Unidrive M Energy Savings

Transcription

1 Unidrive M Energy Savings

2 Why is this important? Some Data: Money, Lots of Money >13.5m electric motors 1Hp or greater installed in US industrial process operations. Industry spends >$33b annually on electricity for electric motor driven systems. Industrial motors system electricity accounts for 24% of all electricity sold in Industry consumed 691b kwh in process motor driven systems plus an additional 68b kwh per year on HVAC. In the US industrial sector, 70% of all electricity consumption involves motor driven systems. 59% of this goes to pumps, fans, blowers and compressed air systems large plants account for 35% of total industrial motor energy consumption. (Chemical, Paper, Mining, Metals) Global Competition US energy consumption is 60% higher per person than our European competitors Source: Department Of Energy Slide 2

3 Energy Savings Agenda: Increase profitability through best in class energy savings technology All Unidrive M models include control algorithms that can save energy in all applications particularly fans and pumps Unidrive M drives can be connected in energy savings common bus and regeneration configurations for multi axis and overhauling load applications Unidrive M600-M810 when coupled with Emerson Permanent Magnet motors from Leroy-Somer provide exceptional energy savings Reduce operating costs Slide 3

4 Energy Savings Opportunities by Type of Load Variable Torque loads offer the greatest potential for Energy Savings due to inherent operating characteristics Load torque (increases) with speed. Centrifugal Fans & Pumps Some Constant Torque & Constant Power loads offer energy savings but are typically implemented to improve the process and reduce a wide range of costs Conveyors, Positive Displacement & Reciprocating Pumps & Compressors, Web Handling, Production Machinery Slide 4 4

5 Introduction How do AC Variable Speed Drives Save Energy? Slide 5

6 Variable Torque Loads Load requires much lower power at low speeds than at high speeds. Fan and Pump loads obey the AFFINITY LAWS. Volume Flow is proportional to the speed. Pressure is proportional to the speed squared. Power is proportional to the speed cubed. Audible noise is proportional to speed to the 5 th power. Therefore, if the speed can be reduced, the opportunity for energy savings is great. Slide 6

7 Variable Torque Load Characteristics At 80% Speed (Flow), theoretical Power consumption is 50% of rated. % HP and Torque HP Torque Flow % Speed Reduction in speed = significant reduction in energy Slide 7 7

8 Variable Torque Load Characteristics NOTE: At 50% Speed (Flow) the theoretical Power consumption is only 12.5% of rated. % HP and Torque HP Torque Flow % Speed Slide 8

9 Fan Power Requirements with Different Control Methods Input Power (%) Damper Inlet Guide Vanes Disc Throttle Variable Pitch Axial Fan Unidrive M Flow Rate (%) 9

10 Unidrive M Dynamic Volts/Hz Feature: Slide 10

11 Unidrive M Dynamic Volts/Hz Feature: Variable (Dynamic) Volts/Hz - Maximizes Energy Savings. - Automatically Optimizes the drive output voltage to match the requirements of the load. - Also minimizes motor noise. - Results in about 10% more energy savings. Even at 60Hz. Voltage Slide % Speed

12 VFDs and Fans Common applications in Industrial and HVAC systems. Exhaust Fans Dust Collectors Condenser Fans Fume Hoods Cooling Tower Fans Oven Fans Air Circulation Fans Slide 12

13 VFDs and Fans Typically sized for maximum flow Systems typically operate at less than designed levels Flow control is normally achieved using either an output damper or inlet guide vanes Engineering safety factor is typically 20 to 30%. Consumed Power ~ Speed 3 Slide 13

14 Owens Corning 500HP fans. 3 x 500HP fans on fiber glass production line. Changed from damper to variable speed control. VSD Installed cost - approx $390,000. Energy savings - $225,000 per year Payback period - 1 year 9 months. Increased equipment life. Reduced maintenance / noise / vibration $225k on the bottom line every year after payback! Slide 14

