A Review of Variable Speed Drive Technology:

How fluid drive, eddy current drive and wound rotor motors work to achieve true
variable speed control.

To achieve true variable speed control of a centrifugal pump, this article will look at
the following methods or technologies: fluid drive, eddy current drive, wound rotor
motor, adjustable voltage direct current (DC), adjustable frequency alternating current
(AC), magnetic drive and steam turbine.

Part 1 of this article will focus on fluid drive, eddy current drive and wound rotor
motor. Part 2, which will be published in an upcoming issue, will focus on electronic
speed control drives, adjustable frequency drives, magnetic drives and steam turbine
drives.

Fluid Drive:

Variable speed fluid drives, known as hydro-kinetic, are typically used in high
horsepower (hp) applications. However, this type of fluid drive can be made from a
few horsepower to over 40,000 hp. For horsepower ratings under this level, other
methods of speed control are generally used. It should be noted the terms fluid
coupling and hydraulic coupling are sometimes used interchangeably with fluid drive.

In most applications, a variable speed fluid drive is driven by a constant speed motor
of either induction or synchronous type and delivers variable speed power to a process
pump. The fluid drive output shaft speed (pump speed) is controllable in step-less
speed changes in a range, typically, from 20 to 97.5 percent of the input shaft speed.
The output shaft speed is extremely smooth, eliminating torsional excitation
pulsations. Fluid drive technology is still popular for boiler feed and fan applications
such as forced and induced draft.

It should be noted that every type of variable speed drive can be used with a constant
ratio gearbox to achieve the actual speed range desired by the pump application.
However, the only type of variable speed drive that includes a gearbox within the
drive is the type called “variable speed geared fluid drive.”
Image 1. Fixed speed motor and eddy current clutch.

Eddy Current Drive or Coupling:

An eddy current drive, also known as electo-mechanical drive, consists of a fixed

speed motor and an eddy current clutch. The clutch contains a fixed speed rotor and
an adjustable speed rotor separated by a small air gap. A DC in a field coil produces a
magnetic field that determines the torque transmitted from the input to the output
rotor. The controller provides closed-loop speed regulation by varying the clutch
current, allowing the clutch to transmit enough torque to operate at the desired speed.
Speed feedback is provided by an integral AC tachometer.

By regulating voltage to the clutch coil, a magnetic flux field is generated in the gap
and distortion of the flux field creates torque. Output speed is governed by the digital
control. The greater the power is to the clutch coil, the greater the strength of the
magnetic flux field, and the greater the output torque or speed.

The tachometer’s feedback signal is compared to a reference signal within the

controller to maintain accurate speed within 0.5 percent. This closed-loop speed
system typically uses less than 1 percent of the total AC input current to the motor.
The only wear parts are bearings and brushes, since the motors and drives are
separated by an air gap.
Efficiency:

Eddy current drives use a DC magnetic field to link two members, one on the input
shaft and one on the output shaft. Increasing the DC to the coil increases the coupling
of the two members, thus delivering more torque to the load. A tachometer is used to
control the velocity and torque.

Eddy current losses in efficiency in an AC motor are equal to nameplate rating as the
motor is running across the line. This is true for power factor and efficiency. With DC
control losses in efficiency are typically 2 percent or less.

And in a slip the reduction in speed is dissipated in the drum and rotor (the coupled
members). It reduces efficiency in proportion to reduction in speed.

It is best to run an eddy current device at or near rated speed. Typically, 82 to 100
percent is best to optimize efficiency.

Maintenance:

Bearing lubrication is needed to maintain an eddy current drive. The control, which
can be a single printed circuit board, requires no maintenance. A typical eddy current
drive should last 40 years.
Image 2. By changing the external impedance connected in the rotor circuit, the speed
or current and speed or torque curves of the induction motor can be altered.

Wound Rotor Motor:

Wound rotor (also called slip ring) motors are based on inserting external resistances
into the induction motor rotor circuit for induction motor torque controls. Prior to the
advent of variable frequency drives (VFDs), there was no other way for an induction
motor to develop high overload torques (200 to 280 percent) over a wide speed range
as required for many industrial applications such as crane hoists, pulpers or trolley
drives and in some centrifugal pumping applications where the solids in the pumpage
may have dropped out of suspension during brief shutdowns.

