schneider iiee 2013
TRANSCRIPT
It’s now time to save the world with…
ALTIVAR Variable Speed Drives
Altivar 12 Altivar 212 Altivar 312 Altivar 61 Altivar 71
Charles Nierves
Drive Champion
Make the most of your Energy
Efficient Motor Control With
Power Drives Systems
2Schneider Electric IIEE2013Summary
Efficient Motor Control With Power Drives SystemsSummary
> Energy consumers
> What is a Power Drive System ?
> EE by Motor optimization
> EE by EE by Gear optimization
> EE by Speed control of pumps and fans
> EE by Speed control - other opportunities
> Conclusion
3Schneider Electric IIEE2013Summary
> Energy consumers
> What is a Power Drive System ?
> EE by Motor optimization
> EE by Gear optimization
> EE by Speed control of pumps and fans
> EE by Speed control - other opportunities
> Conclusion
Efficient Motor Control With Power Drives Systems Summary
4Schneider Electric IIEE2013
Energy consumersMain Energy Consumers
Buildings + Industry are big energy consumers!
28%Transportation
31%Industry
& Infrastructure
21%Residential
18%Buildings
>2%Data centres &
networks
5Schneider Electric IIEE2013
Energy consumersMotor consumption in the world.
85% of drive systems are
Pump, Fan, Compressor
● in Building, Motors consume
36% of electricity *
● in Indu&Infr, Motors consume
69% of electricity *
* SAVE Programme of the European Union
6Schneider Electric IIEE2013
Energy consumersGlobal Motor Costs
Energy bill = Motor cost x 100
Energy
97%
Investment : 1%
Installation
& Maintenance : 2%
Global costs during Motor Life (average 15 years)
• Where goes your money ?
Big Motor:1 Month Energy Bill = Motor Cost
Beyond the investment, the key point is to secure an efficient motor control
7Schneider Electric IIEE2013Summary
Efficient Motor Control With Power Drives SystemsSummary
> Energy consumers
> What is a Power Drive System ?
> EE by Motor optimization
> EE by Gear optimization
> EE by Speed control of pumps and fans
> EE by Speed control - other opportunities
> Conclusion
8Schneider Electric IIEE2013
What is a PDS ?
Driven
Machine
Process
ControlVariable
Speed
Drive
Motor Gear
PDS
PDS = Power Drive Systems
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Compressor Example
Motor Control
Star/delta starting
Induction Motor
Gear
Pulley/belt
Driven machine
compressor
Process
AIR pressure
regulation
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Hoist Example
Motor
Planetary
Gear
Driven machine
Vertical Hoist
Speed control
By VSD
Process
Hoisting vertical
movement
11Schneider Electric IIEE2013Summary
Efficient Motor Control With Power Drives SystemsSummary
> Energy consumers
> What is a Power Drive System ?
> EE by Motor optimization
> EE by Gear optimization
> EE by Speed control of pumps and
fans
> EE by Speed control - other
opportunities
> Conclusion
12Schneider Electric IIEE2013
Driven
MachineGear
EE by Motor optimization
Process
VSD*
PDS
* Variable Speed Drive
Motor
2 main factors for energy savings :
Technology
Sizing
13Schneider Electric IIEE2013
Motors optimization Motor Efficiency
● Electrical motor efficiency (η) is the ratio between the mechanical shaft output power and
the electrical input power
● Internal losses (electrical, mechanical, magnetic, …)
0,80 0,87 0,93
Pmeca= Pelec * η Cosφ3IUPe T.ωPm
● For a similar motor power range the motors have not all the same efficiency
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Motors optimization IEC classification
New motor classification from
IEC 60034-30 (21/10/2008)For low voltage motors up to 375kW
Classe IEC 60034 Previous (EU) NEMA (US) *
Premium efficiency IE3 Premium
High efficiency IE2 EFF1 Energy Efficient
EPAct **
Standard efficiency IE1 EFF2 Pre-EPAact
Below - EFF3 Pre-EPAact
* Closest NEMA catégory there are slight differences, ** Energy Policy Act (1992)
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Motors optimization IEC classification
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Motors optimization Technology
● We are not motor manufacturer but ….
