelerate inertia of motor and pulleys when full load is restored. 4

6 PRODUCT ADVANTAGES OVERVIEW Perfect for start/stop applications and widely varying loads; less harsh on electric motor and other components. B E N E F I T S VERSUS VFD Start-up load eliminated. Prime mover torque output multiplied as equipment brought to operating speed, increasing component life. Longer prime mover life as it maintains constant, most efficient operating speed regardless of equipment operating condition. Maintenance may be performed by on-site staff; reduced down times. Motor starting torque requirement due to equipment is ELIMINATED as electric motor is at operating speed prior to equipment (e.g. fan, pump, rotating machinery, etc.) being started. The only start up torque requirement is that required to get the motor alone up to speed. Machinery is gradually brought up to speed, with minimal motor load. The HVD system is excellent for start/stop operations as the electric motor is never required to start or accelerate with any applied external load on it. The HVD system allows the electric motor to operate at a constant speed and brings the equipment (e.g. fan, pump, rotating machinery, etc.) up to speed as desired. This allows an ideal starting condition, far superior to the "smooth" or "soft" start-ups advertised by fluid coupling and VFD suppliers. When the system is restored from a stopped or reduced condition, the HVD effectively multiplies the torque output of the electric motor to reduce the load on the electric motor. Additionally, as mentioned above, the electric motor operates at a constant speed, regardless of device operating condition. This severely reduces load and shock loading on all components and tremendously reduces power consumption during start up as well as significantly reducing start up time for large inertia equipment. Less expensive replacement parts. Single system has ability to run multiple pieces of equipment independently. VERSUS FLUID COUPLING Start-up load eliminated. Prime mover torque output multiplied as equipment brought to operating speed, increasing component life. Longer prime mover life as it maintains constant, most efficient operating speed regardless of equipment operating condition. Single system has ability to run multiple pieces of equipment independently. Cost effective maintenance and repair as well as reduced down time. The HVD system can easily be serviced by a general hydraulic technician if the need arises. There is no need to have the HVD supplier send a technician as most service can be done by plant maintenance crew although EDS is available for any technical assistance needed. Reduced cost of components allows the purchase of back-up components to be much more financially feasible thus further reducing down time in case of an issue. Run multiple fans or pumps with one system and one electric motor. With the HVD system, the option exists to operate multiple fans or pumps with a single electric motor while maintaining independent control of each fan or pump. In this scenario, cost savings are multiplied as compared to purchasing multiple VFDs and multiple electric motors for multiple fans or pumps. Cost savings may further be increased due to reduction in required components. Instead of an electric motor for each fan or pump, a single electric motor may be used to run many fans or pumps. Eliminating the need for multiple motors/vfds, etc. Space consumption is dramatically reduced as compared to purchasing a drive system and electric motor for each fan or pump. Much more economical to setup redundant/backup system. 5

7 PRODUCT ADVANTAGES OVERVIEW Flexible configurations/broad application. B E N E F I T S VERSUS VFD Much smaller packaging. Better logistical packaging as orientation or location is not critical. May be used on any prime mover regardless of specific characteristics such as voltage, frequency or age. With the HVD system, there is no required orientation of the electric motor with respect to the fan or pump such as required with belt drive, direct drive and other mechanical drive systems. This allows more effective packaging of components and increased plant real estate. Electric motor and most of the HVD system may be placed in a remote location away from the fan or pump to further save space. HVD can be used on any prime mover, regardless of type, energy source, age, voltage, frequency or configuration. An HVD system may also be configured to provide lubricating oil to sleeve or other types of bearings, saving the need for an alternative pump, reservoir and related equipment. Easily formatted for computer or electronic control. VERSUS FLUID COUPLING Better logistical packaging as orientation or location is not critical. Electronic control of operation possible. For minimal cost, a basic manually controlled HVD system may be converted to allow computer or electronic control of the speed of the fan or pump. Requires any electronic system that can supply an analog voltage or current signal for control of HVD system. Easily configured for feedback type systems. HVD may be configured with a speed sensor to relay operation speed back to a control system. 6

