“Application of VFD in Power Plants”

Made By: Azeem Sajid

Electrical Engineer |HSE | Controls & Automation
linkedin.com/in/azeemsajid53

 [email protected]
Why to Use VFD

 Energy savings on most pump and fan applications.

 Better process control and regulation.
 Speeding up or slowing down a machine or process.
 Inherent power-factor correction
 Protection from high in-rush currents
 Safe Acceleration and braking
Electric & Power Basics

All VFD’s must:

 Run a machine or process at a desired speed.
 Produce adequate torque to handle the load.
 Use power efficiently to produce the necessary torque at a given speed.
Electric & Power Basics

 The typical waveform consists of the frequency portion (time based) of the
wave and the amplitude portion (the magnitude). This wave is actually in
sine-wave form, commonly referred to as the fundamental.
 Electric & Power Basics

Sinusoidal Waveform With Frequency & Amplitude Components

AC-Induction-Motor Theory
AC Induction Motor Theory

AC Induction Motor – Squirrel Cage Design

 AC Induction Motor Theory

Three-phase induction motor

AC Induction Motor Theory

How a motor shaft rotates?

❖ Torque is produced as the induction motor generates flux in its rotating field.
❖ As shaft torque load increases, the slip increases and more flux lines cut the
rotor windings, which in turn increases rotor current, which increases the rotor
magnetic field and consequently the rotor torque.
AC Induction Motor Theory

Typical speed versus torque curve for a NEMA design B motor.

% Synchronous Speed
AC Induction Motor Issues

Starting Induction Motors

❖ The starting current is very high, between 3 to 8 times the full load current.
Depending on the size of the motor, this can result in voltage sags in the power
system.
❖ The full torque is applied instantly at starting and the mechanical shock can
eventually damage the drive system, particularly with materials handling
equipment, such as conveyors.
❖ In spite of the high starting current, for some applications the starting torque
may be relatively low, only 1.0 to 2.5 times full load torque.
AC Induction Motor Theory

The speed of the rotating electric field within the induction motor.

Synchronous Speed = 120 x frequency / No. of motor poles

AC Induction Motor Theory

AC motor speed change can be

accomplished in three ways:
 Change the number of poles in the motor; this means separate windings.
 Change the slip characteristics of the motor; this is done with varying
resistors, such as is done with a wound-rotor motor or by varying the stator
voltage; or
 Change the frequency of the power supplied to the motor. This can be
achieved by VFD .
VFD Basics

The main objective of the VFD is to vary the speed of the motor while
providing the closest approximation to a sine wave for current (while pulsing
DC voltage to the motor).
Components of VFD System

1.Operator Interface
2.Variable Frequency Controller
3.AC Motor
VFD Controller

The variable frequency drive controller is a solid-

state power electronics conversion system
consisting of three distinct sub-systems
1. A rectifier bridge converter
2. A direct current (DC) link
3. An inverter
Rectifier bridge converter

All VFD’s need a power section that converts AC power into DC power. ❖ This
is called the Rectifier bridge.
❖ The Rectifier is commonly a three-phase, full wave-diode bridge.
Direct current (DC) link

The DC link may consist of a capacitor/inductor which smoothens out the

converter's DC output ripple and provides a stiff input to the inverter. If not, this
distortion will show up in the output to the motor.
Inverter

❖ The inverter section is made up of modules that consist

of a transistor and diode in combination with each other
which inverts the DC energy back to AC.
❖ The power semi-conductors in the inverter section act
as switches, switches of the DC bus, and therefore, are
pulsing the motor with some voltage.
❖ By switching the inverter transistor devices on and off
many times per half cycle, a pseudo - sinusoidal current
waveform is approximated.
VFD Types

1. Voltage-source inverter (VSI) drive

The DC output of the diode-bridge
converter stores energy in the capacitor bus
to supply stiff voltage input to the inverter.
The vast majority of drives are VSI type with
PWM voltage output.
2. Current-source inverter (CSI) drive
The DC output of the SCR-bridge
converter stores energy in series-reactor
connection to supply stiff current input to
the inverter. CSI drives can be operated
with either PWM or six step waveform
output.
VFD Types Cont..

