2012年11月27日星期二

Variable Speed Drives – Understanding Your Application – Part II


In Part I, defining your application and its specific characteristics is critical to ensuring a cost-effective and successful drive installation. In addition to the mechanical considerations we discussed in Part I, there are several electrical line and load-side issues which should be factored in when deciding on the right drive (or no drive) for your process. Because there are many factors involved we will cover supply side issues for AC drives this week, and load side next week. Future posts will discuss DC drive applications in detail.
Line (Supply) Side Considerations:
  • Voltage: Modern variable frequency drives (for AC motor applications) are rated to accept a nominal voltage with a typical +10/-10% tolerance. Outside of this range, the drives will usually trip out to protect themselves. In the case of an over-voltage condition, the risk is to the DC bus, which typically runs at about 1.2x the incoming voltage level. Once that level exceeds about 1.4x of the upper end of the incoming voltage range, the drive will trip out on OV. (Note that unlike AC drives,  due to the nature of their output electronics DC drives up to 500V can operate at lower incoming voltages; however, their output voltage reduces accordingly.) Output voltage, although tightly controlled by the drive, essentially peaks at the incoming voltage level, so in effect you get out what you put in. With a few special exceptions, drives will not replace step-up/down transformers.
  • Phase: Nearly all drives provide a 3-phase output, most often fed by a 3-phase supply. But drives are also specified for their ability to convert single-phase voltage to 3-phase, often instead of rotary or electronic phase converters. However, they do so at a cost – their DC electronics must be beefed up to handle the single-phase input. In essence, this is because the DC link capacitors are charging only 1/3 of the time they would if fed with 3 phase, so in order to smooth the DC bus ripple and supply the inverter with the proper voltage level they need to be higher capacity. Also, single-phasing results in higher line currents, so more conducting capacity is needed. Generally, an AC drive operated on single phase will need to be de-rated about 50% from its 3-phase rating, effectively doubling the size of the drive needed. You will find lower-power drives rated “out of the box” for single-phase input; these are simply drives manufactured to handle the higher capacity. Such drives are difficult to find at ratings above about 3kW.
  • Impedance: In cases where the upstream line impedance is too low (a.k.a. “stiff”), as for example with a drive system connected very closely to a main switchgear, the impedance may need to be increased to reduce the stresses on drive electronics caused by high current rate of change (i.e. di/dt). This is often accomplished by inserting line reactors on the AC line or chokes on the DC bus. Many modern drives come equipped with line reactors, typically providing 3% impedance; if more is needed, optional reactors can be obtained. These reactors have the added benefit of reducing harmonics on the supply line, the generation of which is inherent to most drive designs and which can cause operational problems for sensitive upstream equipment. (More on harmonics in a later post…)
  • Over-current protection: Drives provide extensive, user-programmable motor protection. However, they have limited built-in protection for their electronics, and proper installation requires the use of high-speed, low “I-squared t” over-current protection. Typically class J/gG fuses are specified to limit current and clear it very rapidly, before sensitive electronic components can be damaged. In some cases, drive manufacturers have tested and approved circuit breakers for this purpose. However, they tend to offer less rapid response, more challenging coordination with other protective devices, and, if set too tightly, trade nuisance trips for the convenience of not having to replace the unit once tripped. In any case, it is always advised to use manufacturer-recommended devices and ratings.
Next week we’ll move to the down-stream (load) side of the drive to discuss issues regarding motor supply and protection. In the meantime, please feel free to share your thoughts, questions, concerns, etc. in the Comments section. And as always, you can contact me with any questions, comments or application needs you may have at simon.fan@vtdrive.com. Thanks for reading!