8 Annual Energy Cost Savings (%) INDICATORS OF NEED FOR HVD You may be a viable candidate for cost savings by use of a HVD if you experience any of the following on your fans, pumps, or rotating machinery: C O S T S A V I N G S FAN OPERATIONS For constant fan efficiency and damper position, a reduction in fan speed of 10% results in 27.1% reduction in energy consumption. Reduction of 50% operating speed of 1,000 hp fan for 8760 hours of annual operation would result in an annual savings of approximately $285K based on $ER of $0.05/kWh. The figure below, right illustrates potential savings for various fan sizes versus percent reduction in fan speed. This assumes 8760 hours of annual operation and $ER or $0.05/kWh. These savings can be realized by implementation of an HVD. Damper, control valve, or similar device is often times less than 80% open. o Equipment speed should be reduced by use of HVD. Spill or bypass control is used. o Equipment speed should be reduced by use of HVD. Systems that serve variable loads and speeds. o Equipment speed should be controlled by use of HVD. Systems with common maintenance problems. o Flow may be excessive, equipment speed should be reduced. Systems in which upgrades are planned. o Perfect opportunity to consider use of HVD. Systems that have large fans, pumps or other rotating machinery. o Large pieces of equipment are prime candidates for energy optimization by use of HVD. Use of device in which speed may be altered for optimal operation. o HVD is great alternative to VFD and other devices to efficiently and costeffectively control operation of equipment. HVD SAVINGS EDS GUARANTEES payback periods. Actual payback periods with HVD are commonly 24 months or less. Additional savings are incurred from reduced maintenance and repair costs. If your equipment meets any of the listed conditions, contact EDS today to setup your FREE consultation and assessment of how a HVD can start saving you money. $1,800,000 $1,600,000 $1,400,000 $1,200,000 $1,000,000 $800,000 $600,000 $400,000 $200, hp 1000 hp 2500 hp 5000 hp $0 0% 10% 20% 30% 40% 50% 60% 70% 80% Reduction in Fan Speed (%) 7

9 Advertised Total Drive Efficiency (%) TECHNICAL DATA EFFECIENCY AT NORMAL OPERATING CONDITIONS E F F I C I E N C Y GENERAL FACTS AND INFO VFD manufacturers commonly show a Total Drive System Efficiency which can be misleading as this is not the efficiency in which the electrical input power is converted to mechanical work to the equipment. This Total Drive System Efficiency is actually the efficiency in which electrical input power to the VFD is converted to electrical input power to the electrical motor. True Total Drive System Efficiency is how efficiently electrical power is converted to mechanical work to the equipment. We call this efficiency Wire to Shaft Efficiency. Total drive system efficiency is commonly misunderstood by many purchasers of variable drives. Many manufacturers of variable drive systems, such as VFDs, illustrate this data and show a Total Drive System Efficiency which is simply the efficiency in which input electrical power is converted to electrical motor input electrical power. This Total Drive System Efficiency neglects the motor efficiency which is adversely affected by systems such as VFDs. The total drive system efficiency that is useful to the consumer is the efficiency in which electrical energy at the power source is converted to input power at the equipment input shaft. Therefore we will consider the total efficiency in which input electrical power is converted to shaft power input to the equipment. Engineering Driven Solutions recognizes this term as Wire to Shaft Efficiency. Wire to Shaft Efficiency for a VFD includes efficiency of the drive, the transformer, the electric motor and the mechanical connections. For this analysis, we will assume a direct connection and therefore have a mechanical connection efficiency of 100%. For VFD, the Wire to Shaft Efficiency is equal to the product of the aforementioned efficiencies (drive, transformer and motor). A major VFD manufacturer has published their average Total Drive System Efficiency which is the sum of the drive efficiency and the transformer efficiency. These values are illustrated below. 97.3% 97.2% This Wire to Shaft Efficiency is the true efficiency representation that correlates to power consumption and allows you to determine true efficiency of the drive system. This Wire to Shaft Efficiency is the true indicator of how much energy you need to purchase to get the required shaft power to the equipment. This is what is truly important to you, the consumer. 97.1% 97.0% 96.9% 96.8% 96.7% 96.6% 96.5% Average Low High 96.4% 50% 60% 70% 80% 90% 100% Fan Speed (%) 8

10 Motor Efficiency (%) TECHNICAL DATA EFFECIENCY AT NORMAL OPERATING CONDITIONS E F F I C I E N C Y TOTAL VFD EFFECT ON MOTOR EFFICIENCY VFDs have adverse effects on motor efficiency. Varying voltages and frequencies from nominal values results in decreasing motor efficiencies. These decreases in motor efficiency are significant. These decreases in motor efficiency result in increased power consumption. VFD WIRE TO SHAFT EFFICIENCY As shown in the bottom figure, VFD Wire to Shaft Efficiency is significantly less than the published Total Drive System Efficiency. This efficiency is the true efficiency that describes how effectively a VFD system converts electrical power into shaft power. Neglecting these decreases in motor efficiency and considering Total Drive System Efficiency instead of Wire to Shaft Efficiency can result in conclusions based on misleading data. The altered electrical power from a VFD into the electric motor adversely affects the motor efficiency. Engineering Driven Solutions has performed testing to measure the performance of a fan system utilizing a VFD, damper control and a HVD. Mechanical power produced by the electric motor was measured as well as electrical power input. From this, electric motor efficiency was calculated. The figure below illustrates the calculated motor efficiency for a fan driving motor utilizing a VFD, damper control and the HVD. 100% 95% 90% 85% 80% 75% 70% VFD 65% Damper HVD 60% 30% 40% 50% 60% 70% 80% 90% 100% Air Flow Rate (% of Free Flow) It can easily be seen from the figure that the VFD has a negative impact on electric motor efficiency as frequency and load decrease. The HVD as well as damper control showed greater motor efficiencies than that of the VFD. 9

