It s What s Inside that Counts

It s What s Inside that Counts

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

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

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

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

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

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

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

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

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

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.

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

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

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

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% 0 10 20 30 40 50 60 Frequency (Hz)

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

Applications, Fans and Blowers Outlet Control - Operating Points 140 120 Throttled System Curves Operating Points 100 % Pressure 80 60 Fan Curve 40 Design System Curve 20 ABB Inc. - slide 17 0 20 40 60 80 100 120 140 160 % Flow

Applications, Fans and Blowers Outlet Control - Power Requirement 100 80 % Input Power 60 40 Relatively small decrease in power requirement for large decrease in flow 20 ABB Inc. - slide 18 0 20 40 60 80 100 120 % Flow

Applications, Fans and Blowers 140 Variable Speed - Operating Points 120 100 Design System Curve Operating Points % Pressure 80 60 Rated Speed Fan Curve 40 20 Reduced Speed Fan Curves ABB Inc. - slide 19 0 20 40 60 80 100 120 140 160 % Flow

Applications, Fans and Blowers Variable Speed - Power Requirement 100 80 % Input Power 60 40 Large decrease in power requirement for relatively small decrease in flow 20 ABB Inc. - slide 20 0 20 40 60 80 100 120 % Flow

Applications, Fans and Blowers Power Requirement Comparisons 100 % Input Power 80 60 40 Outlet Inlet Vane Variable Speed 20 0 ABB Inc. - slide 21 20 40 60 80 100 120 % Flow

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

Applications, Economic Justification Base Assumptions : Full rated flow = 178,000 CFM @ 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

Applications, Economic Justification 800 Fan Energy Usage Variable Speed vs. Damper Control 700 600 Energy Usage (MWh) 500 400 300 Variable Speed Damper 200 100 ABB Inc. - slide 24 0 30% 40% 50% 60% 70% 80% 90% 100% Flow

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

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

It s What s Inside that Counts