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Speed Control and Customer Benefits

Structure
1. 2. 3. 4. 5.
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What does Variable Speed mean? Why Variable Speed? Speed Control versus Throttle Control Speed Control versus Inlet Guide Vane Control Advantages of Voith Variable Speed Couplings

1. What does Variable Speed mean?


What is being Speed controlled : Pumps Fans
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Motor
(constant speed)

air

Compressors Conveyor belts Coal mills

Variable Speed means : Change of Speed of the driven Machine

2. Why Variable Speed?


Generally

Energy Saving Reduction of Emission To adapt Pressures and Flows to the Process Conditions
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To minimize Wear of the Driven Machine To facilitate Start-up of the Driven Machine Reduction of Maintenance Costs

2. Why Variable Speed?


Especially for Compressor Drives

Varying Gas Compositions (Flash Gas Compressors, Injection


Compressors, Export Gas Compressors ...)

Varying Process Conditions (DHDT Recycle Compressors,


Refrigeration Compressors, BOG Compressors ...)
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Varying Product Demand (Pipeline Compressors ...)


Speed Control makes the whole Plant / Process more flexible

3. Speed Control vs. Throttle Control


Throttle Control
Advantages
Low Capital Costs Only one Control Element
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Disadvantages
High Maintenance Low Reliability and Availability Very low Efficiency High Noise Level High Stress for the entire System

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3. Speed Control vs. Throttle Control

3. Speed Control vs. Throttle Control BFP Characteristic - Throttle Control


150 140 130 120 110 100 Pump @ Design Speed (105 %) Test

Pressure [%]

90 80 70 60 50 40 30 20 10 0 0

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Boiler Characteristic Pump Efficiency

10

20

30

40

Flow [%]

50

60

70

80

90

100

110

3. Speed Control vs. Throttle Control BFP Characteristic - Throttle Control 150
140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 110 Pump Efficiency Boiler Characteristic Pump @ Design Speed (105 %) T 100 Test

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Pressure [%]

Flow [%]

3. Speed Control vs. Throttle Control BFP Characteristic - Throttle Control 150
140 130 120 110 100 Pump @ Design Speed (105 %) Test

Pressure [%]

90 80 70 60 50 40 30 20 10 0 0

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Boiler Characteristic Pump Efficiency

10

20

30

40

Flow [%]

50

60

70

80

90

100

110

3. Speed Control vs. Throttle Control BFP Characteristic - Throttle Control 150
140 130 120 110 100 Pump @ Design Speed (105 %) Test

Pressure [%]

90 80 70 60 50 40 30 20 10 0 0

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Boiler Characteristic Pump Efficiency

10

20

30

40

50

60

70

80

90

100

110

Flow [%]

3. Speed Control vs. Throttle Control BFP Characteristic - Throttle Control 150
140 130 120 110 100 Pump @ Design Speed (105 %) Test

Pressure [%]

90 80 70 60 50 40 30 20 10 0 0

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Boiler Characteristic Pump Efficiency

10

20

30

40

50

60

70

80

90

100

110

Flow [%]

3. Speed Control vs. Throttle Control BFP Characteristic - Throttle Control 150
140 130 120 110 100 Pump @ Design Speed (105 %) Test

Pressure [%]

90 80 70 60 50 40 30 20 10 0 0

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Boiler Characteristic Pump Efficiency

10

20

30

40

50

60

70

80

90

100

110

Flow [%]

3. Speed Control vs. Throttle Control BFP Characteristic - Throttle Control 150
140 130 120 110 100 Pump @ Design Speed (105 %) Test

Pressure [%]

90 80 70 60 50 40 30 20 10 0 0

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Boiler Characteristic Pump Efficiency

10

20

30

40

50

60

70

80

90

100

110

Flow [%]

3. Speed Control vs. Throttle Control BFP Characteristic - Throttle Control 150
140 130 120 110 100 Pump @ Design Speed (105 %) Test

Pressure [%]

90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 110 Boiler Characteristic Pump Efficiency

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Flow [%]

3. Speed Control vs. Throttle Control BFP Characteristic - Speed Control 150
140 130 120 110 100 Pump @ Design Speed (105 %) Test

Pressure [%]

90 80 70 60 50 40 30 20 10 0 0

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Boiler Characteristic Pump Efficiency

10

20

30

40

50 60 Flow [%]

70

80

90

100

110

3. Speed Control vs. Throttle Control BFP Characteristic - Speed Control 150
140 130 120 110 100 Pump @ nominal Speed (100 %) S100 Pump @ Design Speed (105 %) Test

Pressure [%]

90 80 70 60 50 40 30 20 10 0 0

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Boiler Characteristic Pump Efficiency @ 100 % Speed

10

20

30

40

50 60 Flow [%]

70

80

90

100

110

3. Speed Control vs. Throttle Control BFP Characteristic - Speed Control 150
140 130 120 110 100 Pump @ nominal Speed (100 %) Pump @ Design Speed (105 %) Test

Pressure [%]

90 80 70 60 50 40 30 20 10 0 0

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Boiler Characteristic Pump Efficiency

10

20

30

40

50 60 Flow [%]

