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Summary
This paper explains the cost savings obtained controlling motor current at startup while
when flow is varied by changing the speed of a delivering torque required by the load.
pump or fan instead of using a control valve or • Some applications use two or more pumps in
damper. After illustrating several ways to vary parallel, some running at constant speed,
pump or fan speed, two very different methods while the others are under variable speed
are discussed in detail: hydraulic drives and control to produce the desired process flow.
electric drives. Both systems work well, and each For example, three pumps can share one or
system has good reliability and comparable two EVFDs. An HVSD is dedicated to each
installed cost. However, the electric drive has motor, so three are required.
higher energy efficiency than the hydraulic drive • EVFDs can increase the load carrying
counterpart. capability of a system bus with a given
An electrical variable frequency drive (EVFD) has switchgear rating. Starting currents are low in
advantages over a corresponding hydraulic magnitude and of relatively high power factor
variable speed drive (HVSD) in the following when compared to across-the-line starting of
situations: conventional, squirrel-cage induction and
synchronous motors. Contributions by motors
• The efficiency of the electric drive is superior to bus short circuit currents under faults are
over the whole speed range. Over the 70 to greatly reduced by EVFDs when compared to
100% speed range the electric drive has an across-the-line connections.
efficiency advantage over the typical HVSD of • Electric drives can be configured with a fail-
4-5% on the average. Below 80% speed, the safe characteristic. In the event of an EVFD
EVFD advantage is quite large. failure, a bypass contactor can be closed,
• Because of the higher efficiency, considerable driving the pump at full speed. Therefore a
energy savings can be realized by installing failure of an EVFD will not take down the
an electric VFD. In the 10,000 hp example plant, where failure of a HVSD probably
studied later, the savings are $230,000.00 per would.
year. With energy and electricity costs rising, • If periods of full speed operation are required,
these savings will increase year by year. the EVFD can be smoothly bypassed with
• With an EVFD, the motor current is always optional synchronized bypass circuitry and put
under control. There are no locked-rotor across the line, so there is no power lost in
starting currents, excessive temperatures, or drive efficiency at full speed. An HVSD is
mechanical stresses put on the motor. With dedicated to its machine and cannot be
constant speed motors used with most bypassed.
HVSDs, the driven equipment is subjected to
hard starts, and the heat, caused by the Since the installed costs of the EVFD and HVSD
starting current, degrades the motor insulation are roughly comparable, and the electrical VFD
and shortens its life. provides advantages including significant energy
• Some large motors cannot be started across savings, the EVFD is usually the best choice.
the utility line because of large voltage drop in
the supply. An EVFD eliminates high utility
currents and disruptive voltage drops by
Head
High Low
Pressure Pressure
Loss
B C
C Pump Efficiency
Electric Control Flow, 50% of After at A = 77%
Motor Valve design point throttling at B = 62%
0 50 100
Fixed speed Pump or Fan
Percent Inlet Flow
Figure 2. Flow Control Valve Figure 3. Head Loss Caused by Control Valve Throttling
C
Example - Energy savings using a Variable
70 hp Speed Drive
In this example, the pump was consuming 400 hp
0 50 100 at B but at C is only consuming 70 hp, so the
Percent Inlet Flow energy saved by not throttling is 330 hp. As a
Figure 4. Reduced Motor Speed Eliminates Head Loss quick estimate, assume operation at point C for
60% of the time and at point A for 40% of the
time. With 90% motor efficiency and power costs
Flow head is composed of pressure and velocity of $0.05 per kWh, annual savings would be just
components. Point C is the head and flow under $60,000. Significant! Of course the larger
downstream of the valve. Head is lost as pressure the motor the larger the savings would be, and
drops from B to C, and the lost energy is supplied they will probably go up with time. If a hydraulic
by the motor. This energy lost over extended VSD is used instead of an electrical VFD, the
periods has an economic impact that can be quite savings will be less because of the lower
large. efficiency.
Input Shaft
Figure 5. Rotating Primary
Wheel Throws Oil Outwards
into Secondary Wheel
Section X-X X
Oil Surface
in Coupling
Movable
Scoop Tube
to Change
Output Speed
-D
Oil Supply
to Cooler
and
Rotating Oil
Coupling Return
Oil
Pump
Oil Tank
Design Ranges
Various coupling designs offer power ranges of up • As a retrofit, may not fit into existing
to 10,000 kW, and speeds up to 5,000 rpm. One installations with limited space near the motor
of the largest couplings offered runs at 900 rpm and driven equipment
and transfers 10,000 kW. The transmission Limitations:
efficiency is 93% at 100% load, and drops down • At low speeds the coupling is inefficient and
to about 74% efficiency at 50% load. wastes energy. Costs are high for extended
running at low speeds (see pg. 20)
Summary of Turbo Coupling Features • Cannot increase the input speed, only reduce
Advantages: it
• Moderate initial cost • The coupling is located between the motor
• Good reliability and the pump or fan, and must be aligned
• Compact, often less than half the size of the with both of them
electric motor • Cooling water must be continually supplied to
the oil heat exchanger
Table 1. Various Combinations of Fixed and Movable Gears Available in Planetary Gear
Figure 8 shows a torque converter with its rotating blades around the periphery of the wheel. These
input wheel and output turbine. The torque blades drive the power take off, which goes
converter uses centrifugal force to throw oil out of through a fixed gear and then to the planetary
the buckets on the wheel and impinge it on turbine gear of the HVSD.