3. Six-step inverter drive

The DC output of the SCR-bridge converter is smoothed via capacitor bus and series-reactor
connection to supply via Darlington Pair or IGBT inverter quasi-sinusoidal, six-step voltage or current
input to an induction motor.
4. Load commutated inverter (LCI) drive
The DC output of the SCR-bridge converter stores energy via DC link inductor circuit to supply
stiff quasi-sinusoidal six-step current output of a second SCR-bridge's inverter and an overexcited
synchronous machine.
5. Cycloconverter or matrix converter (MC)
Cyclo converters and MCs are AC-AC converters that have no intermediate DC link for energy
storage.
6 Doubly fed slip recovery system
A doubly fed slip recovery system feeds rectified slip power to a smoothing reactor to supply
power to the AC supply network via an inverter, the speed of the motor being controlled by adjusting
the DC current.
Pulse Width Modulation

 Pulse-width modulation (PWM), or pulse-duration modulation (PDM), is a

commonly used technique for controlling power to electrical devices.

Pulse-width-modulated voltage and current waveforms.

VFD Motor Selection issues

 The switching of insulated-gate bipolar transistors (IGBTs) to accomplish

PWM on the output of a VFD creates voltage spikes on the line out to the
motor.
 These spikes are amplified over distance and, in time, break down the
insulation of a motor, shortening the motor’s life.
 For VFD applications, Class F or higher insulation should be selected when
possible.
VFD Motor Selection issues Cont..

 In constant power applications, for higher torque, the speed would be low.
 Reduced speed may affect the cooling of the motor windings for high
torque applications.
 When a VFD applies high-frequency pulses to a motor, the parasitic
capacitance between stator and rotor generates voltage on the motor
shaft. This creates discharge arcing and shaft current, which may damage
the shaft and bearing surfaces.
Sample PWM-Equivalent Circuit
Application in Power Plants
VFD APPLICATION TO CEP/ID fan (for
Energy Savings)

 Variable speed control is the most energy efficient control method

How VFD Saves
Energy ?
 There is a gap between
design point and the rated
operating point.

Design margins are to take

care of extreme operating
conditions.

CEP/ID Fan
VFD ensures energy savings by
reducing speed at the
operating point.

Margin to take care of

operation at 47.5Hz. is not
needed
VFD APPLICATION IN COMPRESSOR
VFD in Compressors

Instead of loading and

unloading in a cyclic manner, System saves energy as the
the compressor is start/stop as motor does not run in idle
per desired duty requirement mode.
to maintain the set pressure.

VFD in compressor allows

Lower maintenance of the
frequent start/stop of motor as
system due to smooth start.
per duty requirement.
Coal Conveyors

Idle running of
Coal conveyors are motor during stop
Only 2 starts/hour
subjected to by disengaging the
are permissible.
frequent start/stop. hydraulic coupling
causes energy loss.

Conveyors have to
VFD can provide
be designed to start Generally, motors
ideal solution for
while fully loaded, are run at part load.
Conveyors.
i.e. high torque.
REELING DRUM APPLICATION cont….

The present scheme

 Cables reeling drum provided with brake motor
 The brake motor stops and holds the drum, as and when the paddle-
feeder or stacker-reclaimer stops moving
 It protects the cable from slackness.
 The brake is released on restart and motor rotates the drum to
maintain safe tension in the cable.
 The motor with conical rotor with spring loaded brake and brake-shoe
arrangement are prone to high maintenance.
 Many times causes unreeling of cable resulting in snapping or damage
of it.
REELING DRUM APPLICATION

VFD Alternative Scheme

• The arrangement is an innovative solution of brake motor.
• The VFD maintains constant torque on the cable reeling
drum continuously even at zero speed (i.e. stop
condition).
• This constant torque maintains safe tension on the cable.
• Power consumption at zero speed is equal to no load and
part consumption during movements, as and when the
drum rotates
VFD APPLICATION IN BOILER AREA

Axial blade pitch

control and VFD • VFD control for PA fan, ID fan, Coal Feeder and
control give the Fuel Oil motors can be implemented for old
210MW units.
same level of • VFD control for ID fans, Coal Feeder and Fuel Oil
efficiency in motors can be implemented for old 500 MW units.
• New units should have VFD for coal feeder speed
power control as against eddy current clutch control.
consumption at • Sipat-I coal feeder motors already have VFD
part load controls
operations.
VFD APPLICATION TO BFP (for smooth start)
Advantages of Using VFD

Increased motor life due to

the lower thermal and
mechanical stressed in view No limitation on the number No contribution to fault
of the absence of starting of starts. current.
inrush currents and reduced
speed operation.

