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PCRA & BEE LSP WORKSHOP GUJARAT SME DAIRY CLUSTER

Presenter:

Madhukar Parikh h-Power Solutions Pima Controls Pvt. Ltd.

h-Power Solutions MISSION STATEMENT

Engineer and deliver advanced technologies and practices that enable industry to improve energy efficiency and global competitiveness.
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SYSTEM v/s COMPONENT APPROACH


Component Approach is to select each component & size considering wo rst case loading and oversize. Sized on a particular Design Parameter Advantage : Simplifies design and selection Disadvantage : Ignores interaction of Components : Can create performance issues : When under-loaded becomes highly inefficient

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SYSTEM v/s COMPONENT APPROACH


SYSTEMS APPROACH Industrial Systems do no operate under one condition all the time. Loads vary according to : Production Demands : Environment Conditions : Customer Requirements etc A Systems approach analyzes both supply and Demand sides of a system to optimize Total System Performance. Advantage : Components configured to maintain High Efficient Performance over range of Operating Conditions
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System Components

PowerFlex 400 HVAC Dedicated VFD


Agenda

Operator Interface

Controller

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Operating Cost vs. Purchase Price


Automobile Purchase Price Annual Use Efficiency Fuel/Energy Cost Annual Operating Cost 60 HP Motor INR1,26,000

INR 5,00,000
18,000 Km/yr. 15 Km / Ltr INR 60 / Ltr INR 72,000 / Yr 15%

8,760 hrs.
93.6% INR 5.0 / Kwh INR 20,94,538 / yr. 1662%

Annual Operating cost as a % of Purchase Price

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The Global Move to Higher Efficiency Motors


Efficiency Levels Efficiency Classes IEC 60034-30 Global 2008 Super Premium efficiency Premium efficiency High efficiency Testing Standard IEC 60034-2-1 incl. stray load losses 2008 Performance Standard Mandatory Policy goal

IE4 IE3 IE2


USA 2011 USA Canada Mexico Australia New Zealand Korea 2008 Brazil 2009 China 2010 Europe 2011?

Standard

IE1

China Brazil Costa Rica Israel Taiwan

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IEC60034-30 efficiency classes

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EFFICIENCY STANDARDS IN INDIA

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Efficiency Comparison across the Globe


IEC / NEMA Comparison
100

95

Efficiency

90

EPAct NEMA Premium


85

EFF2 EFF1 EFF3

80

75

1.1

2.2

5.5

11

30

45

75

110

187

250

18.5

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Power kW

340

Stray losses comparison between different methods


Stray losses comparison between Existing and Proposed methods Stray losses comparison between Existing and Proposed methods

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VARIBLE FREQUENCY DRIVES

Centrifugal loads, such as pumps and fans, offer the greatest energy savings potential when less than 100% flow or pressure conditions are required

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How does change in speed benefit?

Affinity Laws for centrifugal pumps/fans


HP a PRESSURE * FLOW PRESSURE a SPEED2 FLOW a SPEED

a SPEED3 HP
20 % REDUCTION IN SPEED REDUCES 50 % ENERGY CONSUMPTION
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Affinity Laws for Centrifugal Loads


Speed Volume

Pressure/ Head

Horsepower Required

100% 90% 80% 70% 60% 50% 40% 30%

100% 90% 80% 70% 60% 50% 40% 30%


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100% 81% 64% 49% 36% 25% 16% 9%

100% 73% 51% 34% 22% 13% 6% 3%

Compressors Traditional Operational Strategy


Load / Unload Type Operation
P 7.0 r e s s 6.5 u r e 6.0

Upper Limit

Average Pr.

Lower Limit - Reqd. Pr.

Time
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Compressors - VFD in Closed Loop


PIC

M
Compressor 1

Users

M
Compressor 2
Set Pressure (Reference)

Receiver

Compressor h-Power 3

Solutions

Compressors Using Closed Loop VFD


7% energy 1 kg/cm2 pressure = requirement Upper Limit

Savings
P r e s s u r e
7.0

6.5
6.1 6.0

Average Pr.

Lower Limit - Reqd. Pr.

Time
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Compressors - VFD Advantages

Operates at Lower Avg. Pressure Proportional Savings No Unloading / Loading Cycles Less Leakages Better Motor Efficiency
Higher Power Factor Lower Starting Torque Lower Starting Current
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Constant Lower Pressure Process Feedback

Controlled Acc/Dec Time

NEW DIRECT MOTOR DRIVE TECHNOLOGY


Matched Performance VS1CTD drive and RPM-AC Motor Baldor VS1CTD drive designed for variable speed operation

High Torque Direct Drive Motor:


Laminated Frame IPM (Permanent Magnet) Motor is designed as a drop in replacement for existing gearbox packages; matching bolt holt patterns (may require a mounting plate) Water tight motor uses fan air stream for optimal cooling Improved efficiency over standard gearbox and motor

Fan couples directly to the motor shaft

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DIRECT MOTOR TO FAN & SAVE 15%

Fan

AC Motor

Disc Coupling

Drive Shaft

Disc Coupling

Gear Box

Benefits: Eliminates gearbox, drive shaft, disc couplings, oil level switch and existing motor Runs Quieter & Saves Energy Increases safety due to fewer components Improves reliability & reduces maintenance Lower installation cost by eliminating alignment issues of mechanical components Reduces cooling water contamination from gearbox oil and leakage

Fan

AC Motor

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About Pima Controls Pvt. Ltd.

Pima Controls has been a pioneer in Industrial Automation in Gujarat Pima Controls continue to be Industrial Leaders providing cutting edge technology since 1986, leveraging International partnership and tie-ups
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Pima Is..

Authorized Distributor

Rockwell Automation, USA


Allen Bradley Rockwell Software Sprecher + Schuh

Baldor Electric, USA Electrex, Italy Prosoft-Technologies


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In Summary
Understands its Customers Energy Objectives Site Visit to Study Your System Delivers a Broad Scope of Energy Solutions Provides a Cost-saving Return On Investment Financing options like pay-as-you-save

Integrated ENERGY Solutions

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Thank you for your attention!


Questions???
Pima Controls Pvt. Ltd. A-4 New York Corner, Bodakdev, Ahmedabad 380 015 Tel: +91-79-4021 0400 Fax: +91-79-4021 0410

email: info@pimacontrols.com www.pimacontrols.com

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