VFD Drives for Energy Efficiency Improvement -Reducing Life Cycle Cost

Transcription

1 VFD Drives for Energy Efficiency Improvement -Reducing Life Cycle Cost

2 Danfoss Drives Danfoss is a leading supplier to the Water sector world-wide, with a dedicated product range and organisation. The company has over 40 years experience in the application, commissioning and service of VLT Series variable speed drives & soft starters. This includes supply of standard factory production and engineered high power package solutions for a broad array of applications on numerous Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

3 Dedicated since 1968 Complete product range up to 690 V From 0.18 kw to 1.4 MW VLT AutomationDrive VLT AQUA Drive VLT HVAC Drive VLT 2800 VLT MicroDrive VLT Decentral drives Customized drives Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

4 Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

5 Energy Saving Changing the speed of a pump reduces power At 50% speed pumps only consume 20% energy (theoretical) Considering all factors the real saving is around 60% Over an average duty cycle the saving is typically 25% Simulation of actual savings in dedicated software Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

6 Beyond Installed Cost Low component cost can result in: High maintenance cost High operating cost Long real payback time Increased need for additional components Higher requirement for clean environment Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

7 Heat Dissipation Heat Loss [W] The actual energy consumption depends on all components Heat dissipation is different Danfoss Required air-conditioning of panels Competitor and control rooms are different Difference can be more than 30% Cooling require 3kW for every 1kW of heat dissipated (with A/C) Heat dissipation should be part of specifications Power [kw] Competitor NO 11 FC202 - NO Competitor NO FC202 - NO FC202 - NO Competitor NO Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

8 Cooling Concept Back channel cooling removes 85% heat from panel and control room With back channel cooling A/C is not required in most control rooms Liquid cooling is an alternative, but introduces water in electrical installation Liquid cooling may also require installation of water cooler Panel through removes 75% heat from panel Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

9 All In On Package Supply of a high enclosure rating from factory (IP54 or IP66) Factory built-in options like: Disconnect Fuses RFI filter Harmonics filter Cascade controller Built-in compensation for long motor cables Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

10 Pump dedicated functions Pump controller built in as standard 3 pump standard cascade control Or 2- pump with lead pump alternation Extended option card for up to 5 pumps Advanced option card for up to 8 pumps with master / follower function Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

11 Reducing Harmonic Distortion Harmonics increase the dimensions of cables and transformers Built-in AC or DC coils reduce harmonics to acceptable basic level Advanced passive or active filters can reduce it further Manufacturers can offer simulation based on system Danfoss MCT31 is a downloadable freeware tool Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

12 Coated PCB In harsh environments the lifetime of electronic equipment is reduced due to the impact of the environments. To increase the lifetime the PCB s can be conformal coated according to IEC There are several levels of conformal coating described in the IEC norm. Water applications: Chlorine etc. Wastewater applications: Hydrogen sulphide, Amonium etc. Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

13 Location. Definition of where to use what? Class 3C1: Applies to rural and urban areas with low industrial activities and moderate traffic. Be aware of that salt mist may be present in sheltered locations of coastal areas Class 3C2: Applies to locations with normal levels of contaminants, experienced in urban areas with industrial activities scattered over the whole area, or with heavy traffic. Class 3C3: Applies to locations in the immediate neighbourhood of industrial sources with chemical emissions. Environmental conditions may be affected by other influences like heating, dust and special process conditions. Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

14 Typical enviromental conditions in water applications In waste water plants there are several gasses in the air Hydrogen Sulphide, Ammonia and Nitrogen Oxides + etc. Dust and high humidity is present as well In drinking water applications, Chlorine is quite often present. In all water applications there might be a pretty high humidity which will lead corrosion etc. Hydrogen Chloride will also be present in most of the applications Specifications for use in extreme or special environmental conditions are always a matter for negotiation between supplier and user. Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

15 Conformal Coated PCB s For harsh environments Water applications: Chlorine etc. Wastewater applications: Hydrogen sulphide, Ammonium etc. IEC Class 3C2: standard. Class 3C3: option </=250kW. (Standard on 315kW 1.2MW, E & F frame) Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

16 Maintenance of Drives Some drives require exchange of fans and app. 2 years Design life specification differs: Some state 80% load Others 100% load When operating outside design life specification lifetime is reduced A minor added cost can extend life time significantly Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

17 The Intelligent Drive Built-in PID controller can save EUR 160,- plus installation cost Panel door mounted keypad can save: Meters (voltage, amperes, power, pressure, flow etc. app. EUR 100,- each) Hand-Off-Auto from keypad (EUR 10,-) Trend curves Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

18 Protecting The Installation Motor preheat with DC injection Prevents motor condensation Saves cost of motor heater Motor overload and thermal protection Saves cost of motor thermal protection No flow / low flow monitoring Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

19 Ramp control Pumps and other applications have specific start and stop requirements Multiple ramps are required to provide optimum operation Pumps started too slow are damaged due to low cooling and cavitations Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

20 Check Valve Protection Check valves are damaged when closing too quickly or in case of water hammer To prevent damages special check valves are used with additional cost of 60% Using the check valve ramp a standard valve can be used in stead saving this add-on cost (DN40 = EUR 189,04 = 5,5kW pump) Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

21 Ramp control Pipe fill mode can protect against water hammering In the event of water hammer pipes and equipment could be damaged In a calculated example one damage on a 110 mm pipe cost more than EUR 1.000,- in labour and pipe cost In addition check valves and pressure gauges had to be replaced Training on water hammer evaluation in April Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

22 Built-in scheduler Alternating the spare and lead pump will secure operation of spare unit, when needed Application specific actions can be scheduled without the need for a PLC, i.e. filter flushing Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

23 Communication Cross Road Remote I/O via serial communications built-in Decentralising I/O points Reduced cable cost Savings on PLC I/O modules Easier sensor and cable trouble shooting Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

24 Purchase vs. installed cost 12/1/09% Drives purchase cost Reduced panel Instruments IP 55 enclosure reducing cabinet space & ventilation Reduced installation time & cabling Stand alone control via RTC Disconnect switch RS485 Connectivity Real cost of Drive Just some of the Applied (System) Cost Savings utilising built-in drives features Confidential/Property of Danfoss Drives A/S Tuesday, December 1,

25 Please consider the environment and use VLT Drives for your next water or wastewater application. Danfoss can accept no responsibility for possible errors in printed material. Please consult equipment design guides / man uals for specific details / verify data. All images contained in this presentation are the property of Danfoss A/S or other parties where relevant & must not be copied. VLT is a registered trademark of Danfoss Drives) Confidential/Property of Danfoss Drives A/S Tuesday, December 1,