Energy Conservation & Speed Control Of Air Blower

Motor By VFD Using PLC

Anirudh A Urs, Manikantan P S, Manojkumar R, Sreemidhun V S
1
Students of Dept. of Electrical & Electronics, SVIT, Bengaluru-560064, India.
a
anirudhau.15ee@saividya.ac.in
Ph.: (O) 080-2846 8191 / 96/97, (Fax): 080-2846 8191

Prof. Manjunath T G2, a

2
Associate Prof. & HOD, Dept. of Electrical & Electronics, SVIT,
Bengaluru-560064, India.
a
hod.eee@saividya.ac.in
Ph.: (O) 080-2846 8191 / 96/97, (Fax): 080-2846 8191

Abstract— This project describes the use and Keywords-VFD, PLC, Heat treatment, Speed control,
importance of VFD and PLC in firing of ceramic SCADA
insulators. The ceramic insulators undergo heat
treatments before being subjected to some mechanical I. INTRODUCTION
and electrical test. This treatment makes the insulator In the various industrial applications the induction
durable and moisture less. This generally takes place in motor is mostly used. The loads on induction motor always
a kiln. Volume of air pumped into the kiln is controlled vary as per its application but speed of induction motor is
by air blower motor which is a three phase induction constant & cannot match with the load demand. If load on
motor, which is necessary for firing of insulators. induction motor decrease, the speed of induction motor cannot
Installation of VFDs to control these motors offers high be decreases as per the load. Hence it takes rated power from
and savings in cost due to less power consumption. In supply so the energy consume by the motor is same. Hence
addition, speed control is generally the most energy there is energy consumption is same during load varying
efficient flow control technique because it requires the condition also. To overcome this problem a VFD is used in
least amount of energy to meet the given load. industrial application to save the energy consumption and
Nowadays industries have gradually shifted from electricity billing. Variable frequency drive (VFD) usage has
conventional relay logic control to intelligent increased dramatically in industrial applications. This device
programmable logic control. Three phase induction uses power electronics to vary the frequency of input power to
motors are the widely used motors all through the the motor, thereby controlling motor speed.
globe in industry for various operations. Here the
review of monitoring and control system for the II. HEAT TREATMENT OF INSULATORS
induction motor based on programmable logic
controller (PLC) & SCADA is described. Also the
implementation of a hardware and software for speed
control, direction control, parameter monitoring on
SCADA screen is provided. Variable Frequency Drives
(VFD) can also be used to control the motor rotation
direction and rotation speed of the three phase
induction motor. All the required control and motor
performance monitoring parameter data will be taken
to a personal computer by SCADA Software via PLC
for further analysis.
The paper is designed to highlight the use of VFDs
and PLC for the control of air flow in the kiln used for
firing of insulators by varying the supply frequency
and monitoring the system. Figure 1.1.Heat treatment of insulators