Variable Speed Drives – Understanding Your Application – Part III


In Part II, we discussed several electrical line-side issues which should be factored in when selecting a drive. Life would be too easy if this were the whole story. There are several critical load-side (i.e. from the drive output to the motor) concerns which should be examined carefully because they can impact equipment life and your prime mover’s ability to perform the work necessary for the process.
Load Side Considerations:
  • Motor amperage: Drives are properly sized by amperage, not horsepower. In order to ensure proper output capacity, the driven motor nameplate full load amperage (FLA) should be known. It is important to note that sizing the drive based on FLA is not merely being conservative. Under the working assumption that the motor is sized correctly for the load torque needed, sizing a drive for only what the motor draws under “normal” (i.e. non-peak) load conditions may not provide sufficient torque to drive the process under heavy load conditions. Also, sizing a drive by horsepower alone ignores the amount of overload the drive can provide. For example, a 460-volt drive suited for a 75hp motor under variable torque conditions may be capable of putting out 96 amps continuously; under constant torque conditions (a.k.a. heavy duty) that same drive would only be suitable for 60hp and 77 amps. This is because under heavy load conditions the output electronics (typically IGBT’s or insulated gate bipolar transistors) are asked to fire for longer periods and are more subject to over-heating, so the ratings are backed down to protect them.
  • Voltage frequency and magnitude: These same IGBT’s are controlled by the drive circuitry to fire (switch on and off) at a high frequency, typically from 2kHz to 16kHz, creating high frequency voltage transients at the drive output. And unlike a pure, nicely balanced three-phase sine wave, the transients do not cancel each other out.  As a result, they can result in voltages at the motor terminals of 2-3x or more of the incoming supply voltage. This effect is greatly exacerbated by long motor lead length. Modern premium efficiency motors, particularly those in compliance with NEMA MG-1 standards, are built to withstand these transients, to a point. Once the motor lead lengths become excessive (depending on manufacturer and testing agency, anywhere from perhaps 30 meters and up), output filters are recommended.
  • Motor age/condition: In large part due to the factors mentioned above, care must be taken when attempting to control an older motor or one with a marginal insulation system with a variable frequency drive. The high frequency voltage transients can place a lot of stress on motor winding insulation, eventually causing breakdown of the dielectric and shorting out the windings. Also, common mode (i.e. line to “earth”) noise generated by the drive electronics can cause currents to flow in the motor frame, shaft and bearings; these currents will seek a path to ground, often resulting in pitting of bearings and races. This is not typically a significant factor for smaller frame motors (say, less than 500 NEMA/315 IEC), but larger motors often require insulated bearings and shaft grounding to prevent premature wear of the bearing components. And again, the problem is exacerbated by lead length, so even smaller motors may need protection if a sufficient distance from the drive.
  • Wiring: For the drive to operate cleanly and with minimal problems, good wiring practices must be followed – segregate power connections (line and load) from each other and from control wiring; use shielded cable, correctly grounded, where susceptible to common mode noise; provide metallic raceway where possible; and ensure the conductors are sized for the drive output current, with a properly sized grounding conductor. Consult the local/regional governing electrical codes for additional information.
So with all of the issues and concerns expressed in the first three parts of this series, why choose a drive in the first place? There are two primary reasons: energy savings, and reduction of electrical and mechanical stresses on driven components. Next week, we will discuss the first of these, and look at ways that drives can increase overall operating efficiency by effectively controlling the process for optimum output.
In the meantime, please feel free to jot down some thoughts in the Comments section. And as always, you can contact me with any questions, comments or application needs you may have at simon.fan@vtdrive.com. Thanks for reading!

VFDs and Energy Savings


Variable frequency drives (VFD’s) can provide significant energy savings and increases overall process/system efficiency by effectively matching the power applied to the level the process requires. By controlling motor speed, changes in load demands can be adjusted for quickly and automatically to maintain optimum process conditions. Also, the energy the driving motor needs to begin rotating, manifested as a high amperage commonly referred to as “in-rush” current, can be slowly increased to ramp up the motor while minimizing current draw. The VFD shares this soft-start functionality with the reduced voltage starter, often referred to as a soft-starter, but goes beyond this by allowing adjustable speed control. Let’s examine these two characteristics of the VFD – speed control and controlled starting and stopping – to understand how energy savings and other cost benefits are achieved.
 VFD controls motor speed by comparing a reference signal to a pre-set value. The reference signal can be generated externally, for example via a process setpoint, or internally by the VFD using software to model motor parameters. The latter is accomplished by most VFD’s through the auto-tuning process during initial drive setup. It then adjusts the frequency and voltage to match the reference signal, which in turn results in adjustments to motor speed – frequency and speed are directly proportional. If the reference signal indicates the motor is not required to run at full (base ) speed, the drive slows it down accordingly. For variable torque loads such as centrifugal pumps and fans, power is produced in relation to the cube of the speed, so if speed is reduced by just 10%, power is reduced by (10%) cubed, or approximately 27%. Although constant torque load savings are not identical, they are significant as well.
Debate continues as to the savings generated by reducing motor speed in some applications versus the capital cost of upgrading to VFD’s. In essence, if the process is significantly over-sized, or is dominated by friction losses, then there is value in reducing the speed of process flow. Various on-line tools exist to assist in determining potential energy savings; for example, ABB and Weg have links to such tools on their Corporate web sites. Keep in mind also that more care must be exercised when evaluating processes requiring high torque or constant torque, since in general the savings through VFD use in such systems is not as great.
During motor starting, significant current must be supplied to the motor windings to overcome the inertia of the load and the mass of the motor armature. When motors are started “across-the-line”, the resultant current draw can be as much as 6 – 12 times the full-load amperage, and can place great stresses on driven equipment. In cases where motor loads comprise a significant portion of the total electrical demand, in-rush current can result in high electrical peaks and thus higher utility costs. A soft-start function, such as that provided by ramping up a motor slowly via VFD, can reduce in-rush to 3 – 6 times the full-load amperage, reducing peak demand. Also, costs for preventive maintenance of couplings, shafts and other driven components are reduced because they are not subjected to the larger stresses caused by full-voltage starting.
In addition to support available from most manufacturers, Joliet Technologies can assist you in determining whether a VFD is right for your application. Please call or email us at simon.fan@vtdrive.com with your application. And as always, visit our Comments section to provide any thoughts, suggestions, or questions you might have. And remember to visit us on-line at www.vtdrive. com. 