The wound rotor motor is an induction motor where the rotor circuit is terminated in
slip rings to which external impedances can be connected. The stator is essentially the
same as used in any standard squirrel cage motor. By changing the external
impedance connected in the rotor circuit, the speed or current and speed or torque
curves of the induction motor can be altered. A three-phase wound rotor induction
motor consists of a stator core with three-phase winding; a wound rotor with slip
rings, brushes and brush holders; and two end shields to house the bearings that
support the motor shaft.
While this technology is popular in many large motor applications, there are still a
few wound rotor applications in the 20- to 500-hp range. Wound rotor technology is
not the most cost-effective solution for high-torque variable torque applications,
especially with centrifugal pumping (variable torque) applications. A few advantages
of wound rotor motor technology include: high capacity of overloading; lower starting
current as compared to squirrel cage motor; maintains a constant speed while running;
high-torque value at the start; and ability to vary speed by use of external rotor
resistance.

Maintenance:

While the resistor banks may not be prone to failure, the contractors, which switch
resistor banks in and out of service for speed control of the wound rotor motor, can be
replaced or serviced yearly, or more depending on usage. Wound rotor motors may
experience slip ring brush contamination; slip ring brush maintenance; slip ring brush
rigging, burning and melting; resistor contactor bank pitting and maintenance; and
energy losses in the resistor bank during low speed operation.

Users occasionally inquire about the feasibility of converting an existing wound rotor
motor to operate as a squirrel cage design. One way is to short circuit the slip rings
and eliminate the variable resistance speed control in the external circuit. This can
cause inrush current to become high, with starting torque so low that the motor may
be unable to accelerate its load. And the rotor winding remains a potential source of
failure caused by the effects of heat, vibration and centrifugal force.

A conversion is best done by replacing the rotor shaft assembly with a simple “deep
bar” rotor, based on what would be used in a squirrel cage design for the parts
involved. Some increase in horsepower may be possible because of the elimination of
the rotor slot space taken up by insulation.
Part 2: How electronic speed control drives, adjustable frequency drives,
magnetic drives and steam turbine drives work to achieve true variable
speed control.

To achieve true variable speed control, we are looking at the following methods or
technologies: fluid drive, eddy current drive, wound rotor motor, adjustable voltage
direct current (DC), adjustable frequency alternating current (AC), magnetic drive and
steam turbine. Part 1 of this series reviewed fluid drive, eddy current drive and wound
rotor motor. This article will review the other methods or technologies.

Electronic Speed Control Drives: Adjustable Voltage DC:

The oldest electronic speed control methods are the DC drives, which are also known
as DC motor speed control systems. The speed of a DC motor is directly proportional
to armature voltage and inversely proportional to motor flux; either armature voltage
or field current can be used to control the motor speed. DC motors have become
expensive and most DC motor speed control systems have been retrofitted with an AC
motor and AC variable speed drive. AC variable speed drives are less expensive,
more available and more efficient than DC systems. Many DC drive systems have
been replaced where possible with AC variable frequency drives (VFDs).

Adjustable Frequency Drives:

A VFD is the most popular method to control the speed of an electric motor driven
pumping system.

Image 1. Basic drive system

A VFD is defined as an electronic device used for controlling the rotational speed of
an AC electric motor by controlling the frequency and voltage of the electrical power
supplied to the motor. A basic drive system consists of an AC motor and VFD
managed by a control system (Image 1).

A method of control is required to vary the speed of the drive. This control method
can be as simple as an on/off switch and a speed potentiometer controlled by the
operator. More complex systems often incorporate a programmable logic controller
(PLC).

Larger systems will usually use a distributed control system. This is basically a host
computer running a software package that allows the operators to both monitor and
control their overall system by one or multiple interface screens.

The drive has an embedded microprocessor that governs the overall operation of the
VFD controller. This microprocessor has an operating system firmware that is not
accessible to the VFD user. User-defined programming and parameter adjustment is
usually done through the operator keypad. This allows the user to customize the VFD
controller to meet specific process, motor and equipment requirements.

Unlike the other speed control methods discussed in this article when applying a
VFD, the following concerns must be addressed to ensure optimum reliability: added
heating of winding (Class F or H Insulation); added winding insulation stresses;
reflective wave or voltage overshoot; added chance of bearing currents (insulated
bearing, grounding brush, earth ground); added chance of vibration issues; effect on
sound levels; large motor concerns; how VFD will be used and key details needed to
choose large motors for VFDs.

The non-sinusoidal VFD waveform contains harmonics and peak voltage or current in
excess of normal sine wave grid power. On low voltage VFDs, it is common for the
motor to see an additional 10 to 15 degree temperature rise. On medium voltage
VFDs, motors typically see only a 3 to 5 degree temperature rise.