The parameters of the block diagram are explained below

A. FUEL TANK: The fuel used in this kiln is gas.
Huge cylinders made out of steel are used for storing
the gas fuel. This is placed in a remote place and the
fuel is carried through steel pipes to the required
areas.
B. FUEL PRESSURE CONTROL: The pressure of
the incoming fuel plays as important role in the
prevailing temperature inside the kiln. The pressure
and the air to the kiln decide the temperature inside
the kiln. Dampers are used for the fuel pressure
control and they are witnessed by using manometers.
C. BURNER: Gas is supplied to the kiln using
burners made of heat resistant materials. These
burners are connected to the gas supply pipes through
valves. The figure shows one of the burners in the
kiln. A mixture of air and gas is sent inside the
heating chamber. There is an ignition sparkplug
called a lighter which ignites the flame whenever
required. The lighter operation is controlled
manually.
D. GAS SUPPLY: The gas is supplied to the kiln by
burners made of heat resistant materials. These
blowers are connected to the gas supply pipes
through valves.
E. KILN: The kiln is the heating chamber where the
insulators are treated. The kiln is build with bricks
and they are coated with heat resistive paints. Care is
taken such that heat does not leak out as this leakage
not only reduces the efficiency of the process but also
affects the quality of the insulators.
F. AIR BLOWER: Air blower controls the internal
heat of the chamber. This setup consist of a three
phase induction motor connected to a fan or blower.
The pressure of air entering the kiln is controlled by
using damper of speed drive arrangement.
G. BURNING PROCESS: Liquid petroleum gas
(LPG) is used as fuel in the burner. A small amount
of fuel is passed through pilot valve to the ignition
chamber and at the same time a voltage of about 5kV
is applied across the sparkplug through the ignition
transformer. If the fuel is ignited the ultra violet (UV)
sensor senses the blue flame and correspondingly a
feedback is sent to the main valve for the continued
supply of fuel. If the UV sensor doesn’t sense the
blue flame a feedback is sent to stop the further
supply of fuel. Air is supplied to the ignition chamber
from primary and secondary air panel through
blowers. The primary air panels supplies air
necessary for burning and secondary air panel helps
in the uniform distribution of air throughout the
chamber. Blowers work on the principle of
centrifugal force. The amount of air flow into the
blower is controlled by variable frequency drive
(VFD).
H. DAMPERS: An air damper comprises a cylinder
having air ports at its upper and lower portions, a
piston rod, a piston movably mounted on one end of
the piston rod, a return spring, an air passage
provided between upper and lower within the
cylinder which passage is opened and closed by the
movement of piston, and an regulating valve press-fit
into the lower airport portion of the cylinder.
III. SPEED CONTROL METHODS OF INDUCTION MOTOR
An induction motor is practically a constant speed
motor, that means, for the entire loading range, change in
speed of the motor is quite small. Speed of a DC shunt motor
can be varied very easily with good efficiency, but in case of
Induction motors, speed reduction is accompanied by a
corresponding loss of efficiency and poor power factor. As
induction motors are widely being used, their speed control
may be required in many applications. Different speed control
methods of induction motor are explained below.
A. INDUCTION
MOTOR SPEED CONTROL FROM STATOR SIDE
1) By changing the applied voltage:
From the torque equation of induction motor:
Rotor resistance R2 is constant and if slip s is small then (sX 2)2
is so small that it can be neglected. Therefore, T ∝ sE22 where
E2 is rotor induced emf and E2 ∝ V
Thus, T ∝ sV2, which means, if supplied voltage is decreased,
the developed torque decreases. Hence, for providing the same
load torque, the slip increases with decrease in voltage, and
consequently, the speed decreases. This method is the easiest
and cheapest, still rarely used, because
1. large change in supply voltage is required for
relatively small change in speed.
2. large change in supply voltage will result in a large
change in flux density, hence, this will disturb the
magnetic conditions of the motor.
2)By changing the applied frequency
Synchronous speed of the rotating magnetic field of
an induction motor is given by,
where, f = frequency of the supply and P = number of stator
poles.
Hence, the synchronous speed changes with change in supply
frequency. Actual speed of an induction motor is given as N =
Ns (1 - s). However, this method is not widely used. It may be In this method of speed control, two motors are used.
used where, the induction motor is supplied by a dedicated Both are mounted on a same shaft so that both run at same
generator (so that frequency can be easily varied by changing speed. One motor is fed from a 3phase supply and the other
the speed of prime mover). Also, at lower frequency, the motor motor is fed from the induced emf in first motor via slip-rings.
current may become too high due to decreased reactance. And Motor A is called the main motor and motor B is called the
if the frequency is increased beyond the rated value, the auxiliary motor.
maximum torque developed falls while the speed rises. Let, Ns1 = frequency of motor A
Ns2 = frequency of motor B
3) Constant V/F control of induction motor P1 = number of poles stator of motor A
This is the most popular method for controlling the P2 = number of stator poles of motor B
speed of an induction motor. As in above method, if the supply N = speed of the set and same for both motors
frequency is reduced keeping the rated supply voltage, the air f = frequency of the supply
gap flux will tend to saturate. This will cause excessive stator
current and distortion of the stator flux wave. Therefore, the Now, slip of motor A, S1 = (Ns1 - N) / Ns1.
stator voltage should also be reduced in proportional to the frequency of the rotor induced emf in motor A, f1 = S1f
frequency so as to maintain the air-gap flux constant. The Now, auxiliary motor B is supplied with the rotor induce emf
magnitude of the stator flux is proportional to the ratio of the