11 Wire to Shaft Efficiency (%) TECHNICAL DATA EFFECIENCY AT NORMAL OPERATING CONDITIONS E F F I C I E N C Y COMPARISON TO VFD From the power input and the required fan power, Wire to Shaft Efficiency was calculated. The figure below illustrates these efficiencies for the VFD and the HVD. As can easily be deduced from the figures, the motor efficiency for a HVD system is significantly 100% greater than that for a VFD system. However, it can also be see that the HVD system efficiency is less 95% 90% HVD VFD than that of the VFD. 85% Therefore, if the misleading data presented by VFD manufacturers 80% is considered, one could easily be confused into thinking that the 75% VFD is significantly more efficient than the HVD. 70% 65% 60% 55% 50% 30% 40% 50% 60% 70% 80% 90% 100% Fan Flow (% of Free Flow) The figure above shows that Wire to Shaft Efficiency is comparable for the HVD and VFD. As a matter of fact, at lesser fan speeds, the HVD efficiency is actually greater than that of a VFD. This efficiency for the VFD is much less than the advertised Total Drive System Efficiency provided by the manufacturers. This is why VFD manufacturers publish Total Drive System Efficiency but do not consider motor efficiency effects. When motor efficiency effects are considered (as in reality), the VFD is much LESS efficient than advertised and comparable efficiency to the HVD. ww.engineeringdrivensolutions.com info@engineeringdrivenslutions.com 10

12 Power Consumption (kw) TECHNICAL DATA EFFECIENCY AT NORMAL OPERATING CONDITIONS E F F I C I E N C Y HVD WIRE TO SHAFT EFFICIENCY The figures show that the resulting HVD Wire to Shaft Efficiency is comparable to that of the VFD. In general, the HVD system is approximately the same efficiency as the VFD when talking about effectiveness of converting electrical power to shaft work. Despite approximately 5%-10 greater drive efficiency for the VFD as compared to the HVD at 50% fan speed, the total conversion of electrical power to shaft work is more efficient with a HVD than VFD as shown in the figures. Total Wire to Shaft Efficiency for the HVD is approximately 5% greater than that of the VFD at 50% fan speed. The figure below illustrates the most important figure to the end user: total power consumption HVD VFD Damper 0 30% 40% 50% 60% 70% 80% 90% 100% Fan Air Flow (% of Free Flow) Total power consumption for the fan system utilizing a VFD, damper control and the HVD are shows above. This side-by-side comparison illustrates a couple important things. First, it confirms the well-known fact that a variable speed drive can offer substantial energy reduction benefits when compared to a damper or valve control for fans and pumps when the output is desired to be much less than 100%. Second, the figure illustrates that the power consumption of the HVD and the VFD are very similar throughout the range of operation with exception of free flow. When considering the considerable price difference between the HVD and the VFD, coupled with the other listed advantages of the HVD such as maintenance and such, it is easy to see why the HVD is a viable alternative to a VFD for your variable speed application. 11