Starting January 1,
2015
Only IE3 can be
connected direct on-
line
IE2 will only be
accepted when managed
by speed drives
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Motors optimization Motor Sizing
● There are many good (and bad) reasons for oversizing
● Safety margin (cheapest way to ensure that there is no chance of the motor being overloaded)
● Forecast of installation life extension or production increase
● Need of very high transient power or torque …
● But as energy costs rise, and oversizing can rapidly becomes a wasteful and
expensive answer to this design issue
● Significantly over sizing a motor :
● Increases the capital cost
● Decreases the functional motor efficiency
● Can increase the motor’s operating speed (and so the energy consumption)
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Motors optimization Near future
● Up to now 90% of the motor are induction motors (they are robust, low cost, reliable)
● But Synchronous motors (with permanent magnets) will be used more and
more …
● They are more efficient than asynchronous motors (induction)● No need of magnetising current for creating the rotor flux
● Low speed and high torque design allow to suppress gearboxes
● The cost is still higher than asynchronous motors but as the quantities are
growing, the price should be less and less …
● We start to see some applications in pumps …
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Motors optimization
● Synchronous motors have to be
managed by frequency converters
● ATV71-61 (up to 800kW)
● Synchronous motor control open loop
● ATV32 (up to 15kW)
● Synchronous motor control open loop
20Schneider Electric IIEE2013Summary
Efficient Motor Control With Power Drives SystemsSummary
> Energy consumers
> What is a Power Drive System ?
> EE by Motor optimization
> EE by Gear optimization
> Speed Control
> EE by Speed control - other opportunities
> Conclusion
21Schneider Electric IIEE2013
Driven
Machine
EE by Gear optimization
Process
VSD*
PDS
* Variable Speed Drive
Motor
2 main factors for energy savings :
Technology
Maintenance
Gear
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Why a gear ?
● Why a gear ?
● Adapt Speed, Torque, Inertia
● Standard motors have generally a high
rated speed compared to machines
needs
● Low speed/high torque motors are
expensive
● Inertia of the load have to be close to
the motor inertia to avoid oscillation
during fast accelerations
● Change movement direction/angle …
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EE by Gear optimizationGear fundamentals
Motor
GearBox
Ratio = k
Efficiency =
Machine
angular speed
T torque
P power
(1) motor shaft
(2) machine shaft
● 2 = 1/k Speed reducer
● T2 = T1.k. Torque amplifier
● P2 = P1. Power transmitter
● J1=J2/k² Inertia adaptor
Power
(1) (2)
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EE by Gear optimization Efficiency
● Gear efficiency (η) is the ratio between the mechanical shaft output power and mechanical
shaft input power.
● Losses are due to mechanical frictions
● They can be speed dependent
● Higher the gear ratio, the higher the losses
Worm
0.50 to 0.80Pulley belt
0.90 to 0.95Planetary
0.85 – 0.90
● For a similar ratio, function of the technology, gears do not have the same efficiency
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EE by Gear optimization Maintenance
● Gear efficiency decreases with aging
● Pulley-belt system have to be well set and controlled
(tension and alignment)
● Gear needs oil or grease
● Careful sizing is needed (not to overload the pinions)
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EE by Gear optimization Opportunities
We are not gear manufacturer but ….
● ATS Soft Starter and ATV Speed Drives allows :
● Smooth start and stop -> avoid belt slip
+● Torque limitation -> protect pinion gears teeth
= Increase the life time of mechanical transmission and preserve efficiency
tAcc
ramp
Slow
down
ramp
Stop
ramp
Rated
speed
Low
speed
Spee
d
Time
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EE by Gear optimization Gearless systems
● Removing the gearbox is a way to simplify mechanical systems, save space
and allow for energy savings.
● But It needs specific motors high torque and low speed (multi-poles)
● However it occurs more and more
● Example for lift motors and extruders
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EE by Gear optimization Gearless systems
Conventional motor + gear
Low cost but …
● Poor efficiency
● Mechanical stress
● Oil in the gear box
Gearless systems
● Fewer mechanical parts
● Less space required
● Energy savings
● Noise reduction
● Need a speed drive to be controlled
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EE by Gear optimization Opportunity
● Gear less motors have to be managed by
frequency converters
● ATV71Lift (up to 75kW)
● For lift Asynchronous and Synchronous
motors open loop and close loop
● ATV71 (up to 800kW)
● Synchronous motor open loop
30Schneider Electric IIEE2013Summary
Efficient Motor Control With Power Drives SystemsSummary
> Energy consumers
> What is a Power Drive System ?
> EE by Motor optimization
> EE by Gear optimization
> EE by Speed control of pumps and fans
> EE by Speed control - other opportunities
> Conclusion
31Schneider Electric IIEE2013
Driven
MachinePDS
Motor
Main factors for energy savings :
Speed control
Process regulation
Start/stop management
Gear
Process
VSD
EE by Speed control of pumps and fans
32Schneider Electric IIEE2013
EE by Speed control of pumps and fansElectricity Consumption
For the processes and the building utilities :
● 65 % of energy is used for the fluid applications
In a typical building :
● 50% of all energy is used is for HVAC operations.
● Electricity consumption growth for air conditioning was around 55% in the last 10 years.