stator voltage and the frequency. Hence, if the ratio of voltage therefore, Ns2 = (120f1) / P2 = (120S1f) / P2.
to frequency is kept constant, the flux remains constant. Also,
by keeping V/F constant, the developed torque remains now putting the value of S1 = (Ns1 - N) / Ns1
approximately constant. This method gives higher run-time
efficiency. Therefore, majority of AC speed drives employ
constant V/F method (or variable voltage, variable frequency
method) for the speed control. Along with wide range of speed
control, this method also offers 'soft start' capability. At no load, speed of the auxiliary rotor is almost same as its
synchronous speed.
4) Changing the number of stator poles i.e. N = Ns2.
From the above equation of synchronous speed, it can from the above equations, it can be obtained that
be seen that synchronous speed (and hence, running speed)
can be changed by changing the number of stator poles. This
method is generally used for squirrel cage induction motors, as
squirrel cage rotor adapts itself for any number of stator poles.
With this method, four different speeds can be obtained
Change in stator poles is achieved by two or more independent
stator windings wound for different number of poles in same
1. When only motor A works, corresponding speed =
slots.
Ns1 = 120f / P1
For example, a stator is wound with two 3phase windings, one
for 4 poles and other for 6 poles.
2. When only motor B works, corresponding speed =
for supply frequency of 50 Hz
Ns2 = 120f / P2
i) synchronous speed when 4 pole winding is connected, Ns =
120*50/4 = 1500 RPM
3. If commulative cascading is done, speed of the set =
ii) synchronous speed when 6 pole winding is connected, Ns =
N = 120f / (P1 + P2)
120*50/6 = 1000 RPM
4. If differential cascading is done, speed of the set = N
= 120f (P1 - P2)
B. SPEED CONTROL
FROM ROTOR SIDE: 3) By injecting EMF in rotor circuit
In this method, speed of an induction motor is
1) Rotor rheostat control controlled by injecting a voltage in rotor circuit. It is necessary
This method is similar to that of armature rheostat that voltage (emf) being injected must have same frequency as
control of DC shunt motor. But this method is only applicable of the slip frequency. However, there is no restriction to the
to slip ring motors, as addition of external resistance in the phase of injected emf. If we inject emf which is in opposite
rotor of squirrel cage motors is not possible. phase with the rotor induced emf, rotor resistance will be
increased. If we inject emf which is in phase with the rotor
induced emf, rotor resistance will decrease. Thus, by changing
2) Cascade operation the phase of injected emf, speed can be controlled. The main
advantage of this method is a wide rage of speed control
(above normal as well as below normal) can be achieved. The
emf can be injected by various methods such as Kramer
system, Scherbius system etc.
IV. VARIABLE FREQUENCY DRIVES
A variable-frequency drive (VFD) or adjustable-frequency
drive (AFD), variable-voltage/variable-frequency (VVVF)
drive, variable speed drive, AC drive, micro drive or inverter
drive is a type of adjustable-speed drive used in electro-
mechanical drive systems to control AC motor speed and
torque by varying motor input frequency and voltage.
Figure 3.1 Variable frequency drive
Operating Principle
The induction motor is basically a constant-speed
motor, as it operates within 3% of the synchronous speed,
which is determined by the frequency and number of poles in
the machine:
Ns=120×f/P
Although torque at a given slip is proportional to the
voltage squared, changing the magnitude of the applied
voltage has a very little effect on the operating speed of the
motor.
At rated voltage, the operating point for the motor
and load will be where the motor provides exactly the torque
required by the load (plus losses, of course). That point is
indicated at P, in Figure 1. The power delivered to the load
could be found from the horsepower-to-torque relationship:
HP=n×T/5252
Where HP is the horsepower delivered, T is the
torque in lb. ft, n is the RPM of the motor, and 5252 is a
constant arising from unit conversions.
Reducing the voltage applied to the motor will reduce
the torque provided by the motor at a given operating speed.
V. PROGRAMMABLE LOGIC CONTROL
A programmable logic controller (PLC) or programmable
controller is an industrial digital computer which has been
ruggedized and adapted for the control of manufacturing
processes, such as assembly lines, or robotic devices, or any
activity that requires high reliability control and ease of
programming and process fault diagnosis.
Figure 4.1 Block diagram Of PLC
VI. SUPERVISORY CONTROL SUPERVISORY CONTROL
AND DATA ACQUISITION (SCADA)
It is a control system which uses computers,
networked data communications and graphical user interfaces
for high-level process supervisory management, but uses other
peripheral devices such as programmable logic controller
(PLC) and discrete PID controllers to interface with the
process plant or machinery. The use of SCADA has been also
considered for management and operations of project-driven-
process in construction.
The operator interfaces that enable monitoring and
the issuing of process commands, such as controller set point
changes, are handled through the SCADA computer system.
However, the real-time control logic or controller calculations
are performed by networked modules that connect to the field
sensors and actuators.
VII. DRIVES AND ENERGY SAVINGS
The damper is used for lowering the air capacity or
flow of the fans or pumps operated at a constant speed. In this
case, because of commercial operation, the speed of the motor
is constant. Therefore the motor power does not change much
as curve relative to the load variation due to controlled
damper.
On the other hand, when the speed is decreased in
order to reduce the air capacity or flow of fans or pumps, the
motor power will extremely drop because it is ideally in
proportion to the cube of speed as desired in items.
Therefore, the output can be lowered to the minimal
level by controlling the speed with inverter drive. For the
energy saving effect, the greater the variation of air capacity or
flow becomes the larger effect it is expectable to have.
However, there is no effect with a constant or slightly-changed
(app 95-100%) air capacity or flow.