13 Load of Electric Motor During Startup (%) TECHNICAL DATA STARTING OPERATIONS P R O C E S S S T A R T - UP GENERAL FACTS AND INFO During process start-up, the electric motor experiences the highest load it ever experiences, sometime experiencing current 3-4 times that of its full load amps. The start-up is often time the most strenuous time on components and the electric motor. An HVD system is the ideal device for use in operations with starting and stopping. The electric motor operates at a constant speed regardless of equipment operating conditions. During electric motor start-up, there is no external applied load on the motor. This results in the most optimal soft or smooth start imaginable. The figure below illustrates the load experienced by the electric motor during operation start-up. Keep in mind that the motor is operating at full speed prior to beginning to resume operations. The loads are based upon centrifugal relations. 100% 80% This start-up procedure can significantly contribute to the reduction in component life. In normal configurations, the electric motor is loaded during this start-up operation, further increasing the harshness of the operation. By use of an HVD, the start-up procedure can be reduced to simply turning on an unloaded electric motor. Furthermore, with the HVD, the load can be gradually applied to the electric motor in virtually infinitely small portions. Additionally, due to the inherent properties of the HVD, torque is multiplied (and thus load reduced) for all equipment speeds less than that of the electric motor. 60% 40% 20% 0% 0% 20% 40% 60% 80% 100% Percent of Start-Up TIme (%) Despite claims made by fluid coupling and VFD manufacturers that their product produces the softest start on the market, the HVD owns that distinction. While a fluid coupling reduces the external load on the electric motor during start-up, the HVD ELIMINATES it. Although VFDs limit the inrush of current to the electric motor during start-up, the motor is still experiencing an applied external load during start-up, maintaining stress and strain on the components. In the end, if soft starts are what you are looking for, then a HVD from Engineering Driven Solutions is what you need. 12

14 DEPENDABILITY & MAINTENANCE H V D EXCEPTIONAL DEPENDABILITY The HVD is designed for rugged working conditions. On-site crew may perform maintenance and repair. HVD components, in the rare case of failure after years of operation, typically show advance symptoms prior to failure, allowing preparation by the user. Impervious to power surge/failures. EDS offers comprehensive warranties for peace-of-min purchasing. EDS offers maintenance and repair including periodic inspection and preventative maintenance and technical support. When fluid is kept clean and filtered, and the fluid temperature is maintained at an acceptable level, extremely long life is expected; this system is virtually trouble and maintenance free. All of these factors result in REDUCED DOWN TIME. The HVD system consists of industrial hydraulic components designed for years of trouble-free continuous use. These industrial hydraulic components are typically used in operating conditions when 50,000+ hours of operation are required. The components of a HVD are intended for industrial, harsh environments. The components of the HVD are tolerant of harsh operating conditions as compared to specific environment requirements of VFD (i.e. temperature, humidity, particulate, etc.). Additionally, the HVD is completely impervious to power surge or failure. When fluid is kept clean and filtered, and the fluid temperature is maintained at an acceptable level, extremely long life is expected; this system is virtually trouble and maintenance free. EDS offers comprehensive warranties for peace-of-mind purchasing. The HVD does not include fragile electronics or computer hardware that may be susceptible to failure in industrial settings or difficult to work on or repair if the need arises. The HVD utilizes common industrial hydraulic components. By utilizing these components, the on-site maintenance crews of most industrial plants feel comfortable working on, maintaining, and repairing the HVD. This is very much unlike a VFD in which calling a tech from the manufacturer is virtually absolutely necessary. The ability to have on-site technicians with the ability to maintain the HVD ultimately saves you time, down time, and in the end, cost. Additionally, unlike many other variable speed drive systems, in the rare occurrence of a failure, HVD system components rarely fail spontaneously. Any problems that may arise typically provide advance symptoms, thus allowing the plant to be prepared and in turn reducing down time if a failure does occur. Additionally, replacement components for a HVD are typically available at a fraction of the cost of the components for a VFD, thus reducing cost once again. EDS also offers a maintenance and repair service. Periodic Inspections Preventative Maintenance System Repair Component Replacement Technical Assistance 13

15 SYSTEM FLEXIBILITY H V D FLEXIBLE CONFIGURATIONS Any orientation of electric motor and equipment. Effective packaging. Operate multiple pieces of equipment with a single HVD system. Affordable/simple implementation of backup/redundant systems for reduced down time. HVD may be configured with manual or electronic control. This electronic control may be setup with a feedback from a sensor resulting in the option for complete automated control of the equipment. All of these options result in the ability to produce the system that exactly meets your needs. The HVD system allows flexible configurations. With the HVD system, there is no required orientation of the electric motor with respect to the fan or pump such as required with belt drive, direct drive and other mechanical drive systems. This allows more effective packaging of components and increased plant real estate. The electric motor and most of the HVD system may be placed in a remote location away from the fan or pump to further save space if this is determined to be advantageous. With the HVD system, the option exists to operate multiple fans or pumps with a single electric motor while maintaining independent control of each fan or pump. In this scenario, cost savings are multiplied as compared to purchasing multiple VFDs and multiple electric motors for multiple fans or pumps. This option is extremely advantageous for multiple fans or pumps in close approximation such as clinker cooler fans in a cement plant. In this scenario, a single electric motor and HVD system can operate and control all of the fans independent from each other. By use of the HVD system with multiple pieces of equipment on a single system, cost savings are further increased due to reduction in required components. Instead of an electric motor for each fan or pump, a single electric motor may be used to run many fans or pumps. Space consumption is dramatically reduced as compared to purchasing a drive system and electric motor for each fan or pump. Fans and pumps can be run on the same HVD system together with a single electric motor while maintaining independent control of each resulting in much more economical opportunity to setup redundant/backup system. At little cost, a basic manually controlled HVD system may be converted to allow computer or electronic control of the speed of the fan or pump. This control may be based upon feedback from a sensor or operator input. A feedback system only requires an electronic system that can supply an analog voltage or current signal for control of HVD system. 14