One more VFD can be kept One VFD can be used to

as standby start all the MDBFPs.
VFD APPLICATION TO BFP – 4 UNITS

VFD solution may be cheaper than the conventional one with other
advantages as bonus.
BFP for 660MW Units- OPTION-B

 The BFP motor rating for 660MW (2x50% TDBFP+1x50% MDBFP) unit is 18MW
and thus causes high electrical and mechanical stress on the system during
starting.
 Instead of 1x50%, it was proposed to use 2x30% rating BFP for 660 & 800 MW
units. However, with VFD it can be retained as 1x50%.
 The size of each VFD for 18MW motor shall be approximately 5MVA equal
to no load MVA rating.
Advantages of Using VFD with OPTION-C

Saving in Plant Cost due to Absence of Associated

BFPs can be placed at 0.0 M
lowering of De-aerator Steam and Condensate
El.
Elevation. piping.

This option is ruled out now

because new CERC
regulation permits only 2%
Flexibility of Layout and Absence of voltage dip
additional aux. power on
Space Saving. problems.
account of BFP, whereas BFP
power consumption will be
4% in supercritical unit.
 Siemens quote for VFD of 300kW Air Compressor
motor:
Rs. 4 million
 Siemens quote for VFD of 4000kW ID Fan
induction motor:
PRICE OF VFD
Rs. 45 million
 ABB quote for VFD of 4000kW ID Fan induction
for BFP Motors
motor:
cont.
Rs. 28.8 million
 Expected Price of VFD of 10MW rating along
with motor
Rs. 80 millions
VFD WITH REMOTE RF CONTROL FOR EOT CRANES
USE:
1. LIFTING / LOWERING LOADS
2. CARRYING LOADS ALONG /ACROSS THE RAILS
MOTORS :
1. MAIN HOIST/ CREEP MOTOR
2. AUXILIARY HOIST / CREEP MOTOR
3. CROSS TRAVEL / CREEP MOTOR
4. LONG TRAVEL / CREEP MOTOR

RANGE OF EOT CRANES IN NTPC:

( 7.5 T – 105 T
CONVENTIONAL
PRACTICE

 SLIP-RING INDUCTION MOTOR

EMPLOYING RESISTANCE CUT-IN/
CUT-OUT FOR SPEED CONTROL .
 CABIN /PENDENT CONTROL.
VFD SYSTEM

 Squirrel Cage Induction Motor in

place of Slip Ring Induction Motor.
 Speed Control by variable Voltage
Variable frequency drives.
 Radio Remote Frequency control
unit.
COMPONENTS &
WORKING PHILOSOPHY

 Variable Frequency Drives

 Radio frequency Remote
Controller
❖Transmitter unit
❖Encoder
❖Receiver
❖Decoder
❖Interface panel
❖Coupling system
❖Control gear
❖Battery
 VFD SYSTEM
SQ.CAGE INDUCTION MOTOR WITH VPI INSULATION AND
INSULATED NDE BEARING.
❖ CHOICE OF MOTION CONTROL FROM OPERATORS
CABIN OR REMOTE CONTROLLER.
SALIENT ❖ STARTING TORQUE UPTO 400% WITH STARTING
CURRENT LIMITED TO 150%.
FEATURES ❖ VFD CAPABLE OF WITHSTANDING UPTO 50° C.
❖ HARMONIC REDUCTION DEVICES.
❖ SPEED CONTROL WITH 6 PULSE DESIGN.
❖ PROTECTIONS: O/L , O/V , E/F , O/ S Ckt., I/P LOSS ,
LOAD LOSS, I/P TRANSIENT PROTECTION
 B) RADIO FREQUENCY REMOTE UNIT
❖ WIRELESS CONTROL WITH DOUBLE JOYSTIC MOVEMENT
TYPE STEPPED CONTROL WITH SPRING RETURN
❖ TRANSMITTER & RECEIVER HAVE A UNIQUE FREQUENCY &
SALIENT FEATURES ADDRESS CODE TO AVOID INTERFERENCE
CONTINUED………. ❖ CAN COMMUNICATE UPTO 100 m DISTANCE.
❖ CRANE OPERATION IS LOCKED IN CASE OF
COMMUNICATION FAILURE.
❖ CHOICE OF TANDEM/SLAVE/SINGLE OPERATION
TECHNICAL ADVANTAGES

