Energy Savings of Variable Frequency Drives in Pumping Applications

Agenda
I. VFD Basics II. How VFDs Save Energy in Pump Applications. III. Calculating Energy Savings IV. Application Considerations V. Q & A

I. VFD Basics - Common Names Adjustable Frequency Drives - AFD Variable Speed Drives - VSD AC Inverter AC Drives Drives Inverters

Brief Snapshot of How a Motor Works

Synchronous Speed = 120 * frequency # poles

= 120 * 60 Hz = 1800 rpm 4

Rotor has fixed magnetic fields. Stator receives current from the drive which creates a magnetic field. This rotating field moves the rotor. The frequency is how often the current flows through the stator. Controlling the frequency to the stator controls the motor speed.

Basic Drive Design

+ _ AC Line Input Diode Bridge Rectifier DC Bus Link IGBT Inverter AC Output

DC voltage leaving converter is pulsing DC

And is smoothed to pure DC after going thru the DC buss

Once entering the inverter the DC is converted back to a waveform that will have varying pulse widths

AC Line
A B C

+
DC Bus

Typical 6-Pulse converter design

_ DC Bus Link Transistor AC Inverter Output

In a 480V unit the dc buss voltage reading will be @ 650-680 peakV
(rms x 1.414) peak voltage or 480V x 1.414 is 678V

AC Line Input

Diode Bridge Converter

Pre-charge circuit limits the inrush of current while the capacitor is trying to charge

Pulse Width Modulation

Drives can have a switching frequency of @ 4000-16000 times per second (kilohertz) The higher the switching frequency the smoother the output waveform.

The transistors in the inverter are switching off and on many times per half-cycle. It applies positive pulses in one half-period and negative pulses in the next halfperiod.

Pulse Width Modulation

The switching pattern controls the width of the pulses out to the motor. The output frequency of the drive is controlled by this pulse.

Pulse Width Modulation

Here we are showing twice the frequency than that of the previous slide, therefore speeding up the motor

VFDs :
Provide precise speed control of an AC Motor Can generate full torque from the motor at very low speed Allow simple setpoint control throughout the speed range Protects the motor and wiring from overload currents Provides built in Power factor correction They are very efficient. Limits inrush current to providing soft-start, as well as, a soft stop Allows a simple connection to a communications network Provides ability for substantial energy savings on centrifigal pump & Fan applications.

How VFDs Save Energy in Centrifugal Pump Applications

Variable Frequency Drives can increase system energy efficiency by providing a means to reduce the motor speed of variable torque loads. The fact these centrifugal loads operate along the Laws of Affinity provide the opportunity for significant energy savings.

Affinity Laws of Centrifugal Loads

FLOW is proportional to motor speed. PRESSURE is proportional to the motor speed squared. POWER is proportional to the motor speed cubed.

Examples of Affinity Laws at Work

A motor running at 50% of full speed capacity has a motor torque of 25% of full speed. The electricity required to operate the motor at 50% of full speed is 12.5% of the amount of the electricity required if the motor was running at 100% full speed capacity. The electricity required to operate the motor at 80% of full speed is 55% of the amount of the electricity required if the motor was running at 100% full speed capacity. Thus, reducing the motor speed can significantly reduce the electrical energy consumption.

III. Calculating Energy Savings

Example: A 20 horsepower Centrifugal Pump operating 10 hours a day 260 days a year Energy cost is of $0.10 cents per kilowatt-hour. Cost of running full speed: 20 hp x 0.746 kW/hp x 2600 hours x $0.10/kWhr = $3879.20 per year

VFD Cost Savings Example

Assuming the Pump does not need to run at full speed all of the day, we will use an example of: Running full speed (100%) for 25% of the day 80% speed for 50% of the day 60% speed for the remaining 25% of the day Cost of running with an AC drive controlling the motor:
20 hp x (1)3 x 0.746 kW/hp x 650 hours x $0.10/kWhr = $969.80 per year 20 hp x (0.8)3 x 0.746 kW/hp x 1300 hours x $0.10/kWhr = $993.08 20 hp x (0.6)3 x 0.746 kW/hp x 650 hours x $0.10/kWhr = $209.48

Total = $2172.36 per year Annual savings: $3879.20 $2172.36 = $1706.84 per year

Payback for VFD Installations in VT Applications average 18 to 24 months

Tools Available
Energy Savings Calculators/Tools are readily available from most major VFD Manufacturers. Visit Square D Lean Power website offers such a tool. www.squaredleantools.com

Application Considerations
Selecting VFDs Load Type Environmental Considerations Control/Communication Motor Requirements Cable lengths/harmonic mitigation

Selecting VFDs
Size by Motor FLA and Base Speed whenever possible Typically picked from table based on Voltage, HP and Load Type Its also useful to know the motor base speed, service factor, enclosure type and insulation Class of the motor.

Load Types
Usually for high starting torque requirements. The torque loading is not a function of speed. As speed changes, load torque remains constant and horsepower changes linearly with speed.

Variable Torque Constant Torque Constant Horsepower Impact Load

Depends on speed, may require different torques. Requires very little torque at starting or low speeds

When over speeding the motor is required, grinders, etc.

The torque loading is intermittent and is not a function of speed, punch presses, etc. which uses a large flywheel to deliver the energy needed for the load.

Temperature
Environmental Issues Ambient Temperature Most drives are rated 0-40 degrees C Derating is generally required above 40 degrees C Heating is required below zero degrees C Usually available in Nema 1, 12, 3R & other enclosures.

Altitude
Environmental Issues Altitude Most drives are rated up to 3300 feet above sea level De-rating is required above 3300 due to thinner air 1% for every 300

Control Considerations
How will VFD receive start/stop command and speed reference. Todays Technology provides the ability for VFDs to communicate on numerous communication platforms. Examples include:Ethernet, Modbus, Modbus Plus, DeviceNet, Profibus, BacNet, and many others.

Specifying Motors
Standard Nema B motors with class F HPE insulation class or better with a 1.15 service factor are usually fine for most applications. Consider specifying NEMA MG1, Part 31 motors.
NEMA MG1-1993, Revision 1, Part 31, Section IV Performance Standards Applying to All Machines, Part 31 Definite Purpose Inverter-Fed Motors

This will give you 1600 Peak Input Voltage Rating, better insulation, bearing protection and separation of the input and output leads to the motor.

Other Considerations
Motor lead lengths Is output or DV/DT filter required. VFD Manufacture can provide guidelines. Most major VFD manufacturers provide built in DC chokes & or line reactors to provide means to reduce harmonics. Alternates such as 12 or 18 pulse drive configurations &/or active/passive harmonics filters are available. Square D Lean Tools web site has harmonics calculator configurable for each one line to model whether installation meets IEEE519 requirements.

Some estimates claim 68% of all energy is used in driving motors of which at least half run centrifugal pumps and fans. VFDs can run centrifugal pumps and fans more efficiently due to the Affinity Laws. The energy that can be saved is ENORMOUS! ENORMOUS Most applications pay for themselves in less than two years. VFDs provide precise speed and torque control of AC motors. They provide built in softstart control protecting mechanical equipment and providing the ability to control water hammering in pump systems. They are efficient and can be integrated in most communication networks or facility automation systems.

Determining if a given pump system can effectively operate at reduced speeds for a given period of time will provide the opportunity to analyze the cost/savings benefit of installing VFDs.

Questions & answers Thanks for your attention !!!!