VFD & Energy Conservation

USAGE OF VFD FOR ENERGY CONSERVATION

FOR BETTER TOMORROW

Energy Crisis

Global Energy Scenario:

Current scenario is that everywhere the energy has got a
limited source at continuous increasing cost.
Coal, oil and natural gas, nuclear, hydro are the major
energy resources.
Availability of fossil fuel is limited. It is expected to last for
about a 100 years.
THUS.
Energy can only be earned by saving it

Profit increasing by eliminating waste:

As now a days and henceforth price control is not in hand of
manufacturer, the only option to increase the profit margin
is, eliminate the waste to the best possible.

Kuwait electrical energy data base

Kuwait pay among the lowest prices for power in the world.

The government charges a highly subsidized rate of 2 fills

per kWh while the cost of production is between 20 - 25 fills
per kWh.
Kuwaits power demand has been growing rapidly and is
expected to increase at 7-9 percent, which is well above the
world average of 3 - 4 percent.
MEW estimating the demand for power to climb to
20,000MW by 2015 and 26,000MW in 2020, Kuwait plans
to invest billions in doubling its installed capacity through a
number of projects by 2017, from currently 10,200MW to
27,040MW.

Why energy efficient industry???

Industry is motivated to become more energy efficient for

variety of reasons, including but not limited to:

Cost reduction.
Improved operation reliability & control.
Ability to increase production without requiring

additional & possibly

constrained energy supply.

Recognition as a green company.
Access to investor capital through demonstration of effective management
practices.

Energy usage in Industry

More than half the energy consumed by AC motors powers in any industry.
Electrical energy costs are often the largest expenditure for

industry owners.

Reducing energy demand and improving the working

environment of a industry are main objectives of facility

managers.

The principle reason for using VFDs is to reduce energy costs.

Electric Motor Facts

Electric motors account for more than two-thirds of all energy used in
industry.

63% of the energy consumed is linked to air & liquid flow.

A typical 50HP industrial motor, with an efficiency of 90%, costs over

$25,000 to operate continuously over a year.

Typical Electrical Loads

Heating Ventilation & Air Conditioning (HVAC) ,Fans

& Pumps are some of the largest electrical loads in
commercial buildings. Pumps and Fans are also major
loads in industrial manufacturing processes.

Conventional methods of flow control,

before Variable Frequency Drives?

Dampers & Valves (very inefficient)

Air Dampers & Valves limit flow by placing a
restriction in the system. Most pumps and fans do
not shut down when the system is satisfied.
Imagine pressing the accelerator of your car to the
floor and trying to slow the car down by pressing the
brakes at the same timewasteful!

Scope for energy conservation

Conventional method for controlling process parameters, which

results in under load utilization of motor.

Flow/Volume control by
Throttling output valves.
Adjusting output dampers.

Intermittent loading and unloading at driven

system.

What is a VFD?
A Variable Frequency Drive is like the throttle on a car
It adjusts the speed of an drive based on demand, to save

energy and prolong motor / mechanical component life.

Without a VFD, an HVAC fan, pump

motor or Blower motor is either 100% on or 100% off

A VFD eliminates the initial power surge

and mechanical shock of switching the

motor from off to 100% on

VFD Applications
A VFD conserves energy :when an
1).HVAC control systems senses that a fan or
pump motor can meet heating or cooling needs,
with reduced operation of electrical drives.
2).Damper controlled Blower motor, is replaced by
VFD driven motors.
3).Throttled Discharge Valve Pump Motor, replaced by VFD driven pump motors..
..
All the above conditions can be met by running the electrical motors main driving
component of the industry at less than 100% power consumption.

How Does A VFD Work?

It changes the speed of a fan or pump motor by adjusting or varying the

frequency and voltage.

Typical frequency adjustment range in

Motor applications is from 10 - 50Hz AC.

A VFD is wired in series between main

power and motor.

A Bypass is added to Bypass the VFD

and run on main line power so HVAC

operation is not interrupted if the VFD
needs servicing

How Does A VFD Vary the Frequency?