Variable Speed Drive (VSD) Enclosure Climate Control


One factor that if over-looked can cause significant equipment issues is proper environmental protection of variable speed drives (VSD’s) and other electronic equipment. We are often requested to install VSD’s and other control components in custom enclosures which will be installed under a wide variety of ambient conditions, including high temperature and/or high humidity environments. The drive electronics are rated for operation within given temperature and humidity ranges in order to ensure longevity and proper current output, so there are real risks and cost impacts associated with ignoring environmental constraints.
Temperature:
Although there is some variability from manufacturer to manufacturer, VSD’s are generally de-rated – that is, their rated amperage output is reduced – for operation between 40°C and 50°C. F0r instance, ABB specifies that output current is to be reduced by 1% for each 1°C above 40°, and the units are not rated at all for operation above 50°. This is to accommodate the rise in resistance under higher temperatures and to protect sensitive electronics from being over-stressed. Sometimes the 50°C maximum rating will be shown in manufacturers’ information as intended for “heavy duty” or “overload” use. This should not be confused with the overload capability required for constant torque applications – the higher load demands under constant torque use should be considered aside from any temperature de-rating required. Manufacturers can provide de-rating curves for their VSD’s which provide the relevant details.
Even with de-rating, additional control is required to maintain temperatures at acceptable levels. This is largely because VSD’s generate significant heat while they are operating. Smaller drives (e.g. below 5 HP (3.7 kW)) are usually equipped with external heat sinks alone, while larger units have one or more internal fans used to draw air over the electronics.  According to data from Emerson/Control Techniques, a 100 HP (75kW) drive may dissipate 5,100 Btu/hr (1.5kW) or more under normal operating conditions. If that heat is contained within a cabinet, the temperature within can easily exceed upper temperature limits and cause premature drive failure. Manufacturers provide very specific requirements for installation clearances and mounting methods in order to ensure their drives are adequately cooled. When drives are wall- or floor-mounted as stand-alone units these methods may be all that are needed, but installation within cabinets often demands supplemental temperature control. This temperature control is typically provided by forced air ventilation or refrigerative cooling.
In cases where the ambient temperature is not excessive, fans can be installed in enclosure walls or doors. The fans are sized to provide air flow per manufacturers’ recommendations, which take into account the drive’s heat dissipation  and assume a rated maximum ambient temperature. Fans are also often equipped with suitable filters to protect the cabinet contents from dust and debris; filter kits can be specified for indoor or outdoor use depending on need.
For larger VSD’s, particularly when the cabinets are installed outdoors in warm climates, refrigerative cooling (i.e. air conditioning) is needed. It is not uncommon to require 8,000 Btu (2.3 kWh) or more cooling capacity within the panel for a 100 HP (75kW) drive and associated control components. Cooling requirements can be affected by installation location as well. For example, manufacturers recommend that drives/drive cabinets not be installed in direct sunlight; if this cannot be avoided, then some type of shelter or sun screen is recommended. Simply siting the drive in a location shaded from the sun during the hotter parts of the day can significantly reduce cooling demands; specific tools for calculating cooling demand can be found on several temperature control manufacturers’ web sites, including among others Pfannenberg, IceQube, and Kooltronic.
Humidity/Condensation:
Operating ranges for most VSD’s range from 5% – 95% relative humidity (non-condensing), so in all but extreme cases humidity is not a problem. However, drives/drive cabinets subjected to wide temperature swings can be exposed to condensation. For example, a cabinet mounted outdoors in a temperate climate may see winter temperatures of 0°C or lower. This may not be an issue while the drive is operating, but if it is off for an extended period of time, condensation can develop on internal components. This problem is typically addressed by installing one or more space heaters within the enclosure; the heaters are thermostatically controlled and typically interlocked for operation based on drive status.
If you have a specific or unusual drive climate control application, please feel free to share it with our readers in the Comments section. There is a great deal of experience out there which can be brought to bear on your problem. And we are always glad to hear of any suggestions or thoughts you might have.
Proper climate control will help to ensure you get rated output and operating life from your VSD. Should you need additional guidance, please feel free to contact us at simon.fan@vtdrive.com. And remember to visit us on-line at www.vtdrive.com. 

