SEMINAR

ON
ENERGY CONSERVATION
BY
VARIABLE FREQUENCY DRIVES
FROM

M/s AMTECH ELECTRONICS (INDIA) LTD.

Application of AC drives
1. Energy conservation
Fans
Pumps
Compressors
2. Variable Speed
3. Automation

Rs

ENERGY DATA

100% Power consumption = 80% Industries + 20% Agriculture & domestic.

100% Industries' Power = 80% AC motor + 20% Other load.
100% AC motor Power = 80% Fan, Pump & Blower + 20% other applications.
Means, out of 100% power consumption 50% power consume by Fan/Pump.
In fan/pump/blower energy saving potential by using AC drive is 20-30%.
To save 100 KW power in Fan/Pump/Blower application, 300-500 KW AVCFD to be
required which is costing Approx. Rs.15 L.
For 1000 KW (1MW) power saving investment of ACVFD system is Approx. Rs.150 L
(Rs.1.5 cr.)
This 1.5 Cr. Can provides 1 MW power up to 7-8 year without any extra cost.
Against this if we generate power 1MW by putting power plant then initial investment is
Rs. 12.19 Cr. = Rs. 5cr. power plant installation cost + Running cost Rs.1500/hr*24
hours*7 years (2555 days) Depreciate value of power plant after 7 years (40% of Rs.5
Cr.) , And at a cost of Pollution and natural resource.

Rs.

Energy Saving in Pump or Fan

Formula for power drawn by Pump or Fan

Power

Energy per second

(Work done) per second

(Force x distance) per second

(Pressure x area) x (distance) per second

Pressure x flow

Hence HP(Power) =

P (pressure) x Q (flow) ..... (1)

Affinity laws for pump

P

K1N ....................................................... (2)

K2N ......................................................... (3)

Where K1 & K2 are constants.

From (1), (2) and (3)
HP

PQ

K N ...................................................(4)

Conventional flow control by Pump or Fan

Outlet damper control for fan

Inlet vane control for fan
Throttling valves for Pump

Recommended flow control in Pump or Fan

Remove damper/valve or make it 100% open

Install AC VFD for speed control of motor
Adjust the required flow by changing the speed of motor
Closed loop operation or automation is also possible

PRESSURE (P)

PRESSURE (P)

Energy saving in fan

FLOW (Q)
FAN CURVE

System Curve

Fan Curve

FLOW (Q)
SYSTEM CURVE & FAN CURVE

120

120

100

100

80

80

% PRESSURE

% PRESSURE

Energy saving in fan : Output damper

60
40

60
40

20

20

0
20

40

60

80

100

120

140

160

OUTLET DAMPER - SYSTEM CURVES

20

40

60

80

100

120

140

160

%FLOW

OUTLET DAMPERHORSEPOWER REQUIREMENTS

OUTLET DAMPERS

Energy saving in fan : Inlet vanes

120

% PRESSURE

100

VARIABLE INLET VANES

80
60
40
20
0

120

20

40

60

80

100

120

140

160

I/P POWER

100
80

VARIABLE INLET VANES SETTINGS

60
40
20
0
20

40

60

80

100

120

140

160

VARIABLE INLET VANES

HORSEPOWER REQUIREMENTS

Energy saving in fan :Variable speed drives

Application case study for Fan/Pump

Industry

Grasim-Nagda

TATA Motors

Application

ID Fan

Water Pump

Motor KW

90KW

45KW

Starter

DOL

Star/Delta

Damper/Valve opening

65% open

52% open

Previous power

65KW

18.5KW

VFD speed with 100% damper

38Hz

32Hz

Power with VFD

43KW

9.7KW

Saving per hour

22KW

8.8KW

Payback

6 Month

8 Month

Different fan application in industry

ID fan
FD fan
PA fan
SA fan
Dust collector fan
Cooler fan
HVAC fan
Cooling tower fan
Exhaust fan

Different pump application in industry

Process Pumps
Cooling tower pump
Injection molding
Water supply pump
Sewage pump
ETP pump
Hydraulic pump
Vaccum pump

Energy conservation in Air Compressors

Rs.

Air Compressors
Common Equipment in All
Industries
Power Consumption - 5 to 30%
Engineering Industry - 30%
Paper, Cement & Chemical - 5 to 10%
Rs.

Savings Potential - 15 to 50%

Objective of AC VFD for compressors

Less maintenance
Rs.

Energy
conservation

Smooth Control

Type of compressors
Reciprocating
Screw
Centrifuge
Chiller
Lube

Concept - Conventional Control

P
r
e 7.0
s
s
u
r 6.5
e
Ksc 6.0

Upper Limit

Average Pr.

Lower Limit - Reqd. Pr.

Time

Install Variable Frequency Drive for

Air Compressor
PID

Compressor 1

VFD

Power In

Users

Receiver

Compressor 2

Compressor 3

With Pressure Sensor

Advantages

Operates at Lower Avg. Pressure

Proportional Savings

No Unloading
Less Leakages
Lower Pressure
Better Motor Efficiency

Concept - VFD Control

P
r
e
s
s
u
r
e
Ksc

Savings Due
to Pressure

6.5
6.1
{
6.0

With VFD
Reqd. Pr.

Time

Precautions (Reciprocating Compressors)

Lubrication Oil Pump Connected to
the same shaft
Lubrication Pump Output Depends
on the Speed
More than 30% Speed Reduction
Leads to Mechanical Problems

Alternative
Install Separate Lubrication Pump
Complicated
Details to be Studied

Case Study...
Company

TI Cycle

ACC

Duke

Make

Atlas Copco

Ingersoll R

ELGI

Motor Rating

50 HP

40 HP

50 HP

Power Without VFD

21 KW

12.5 KW

32 KW

VFD Frequency

40 to 45 Hz

38 to 43 Hz

35 to 40 Hz

Power with VFD

15 KW

6.5 KW

25 KW

Saving per Hour KW

6 KW / Hour

6 KW / Hour 7 KW / Hour

Pay back periods

1.8 year

1 year

1.5 Year

Conclusion
Good Potential in
Compressors

Savings Depend on
Operating Conditions
Advantageous for New
Compressors or Retrofit