15 Owens Corning Fan Drives Slide 15

16 Pumps Typically sized for maximum flow Systems typically operate at less than designed levels Flow control is normally achieved using an output control valve Centrifugal Pumps will be considered Slide 16

17 Pumping Systems Efficiency Average pumping efficiency is below 40% Over 10% of pumps run below 10% efficiency 70% is a typical design efficiency for a pump Major causes: Oversized pump & system not designed to run near pump s best efficiency point (BEP). Pump draws too much power - results in added vibration, bearings run hot with substantially reduced life, packing has short life, high rate of mechanical seal failure. Over-use of Bypass Valves & Throttling Valves Oversized valves make good process control nearly impossible. 65% of control valves <50% open, with many <30% open and 15% at startup. Source: Finnish study of 1,690 pumps at 20 process plants (Expert Systems for Diagnosis of the Condition and Performance of Centrifugal Pumps) Slide 17

18 Pump Operating Principles The Pump characteristics are Head (pressure differential across the pump) in ft or lb/in 2 Flow in GPM (this is what we want to control) Slide 18

19 Pump Operating Principles Slide 19

20 Pump Energy Savings Slide 20

21 VFDs and Pumps Control Pump Speed for process control Regulate Flow Save Energy Payback periods of 8 months to 2 years depending on: Duty Cycle Energy Costs Slide 21

22 VFDs and Pumps Provide significant energy savings when: Centrifugal Pumps are operated at low flow rates Existing system has bypass control Local electricity costs are high High utilization Low static head Any one item will often provide payback within 1 to 2 years. Slide 22

23 Unidrive M - Additional Benefits Elimination of expensive valves and valve controls Reduces power surges and stress associated with across the line starting Provides accurate flow control Longer pump and seal life Reduced wear Less audible noise Better power factor Slide 23 23

24 Fan & Pump Easy Energy Savings Estimator Data inputs: Duty cycle Rebates/Incentives Cost/kWh Motor efficiency Calculates: Cost Savings CO2 savings Payback time Slide 24 24

25 Overhauling Loads In some constant torque applications, process tension differences, downhill loads, or machine inertia may cause the driven machine to overhaul the drive motor In these cases the motor must provide hold-back torque to brake the load Historically this has been done with mechanical brakes, braking resistors or DC regenerative drives There are two energy savings solutions available with Unidrive M Slide 25

26 Unidrive M Regeneration Enhanced Active Front End (AFE) power quality converter (REGEN) Active Front End (AFE) to return excess braking energy back onto the power line, reducing energy costs instead of dissipating this energy as heat The AFE provides power factor control for power quality management and greatly reduces unwanted power harmonics Bi directional power flow Slide 26

27 Unidrive M Common Bus Unidrive M products frame 2 and up have DC bus terminals for easy connectivity Connecting multiple drives together allows power to circulate and the only energy required to overcome system losses is consumed Applications include winders and other continuous process lines Slide 27 27

28 Unidrive M Energy Efficiency Features Low losses, up to 98% efficient Fan speed intelligently managed to the loss requirements of low load Energy saving low power standby mode In some applications, drives can sit idle for significant periods; Unidrive M s reduced standby power saves energy Selectable hibernation of keypad and I/O 2kHz switching frequency Reduced drive losses Less requirement for motor dv/dt filters Slide 28

29 The Energy Challenge for Electric Motors Total cost of a drive system Over 10 years Slide 29

30 PM Motor Advantages Key benefits of VFD control of Permanent Magnet motors: 1. Higher efficiency than induction motors 2. Smaller frame size and lower weight PM IM Efficiency Permanent Magnet Induction Motor Speed Emerson Permanent Magnet Motors to 550hp Use Unidrive M to control PM motors Slide 30

