It s What s Inside that Counts

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1 It s What s Inside that Counts

2 Drive Basics Adjustable Frequency Drive Description: Solid State Device Controls the Frequency and Voltage Speed Range Depends on the Motor HP Range - Fractional to 10,000 ABB Inc. - slide 2

3 Drive Basics Why Use Adjustable Speed Drives? Soft Start Capability Allows for Process Changes Improves Product Quality ABB Inc. - slide 3

4 Drive Basics Adjustable Frequency Drive Definition (AFD): An Adjustable Frequency Drive controls an AC motor. It converts the incoming line constant voltage and frequency to an adjustable voltage and frequency. The adjustable voltage and frequency is applied to a squirrel cage induction motor. ABB Inc. - slide 4

5 Drive Basics AFD Capabilities: Controllable Acceleration Controllable Deceleration Controllable Speed Torque Limiting Inrush Current Limiting ABB Inc. - slide 5

6 Drive Basics AFD Capabilities (Continued) Controlled Jog / Thread Electronic Overload Programmable Settings Output Contacts and Signals Multiple Control Methods ABB Inc. - slide 6

7 Drive Basics How Do Induction Motors Work With Drives? Control of Speed and Torque Control of Frequency and Voltage ABB Inc. - slide 7

8 Drive Basics Advantages: Uses Squirrel Cage Motor High Input Power Factor Low Operating Cost Soft Start and Stop Easy to Retrofit ABB Inc. - slide 8

9 Drive Basics Advantages (continued): Multiple Motor Capability Electronic Reversing Master Reference Capability Closed Loop Capability Bypass Capability ABB Inc. - slide 9

10 Drive Basics Why Use Adjustable Speed Drives? Reduced Energy Consumption Improved Process Control / Efficiency Increased Product Quality Expanded Automation / Integration Broader Equipment Flexibility / Versatility Increased Reliability / Availability Reduced Maintenance $ ABB Inc. - slide 10

11 Drive Basics Typical Adjustable Speed Drive Configuration Variable Power (AC or DC) Variable Speed Process Output Utility Power Adjustable Speed Drive Motor(s) Process Equipment Appropriate Feedbacks Process Reference ABB Inc. - slide 11 Variable speed is used to replace inefficient mechanical regulator devices such as valves, dampers, clutches, etc.

12 VS Drives Process Advantages ABB Inc. - slide 12 Speed vs. mechanical control Increased process efficiency, Reduced energy usage, Lower operating costs Accurate speed regulation Increased flow / volume accuracy, Product quality improvement Dynamic Speed Response Minimized process disturbances, Product quality improvement Higher input power factor Lower operating costs

13 Applications, Types Constant Torque Constant Horsepower Variable Torque Primary Focus ABB Inc. - slide 13

14 Applications, Types Variable Torque Loads Fans Centrifugal Pumps Centrifugal Blowers Mixers (material dependent) ABB Inc. - slide 14

15 Applications, Types 100% 90% 80% Variable Torque Flow varies linearly with speed % Flow, % Torque, % Power 70% 60% 50% 40% 30% 20% 10% Torque requirement varies as the square of speed Power requirement varies as the cube of speed ABB Inc. - slide 15 0% Frequency (Hz)

16 Applications, Types Conventional Flow Control Bypass Outlet Inlet Inlet Vane ABB Inc. - slide 16

17 Applications, Fans and Blowers Outlet Control - Operating Points Throttled System Curves Operating Points 100 % Pressure Fan Curve 40 Design System Curve 20 ABB Inc. - slide % Flow

18 Applications, Fans and Blowers Outlet Control - Power Requirement % Input Power Relatively small decrease in power requirement for large decrease in flow 20 ABB Inc. - slide % Flow

19 Applications, Fans and Blowers 140 Variable Speed - Operating Points Design System Curve Operating Points % Pressure Rated Speed Fan Curve Reduced Speed Fan Curves ABB Inc. - slide % Flow

20 Applications, Fans and Blowers Variable Speed - Power Requirement % Input Power Large decrease in power requirement for relatively small decrease in flow 20 ABB Inc. - slide % Flow

21 Applications, Fans and Blowers Power Requirement Comparisons 100 % Input Power Outlet Inlet Vane Variable Speed 20 0 ABB Inc. - slide % Flow

22 Applications, Economic Justification Representative Sample: Fan, Variable Speed vs. Damper Control Three Criteria: Energy Usage Efficiency Improvement Annual Savings ABB Inc. - slide 22

23 Applications, Economic Justification Base Assumptions : Full rated flow = 178,000 3 H 2 O Fan / blower efficiency = 85% Motor efficiency = 94% Drive efficiency = 98% Rated shaft power = 100 hp Cost per kwh = $ 0.10 ABB Inc. - slide 23

24 Applications, Economic Justification 800 Fan Energy Usage Variable Speed vs. Damper Control Energy Usage (MWh) Variable Speed Damper ABB Inc. - slide % 40% 50% 60% 70% 80% 90% 100% Flow

25 Applications, Economic Justification 70% Fan Efficiency Improvement Variable Speed vs. Damper Control 60% 50% Efficiency Improvement 40% 30% 20% 10% ABB Inc. - slide 25 0% (10%) 30% 40% 50% 60% 70% 80% 90% 100% Flow

26 Applications, Economic Justification $35,000 Fan Annual Savings Variable Speed vs. Damper Control $30,000 $25,000 $20,000 Savings $15,000 $10,000 $5,000 ABB Inc. - slide 26 $0 ($5,000) 30% 40% 50% 60% 70% 80% 90% 100% Flow

27 It s What s Inside that Counts

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