70

80

90

100

110

3. Speed Control vs. Throttle Control BFP Characteristic - Speed Control 150
140 130 120 110 100 Pump Speed Pump @ Design Speed (105 %) Test

Pressure [%]

90 80 70 60 50 40 30 20 10 0 0

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Boiler Characteristic Pump Efficiency

10

20

30

40

50 60 Flow [%]

70

80

90

100

110

3. Speed Control vs. Throttle Control BFP Characteristic - Speed Control 150
140 130 120 110 100 Pump Speed Boiler Characteristic Pump Efficiency Pump @ Design Speed (105 %) Test

Pressure [%]

90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 Flow [%] 70 80 90 100 110

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3. Speed Control vs. Throttle Control BFP Characteristic - Speed Control 150
140 130 120 110 100 Pump @ Design Speed (105 %) Test Pump Efficiency

Pressure [%]

90 80 70 60 50 40 30 20 10 0 0

Pump Speed

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Boiler Characteristic

10

20

30

40

50 60 Flow [%]

70

80

90

100

110

3. Speed Control vs. Throttle Control BFP Characteristic - Speed Control 150
140 130 120 110 100 Pump @ Design Speed (105 %) Test

Pressure [%]

90 80 70 60 50 40 30 20 10 0 0 10 20 Pump Speed

Pump Efficiency

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Boiler Characteristic

30

40

50 60 Flow [%]

70

80

90

100

110

3. Speed Control vs. Throttle Control BFP Characteristic - Speed Control 150
140 130 120 110 100
Pump Speeds

Pump @ Design Speed (105 %) Test

Pressure [%]

90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 Boiler Characteristic Pump Efficiency Curves

S100

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Flow [%]

100

110

4. Speed Control vs. Inlet Guide Vane Control


Inlet Guide Vane Control
Advantages
Low Capital Costs Only one Control Element
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Disadvantages
High Maintenance Low Reliability and Availability Low Efficiency Erosion and mechanical Wear

5. Advantages of Voith Variable Speed Couplings Experience


Market Leader 1,000,000 Installations

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5. Advantages of Voith Variable Speed Couplings Experience


Combined Cycle Power Plants Conventional Power Stations More than
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500 Units Installations

More than S - Couplings 5000 Units Installations RK Couplings

5. Advantages of Voith Variable Speed Couplings Experience


Compressor Drives More than
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150 Units Installations, more than 100 of them are VORECONs

5. Advantages of Voith Variable Speed Couplings Technical Advantages


Separation of Drive Train Shock and Vibration Damping

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OIL

5. Advantages of Voith Variable Speed Couplings Technical Advantages


Fan rated power: 3123 kW (4188 HP) @ 710 RPM With Fluid Coupling Torque, Speed [%] 50 100 150
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No Load Start-Up
Without Fluid Coupling Torque, Speed [%] 100 150 200 600 % I IN

I 600 % IN

Motor speed

Motor & Fan speed

100 %

50

Fan speed

100 % 0 10 Time [sec] 20

25 Time [sec]

50

5. Advantages of Voith Variable Speed Couplings Technical Advantages


Integral Lube Oil System

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Baseframe designed as Lube Oil Reservoir

5. Advantages of Voith Variable Speed Couplings Technical Advantages


Application under severest environmental Conditions

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5. Advantages of Voith Variable Speed Couplings Economic Benefits


1.
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Reliabilty, Availability, MTBF


2. Availability based on Overhaul

Reliability based on Failures

Reliability: Operating Hours - Non-Availability Time Operating Hours = 0.9994 99,94 % 3.

Operating Hours between Overhauls - Non Availability Time Operating Hours between Overhauls = 0.9983 = 99,83 %

Mean Time between Failures (MTBF) Operating Hours No. of reported Failures

MTBF:

= 281 818 Hours (over 24 Years)

5. Advantages of Voith Variable Speed Couplings Economic Benefits


Simple, compact, robust

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Very easy Maintenance

only a 4-20 mA Signal is necessary to operate the Unit

5. Advantages of Voith Variable Speed Couplings Economic Benefits


Efficiency

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5. Advantages of Voith Variable Speed Couplings Economic Benefits


Load Load Pattern [h/yr] No. of Pumps Power Savings [kW] Energy Savings [kWh]

Payback Time
Test 420 MW 415 MW 410 MW 400 MW 10 3330 1330 3000 330 2 2 2 2 2 -58 180 189 197 213 -1160 1 198 800 502 740 1 182 000 140 580 3 022 960 kWh x S $ 0.07/kWh = S $ 211,607 or US $ 130,000 or Baht 4.8 million S $ 100,00 3 S $ 300,00 or US $ 180,000 or Baht 6.7 million US $ 0.043 US $ 130,000 US $ 180,000

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Cost Savings per year [S$] Cost per Coupling [S$] No. of Couplings Total Cost [S$] Energy Cost per kWh: Total Cost Savings per Year: Cost per 3 Units:

17 Months

5. Advantages of Voith Variable Speed Couplings Economic Benefits


Long Life

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5. Advantages of Voith Variable Speed Couplings

Experience
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Technical Advantages

Economic Benefits

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