The Digital Sugar Mill

Seminar on Sugar & Ethanol Automation

Variable Frequency Drives and Motors

Omar Javed – Business Manager Sales

Variable Frequency Drives

AgendaThis session explains very brief overview

of Variable Frequency Drives; general introduction followed by industrial examples, applicable industries and

operations to be focused.

What is VFD?

What are the concerns?

What to do about it?

3

What is VFDElectrical/electronic pieceof equipment that variesthe speed of a 3 phase orAC motor.

Also Called:

VSD [ Variable Speed Drive]

ASD [Adjustable Speed Drive]

AFD [Adjustable frequency drive]

4

Basic VFD Operations

Convert AC power to DC power.

Filter DC power.

Invert DC power to variable voltage and variable frequency AC power

5

VFD Block Diagram

Motor Load Groups: Constant Torque Load

100

Horsepower Demanded by the Load %

Speed %

100

Torque Demanded by the Load %

Speed % 100 100

7

Constant Torque “CT” Applications

Positive Displacement Pumps

Reciprocating Compressors

Rotary Compressors

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Variable Torque Load

Torque Demanded by the Load %

Speed % 100

100

Horsepower Demandedby the Load %

Speed %

100

100

9

Variable Torque “VT” Applications

Centrifugal Fans

Centrifugal Pumps

Centrifugal Blower

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Output or Cable Device Termination

Required if motor cable lengths exceed stated

values

AC Drive*Normal Duty vs. Heavy

Duty ratings

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capacitatorsb) Power interruptions or voltage dipsc) Transformer larger than drive

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AC Motor

Normal Duty or Heavy Duty

If a normal duty overload characteristic is chosen, an oversize motor allows up

to 110% torque performance for up to 1 min. in both CT and VT.

This function is used mainly for pumps and fans, since these applications do not

require an overload torque.

If a heavy duty overload characteristic is chosen, a rated motor with the

frequency converter obtains up to 160% torque for 1 min. in both CT and VT

12

What do You Need to Know to Select a Drive?

Current rating (A) of the motor

kW rating of the motor

Type of Machine (Application)

IP Rating

• IP20 = Clean Switchroom, Switchboard

• IP54 = Dust/Damp Wall Mount

• IP66 = Washdown

Functionality

• How is the drive being controlled?

• I/O?

• Communications?.

Least Important

Most Important

What Rockwell Automation is Offering

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PowerFlex Family of Low Voltage Drives

PowerFlex Drives meet worldwide standards out of-the-box, achieving EMC, global voltage and safety requirements.

All Power Flex Drives offer commonality in networks, operator interface and programming — factors that significantly contribute to ease-of-use and faster application start-up

PowerFlex Compact Drives offer cost-effective motor control for machine-level and stand-alone applications (PowerFlex 523, 525, 527, 40, 40P)

PowerFlex Standard Drives are designed for application flexibility and control system integration (PowerFlex 400, 70, 700, 753)

PowerFlex Premium Drives are designed for advanced applications with tight control system integration and extended Power Ranges (PowerFlex 700L, 700H, 700S, 755)

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Power

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Compact

Standard

Premium

PowerFlex Family of Low Voltage Drives

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PowerFlex 750 Series AC Drives

PowerFlex 755Premium Integration

AC Drive

PowerFlex 753General Purpose

AC Drive

Panel Mount Drives0.75 to 250 kW @ 400V1.0 to 350 Hp @ 480 V.5 to 300 Hp @ 600V5.5 to 250 kW @ 690V

Panel Mount Drives0.75 to 250 kW @ 400V1.0 to 350 Hp @ 480V.5 to 350 Hp @ 600V5.5 to 250 kW @ 690V

Floor Mount AC Drives315 to 1400 kW @ 400V400 to 2000 Hp @ 480V250 to 1500 Hp @ 600V200 to 1500 kW @ 690V

PowerFlex 750-Series AC Drives

Ratings to 250 kW/350 Hp Ratings to 1500 kW / 2000 Hp

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Value Delivered

Faster Time to Market

$ $$

Lower Total Cost of Ownership

Improved Asset Utilization

Enterprise Risk Management

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Timeline Review

19

Original Hardwired SystemTypically configured using:

Two different software tools

Two different cables or converters

Sometimes by two different people

20

Early NetworksSame as hardwired system

Typically configured using two different software tools

Two different cables or converters

Sometimes by twodifferent people

21

Use of Dual NetworksTypically configured using two different software tools

22

Typical Single Network TodayTypically configured by oneperson using two different software tools

23

Integrated Software TodaySingle Software Tool

Configure network i/o connection to the drive One time, in One place & by One person

Eliminates potential for user error when configuring network i/o

24

Introduction to WEG Motors

25

History of WEG

26

27

Global Presence

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> Distributors & Agents in over 85 countries

> Over 1100 Service Centers covering all 5 continents

> Sales to over 110 countries

Factories in 5 countries

Commercial branches in 22 countries

Employees

28

28 25/08/2016

14,159

15,292

19,446

20,974

22,716

8,343

9

7,808

409

3,542

1961 1970 1980 1990 2009 2010 2011 2012 2013 2014

3542

78088343

Outside Brazil

Brazil

12,587

13,545

17,549

18,664

19,861

15721747

2310

2855

1897

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Manufacturing Plants - MOTORS