 VFD SYSTEM
❖ No slip ring related maintenance.
❖ Creep motor not required.
❖ Gear box not required.
❖ Electrical braking before mechanical breaking-break life is more.
❖ Online fault display- hence less down time.
❖ Starting current is less than dol starting.
❖ Smooth starting and stopping offers jerk less operation – longer life due to less mechanical
fatigue.
❖ Wide speed range- step less speed control.
❖ 100% holding torque available at standstill.
❖ More energy efficient
TECHNICAL ADVANTAGES

RF CONTROL
❖ EASE IN HANDLING
❖ UNRESTRICTED OPERATOR MOBILITY
❖ NO ROUTINE MAINTENANCE REQUIRED
❖ WIRELESS OPERATION
COST ANALYSIS

A) VFD SYSTEM IN 105T

B) RF REMOTE
EOT CRANE IS COSTLIER
CONTROLLER COSTS
BY Rs 1,39,750 ie 0.7%
1.15 Lacs WHICH IS
OF COST OF ONE EOT
0.57% OF COST OF ONE
CRANE (Approx. 2
EOT CRANE.
crore).

BOTTOM LINE: The 1.27% extra cost is

•+ B) COMBINED TOGETHER insignificant, in lieu of
SUMS UP TO BE 1.27% benefits on energy
COSTLIER THAN THE PRESENT savings, reduction in
SYSTEM.
manpower and low
maintenance.
AIR CONDITIONING
 Higher space requirement for installation of equipment.
AC plant room is required.

Not suitable for frequent load variation.

Limitations Not efficient at part load operation.

of
Centralized Difficult to retrofit.

AC
Operators' intervention is required to control/ vary inside
conditions. Water Cooled systems although are very
efficient, require large quantity of make-up water.
Limitations of Localized AC system

❖ Envisaged normally for small buildings.

❖ Available upto 15 TR capacity as a single unit.
❖ No humidity control.
❖ No arrangement for fresh air supply.
❖ Distance of outdoor unit can not be more than 10M.
❖ Part load operation is not possible.
❖ Noise in operation
VRV (Variable Refrigerant Volume)

❖ Based on limitation of the above two systems a

need was felt for an intermediate of the above
two systems. VRV system has been developed
to overcome the limitations imposed by
centralized and localized systems.
❖ The Variable Refrigerant Volume (VRV) system is
also Known as Variable refrigerant Flow (VRF)
system.
Schematic diagram of VRV system
 VRV (Variable Refrigerant Volume)
System

Similar to split The refrigerant By the combination VRV conditions

type of air VRV comprises of no. of flow is varied with the inverter air for each
conditioning. indoor units which share by using compressor and the room
a common refrigerant inverter constant speed individually as
circuit, served from a controlled compressor, the per load
common outdoor unit variable speed comfortable room requirement.
comprises of multiple compressor to condition will be
compressors of varying respond to obtained by
capacity. changes in the changing the
cooling or compressor
heating operation condition.
requirement.
Layout of VRV system
VRV/VRF

VRV system can

work as VRV system can Operating cost Make up water is VRV system can Total Piping
centralised work as localized of the system is not required. operate at part length from
system. system. minimized by use load. outdoor to
of variable indoor unit can
refrigerant flow be as maximum
concept. as 150M.
VRV/VRF (Comparison with chillers)
Conclusion

For All old stations, VFD For Large size units, VFD in VFD can be useful for
VFD Can be used in CEP
can be installed in CEP BFP Motor offers a number conveyor motors,
for future projects for
based on techno- of advantages and can compressor and reeling
energy saving.
economics. be considered in future. drum motors.

Boiler Auxiliaries such as PA

fan , ID fan ,Coal Feeder
New units of all sizes should VFD is becoming popular
and Fuel Oil motors can
have VFD for coal feeder for VRV air-conditioning ,
be upgraded with VFD
speed control. Hoists, Lifts and EOT Cranes
control, for old 210 MW
and 500MW units.
THANK YOU