Compression
30 %
Pumping
20 %Ventilation
15 %
Process
35 %
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0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0% 20% 40% 60% 80% 100%
Flow
Power
Speed
Pumps and fansPower consumption
Power=K . Speed3
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How to waste energy ?Flow regulation with a valve
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This solution is bit like …
…regulate the speed of your car
by keeping one foot on the accelerator
the other on the brake.
Brake
still one of the most commoncontrol methods
….. with a considerable waste of energy
EE by Speed control of pumps and fansEnergy Wastes
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How to save energy ?Speed control
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EE by Speed control Potential energy savings with pumps
Depends on the design
and duty cycle.
With Speed control :
20% to 50%
savings
Power
Valve
Speed Control
Flow
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EE by Speed control Potential energy savings with fans
Depends on the design
and duty cycle,
With Speed control :
20% to 70%
savings
Speed Control
Power
Flow
Output valve
Input valve
DEMO
39Schneider Electric IIEE2013
EE by Speed control Energy saving motor control law
● Altivar integrates specific motor control laws which allow optimization of energy consumption
● Quadratic law (U/f = kN²)
● Command law dedicated to centrifugal pumps and fans
● Energy Saving law (NoLD)
● This law integrates a flux vector control that adjusts the magnetizing current as a function of torque.
Function of the load :
Up to 5%
savings more
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EE by Speed control PID Regulator – Sleep Wake up
● Altivar integrates functions to run the motor only when needed
● PID Regulator
● Function used to regulate a process (i.e. pressure in water circuit)
● Sleep / Wake Up Function
● Function which sleeps the application when there no demand
Sleep /
Wake UpPID Motor
Sensor
Reference
Output
Frequency
Feed
ba
ck
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● In addition to Energy Savings, using a Variable speed drive has
many other advantages :
● Less mechanical stress on motor and system (water hammer,
cavitations, ...)
● Less mechanical devices – Less Maintenance
● Reduce pumps or fan noise
● Flexibility
● Can be controlled with BMS, field bus, …
EE by Speed control Other Benefits ...
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what Schneider Electric can
offer to you ?
a wide range of
products
solutions
services
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To optimize your installationa complete range from 0.25 HP to 2400HP
from Compact to Engineered Drives
EE by Speed control Altivar Ranges
ATV12ATV312
ATV212
ATV32
ATV71-ATV61
Drive system
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EE by Speed control of pumps and fansATV212
HVAC applications for Buildings
ATV 212 up to 75kW
• low Harmonics
• PID Regulation
• no need for line Inductance
• reduced Losses
• easy integration in BMS (Building Mgt System)
• energy Saving Motor Control laws
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EE by Speed control of pumps and fansATV61
Pumps & Fans in Industry and Infrastructure
ATV 61 up to 800HP
Common features
● PID regulation
● connectivity with all Field Buses
● easy Settings
● guaranteed Performance & simulation Tools
● energy Saving Motor Control laws
Specific applications
● Ventilation : mastered Harmonics & enhanced Safety
● Pumping : Multi Pumps management
46Schneider Electric IIEE2013
EE by Speed control of pumps and fansEngineered Drives
Drives systems ready to use
ATV 61/71 Plus up to 2400kW
• High degree of protection
• Compactness
• Mastered harmonics
• Flexible offer
47Schneider Electric IIEE2013
EE by Speed control of pumps and fansECO2 calculation of energy savings
● ECO2
● Show the potential energy savings in a few
clicks
● Select the ATV
● Provides a report :
● The consumption with and without the ATV
● The potential savings
● The payback
● Based on the application and it’s duty cycle
ECO2
48Schneider Electric IIEE2013
Without
VSD
With
VSDSaving
Average Power / motor 104 kW 40 kW
62%CO² rate per year 459 t 175,5 t
Total annual Cost 34,9 k£ 13,3 k£
Payback period 10 months
EE by Speed control of pumps and fansExample : Tarmac (UK) : Extract Fan
● SE Commitment to reduce CO² levels
● Project & Services actions
● Audit to confirm the key point: extract fan
● Monitoring to analyze consumption
● Speed Drive installed
● Confirmation of final Saving
● Tarmac Benefits :
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Period April - February 2007- 2008
Without
VSD
2008 - 2009
With
VSDSaving
Electric
Consumption277 MWh 106 MWh 61,7%
EE by Speed control of pumps and fansExample : Schneider Electric Grenoble (F) : Primary Pumps on Heating
● Services actions
● Installation of Variable Speed Drives on primary
pumps of the installation of heating
● Two Altivar 61 15 kW installed on the 2 primary
pumps which provide the heating of buildings
T1, T2 and T7 on Grenoble plant
● Project in collaboration with Dalkia
● Schneider Benefits :
50Schneider Electric IIEE2013Summary
Efficient Motor Control With Power Drives SystemsSummary
> Energy consumers
> What is a Power Drive System ?