16 MEETING YOUR NEEDS Engineering Driven Solutions (EDS) includes a qualified team of engineers and field technicians capable of tackling any task you may require. This includes installation of new products from EDS and others, as well as maintenance of these items. No project is too large or too small for the EDS team of engineers and/or technicians. EDS also includes a full in-house engineering staff as well as in-house fabrication and manufacturing facility. Rest assured EDS can meet any Product Design, Manufacturing, Installation and Maintenance needs that you may have. EDS can meet your HVD needs from start to finish. EDS can perform all services from to initial free consultation and assessment to determine need of HVD, all the way through the completion of installation, and to routine maintenance and repair. EDS has the expertise to meet any requirement that you might have. EDS's area of expertise includes a wide range of areas in the field of manufacturing, installation and maintenance. This allows EDS to see a product or idea from conception to reality. EDS specializes in the following areas: Design Component selection Component layout Component design, Fixture/bracket design Failure analysis (yield and fatigue) Vibration analysis Thermal analysis Generate drawings Component foundation design Manufacturing General fabrication Welding Installation Machining (including CNC operations) Part assembly Installation of new industrial components (motors, fans, pumps, etc.) Designing and fabricating all required brackets and fixtures Relocating and retrofitting of existing devices Maintenance Preventative maintenance Component repair General product service 15

17 OTHER SERVICES & CONTACT US Industrial Energy Consulting and Assessment A R E A S O F I M P R O V E M E N T FAN AND PUMP SYSTEMS Non-optimized fan/pump type. Excess fan/pump speed. Control losses (dampers/valves, spill or bypass control). System effects (improper outlet connection, improper inlet connections, excess swirl in inlet stream). PROCESS HEATING SYSTEMS Combustion control (improper quantity of air). Heat transfer for melters, furnaces and ovens. Wall losses and air infiltration. Flue heat losses Control system (sensors and control strategy) Furnace scheduling - operations COMPRESSED AIR SYSTEMS EDS, also offers industrial energy consulting and assessment (energy audit) to help you reduce operation costs, with or without a product from EDS. Typical energy consulting areas involve large plant equipment. Common equipment analyzed is fan systems, pump systems, process heating systems (boilers, furnaces, melters, ovens, kilns, etc.) compressed air systems, and other areas. * Members of the EDS team are prepared to travel to your plant for an inspection and There are many ways in which efficiency may be measurement of operation. From this improved in industrial plants. EDS can highlight inspection and measurement, the EDS will be able to perform calculations, prepare those areas and illustrate the amount of savings that reports and advise the client concerning may be generated by correction of these efficiency available methods to reduce operation losses. Members of EDS are well qualified, including costs and improve efficiency, ultimately increasing profits. Contact EDS so your energy consulting certifications from the United savings can begin today! States Department of Energy. About Us C O N T A C T US Engineering Driven Solutions (EDS) was ROBERT T. TOLBERT, P.E. formed by highly motivated, experience and Project/Design Engineer educated engineers. These Mechanical Engineers Office: each have a passion for producing cutting-edge Cell: technology that not only works on paper but also in Robby@EngineeringDrivenSolutions.com the field. Improper compressor type When you choose EDS, you choose a qualified JOSHUA A. TOLBERT Leaks Compressor scheduling - operations Waste heat recovery company whose members are both highly educated and widely experienced. With decades of education as well as nearly half a century experience in the field, the members of EDS have both the knowledge and the means to meet any requirements that you Assessment/Design Engineer Cell: Josh@EngineeringDrivenSolutions.com BENJAMIN J. TOLBERT may have. Feel free to contact EDS with any questions/comments you may have. Manufacturing/Installation/Maintenance Engineer Cell: The information provided in this brochure contains general descriptions and/or characteristics of performance which in actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of the contract. All product designations may be trademarks or product names of Engineering Driven Solutions, LLC or supplier companies whose use by third parties for their own purposes could violate the rights of the owners. Ben@EngineeringDrivenSolutions.com 16