VIII. METHADOLOGY
The speed of the induction motor is directly proportional to
the supply frequency and no. of poles of the motor. Variable
speed drive by using frequency control method is commonly
used method to control and change the speed of the induction
motor. It can vary the desired speed by changing the frequency
using switching sequence of IGBT. To get low cost high VFD plays vital role in protecting motor from various
control circuit is designed. faults like overload, overvoltage, over current etc., Whenever
The proposed system is to monitor parameter on SCADA fault occur, VFD indicates the same on its diplay. By referring
screen. This system consists of different working arrangement code user will be able to find solution for the same within a
which mainly consists of an Induction Motor, VFD, PLC, short period of time. Here the system is set to sense motor
Control Unit and a PC. parameters are sensed, PLC will decide wheather measured
parameters are within limit or not. If the parameter crosses the
limit set by the user, SCADA screen will give warning

Flow rate Hours With damper

(m’3/hr) kW kWh

300 19 11.3 215.1

350 2 11.4 22.8

400 14 11.9 166.2

Figure 7.1 Block diagram
625 2 11.9 23.8

The control unit acts as an external control which 800 2 12 24

consits of push buttons, light emitting diodes, 4-channel relay
and switch mode power supply. 825 2 12.5 25

860 2 12.6 25.2

875 2 12.6 25.2

725 2 12.5 25

850 5 12.5 62.5

900 2 13.2 26.4

770 2 12 24

330 2 12 24
Here the PLC is programmed using Ladder logic.
Ladder logic is a programming language that creates and 360 2 12.3 24.6
represents a program through ladder diagrams that are based
on circuit diagrams. 400 2 11.6 23.2

500 2 11.6 23.2

600 2 11.4 22.8

850 2 11.9 23.8

900 3 12.6 37.8

950 2 12.7 25.4

1060 2 13.3 26.6

1775 2 14.4 28.8

Total 77 925.38
message on its screen. So at supervisory level, user will be
able to see motor condition, its parameters wheather they are
crossing threshold or not. User will also be able to control the
motor.
IX. OBSERVATIONS
TABLE 1: The readings obtained for power consumption during the
heating cycle of hollow insulators with the damper systems:
TABLE 2:The readings obtained for power consumption after installing VFD

X. ENERGY SAVING ANALYSIS

Flow Hours With VFD
rate As already mentioned, the employment of VFDs result
Speed Frequency kW kWh in considerable saving in energy for the organization.
(m’3/hr)
The payback period of the invested amount into the
300 19 840 14 4.14 78.8 VFD is also very less. From the comparison of power
consumption in between damper technique and the
350 2 1080 18 4.41 8.8 VFD system of speed control, the energy saving per
annum was calculated as below:
400 14 1320 22 4.8 67.1
 Energy consumed (in kWh) with damper:
925.3kWh
625 2 1340 22.3 5.57 11.1
 Energy consumed (in kWh) with VFD:
800 2 1410 23.5 6.09 12.1 416.3kWh

825 2 1490 24.8 6.14 12.8  Difference in kWh per cycle: 925.3-
416.3=509 kWh
860 2 1560 27.5 6.55 13.1
 No. of cycles per hour: 55
875 2 1620 27 6.59 12.2
 kWh saving per annum: 55*509=27995kWh
725 2 1680 28 6.14 12.3
Cost paid per unit of energy consumed for commercial
purpose is Rs. 45
850 5 1740 29 6.55 32.4
 Total cost saving per annum: 27995*4.5=1.26
900 2 1800 30 6.59 13.9 lakh

770 2 1830 30.5 6.14 12  Cost of VFD: 1.25 lakh

330 2 1845 30.75 6.48 9.1  Simple payback period: 1year

360 2 1920 32 6.97 9.6

XI. CONCLUSION
400 2 2010 33.5 6.02 9.4 In this paper, the use of Variable frequency drives
for changing the speed of the motor by changing then
500 2 1845 30.75 4.55 10.1 frequency and PLC is presented. As variable frequency
drives are more accurate in firing of insulators, also
600 2 1845 30.75 4.8 10.5 requires less manpower even reduces the cost of
insulators and also loss of energy can be minimized.
850 2 1830 30.5 4.69 12.3 By the above estimate we would like to conclude that
by the use of this concept the efficiency can be
900 3 1860 31 5.04 20 increased drastically.
Finally it is concluded that the method of speed
950 2 1950 32.5 5.26 13.7 control of three phase induction motor using variable
frequency drive is the effective and efficient method.
1060 2 2000 33.3 7.41 14.8 When the operation of VFD is control by PLC. The
whole system gives the operation to a level of
1775 2 2040 34 9.51 19 accuracy, ability and totally with maximum

Total 77 416.3
 safety. It is possible that, the speed control system can be used in this paper also used for monitoring and controlling the
implemented to control multiple motors with the same drive other parameter of the motor with the same drive.
and programmable logic controller, the PLC system which is

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