> EE by Motor optimization
> EE by Gear optimization
> EE by Speed control of pumps and fans
> EE by Speed control - other opportunities
> Conclusion
51Schneider Electric IIEE2013
The main target(first priority)
The next step
(second priority)
EE by Speed control - other opportunitiesWhat about other loads
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Modulation
All or NothingVar. Speed drive
EE by Speed control - other opportunitiesScrew Compressors
Different ways to regulate the pressure with a compressor :
● All or nothing
● Valve at the aspiration side, the valve is closed or open according to
the pressure demand
● Modulation with valves
● If the demand decrease an auxiliary valve opens progressively and
send back the air to the input.
● Speed variation
● Regulation with a variable speed drive
● Speed control benefits
● Savings up to 20%
● No current peaks
● Reduced mechanical stress
● Precise pressure regulation
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Centrifuge Compressor
Variable torque kN²
EE by Speed control - other opportunitiesCompressors with potential
Screw Compressor
Near constant torque
Scroll Compressor
Near constant torque
54Schneider Electric IIEE2013
EE by Speed control - other opportunitiesDC Bus connection
With Sharing of DC bus
MotorWinder
Unwinder
Generator
+-
Example of winder/unwinder
MotorWinder
Unwinder
Generator
Without Sharing of DC bus
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● Bus DC connection :
● Example :
Process machine with
Winder/Unwinder
EE by Speed control - other opportunitiesDC Bus connection
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EE by Speed control - other opportunitiesDC Bus connection
Example of multiple hoisting or elevators
+-
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● ATV71 option : the Network Braking Unit
● The power is regenerated onto the network
when the drive system is working as a
generator
● May replace braking resistors in system with
long generating cycle or high braking power :
hoisting, high inertia machines …
● For such applications, it's a good compromise
volume / efficiency / cost
● And the energy saving allows a quick
paying back (less than 3 years)
EE by Speed control - other opportunitiesRegenerative units
Drive
NBU
Generator modeMotor mode
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EE by Speed control - other opportunitiesActive Front End (AFE)
Feedback energy
Reduce energy costs
Increase power quality
Harmonic mitigation
… is an option to Altivar ATV61 and ATV71 range
59Schneider Electric IIEE2013
EE by Speed control - other opportunitiesActive Front End (AFE)
● Hoisting
● Downhill conveyors
● High inertia and high
dynamic applications
● Test stands
● Winches
Regenerative operation
● Weak main supply
● Utilization of full transformer power
● Generator supply
● Compliance to IEEE 519 THD
● Power factor correction
Harmonic mitigation
60Schneider Electric IIEE2013
Example of a Crane
EE by Speed control - other opportunitiesRegenerative units
Hoist1
250kw
Hoist2
250kw
NBU
or
AFE
Boom
250kw
NBU
or
AFE
Gantry1
160kw
Gantry2
90kw
Hoist3
250kw
Hoist4
250kw
NBU
or
AFE
Main Power
Supply
4x345kw 1x90kw1x200kw
61Schneider Electric IIEE2013Summary
Efficient Motor Control With Power Drives SystemsSummary
> Energy consumers
> What is a Power Drive System ?
> EE by Motor optimization
> EE by Gear optimization
> EE by Speed control of pumps and fans
> EE by Speed control - other opportunities
> Conclusions
62Schneider Electric IIEE2013
Driven
Machine
Energy Saving in PDSPotential of Energy saving
Process PDS
VSD* Motor Gear
Sizing
Technology
5 – 10%
Technology
maintenance
5 – 10%
Speed control
Process regulation
Start/stop
management
20 – 70%(Process + VDS)
* Variable Speed Drive
63Schneider Electric IIEE2013
How to optimize Power Drive System ?
● … But first of all think variable speed drive
Its about 5% to 10% of saving …
it can be 20% to 70% of saving
● You can improve the couple Motor + Gear …
Conclusions
64Schneider Electric IIEE2013
Conclusions
It is natural for
Bulbs
What has changed …..
● Consumption ÷5
● Life duration x5
Traditional
generation
New
generation
Speed Drives
……. what could change !
● Consumption, up to - 70%● Less Mechanical stress & less
Vibration Noise
… do the same for
Motors !Electromechanical
Speed Drive usage must become obvious !
65Schneider Electric IIEE2013Summary
uestions and Answers
Efficient Motor Control With Power Drives
Systems
66Schneider Electric IIEE2013Summary
Thanksfor your attention
Motion & Drives training
Make the most of your energy !