A VFD, AC inverter, or electronic speed controller for AC motors

converts the AC supply to DC using a rectifier (diode), then converts it

back to a variable frequency by using a inverter bridge.
VFD Block Diagram

Motor

Main
Power

Rectifier

Capacitor

Switches
(IGBTs)

Motor

Estimating Energy Savings

Motor Nameplate Data

Motor Hp
Motor Efficiency

Operating Hours of the Fan or Pump / Year

Load profile (% amount loaded and for how long) For
industrial processes, this needs to be monitored to develop
accurate savings numbers.
Cost per kWh
Drive and Installation cost
Payback Calculation

Case Study-1

Pumps/Fan flow control

Affinity laws for Centrifugal Equipment

Power Saving

Case Study-2
Volume control by controlling damper opening.
EQUIPMENT : BOILER
ID/FD FAN: It is meant for supplying the air for combustion of fuel for utilization of

thermal energy for production of steam. There will be a change in required amount of
volume of air for combustion as per change in steam demand from processing area.
Existing system for air volume control

An electro-mechanical operated setup is provided for controlling the openings of

damper at the inlet of fan. Damper will be operated as per the change in steam
demand keeping the electrical motor of fan, running at constant speed.
Details of Utilization of system : (8.0 running hours) Fan motor capacity: 25 HP (18.5
KW)
Damper opening Stage /Duration for damper Capacity utilization

of motor capacity
100% Initial firing for 1Hour
75 - 80%
75% Normal running 6 Hours 55 - 60%
Below 25%1 Hour Stopping of fire 35 - 40%

20 - 25%
40 - 45 %
60 - 65%

Loss of design

position

Energy Savings Damper controlled blower

Potential energy savings using a VFD vs. modulating flow with a

damper.
140
130

Damper

120

Input Power (%)

110

VFD

100
90

Ideal Fan
Control

80
70

Energy Saving
Potential

60
50
40
30
20
10

Flow Rate (%)

10

20

30

40

50

60

70

80

90

100

VFD & Air Volume Control

Proposed system for air volume control

To remove electro-mechanical operated setup provided

for controlling the openings of damper and the damper
at the inlet of fan and to install variable frequency drive
(VFD) for fan motor. By this we can achieve the variable
speed of motor resulting required volume of air as per
combustion requirement w.r.t. Steam demand.
CONCLUSION: This method of volume control is energy

efficient and we can eliminate energy wastage by more

than 35 - 40%

Case Study-3
FOR INTERMITTENT LOADING/UNLOADING
EQUIPMENT:AIR COMPRESSOR CAPACITY:300 CFM
MOTOR: 75 HP (55 KW)
EXISTING OPERATION:

Air compressor normally runs at discharge pressure ranging between 7.0 to 8.0
kg/cm2.
Compressor is made 'LOAD' at 7.0kg/cm2 and 'UNLOAD' at 8.0 kg/cm2 pressure,
keeping the motor running at constant speed at both 'LOAD' and 'UNLOAD'
running mode.
Details of Utilization of system : (8.0 running hours)
Running mode %Duration
Capacity utilization
of motor capacity
Load
84 - 85 %
75 - 80% 20 - 25%
Unload 15 - 16%
40 - 45% 55 - 60 %

Loss of deigned

VFD & Compressor Operation

A required output of compressed air (cfm) can be

made variable w.r.t. demand from process area, with

a speed variation option. Speed variation of air
compressor can be achieved by installing variable
frequency drive (VFD).
CONCLUSION: This method of cfm control is energy

efficient and we can eliminate energy wastage by

more than 25 - 30%

Conclusions on Energy Conservation

Energy conservation has saved the need for many power

plants and fuel imports.

It has also avoided CO2 and environmental pollution.
Much has been done, but much more can be done.
In this new era of global warming and high energy costs
and energy shortages, the public must be informed and
politicians sought who are sensitive to these issues.
Using VFDs greatly reduces energy consumption,
hence it is called environmentally GREEN technologyI
like to say it puts $GREEN$ in your pockets

SUMMARY
INSTALLATATION OF VFD FOR
UNDERUTILIZED DRIVES RESULTS IN
CONSIDERABLE SAVING OF ELECTRICAL
ENERGY.
RATHER
VARIABLE FREQUENCY DRIVE IS VERSATILE
MEANS OF ENERGY CONSERVATION.

Questions Sessions & Thanks note