Input
Shaft
Bucket
A Section AA
Figure 8. Power Take Off Through Turbine Blades for Speed Control
Oil path
A
Moving portion of
Fixed portion of Torque Converter
Torque Converter
Detail of Converter
Control Power CP
E F
A
B D
G
Power Output Power
Input C H = MP + CP
Main Power MP
Torque Converter,
Fixed Planetary
oil filled
Gear Gear
Oil tank
Control Power CP
Torque Converter,
Hydraulic Brake, Fixed Planetary
can be drained
can be drained Gear Gear
Oil tank
Figure 10. Hydraulic VSD with Wider Speed Range, Similar to Vorecon® Type RWS
Control Power C
Output
Power
=M+C
Input Shaft Main Shaft Main Power M
Movable Scoop
Tube to change Torque
speed during Oil Converter, Hydraulic Brake, Fixed Planetary
Gear Gear
starting Return can be drained can be drained
Oil tank
Figure 11. Hydraulic VSD with Wider Speed Range & Relieved Start-up, Similar to Vorecon Type RW
Electronic Controls
A typical HVSD has extensive electronic controls, • Clutch control, based on speed feedback
so it is not just a mechanical transmission. For • Vibration pickups (7) and one keyphasor
example, the type RW requires electronic and • Total of 12 RTD temperature sensors
electrical equipment including most of the • AC motor driven auxiliary lubricating pump
following: • Level transmitter
• Electro hydraulic servo to position the • Pressure transmitter
coupling scoop tube, with servo amplifier and • Oil heaters
position feedback • Differential pressure switch for filter
• Electro hydraulic servo to position the torque monitoring
converter guide vanes, with servo amplifier
and position feedback
AC Input DC Current
3 3
Isolation Synchronous
Tansformer motor
SCR Exciter
Control Control
Figure 14. Water Cooled LCI Converter Bridge Showing SCRs (white discs)
and low losses of the IEGT to produce high power 0.7 RMS
levels.
Red = 3-level PWM Voltage output
0.2
Three DC bus levels are used for motor voltages
0 50 100 150 200 250 300 350 400
up to 3,300 volts. Figure 15 shows a PWM
inverter output voltage waveform, illustrating the
three power supply levels used to create the
output sine wave.
Transformer
& Feed Reactor
20% Z
Neutral
Sync Field
[If Applic]
Active Regenerative Source - DC
INDUCTION
OR SYNC.
MOTOR
Figure 16. TMdrive-70 IEGT 3300 Volt Voltage Source Inverter and Active Regenerative Source
Figure 16 shows a power one-line of a voltage The compact, regenerative eight (8) MW inverter
source inverter with an active regenerative source shown in Figure 17 includes all devices shown in
for motor voltages up to 3300 volts. The two Figure 16.
capacitors store energy on the dc bus.
Control Cabinet Source Cabinet Inverter Cabinet
Figure 17. TMdrive-70 IEGT, 3300 Volt, 8 MW, Regenerative Inverter from TMEIC
EVFD Bus B
EVFD Bus A
Energy Efficiency
Both electric drives provide a higher efficiency and Figure 20 compares them at various speeds.
than the hydraulic drive across the entire load and This data was obtained from GE, Voith users, and
speed range, especially at the lower speeds the Voith web site; some intermediate points are
where the HVSD has very low efficiency. Figure interpolated.
19 compares four different drives at various loads,
Energy
Savings n RW
x
. . o .
x
o
Voreco
o
o
90 o RWE o
con
Vore
.
Efficiency
. .
%
80 . c Co
upl
in g
uli
dra
Hy
70
. .
60
30 40 50 60 70 80 90 100
Load %
Figure 19. Comparison of EVFD & HVSD Drive Efficiencies vs. Transmitted Load
The electric drive maintains high efficiency over 80% output speed, the mechanical drive efficiency
the entire load range, but the hydraulic drive falls off very quickly. Over the 70 to 100% speed
efficiency falls off at loads below about 50%. The range, the electric drive has an efficiency
hydraulic coupling efficiency is very low except at advantage over the type RW of 4 to 5% on
close to full load. average. Below 80% speed, the LCI advantage is
Figure 20 illustrates the superior efficiency of the quite large.
electric drive over a wide speed range. Below
100
. .
x x x
x
.
x
x
D
LCI Electric VF o o
Energy o
Savings
90 o
Efficiency
W
.
%
Ro
n
co
80 Vo
re
. n
RW
E
co )
o re ed
V at
tim
( es
g
70 l in
up
Co
c
* a uli
dr
Hy
60
40 50 60 70 80 90 100
Output Speed %
Figure 20. Comparison of EVSD & HVSD Drive Efficiencies vs. Output Speed
Annual
Drive Type Electrical and Mechanical Equipment Energy Cost
with synch-
Variable speed Fixed ratio Variable speed ronous motor)
Hydraulic variable speed drive, 10,000 hp, with LCI electrical variable frequency drive,
auxiliary lubricating pump, RTDs, vibration 10,000 hp, with transformer and 2 link
pickups, speed sensor, and gauges reactors $650,000
Price range: $950,000 to $1,300,000
Total Installed Cost approx. $1,340,000 Total Installed Cost approx. $1,420,000
to $1,690,000
• Real-time Closed Loop Control • Process Audits & Surveys • Control System Design &
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• Statistical Quality Control • Installation and Commissioning • Power System Planning & Analysis
• HMI & Supervisory Control • Remote Monitoring & Diagnostics • Process Computer Integration
IC
TME
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rvic
• Simulation Testing • Motors • Risk Abatement Strategies
Se
• FMEA Studies • Induction Heating Equipment
ale
• Six Sigma Processes
tS
os
•P
n
g
Marketing Voice of the Customer ni
siio
• Product Development is
• Market Research & Analysis mm
Co
• Sales Force Deployment & s•
ystem
Effectiveness rol S
and Cont
ion
Automat