31 Dyneo: performances Losses & efficiencies of an electric motor 75Hp 3600rpm 79.8Hp (Dyneo) 82.2Hp (Nema Premium) Loss = 4.8Hp Losses at 93.9% eff. w/vfd (Dyneo) 75Hp Loss = 7.2Hp Losses at 91.2% eff. w/vfd (Nema Premium) Slide 31 If efficiency increases by 2.7%, Then losses decrease by 33%

32 Dyneo: performances Energy saving 95.5% 97% 95% Efficiencies 4p Vs Cnom & 1800 rpm w/ VFD LSRPM 93.1% 93% 92.1% 91% Standard efficiency 89% 87% 85% 3 3,7 4 4,5 5,2 5,5 6 7,5 8,2 9 10, ,6 18,5 19, , Power Puissance Slide 32

33 Dyneo: performances Energy saving 97% 95.5% 95% 93% Efficiencies 4p vs Cnom & 900 rpm w/ VFD LSRPM 91% 89% 87% 84.8% 85% 83.8% 83% 81% 79% 3 3,7 4 4,5 5,2 5,5 6 7,5 8,2 9 10, ,6 18,5 19, , Power Puissance Standard efficiency Slide 33

34 Dyneo: efficiency / speed 95,00% 90,00% 85,00% 80,00% Rendement Efficiency (%) ) 75,00% 70,00% 65,00% 60,00% 55,00% Rendement AC motor MAS + VFD sur var fonction according vitesse to speed PM efficiency Rendement according PMto fonction speed vitesse 50,00% 45,00% 40,00% Speed Vitesse Slide 34

35 Dyneo Compactness Permanent magnet motors are more compact than asynchronous solution: size reduction up to 3 frame size LSRPM 405 T Range 3600 / 300 Hp 730 lbs Frame size 449T Cast iron motor 2 poles / 340 Hp 3080 lbs Slide 35

36 Energy Savings - SUMMARY Increase profitability through best in class energy savings technology All Unidrive M models include control algorithms that can save energy in all applications particularly fans and pumps Unidrive M drives can be connected in energy savings common bus and regeneration configurations for multi axis and overhauling load applications Unidrive M600-M810 when coupled with Emerson Permanent Magnet motors from Leroy-Somer provide exceptional energy savings Reduce operating costs Slide 36

37 Awards and Standards Compliance Frost & Sullivan Award 2013 Unidrive M has received a product development award from independent global market analyst Patents signify Unidrive M s innovation Unidrive M has gained over 30 patents in its development. Conformal Coating Standard across the family to increase environmental protection RoHS Compliant Meets global standards for haz. mtls. Slide 37

38 Emerson AC Drives Fan and Pump Key Features and Benefits Supply Dip Ride through - The drive can automatically ride through momentary power dips by reducing speed and then returning to set speed when the supply recovers without tripping. Load Speed Supply Voltage Time Slide 38

39 Emerson AC Drives Fan and Pump Key Features and Benefits Flexible Reference Control, choose from: - Analog 4-20mA, 20-4mA, 0-20mA, 20-0mA or 0-10V - Multiple Preset Speeds - BACNet, Metasys-N2, LonWorks, Modbus, Ethernet, DeviceNet, Profibus, more Slide 39

40 Emerson AC Drives Fan and Pump Key Features and Benefits Skip Frequencies For bypassing of mechanical resonance's reduces wear on the system Actual Drive Frequency Actual Drive Frequency jumps past critical points Skip Frequency 1 Skip Frequency 2 Set Point Slide 40

41 Emerson AC Drives Fan and Pump Key Features and Benefits Independent PID loops For stand alone process control of flow or pressure or level No need for external controller, save $$$ Level Set Point Level Transducer Reference Feedback P I D Output Drive Frequency Slide 41

42 Energy and Power Metering Power consumed, operating costs per hour, power up time log and maintenance flags are all standard features providing free Asset Management tools. Provides no cost proof of savings (+/- 5%) kwh Slide 42 42