Variable Frequency Drive

Abhijit Vaidya & Vincy Dsilva

Content
 Introduction

 Types of VFD

 Application and Advantages

 VFDs at DTPS

 Case Study

 Forward Path

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 Introduction

 A Variable Frequency Drive (VFD) is a system for controlling the rotational speed
of an electric motor by controlling the frequency and voltage of the electrical
power supplied to the motor.

 VFDs are also known as Adjustable Frequency Drives (AFD), Variable Speed
Drives (VSD), AC drives or Inverter drives.

 VFDs enhance process operations (particularly where flow control is involved),

provide soft-start capabilities and offer significant electrical energy savings.

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 Concept
120 * Frequency
Motor
Speed
Speed 
Control
Poles

Voltage
Pump
Speed
Torque
Control
Frequency

Flow
Control

If VFD provides power at 40 Hz, the synchronous speed would be 1200

rpm. ( if p = 4 )

Ns = 120x40/4 = 1200 rpm

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Types of VFD

 Based on Technology

- Current Source

- Voltage Source

- PWM

 Based in Voltage

- Low Voltage

- High Voltage

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VFD Applications
VFD applications can be divided into the following Individual load types.

 Constant torque loads: (other than pumps and fans).

Examples:- Conveyors, positive displacement pumps,

reciprocating compressors & rotary compressors.

 Constant power loads:

Examples:- Winders, Wheel grinders, Large driller machines, lathes,

planers & boring machines

Traditionally, these loads were considered DC drive applications only.

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VFD Applications
 Variable torque loads: Variable torque loads are most often found in variable
flow applications.

Examples:- Fans, Centrifugal blowers, Centrifugal pumps, Propeller

pumps, Turbine pumps, agitators, and axial compressors.

VFDs offer the greatest opportunity for energy savings when driving these
variable torque loads

Many of variable torque loads operate for extended periods at reduced load with
flow restricted or throttled.
In these centrifugal machines, energy consumption is proportional to the cube
of the flow rate. Even small reductions in speed and flow can result in significant
energy savings.

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Variable Torque Applications
Affinity Law
HP α Pressure X Flow
Pressure α Speed2
Flow α Speed
HP α Speed3
2 3
Q2 N2 P2  N2  HP 2  N2 
 ;   ;  
Q1 N1 P1  N1  HP 1  N1 
Where: N = Pump Speed
Q = Flow
P = Pressure
HP = Horsepower

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Advantages of VFD
 Energy Saving
 Process Control
 Soft Starting
- Low Starting Current
- High Starting Torque
- Reduction in Thermal Stress on Motor
 Improved Power Factor
 Reduced Mechanical Wear and Tear
 Noise Level Reduction

Disavantages of VFD
 Harmonic Generation
 High Investment

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VFDs At DTPS
 At DTPS we have implemented VFDs for the following
- Condensate Extraction Pump 1A & 2A

- Primary Air Fan 2A & 2B

- Coal Mill Seal Air Fans

- Colony Drinking Water Pump

- Service Water Pump

- Silo Vent Fan

- Silo Classifier A & B

- Silo Classifier Inlet/Outlet Rotary Feeders

- FGD HP Pump

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 Case Study 1 : SAF LV VFD

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 SAF LV VFD Panel

INV/Bypass Selector INV/Bypass Selector

I/P I/P

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 SAF VFD Local Panel
Local Controller

Local Indications

Local Start/Stop PB

Control Supply Source Selector

Remote/Local Selector
Local Potentiometer

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 SAF VFD
Remote Speed
Control

Potentiometer at PCR

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SAF VFD Selection Scheme PCR
Pot

SAF A Module SAF B Module

I/P I/P

VFD VFD
Selector Selector

Bypass Bypass
VFD

Motor Motor
A B

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SAF VFD : VFD Mode PCR
VFD Selected Pot Bypass Selected

SAF A Module SAF B Module

I/P I/P

VFD VFD
Selector Selector

Bypass Bypass
VFD

I/L Damper I/L Damper

Saving : 60 KW Motor Motor
A 100% Open 30% Open B

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SAF VFD : Bypass Mode PCR
VFD Selected Pot Bypass Selected

SAF A Module SAF B Module

I/P I/P

VFD VFD
Selector Selector

Bypass Bypass
VFD

Motor I/L Damper I/L Damper Motor

A 100% Open 30% Open B

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Seal Air Fan Motor : 120 KW
 Energy Saving : 62 KW per Fan

 Soft Starting
- Low Starting Current
- High Starting Torque
- Flashover of Module Eliminated
- Thermal Stress reduction of Motor

 Reduction on Mechanical Wear and Tear

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Case Study 2 : CEP VFD

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 VFD/Bypass Isolator VFD Panel
Panel
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 Motor Breaker Panel PCR Control Desk

SPAJ Relay
Selector Switch
RAMDE Relay

Bypass VFD

VFD - Bypass Indication

CEP VFD Control
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 CEP MV VFD : HMI Pad
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CEP MV VFD : VFD Mode
PCR Deaerator
DCS Command
VFD Bypass Selector

VFD
100%
Open

VFD Bypass IS1 IS3

IS2 Saving : 130 KW

SF6 Breaker
Motor
VFD/Bypass Panel

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CEP MV VFD : Bypass Mode
PCR Deaerator
DCS Command
VFD Bypass Selector

VFD
60%

VFD Bypass IS1 IS3

IS2
SF6 Breaker
Motor
VFD/Bypass Panel

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Alarms & Trippings
 Alarms/VFD Trouble in SOE
- Cabinet Door Open
- Cabinet Fan Fault
- Controller Not Ready
- Power Cell Over/Low Voltage, Over Current
- Power Cell Overheat > 400 C
- Transformer Overheat > 900 C
- Power Cell Bypass (Max 2 Cells)
- AHU Trouble (Cooling Pump or Air Blower not in service)
 Tripping
- Power Cell Overheat > 450 C
- Transformer Overheat > 1000 C
- 3rd Power Cell Bypass
- Motor Fault
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Energy savings through VFD at DTPS

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Energy Saving at DTPS due to VFD
Total amount
Running Energy Total energy
Sr.No. Application Population saved upto Sept
Drives saving saving
2010
Nos Nos KW KWH ` in Lakhs

1 SAF 6 4 251.48 5542070 193.97

2 CEP 1A 2 1 52.97 1248563 43.70

3 CEP 2A 2 1 134.08 3345661 117.10

4 SILO 2 1 26.13 560841 19.63

5 LDO/Service WP 1 1 2.16 260559 9.12

6 CDWP 1 1 16 188348 6.59

Total
390.11

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Energy Saving at DTPS due to VFD
Power Energy Amount
Type Population
Saving/Month Saving/Month Saved/Month
Nos KW KWH ` in Lakhs

LV Drive 8 293.61 6291259 4.02

MV Drive 4 187.05 4594224 4.84

Total 12 480.66 10885482.71 8.87

Average Monthly Saving `10.5 Lakhs/Month

(@ 3.5/unit)

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Thank you
 Power Cell Status
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