Waste to Energy


Waste-to-energy (WTE) is the process of creating energy in the form of electricity or heat from the incineration of waste source. WTE is a form of energy recovery. Most WTE processes produce electricity directly through combustion, or produce a combustible fuel commodity, such as methane, methanol, ethanol or synthetic fuels.
With the garbage landfills worldwide nearing capacity, and exploding populations consuming precious available land, new approaches to Solid Waste Disposal and Alternative Energy Generation Sources have emerged to assist municipalities and governments in dealing with these problems. Waste to Energy Facilities (WTEFs) on Land or Barge based have emerged as the choice solution to the Solid Waste problem faced by cities around the globe.Through the combustion of everyday household trash in facilities with state-of-the-art environmental controls, WTEF’s provide viable solutions to communities that would otherwise have no alternative but to buy power from conventional power plants and dispose of their trash in landfills.
It is a known fact that for every ton of waste processed in a WTEF, almost one ton of Greenhouse Gas is kept out of our atmosphere. While contributing to resource recovery and the reduction of solid waste going into landfills, a major benefit of the WTEF’s revolutionary technology is the production of Electricity and Potable Water (optional on some systems) as a by-product of the Solid Waste Reduction process. Unlike wind or solar power, Waste-to-Energy facilities can operate 24/7, making them the most continuously reliable source of renewable power generation.
Sharif International is actively pursuing three WTE projects along with project investment based on Incineration given its multiple environmental and financial benefits to all stake holders. Incineration, the combustion of organic material such as waste, with energy recovery is the most common WTE implementation. Incineration may also be implemented without energy and materials recovery, however this is increasingly being banned in OECD (Organisation for Economic Co-operation and Development) countries. Furthermore, all new WTE plants in OECD countries must meet strict emission standards. Hence, our modern incineration plants with European and Japanese technology are vastly different from the old types, some of which neither recovered energy nor materials. Our modern incinerators reduce the volume of the original waste by 95-96%, depending upon composition and degree of recovery of materials such as metals from the ash for recycling.
Some of our main plants come from none other than Mitsubishi, Martin and Stoker.
Flue gas cleaning systems enable our customers to reduce air pollution from NOx, SO2, dust, fluorides, hydrochloric compounds, dioxins and furans. Thanks to the know-how of our principals, users of our systems make a substantial contribution to keeping our environment clean. The WTE handling consortium has 20+ years´ experience gained from the completion of over 90 projects for NOx removal from flue gases (all types of fossil fuel and industrial processes) and over 60 projects for ammonia processing plants. ENVIRGY supplies both individual systems and complete plants.
Our hallmark is the arrangement of appropriate WTE project funding for suitable sites. Appropriate sites include locations where the daily available quantum of municipal waste (MSW) is in excess of 1000 tonnes per day. Smaller plants of 500 tonnes per day are also possible but less financially viable. Generally speaking with appropriate quality MSW in the range of 1200 – 2000 tonnes per day about 18 – 20 MW of electricity can be generated. Of this capacity 2 MW is utilised by the plant itself and the rest can be sold off to the utility companies.