Additional concerns specific to the motor when applying a VFD: motor torque, speed
and temperature; operation above base speed; running current; starting current; motor
efficiency; sound levels; motor cable length and grounding.
Image 2. Components of a typical steam turbine driver

Maintenance:

The VFD must be in a clean, filtered environment. Heat the sinks, vacuum away dust
and do not use compressed air. If heavily soiled, used a light natural fiber brush. Do
not use a synthetic brush. For Type 12 enclosures with cooling fans, replace the air
filters as necessary.

Conduct a thermal scan, paying special attention to the connections. Check the cable
lug torque. Use a megger to measure insulation resistance.

The typical life expectancy of a VFD is five to 10 years. After 10 years, most drive
OEMs will discontinue the manufacturer or replacement parts. In addition, VFD
technology continues to change, making older drives obsolete.
Magnetic Drive:

The principle behind a magnetic drive or coupling is like that of an eddy current drive.
The magnetic drive replaces the physical connection between motor and load with a
gap of air. Motor torque is transferred to the load across an air gap. Varying the air
gap between the magnets and conductor changes the strength of the magnetic field
and, hence, controls output speed.

A few features of magnetic drive technology:

• No-contact power transfer. This eliminates vibration, reduces noise, tolerates

misalignment, provides overload protection, extends motor and equipment life
and reduces overall maintenance costs.
• Energy efficiency. The application and load requirements will determine the
efficiency.
• Quality. Technology improves product quality and optimizes process rates.
• Soft start/stop. Reduces the motor’s startup power demands and the resulting
brownouts, alleviates paying for peak power, allows downsizing of motors,
increases motor life and reduces maintenance.
• Simplicity and ruggedness. System can be maintained in-house and used in
harsh conditions.

Steam Turbine Drive:

Steam power is one of the oldest technologies in the industrial sector providing power
through the industrial revolution and into the 20th century. However, there are some
limitations when applying a steam turbine.
First and foremost, you need steam and you need a source to generate the steam. This
requirement limits the use of turbines in certain applications.

The most notable pumping application for steam turbine drivers is powering boiler
feed pumps.

A steam turbine is powered by the hot gaseous steam generated by a boiler. The steam
enters the turbine through a nozzle that controls the speed of the steam (Image 2). The
turbine is fitted with blades mounted on a shaft that is coupled to the driven
component (pump) that turn as the steam blows past them. The blades have tight
clearances that contain the steam, maximizing the efficiency of the turbine. The steam
expands and cools as it flows through the turbine blades.
Image 3. How an impulse turbine works vs. a reaction turbine

The rotating element (shaft and turbine blades) are contained in the turbine’s outer
casing.

This casing must handle the high pressure and temperature produced by the steam.

There are two types of steam turbines:

 • An impulse steam turbine features a jet of steam from a fixed nozzle that
pushes against the rotor blades driving the blades forward (Image 3). Pressure
drops take place in the fixed blade (nozzle).
• A reaction steam turbine does not use nozzles. The rotor blades are configured
to form convergent nozzles using the reaction force produced as the steam
accelerates through the nozzles. The steam is directed onto the rotor by the
fixed vanes in the stator (casing).

Efficiency:

The efficiency of a steam turbine driver or any engine can be defined as its ability to
convert the input energy into useful output energy, which is expressed in Equation 1.
Steam turbine efficiency or isentropic efficiency is the efficiency that compares the
actual output with the ideal isentropic output to measure the effectiveness of extracted
work.

Efficiency (ɳ) = Output/Input

Equation 1

Maintenance:

Steam turbines require the correct steam pressure at the turbine inlet and high steam
quality in order to ensure optimum reliability.

One guideline for maintenance to keep in mind is that the steam must be of highest
quality. Also, steam supply lines, valves and casing should be insulated to prevent
loss of latent energy. The steam supply lines must be properly configured for
condensate removal, correctly sized drip pockets and steam traps.

Additionally, excessive forces to the turbine flanges should be mitigated. They

include pipe dead weight, thermal expansion, thrust and spring rate caused by
different expansion joints.

Impact as a result of improper installation will result in premature bearing failure,

nozzle degradation, turbine blade failure or distortion and premature coupling failure.

Which speed control is best? It depends on the application and business model. Also,
consider your issues and concerns—such as energy efficiency, reliability, uptime,
production concerns or environmental

Courtesy: Pumps and Systems