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Products

• Three phase TEFC / ODP motors / output ratings up to 1200kW (1650HP)Types: * General Purpose

* Explosion Proof* Brake Motors* Inverter Duty * Saw Arbor* Pump Motors* Others

• Single Phase TEFC / ODP motors / output up to 9.2kW (12.5HP)Types: * General Purpose

* Farm Duty * Multi-Mounting Aluminum frame motors* Appliance Motors * Ventilation / Others

Low Voltage Industrial Motors

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Products

• Three Phase TEFC / ODP Induction Motors

- Master Line, frames from 280 to 1800, voltages up to 15kV;

- H Line, enclosed, frames from 315 to 630, voltages from 220V to 11kV;

- DC Motors, frames up to 1800.

Applications: * Mining

* Sanitation

* Steel Plants

* Cement

* Pulp and Paper

* Petrochemical

* Cooling Systems

Medium and High Voltage Motors

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Certifications

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MOTORS Machining Center

In operation

MOTORS Plant VI - Frames: 160, 180,

200

In operation

MOTORS Motors - 355 W21 + HGF up

to 400 and GTA

In operation

ENERGY New Steel Plate Frame

Fabrication

In operation

AUTOMATION Panel Shop Buildings - In operationAUTOMATION New Automation Building To be concluded in 2009> Extension of the capacitors factory and new line of contactors (CWC): US$ 2 Million

> Powder coatings production capacity increase: US$ 3 Million (2007) + US$ 7 Million

Main Investments - 2014 / 2015 (Brazil)

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China

Investments in the production capacity of the following

motor lines already available:

• W21: frame sizes 80 up to 355

• HGF: frame size up to 630

• MGF: frame sizes 315 up to 1000

Main Investments Outside Brazil - 2012 / 2013

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Main Investments Outside Brazil - 2012/2013

First Stage• Production of MV & HV electric motors (M and S Lines)• Frame sizes: 355 up to 1600• Investments: US$ 50 Million (To be concluded in 2010)Second Stage• Production of Transformers and H Line• Investments: US$ 60 Million (To be concluded in 2013)

New Manufacturing Plant In India

36 25/08/2016

References - OEM Ventilation

• FläktWoods

• Springer Carrier

• Riox

• Howden

• Elta Fans

• Zitron

• Penn Ventilator

• Relopa

• Sodeca

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• ITT Industries

• Sterling

• Alfa Laval

• Gusher Pumps

• Goulds Pumps

• Hidrostal

• ABS

• Envirotech

• Ebara

References - OEM Pumps• Sulzer

• Kirloskar Brothers Limited

• KSB

• Ingersoll-Dresser Pumps

• Grundfos

• Weir Pumps

• Flowserve

• Tsurumi Pump

• Marelli Pumps

• Scot Pump

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• Ingersoll Rand

• Schulz

• Atlas Copco

• Puska

• Alup

• Sullair

• Champion

• Campbell Hausfeld

• Mitsui Seiki

• CompAir

• Boge Kompressoren

• DeVilbiss Air Power Company

• Hitachi

• Betico

References - OEM Compressors

References: Oil & Gas

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• Caltex

• Sasol

• Total

• ENAP

• PDVSA

• ESSO

• Petrobras

• Saudi Aramco

• Pemex

• Ecopetrol

• Cepsa

• Sapref

• PetroCanada

• Repsol YPF

• NION

• Conoco

• Pan American Energy

• Dresser Rand

• Dow Chemical

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Contracts with OEM‘s and End Users

• Metso Minerals

• CompAir

• Atlas Copco

• FläktWoods

• Soler & Palau

• Cenibra

• Epal

• Cargill

• Alfa Laval

• Alup Kompressoren

• Usiminas

• Votorantim

• Europac

• Ingersoll Rand

• Sandvik

• Suzano

• Boge

• Sadia

• Weir

• CSN

• Bosch

• ABS

• Klabin

• Cosipa

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• Bechtel

• Tecnimont

• Fluor

• Foster Wheeler

• Black & Veatch

• Alstom

• Cegelec

• Technip

• Saipem

• Snamprogetti

• Placer Dome

• Kvaerner

• EFACEC

• Aker Kvaerner

• SNC - Lavalin

• DRA

• Techint

• CH2Mhill

References - Engineering Companies

Question & AnswersThank You for Your Valuable Time

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Lahore, Pakistan

Headquarters South East Asia

19 Km Main Multan Road

Lahore, Punjab 54660

Pakistan

Phone : + 92 42 111 940 940

Dubai, UAE

Headquarters Middle East And Asia

Office FZS1 BD04, Jebel Ali Free Zone

PO Box 18590, Dubai

United Arab Emirates

Phone: +971 4 88 60 277

Exton, USA

Headquarters Americas

180 Sheree Boulevard, Suite 1400

Exton, PA 19341

United States of America

Phone +1 610 458 8700

Regional Offices and Global Headquarters