Interesting Facts about Waste to Energy – Waste to Energy in brief…
(Courtesy ESWET Website)
  • Essential part of a sustainable Waste Management chain.
  • 100% complementary to recycling.
  • Produces valuable and renewable energy.
  • Has a lower carbon footprint by avoiding Methane emissions from landfill and  offsetting the use of fossil fuels for energy production.
  • Removes all toxic substances from residual waste streams.
  • Up to 95% Landfill diversion rate.
  • Helps diversify energy sources.
  • Reliable European technology.
  • Untapped Energy Source.
  • Today, the energy produced from waste in Europe is enough to supply the equivalent of Ireland or Slovakia with electricity.
  • Carefully collected and sorted residual waste contains on average 10,000kJ/kg of energy. Therefore, each kilogram of waste could power a 12W eco-bulb (~60W) for 75 hours.
  • Waste to Energy has the lowest emission limits of all Industrial Sectors.
  • The European Commission keeps track of pollutants emitted by a wide range of punctual sources. These data can be found on their site.
  • Waste to Energy’s Dioxin Emissions are not an issue.  Since 2005, the German Environment Ministry, then headed by Mr. Trittin from the Green Party, has acknowledged that Waste to Energy does not contribute significantly to Dioxins emissions. The document by the German Environment Ministry stating this can be found online.
Please contact us for further details.

2012年11月26日星期一

Variable Speed Drives – Understanding Your Application – Part I


Variable speed drives (VSD’s) are considered state-of-the-art in controlling driven processes, but it is important to realize they may not be the answer to every process control problem. End users need to understand their application requirements and mechanical and electrical system constraints in order to ensure that a VSD is the right solution, and to specify it correctly. In the first part of this series, we’ll summarize some of the main process and load characteristics which should be taken into account before specifying a VSD:
Process Factors:
  • The need for speed (…control, that is)
Many processes can benefit from the ability to periodically or continuously reduce output by reducing the speed of driven equipment. For example, piping systems are often “over-designed” to accommodate future expansion or simply provide some operating headroom. If driving the motor at full speed results in output that must be “turned down”, via control valves for instance, there is a potential to increase overall system efficiency and reduce energy consumption using a VSD. Bearing in mind that capital costs tend to be higher for VSD use, it is important to determine the percentage of time and reduction in flow needed and use that information to estimate the reduction in motor output that could be tolerated. For example, in centrifugal applications the motor horsepower varies by the cube of the speed. As a result, a reduction in motor speed of just 15% can reduce horsepower required (and thus kW consumed) by almost 40% (.853 = .61).
On the other hand, some systems are designed such that speed reduction provides no operational benefit. For example, in tightly designed piping systems with plenty of static head available, system flow tends to be more efficiently controlled with valves, especially when capital equipment costs are factored in. It is often only when systems are dominated by friction losses and these can be significantly decreased by decreasing flow rate that VSD advantages become clear.
Also, many processes could benefit from reduced stresses during starting even if speed control is not required. In such cases, a reduced voltage (i.e. “soft”) starter can be used. The soft-starter will typically reduce inrush current, which in turn reduces mechanical and electrical stresses on driven equipment. While a VSD also can provide this “ramp up/ramp down” function, it may well be over-kill (adding unnecessary cost and complexity) if variable process speed is not needed.
  •  Load torque
VSD’s are sized directly by continuous amperage output, not horsepower. While the latter can be used to approximate VSD sizing, it is the amount of current required in both steady state and over-load conditions which determines the correct drive to specify. The torque needed to operate the driven load affects the amperage required. Loads with constant torque or constant horsepower profiles require a higher amount of torque during start-up, which places greater amperage demands on the drive at ramp-up. It is therefore important to understand load torque profiles to know which drive amperage rating and overload capacity to select.
  • Variable torque: this profile is characteristic of centrifugal pumps and fans. The torque increases as load speed increases, resulting in lighter demands on the drive at start-up. The torque increases with the square of the increase in speed.
  • Constant torque: typical of conveyors, positive displacement pumps/compressors, and screw feeders, this profile is characteristic of a load requiring effectively the same torque at any speed within the operating range.
  • Constant horsepower: in this profile, typical of machine tool applications, winders, and some load-driven conveyors, the torque required varies inversely with speed (decreases as speed increases).
VSD’s rated for variable torque applications have higher continuous amp ratings because they are not being taxed as much at start-up or when needing to respond to changing loads. For example, a drive sized for a 20 HP variable torque application, capable of supplying a continuous 31 amps at 480 volts, would only be rated for a 15 HP constant torque application, supplying a continuous 23 amps. This is to prevent the drive electronics from over-loading when faced with the need to maintain torque under heavy duty applications.
Next week, in Part II we’ll discuss electrical system considerations in VSD applications. In the meantime, please contact me with any questions, comments or application needs you may have at simon.fan@vtdrive.com. Thanks for reading, and we’ll see you next week!

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